Static Analysis of Differential under Torque Loading

Guilherme Sales, Heitor Bezerra, Matheus Bordignon, Raul Moreira,

ENGR
Dr. Aiman Shibli - Illinois Institute of Technology, Chicago, Illinois
498
60616
The differential plays a critical
role within a machines drive train
by changing the direction of the
power
coming
from
the
transmission 90 degrees to allow
the axles to be driven. They also
allow speed and torque differences
between the left and right axles.
When a machine is turning, the
differential lets the outside wheel
move at a faster speed than the
inside wheel, allowing for easier
turning and less wear on tires or
tracks. The gears in the differential
also provide speed reduction and
torque increases.
Many of failures are caused by:
Lack of maintenance, exceeding
the stress limit of the material and
etcetera. Differential structural

Discussion

Methods

Background
CAD
Model

Analysis
(Mesh surfaces
in 1st and 2nd
order)

Applying
(stresses,
torque,
displacement,
materials)

Figure 2: CAD Model Figure 3: Meshed

Figure 1: Differential
Surfaces

Identificati
on
(Tolerance to
Damage)

Figure 4: 2nd Order

Mesh

Design a CAD model of a differential based on a real one.

Import the CAD file to HyperMesh to create a mesh model in
first and second order.
Understand what will be happening at the Differential.
Choose just the ideal parts that will impact the simulation
results.
Analysis of stress, strain and displacement of the Differential
under torque simulation.

Tf=Final Torque Ti=Initial Torque hp=horsepower gt=gear ratio

r=radius
=stress Ef=Mechanical Efficiency

Results

Acknowledgemen
ts

Armour
College
of
Engineering for funding the
Engineering Themes course
ENGR 498
Brazilian Scientific Mobility
Program for studying at IIT.

References

behavior
has
been
simulated
Materia Young
Yield S.
Ultimate
under
torque (MPa)
loading
to
ls
M. (GPa)
S. (MPa)
4320
205
1225
1505the
determine
whether
8620
205
1036
1324
differential will sustain the
required forces without
yielding.

The 1 order mesh presented

nd
good results but the 2 order
showed more precise results.
Was possible to create a
different
mesh.
However,
keeping the same size at the
teeth, the number of the
nodes stayed under 100,000.
The Heat Treatment is very
important to assure better
proprieties to material.
The design is adequate, it can
support
required
forces
without yielding.
st

Figure 5: SAE 8620 Direct

Quenched result.

Area= 339.08mm
Force (N)
Torque (N.m)
2

Steel
SAE 8620
SAE 4320

Figure 6: SAE 4320

Single Quenched and
Tempered

5020
6713

1.7867x103
2.3367x103

Stresses
(MPa)
36.6282
47.9035

1 - Failure Analysis" Differentials.com.

N.p., Jun. 2011. Web. 20 Jun. 2015.
2 Part Failure Analysis
winningwithemail.com/content/6490/ima
ges/TP0445.PDF. N.p., Apr. 2014. Web. 21
Jun. 2015.
3 - Budynas, Richard G., J. Keith. Nisbett,
and Joseph Edward. Shigley. Shigley's
Mechanical Engineering Design. New
York: McGraw-Hill, 2011.
4 - Braess, Dietrich. Finite Elements:
Theory, Fast Solvers, and Applications in
Solid Mechanics. Cambridge, U.K.:
Cambridge UP, 1997.