DESIGN PROJECT

(ME449)
Phase I Review
By
Chittimoju Deepak
120me0012
Under the guidance of
Dr. R Seetharam, Assistant professor

Department of Mechanical Engineering

IIITDM Kurnool
Jagannathagattu Hill, Dinnedevarapadu, Kurnool-
518007
 CONTENTS
 Introduction
 Definition of the Problem
 Methodology
 Materials used for differential gearbox
 Design parameters
 Design of differential gearbox in Solidworks
 Introduction to Structural (Static) Analysis
 Analysis in ansys workbench 16.2
 Comparison of results
 Conclusion
 INTRODUCTION
 Problem Statement:
DESIGN AND ANALYSIS OF DIFFERENTIAL GEAR BOX IN AUTOMOBILES

Context:
 Leading manufacturers of gearboxes, which are used in various utensil and
sugar mill machinery, faced the following problems:

• Interference
• Surface
• Fatigue fracture

 Gears fail if tooth stress surpasses safe limit. Analysis ensures stress
reduction, preventing failure risks.

 Gear failures incur high costs in replacement/repair and system

downtime
 Methodology:
The modeling and stress analysis of the gearbox have been done in Solid
Works and ANSYS respectively.

Materials used for differential gearbox:

1) Grey cast iron
2) Aluminium alloy

Design parameters:
Part Nominal shaft Show teeth
diameter(mm)
Crown gear 60 80

Driving pinion gear 18 20

Sun gear 25 45

Planet pinion gear 15 15

  Design of the differential gearbox in Solidworks

Fig.1 sun gear Fig.2 driving pinion Fig.3 Planet pinion

Crown gear Assembly of differential gearbox

 Introduction to Structural (Static) Analysis

With the widespread adoption of the CAE approach to design, finite element analysis(FEA)
became integrated with the design and analysis procedure. Structural (Static) analysis is used
to analyze parts and assemblies to find,
1. Total deformation
2. Maximum stresses
3. Von-mises stresses etc..

 Analysis in ansys workbench 16.1:

• Geometry:
The modeling done in Solidworks is saved in IGES format and it is imported in Ansys
software.
• Automatic Mesh Generation :
Mesh generation is one of the most critical aspects of engineering simulation. ANSYS
Meshing technology provides a means to balance these requirements and obtain the right
mesh for each simulation in the most automated way possible
 ANALYSIS OF DIFFERENTIAL GEARBOX
We have used two different materials grey cast iron and aluminium alloy for the
analysis
Density 7200 kg m^-3 Density 2770 kg m^-3
Coefficient of 1.1e-005 C^-1 Coefficient of Thermal 2.3e-005 C^-1
Thermal Expansion Expansion
Specific Heat 447 J kg^-1 C^-1 Specific Heat 875 J kg^-1 C^-1
Thermal Conductivity 52 W m^-1 C^-1 Young's Modulus Pa 7.1E+010 pa
Resistivity 9.6e-008-ohm m
Poisson's Ratio 0.33
Young's Modulus Pa 1.1E+011 pa
Poisson's Ratio 0.28 Resistivity 3.63e-008-ohm m

Tensile Ultimate 2.4E+08 pa Thermal Conductivity 114 W m^-1 C^-1

Strength
Tensile Yield Strength 2.8e+08 pa
Compressive 8.2E+08 pa
Ultimate Strength
Tensile Ultimate 3.1e+08 pa
Strength

Table 1: shows the material properties of grey Table 2: shows the material properties of
cast iron aluminum alloy
 Meshing of Differential Gear Box:

Giving Set up conditions in ansys workbench

Torque acting on the Differential Gear Box:

 Experimental results:
Total deformation of grey cast iron(mm)

Fig: It shows the Total Deformation stress values of the differential gearbox at different torques at 190,
235, 320 (N-m) on Grey Cast Iron
Von-Mises Stress of Differential Gear Box(Mpa):

Fig: It shows the Von-Mises stress values of the differential gearbox at different torques at
190, 235, 320 (N-m) on Grey Cast Iron
 Total deformation for aluminum alloy:

It shows the Total Deformation stress values of

the differential gearbox at different torques at 190,
235, and 320 (N-m) on Aluminium Alloy.

Von-Mises Stress of Differential Gear Box:

It shows the Von-Mises stress values of the differential gearbox at different torques at
190, 235, 320 (N-m) on Aluminium Alloy
 RESULTS & DISCUSSIONS :

Total Deformation and Von-Mises Stresses of Grey Cast Iron

S.no Torque(n-m) Total Von-mises stresses(Mpa)

Deformation(mm)
1. 190 4.76E-04 0.89923

2. 235 5.89E-04 1.1122

3. 320 8.02E-04 1.5145

Total Deformation and Von-Mises Stresses of Aluminium Alloy

S.no Torque(n-m) Total Deformation(mm) Von-mises stresses(Mpa)

1. 190 7.41E-04 0.91607

2. 235 9.17E-04 1.133

3. 320 1.25E-03 1.5429

Conclusions:

From, the above results and graphs we found that both grey cast iron and aluminum alloy are
preferable for performing the application of differential gearbox in automobiles. But, when it
comes to weight for light utility vehicles Aluminium Alloy is preferred.
THANK YOU