Parametric modelling, Kinematic Simulation and FEA of Differential Gear for an Automotive. Name Student ID Arvind Dalal 6582141 Prakul Mittal 6562353 Sambhu Kumar Gupta 7143947 MECH 6451 Computer Aided Design Professor: Dr. Chevy Chen
Jul 08, 2015
Parametric modelling, Kinematic Simulation and FEA of
Differential Gear for an Automotive.
Name Student ID
Arvind Dalal 6582141
Prakul Mittal 6562353
Sambhu Kumar Gupta 7143947
MECH 6451 Computer Aided Design
Professor: Dr. Chevy Chen
PROJECT OUTLINE
Differential Overview
Definition of our technical task
Design calculation for Differential Gear
Tangential tooth load
Dynamic load
Static tooth load
Wear load
Force acting
Parametric Modeling using Catia V5
Parametric design for straight teeth bevel gear
Kinematic simulation of Differential Gear
When vehicle moves straight
While turning
Finite Elements Analysis using ANSYS 14.5
Structural analysis by design Operational load
Product failure load estimation
DIFFERENTIAL OVERVIEW
When turning, the inner and outer wheels have
arcs of different turning radii.
Consequently, the inner wheels travel less
distance than the outer wheels.
Because the turning paths of the inner and outer
wheels are different, the wheels on both axles
need to be able to spin independently of each
other
A differential is used to allow the wheels to spin
at different speeds
DIFFERENTIAL OVERVIEW
DESIGN CALCULATIONS
Differential gear assembly for a vehicle transmit power at different speeds at 2400 rpm.
Material used Aluminum Alloy.
For Crown Wheel
Diameter of crown gear = DG= 800 mm
Number of teeth gear = TG = 80
Number of teeth on Pinion= TP = 20
Module = m=DG/TP= 800/20= 10
Diameter of pinion DP=m TP = 10*20 = 200mm
Velocity ratio (V.R) = TG/ TP= DG/DP= NG/NP
So Velocity ratio is (V.R) = 80/40 = 4
Since the shafts are at right angles therefore pitch angle for the pinion
θp1=tan-1(1/v.r) = tan-1(1/4) = 14.04
Pitch angle of gear
θp2 = 90 - θp1 = 75.96
WEAR LOAD (WW)
WW
DP b q k
cos P1
180
2.601 104
N
Where K = load stress factor k es2
sin 20
180
EG EP
EP EG
1.4 0.721 N/mm2
FORCE ACTING
WN=normal load=WT/ COSØ
WT=tangential force
Where WT = T/ RM (RM = Mean radius)
Axial force acting on the pinion shaft
WRH =WT tan 20 sin ϴP1
WRH = 478.24N
Radial force acting on the pinion shaft
WRH =WTT tan 20 cos ϴP1
WRH = 1912.37 N
DESIGN CALCULATIONS
EP=young’s modulus for material of pinion in N/mm2=70300 N/mm2
EG=young’s modulus for material of gear in N/mm2= 70300N/mm2
PARAMETRIC MODELING USING CATIA V5
PARAMETRIC DESIGN
• Created 5 points to generate involute
teeth profile by parametric equation
• Connected the points by use of Spline.
• Scaled he tooth profile and projected
• Projected the involute profile on
the cone.
FINAL PRODUCT
Later surface was transferred in Part
workbench to create solid par.
PARAMETRIC DESIGN
KINEMATIC SIMULATION While vehicle is Turning
FINITE ELEMENT ANALYSIS USING ANSYS 14.5
MESH GENERATION
• Mesh Generated in Design Modeler
• Type: Coarse , Size: 1.5166e-004m
• We got total nodes= 6459 And
Elements = 3532
LOAD & FIXTURE APPLIED
• We applied fixed support
base of crown gear , and
frictionless at hole.
• Under setup sub tab.
DEFORMATION