Modeling and analysis of Differential gear box

using Ansys
Abstract:
• This research project conducts an in-depth exploration into the structural behaviors of three distinct
materials Aluminum Alloy, Titanium Alloy, and Magnesium Alloy within the framework of a
differential gearbox under varying loads.
• Employing finite element analysis through ANSYS, the investigation systematically scrutinizes critical
parameters such as total deformations, shear stress and strain.
• The primary aim is to offer insights that guide material selection strategies and enhance the
optimization of design processes in automotive applications.
• The results illuminate nuanced material responses when exposed to conditions, presenting
implications for real-world gear assembly scenarios.
• This study significantly contributes to the evolving knowledge base in automotive engineering,
providing a foundation for well in formed decision-making in material selection and design
optimization for differential gearboxes.
Keywords: Differential Grear box, Fusion 360 software, Ansys software.
Introduction:
• The automotive industry perpetually strives for elevated performance, efficiency, and reliability.
Embedded in the intricate machinery of vehicles, the differential gearbox assumes a pivotal role in
distributing among wheels, shaping the dynamics and stability of the vehicle. The crux of this vital
component's functionality lies in the judicious choice of materials capable of withstanding the
dynamic forces inherent in operational processes. This research is a targeted exploration into the
structural behaviors of three distinct materials Aluminum Alloy, Titanium Alloy, and Magnesium Alloy
within the dynamic milieu of a differential gearbox exposed to varying loads. The motivation for this
inquiry arises from the necessity to unravel the nuanced reactions of materials when subjected to
conditions, a fundamental aspect for ensuring the durability and effectiveness of automotive
systems. The selection of materials for automotive components necessitates a delicate equilibrium
between mechanical properties, weight considerations. As the automotive landscape shifts towards
innovative design paradigms, such as electric and hybrid vehicles, the demand intensifies for
materials that can deliver optimal performance across diverse scenarios, underscoring their
increasing significance in the industry.
Objective:
1. Investigate the structural behaviors of Aluminum Alloy, Titanium Alloy, and Magnesium Alloy within
a differential gearbox under varying loads.
2. Utilize finite element analysis with ANSYS to examine critical parameters such as total deformations,
shear stress, and strain.
3. Provide insights to guide material selection strategies and enhance the optimization of design
processes in automotive applications, based on the nuanced material responses observed under
different conditions.
Literature survey
• Congfang Hu et. al. (2021) The effects of mistake randomization and dynamic load sharing were
studied. Our first step is to build a model of stochastic multi-body dynamics utilising closed
differential planetary transmission. We then assess the sampling and stochastic distributions for
the load-sharing behavior in light of the Taguchi technique. After that, we look at how the
production and assembly processes within the tolerance zone affect load-effectiveness sharing.
Finally, the experimental results for a MW wind turbine's main gearbox verify the results obtained
using stochastic errors.
• Mehmet Sarıtaş et. al. (2021) The stress study of the three-stage gearbox is performed using the
finite element analysis method and the commercial Ansys tool. Triple reduction helical gearboxes
are constructed using AISI 5115 (16MnCr5) and AISI 8620 steels. This research involves both
structural statics and stiff dynamic analysis. Firstly, the boundary conditions for helical gears are
established, and then the analysis is performed. Gears' rotational velocities are input during static
structural analysis. If different types of gearboxes are analysed before they are made, the product
can be made with greater care, using the best feasible design parameters and the right safety
factors.
Problem Statement
The following problems due to which Gear failures: -
• 1) Fatigue Fracture
• 2) Interference
• 3) Surface erosion
When the tooth tension exceeds the safety limit the gears break down occur. Therefore, the
maximum capacity of gear at the specified load should be determined. To minimize the stresses on
gear teeth and prevent from failure gears are inspected & analysis should be done. When failures
occur, they are costly in costs associated with machine downtime, but also in terms of replacement
and repair costs, they belong to the system part. We have taken following materials for performing
the analysis i.e., Maraging steel, aluminium alloy, cast steel. For manufacturing of gears and gears
shafts currently Grey Cast Iron, Cast Steel material is used. Therefore, in this project we are checking
as the other material for the differential gear box.
 Proposed system
 The approach adopted for the design of the differential gear involves the utilization of Fusion 360,
followed by subsequent analysis in Ansys.
 This process encompasses the specification of boundary conditions, the creation of meshed
models, and evaluations of the gear assembly incorporating diverse materials for modification and
behavior analysis.
 While loading the differential gear offers distinct advantages over alternative failure mechanisms, it
is crucial to recognize associated drawbacks, such as the emergence of strains and deformations in
the model's components.
 The influence of in input scenarios can be effectively and economically assessed through simulation
techniques like the finite element method.
 A comprehensive 3D finite element model was meticulously developed as part of this experimental
study, facilitating the anticipation of the entire structural deflection fields in the differential gear
across a spectrum of materials.
Advantage:
• Gear drives are used in a wide range of machines, such as rolling mills, cars, material handling
equipment, marine power plants, and metal cutting machine tools,
 Compact layout,
 High efficiency,
 Reliability in operation and
 Constant velocity ratio.
METHODOLOGY
ANSYS SOFTWARE ANALYSIS

3D DIFFERENTIAL GREAR BOX

MODELING FOR FUSION 360

SOFTWARE ANALYSIS

COLLECTION OF DIFFERENT
MATERIALS

APPLYING LOAD

SOLUTION
Working
• The methodology involved conducting finite element analysis using ANSYS to simulate the structural
behaviors of Aluminum Alloy, Titanium Alloy, and Magnesium Alloy within a differential gearbox
under varying loads. Critical parameters such as total deformations, shear stress, and strain were
systematically scrutinized. The analysis aimed to provide insights into material selection strategies
and design optimization in automotive applications. Different conditions were applied to illuminate
nuanced material responses, offering implications for real-world gear assembly scenarios.
System specification
Hardware Specification
• Processor type : i5 processor
• RAM : 8GB RAM, 64 bit
• Storage : 1TB
• Display : 20’ color display
Software specification
• Autodesk fusion 360
• Ansys workbench 2024 R1
References:
1. Congfang Hu, Gaode Geng, Pol D. Spanos, "Stochastic dynamic load-sharing analysis of the closed differential
planetary transmission gear system by the Monte Carlo method", Mechanism and Machine Theory, Elesevier, 165 (2021).
2. Mehmet Sarıtaş, Özgür Gölbol, Paşa Yayla, "Finite element stress analysis of three-stage gearbox", Niğde Ömer
Halisdemir University Journal of Engineering Sciences, 10(2), 784-790, 2021.
3. Prasad Matam, Dr. Nilesh Diwakar, Dr. A. Rajasekhar, "Differential Gear Box To Reduce Vibration Using Different
Materials For Vehicles-A Review", Turkish Journal of Computer and Mathematics Education Vol.12 No.2, 2021.
4. Prathamesh Patil, Abhishek Pathak, Omkar Nikam, "Design And Analysis Of Differential Of LMV Using Composite
Materials", JETIR, Volume 8, Issue 4, April 2021.
5. Sumeet Shinde, Piyush Pawar, Rushikesh Nalawade, "Review Paper On Design Of Types Of Mechanical Differentials
Used In Automobiles", International Research Journal of Modernization in Engineering Technology and Science,
Volume:03, Issue:01, January-2021.
6. Ravi, Nausad Khan, Rone, "A Review Paper on Helical Gear on FEM and AGMA Standard for Computation and
Comparative Study of Stress Induced on Gears" International Journal of Engineering Research in Mechanical and Civil
Engineering, Vol 4, Issue 9, September 2019.
7. Shubham Palve, Purushottam Kumar Sahu, "Review Paper on Analytical and Finite Element Analysis of Spur Gears",
International Research Journal of Engineering and Technology, Volume: 06, Issue: 06, June 2019.