design and stress strain analysis of composite differential gear box

International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014

1881

ISSN: 2278 – 7798 All Rights Reserved © 2014 IJSETR

DESIGN AND STRESS STRAIN ANALYSIS OF COMPOSITE

DIFFERENTIAL GEAR BOX

Nitin Kapoor1, Virender Upneja

2, Ram Bhool

3 and Puneet Katyal

4

1Assistant Professor, Dept. of ME, Panipat Institute of Engineering & Technology, Samalkha, Panipat, Haryana, India 2Assistant Professor, Dept. of ME, Panipat Institute of Engineering & Technology, Samalkha, Panipat, Haryana, India 3Assistant Professor, Dept. of ME, Panipat Institute of Engineering & Technology, Samalkha, Panipat, Haryana, India

4Assistant Professor, Dept. of ME, Guru Jambeshwar University of Science & Technology, Hisar, Haryana, India

Abstract

The main objective of this paper is to developed parametric model of differential Gearbox by using CATIA-V5 under various

design stages. It is observed that Glass filled polyamide composite material is selected as best material for differential gearbox

and is found to suitable for different revolutions (2500 rpm, 5000 rpm and 7500 rpm) under static loading conditions. Comparisons

of various stress and strain results using ANSYS-12 with Glass filled polyamide composite and metallic materials (Aluminum alloy,

Alloy Steel and Cast Iron) are also being performed and found to be lower for composite material.

Key Words: Gearbox Design, Assembly Analysis, Model Analysis, Stress Strain Analysis and Deformation

--------------------------------------------------------------------***----------------------------------------------------------------------

1. INTRODUCTION

Gears are the most important component in a power

transmission system. Advances in engineering

technology in recent years have brought demands for

gear teeth, which can operate at ever increasing load

capacities and speeds [6]. The gears generally fail when

tooth stress exceeds the safe limit. Therefore it is

essential to explore alternate gear material [15]. The important considerations while selecting a gear material

is the ability of the gear material to withstand high

frictional temperature and less abrasive wear [3].

Weight, manufacturability and cost are also important

factors those are need to be considered during the

design phase. [12] Moreover, the gear must have

enough thermal storage capacity to prevent distortion or

cracking from thermal stress until the heat can be

dissipated [20]. It must have well anti fade

characteristics i.e. their effectiveness should not

decrease with constant prolonged application and

should have well anti wear properties [4]. The upcoming requirement of power saving and

efficiency of mechanical parts during the past few years

increased the use of composite materials. Moreover the

use of composite materials have also increased due to

their properties such as weight reduction property

with enough strength , high specific stiffness,

corrosion free, ability to produce complex shapes,

high specific strength, high impact energy absorption

and many more[19]. Product development has

changed from the traditional serial process of

design, followed by prototype testing and manufacturing but to more on computer aids. CAE

(Computer Aided Engineering) has greatly influenced

the chain of processes between the initial design and the

final realization of a product. CAE software helps in

product designing, 3-D visualization, analysis,

simulation and impacted a lot on time and cost

saving to the industry[21], [22].

A Gear box is one of the important mechanical

components of transmission system used in variety of

machines. Differential Gear box increases effective

weight of vehicle which in turn directly affects the performance and efficiency of the vehicle. So there is a

requirement to make light and effective gears [15].

Therefore, in the present work composite materials are

used to make light weight gears in order to perform such

duty efficiently.

1.1 Importance of differential Gear Box

A differential is a device, usually but not necessarily

employing gears, capable of transmitting torque and

rotation through three shafts, almost always used in one

of two ways: in one way, it receives one input and

provides two outputs this is found in most automobiles

and in the other way, it combines two inputs to create an

output that is the sum, difference, or average, of the inputs. In automobiles and other wheeled vehicles, the

differential allows each of the driving road wheels to

rotate at different speeds, while for most vehicles

supplying equal torque to each of them. A vehicle's

wheels rotate at different speeds, mainly when turning

corners. The differential is designed to drive a pair of

wheels with equal torque while allowing them to rotate

at different speeds. In vehicles without a differential,

such as karts, both driving wheels are forced to rotate at

the same speed, usually on a common axle driven by a


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simple chain-drive mechanism. When cornering, the

inner wheel needs to travel a shorter distance than the

outer wheel, so with no differential, the result is the inner wheel spinning and/or the outer wheel dragging, and this

results in difficult and unpredictable handling, damage to

tires and roads, and strain on (or possible failure of) the

entire drive train.

1.2 Background

The Differential Box transmits mechanical energy from a

prime mover to an output device. It also changes the

speed, direction or torque of mechanical energy.

Differential gearbox is used when high speed, large power transmission where noise abatement is important.

Some limitations in existing Differential gear box are as

follows:

It has poor weight to strength ratio so high power loss.

Metallic parts lead to corrosion so need to properly

shielded.

More wear in between the gears so required proper

lubrication.

Due to heaviness of Differential gear box, it

needs to be strongly mounted thus increasing

more weight and decreasing fuel efficiency.

It has less elastic modulus and tensile strength.

Its cost is more due to increasing cost of metals.

Due to poor weight to strength ratio power loses in

gear trains are higher.

Existing differential has low tensile strength, elastic

modulus. Its poison‟s ratio, mass density and shear

modulus is also low. Thus Differential gear box needs

to be redesigned providing energy saving by weight

reduction, providing internal damping, reducing

lubrication requirements and have high tensile strength,

elastic modulus, poison‟s ratio, mass density and shear

modulus without increasing cost. Such a scope is

provided by application of composite material

providing substantial weight reduction in conformance

with safety standards and also providing solution to

other existing problems in current gears available.

2 LITERATURE REVIEW

In this paper, literature has been critically reviewed

involving various studies carried out by various

researchers related to the field of designing and analysis

of Differential gearbox. Differential gearbox is an important part of the automobile i.e. used for

transmitting different speeds, while for most vehicles

supplying equal torque to each of them.

Shoji Haizuka et al. [3], conducted experiments

concerning the friction loss of helical gears with seven

kinds of helix angle using one kind of lubricating oil

under various loads and rotational speeds were carried

out. The results were discussed as follows:

1. The friction loss of the helical gears increases with

the helix angle and height of the teeth. The helix angles

lie in the range of 0, = 0 - 46.5 deg. 2. The friction loss of the helical gears increases with

the helix angle and applied load. This tendency was

expressed with empirical formulas. Dirk Wienecke et

al. [4], showed the influences of gear oils, characterized

by the base oil and the additive package, on the fuel

economy of automobiles are discussed. By optimal oil

formulations friction losses can be reduced resulting in

higher efficiency data. In order to analyze these

influences and lo evaluate the effects the transmission

gear is considered as; In complex tribo-technical system

consisting of different single tribological systems, e. g. characterized by gear wheels, bearings, seals, etc. 'The

tribo-system automobile transmission gear is defined

and described in detail resulting in an analysis of the

tribological stresses in the gear. 'The relationship

between the structure of the single systems, their

technical functions and the function of the lubricant are

described. This systematic analysis was the approach for

the simultaneous development of gear oils and a new

automobile transmission gear. Jay Belsky [5], had

showed the three potential explanations of the

transmission gap pertaining to the limited power of

heretically important determinants of attachment security to actually predict attachment security have

been entertained. The first drew attention to the prospect

that measurements of sensitivity may include a great

deal of measurement error, but also that the same may

be true with respect to Strange Situation assessments of

attachment security. The second explanation raised the

prospect that while mother‟s psychological availability

to the infant, in the form of observed sensitivity, has

appropriately figured centrally in theorizing about the

determinants of attachment security, perhaps insufficient

attention has been paid to the time that mother is simply

physically available to the child. The third explanation

was that those students of attachment theory have not given sufficient consideration to the possibility that, in

the case of some children, security hen security is born,

whereas in others it is made; that is, that infants vary in

the extent to which their felt security is determined by

the sensitivity of the care they receive. F. K. Choy et al.

[6], had provided a comparison and benchmarking of

experimental results obtained from a damaged gear

transmission system with those generated from a

numerical model. Specific conclusions for this study can

be summarized as follows: 1. A study of the dynamic

changes in a gear transmission system due to (a) no gear tooth damage, (b) single gear tooth damage, (c) two

consecutive gear teeth damage, and (d) three consecutive

gear teeth damage is successfully conducted. 2. The

vibration signature analysis using a joint time-frequency

procedure, the Wigner-Ville distribution (WVD), seems

to be quite effective in identifying single and multiple

teeth damage in a gear transmission. Riccardo Morselli

et al. [7], had showed a detailed dynamic model of an

electronically controlled steering differential has been

proposed. To obtain faster and still reliable simulations,


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reduced dynamic models have been obtained by a proper

state-space transformation and simplification of the

detailed model. The steering differential models allow the simulation of the dynamical behavior of the most

common car differentials. The proposed reduced model

has been used to compare the effects of four kinds of

differentials on the vehicle dynamics. F. Cheli, M.

Pedrinelli et al. [8], showed the structure of a new

control system and the analysis of the developed vehicle

dynamics control algorithms for a semi-active

differential has been presented. The experimental results

have shown the capability of the system in following its

time-varying references and in keeping a stable behavior

of the vehicle at its limits while improving traction and absolute performance in terms of driving feeling. Erwin

V. Zaretsky et al. [9], had developed two computational

models to determine the fatigue life and reliability of a

commercial turboprop gearbox are compared with each

other and with field data. These models are (1) the

Monte Carlo simulation of randomly selected lives of

individual bearings and gears comprising the system and

(2) the two-parameter Weibull distribution function for

bearings and gears comprising the system using strict-

series system reliability to combine the calculated

individual component lives in the gearbox. The Monte

Carlo simulation consisted of the virtual testing of 744,450 gearboxes. These results were compared with

each other and with two sets of field data obtained from

64 gearboxes that were first-run to Removal for cause,

refurbished, placed back in service, and second run until

removal for cause. A series of equations was empirically

developed from the Monte Carlo simulation to

determine the statistical variation in predicted life and

Weibull slope as a function of the number of gearboxes

failed. Cuneyt Fetvaci et al. [10], generated the

simulation of conventional spur gear with asymmetric

involutes teeth has been studied. The complete geometry of a rack-type cutter for spur gear with asymmetric

involutes teeth production has been given. In addition to

the given mathematical model for describing generating

and generated surfaces, the mathematical model of the

trochoidal envelope of the cutter tip has been derived.

Computer programs have been developed to obtain

computer graphs of generated tools and generated

surfaces. Variations on the tooth form and effects of

changing tool parameters on the produced tooth form

can be investigated before it is manufactured. A

numerical example using the finite element method is

given to investigate the influence of tool parameters on generated gear tooth stresses. The results of calculations

clarify that tooth root stress decreases remarkably by the

use of a larger pressure angle in the back profile of the

tooth. Lei Wang et al. [11], had researched the theory of

hybrid-driving differential gear trains and carrying out

experiment many times on the designed test-bench,

finally, this article obtains two conclusions: (1)This

paper designed a test-bench of hybrid-driving two

degree of freedom differential gear trains, and its

mechanical properties are reliable and stable, low noise,

smooth running. Generally speaking, it is able to achieve the anticipated purpose. (2)This test-bench uses PLC

component to enable system control more precise, easy

operation, debugging easy, gathering the data accurately

and conveniently. It provides a good experimental platform for the basic theory research in the future. Isad

Saric et al. [12], developed parts by using interactive

modeling are modeled parameter. While geometric gear

modeling in CATIA V5 system, we do not have to

create shape directly, but, instead of that, we can put

parameters integrated in geometric and/or dimensional

constraints. We get resulted 3D solid gear model by

characteristic parameters changing. In this way, designer

can generate more alternative designing samples,

concentrating his attention on design functional aspects,

without consideration of details of elements of shape. Time used for designing is reduced for 50%, by

parameter modelling application and focusing on

preparation phase. Direct financial effects can be seen in

reducing of production costs, and that is the result of

increase production. In that way, better profit and price

of products are lower. C. Fetvaci [13], had developed

mathematical models of external and internal involutes

spur gears according to the generation mechanism with a

gear-type gear shaper. By applying the equations of the

profile of the cutter, the principles of coordinate

transformation, the theory of differential geometry, and

the theory of gearing, the mathematical models of the tooth profile including the fillets, bottom lands, and

working surfaces, have been given. To investigate the

shape of the generated tooth root fillet surfaces, the

mathematical model of trochoidal envelope of cutter tip

has been derived. The cutter tip traces epitrochoidal

curve in external tooth generation and hypotrochoidal

curve in internal tooth generation. Satya Seetharaman

et al. [14], had developed a physics-based fluid

mechanics model was proposed to predict power losses

for gear pairs operating under wind age conditions. The

framework of the model included individual formulations for wind age losses on the periphery and

faces of the gears as well as a compressible fluid model

for power loss due to pocketing taking place in the

meshing zone. The wind age conditions simulate jet

lubrication operating conditions or very low oil-level dip

lubrication conditions. As an example, the wind age

power loss model was applied to two unity-ratio gear

sets with varying gear geometry parameters to quantify

the contributions of each of the components of the total

wind age power loss. For both gear pairs, the wind age

pocketing loss was shown to dominate the total gear pair

wind age loss. Also, the influence of operating conditions, gear geometry parameters, and lubricant

properties on wind age power loss was quantified for the

gear pairs in consideration. B. Venkatesh 1 et al. [15],

had obtained Von-Misses stress by theoretical and

ANSYS software for Aluminum alloy, values obtained

from ANSYS are less than that of the theoretical

calculations. The natural frequencies and mode shapes

are important parameters in the design of a structure for

dynamic loading conditions, which are safe and less than

the other materials like steel. Aluminum alloy reduces

the weight up to 5567% compared to the other materials. Aluminum is having unique property (i.e. corrosive


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resistance), good surface finishing, hence it permits

excellent silent operation. Weight reduction is a very

important criterion, in order to minimize the unbalanced forces setup in the marine gear system, there by

improves the system performance. Dong Yang et al.

[16], through the combination of both experience and

the traditional theory of gear modification, had

developed the concept of isometric modification. By

selecting the appropriate modification size and

modification location, tooth deformation would be

compensated and the stress distribution would be

controlled in the central part of the tooth; the load

concentration, agglutination, pitting of the gear could

also be avoided effectively. According to the gear geometry theory and the normal meshing motion

equation of gear pairs, changes of meshing points and

angles were analyzed, and then, the effect of axial

modification on gear pair‟s meshing movement was

discussed. The establishment of the relationship between

angle changes and modification size provided not only

the basis for calculation and the selection of the

modification size, but also a reference for the detection

of modification effect in the future work. Based on the

3D software Solid Works, a method of drawing

spherical in volute was achieved, and the solid modeling

accuracy of spur bevel gear was improved. After solid

modeling, dynamic emulation analysis was operated by FEA software. The analytical results had shown that

stress distribution was controlled by isometric

modification and the additional load was reduced

effectively. Hui Liu et al. [17], had showed a new

method to study on the coupled vibration characteristics

of gearbox. Both numerical and test mode were deeply

analyzed. Finite element model of gearbox housing was

validated by the comparison of experimental data and

numerical calculation results. It was the basis for the

construction of gearbox model. Multi-source excitations

were theoretically analyzed and numerically obtained to

provide boundary conditions. Non-linear dynamics coupled model of gearbox in consideration of housing

and transmission shafts flexibility was constructed. It

broke through the localization that dynamic

characteristics of gear transmission system and gearbox

housing are separately analyzed. It proved the feasibility

of analyzing the coupled dynamic characteristics of

housing and train system. K. Kawaguchi et al. [18], had

developed a driving unit simulator for differentials able

to reproduce a wide range of driving modes of actual

vehicles. Utilizing rear differentials assembled with the

developed bearing and the conventional one, the torque characteristics under hill climbing and turning modes of

actual driving conditions and the influences of ambient

temperature on oil flow have been verified. As result of

the evaluation, the following findings have been

obtained. C. Veeranjaneyulu et al. [19], had showed

that by observing the structural analysis results using

Aluminum alloy the stress values are within the

permissible stress value. So using Aluminum Alloy is

safe for differential gear. When comparing the stress

Values of the three materials for all speeds 2400rpm,

5000rpm and 6400 rpm, the values are less for

Aluminum alloy than Alloy Steel and Cast Iron. By

observing the frequency analysis, the vibrations are less for Aluminum Alloy than other two materials since its

natural frequency is less. And also weight of the

Aluminum alloy reduces almost 3 times when compared

with Alloy Steel and Cast Iron since its density is very

less. Thereby mechanical efficiency will be increased.

By observing analysis results, Aluminum Alloy is best

material for Differential. Y. Sandeep Kumar et al. [20],

had showed the optimum result to minimize the stress

value whiles the fillet radius of 3mm and face width of

25mm. The Stress at the contact and fillet region

decreases with the increase of face width. The FEA results are found to be in close agreement with the

calculated stresses based on AGMA standards and

Lewis Equation. Anoop Lega et al. [21], the main

objective of the research is to develop the composite

material gear box using computer aided Engineering.

The modeling of gears is done using parametric

methodology; 3D family is generated by set of variables

which controls other gear dimensions related gear design

laws. The tool provides 3D models for a wide family of

gears used as base for stress & deformation analysis

using finite element method. Solid models of gears,

shafts and housing are generated and assembled using CATIA software package. Product Design Specification

sheet was developed for the gearbox and simultaneously

material selection was carried out through detailed study

and past performance of composite materials. Gearbox

assembly is imported in Ansys software package and

evaluated for equivalent (von-Misses) stress and

equivalent (von-Misses ) elastic strain for both

composite material and existing metallic material.

Comparative Results revealed the feasibility of

composite material gearbox with approximately 60%

weight saving and lower stresses then metallic gearbox with other composite material advantages. Pankaj

Chabra et al. [22], the main objective is to develop 3D

Modeled helical gear and stress and deformation

analysis using FEM generation of CNC program, rapid

prototyping etc. 3D family is generated by set of

variables which controls other gear dimensions related

gear design laws. It showed the characteristics of

composite material helical gear at conceptual design

stage for specific weight reduction, corrosion resistance,

noise reduction, higher natural frequency & more

consolidated design the 3D parametric model of helical

gears generated using CATIA V9 is used to perform comprehensive FEM Analysis of composite helical gears

using ANSYS work bench.

3 SOLID MODELLING

Solid modelling consists of set of principles for

mathematical and computer modelling of three-

dimensional solid model. It refers to theories and

computations that defines and manipulates

representations of physical objects, their properties

and the associated abstractions, and that support a

variety of processes. Solid modelling of bevel and spur


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gears is done using parametric approach. Bevel gears

for different dimensions can be generated by changing

the variables (number of teeth, pressure angle, helix angle, tooth thickness, module). Required parameters

that are used as variable for generating bevel gear and

dependent parameters with relations are shown in table

1. In the reference model there are five bevel gears

variable values for each gear as given in table2. Steps

involved in the creation of parametric solid model of

bevel gear are shown in Figure 2 while Figure 3 (a) - (e)

shows the solid model models of gears.

Figure 1 Steps involved in work flow.

Figure 2 Steps involved in the creation of

parametric solid model of bevel gear

Table 1 Variable values for five bevel gear Formulas

for Spur and Bevel Gears

Sr. No.

Pressure

angle (A)

(degree)

Modulus

(m)

(degree)

No. of teeth

(Z1)

(integer)

No. of

teeth

(Z2)

(integer)

Gear 1 20 2 20 12

Gear 2 20 2 25 25

Gear 3 20 2 12 20

Gear 4 20 2 48 25

Gear 5 20 2 12 20


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Table 2 Parameters and Relations are used for generating

bevel gear of Differential Gear box

Table 3 Product - Design Specification Sheet.

Table 4 Properties of glass filled polyamide and

Eglass/Epoxy.

Spur Gear Bevel Gear

Z 21,ZZ

m m

a = 20 deg.

r = (Zm)/2 r = (Z1m)/2

rb = rc cos (a) rb = rc cos (a)

rf = r-1.2m ----

ra = r+m ---

mrr 38.0 mrr 38.0

mha mha

mhf 2.1 mhf 2.1

tt

trbxd

sin

cos

tttrbxd sincos

tt

trbyd

cos

sin

tttrbyd cossin

10 r

10 r

)/tan( 21 ZZadelta

)cos(deltarrc

)sin(deltarclc

.)180/.(\.Re

/.)180/.(\.Retan

axdEval

aydEvalatc

rcB 3.0

)cos(1 deltalcbRatio

mmdz 0

Product Design Specification of Composite

material Gearbox

Density < 2710 Kg/m 3

Creep resistance High

Fatigue strength High

Corrosion

resistance High

Impact strength High

Manufacturing method associated with material

must be high volume production

The component made from this material

must be dimensionally stable and provides

internal damping

The material should have low friction coefficient

Final material for Composite Gear

Material Type Glass filled Polyamide

Material Supplier Dura form

Percentage Of Glass

Filling 20 % by volume

Tensile Modulus 5910 MPa

Tensile Strength 38.1 MPa

Poisson‟s Ratio 0.314

Flexural Modulus 3300 MPA

Density 840 kg/m3

Moisture Absorption 0.30%

Creep Resistance Good

Corrosion Resistance Good

Chemical Resistance Alkalis, hydrocarbons ,

fuels and solvents


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1. Axle Side Shaft Gear

2. Bevel Gear

3. Inner Gear

4. Ring Main Gear

5. Main Assembly

Figure 3 Solid model models of gears.


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Figure 4 Differential gear box.

Figure 5 the meshed Differential gearbox.

4 MATERIAL SELECTION

Engineering data imparts the material properties.

Composite materials made from two or more

constituent materials with significantly different

physical or chemical properties. These constituent

materials combined to produce a material with

characteristics different from the individual

components. The composite material selection for

gearbox is done using if –then approach, using product

design specification sheet [21] Table 3. Glass filled

polyamide in particulate form is used for differential

gear box(bevel and spur gears)having better tensile

strength (38.1 Mpa), recyclability, low density (840

Kg/m 3 ), high creep resistance, fatigue strength, high

impact strength, low Von-Misses Stress, less friction

and low cost. Table 4 gives the properties of glass

filled polyamide and E-glass/Epoxy.

Figure 6.1 Properties of Nickel chrome steel Differential

gear box.

Figure 6.2 Properties of Aluminum Alloy Differential

gear box.

Figure 6.3 Pproperties of Cast Iron Differential gear

box.


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Figure 6.4 Pproperties of Glass Filled Polyamide

Differential gear box.

5 RESULTS

Analysis is the application of analytical techniques for

checking the utility and feasibility of any design under

predetermined specifications. The current work

evaluates 3D modeled concepts for composite material

Differential Gearbox using Finite Element Analysis

(FEA). It is used to calculate deflection, stress, vibration, buckling behavior and many other

phenomena. In this work FEA is applied on solid CAD

models developed on CATIA and deformation and

stresses are evaluated on ANSYS workbench. Figure 4

shows Differential gearbox. Figure 5 shows the meshed

Differential gearbox. Figure 6.1 to Figure 6.4 show

properties of different materials used for Differential

gear box. In the present work, Structural Analysis

system is chosen in Ansys which is capable of

providing solution for Equivalent (von-Misses) stress,

Displacement (total Deformation) and Maximum Shear Elastic Strain for a different revolution i.e. 2500 rpm,

5000 rpm and 7500 rpm under static conditions for

composite Material Differential Gear Box. Figure 7.1 to

Figure 7.3 show the Von-Misses stress, displacement

and Maximum Shear Elastic Strain for tangential

loading at 2400 rpm. Figure 8.1 to Figure 8.3 show the

Von-Misses stress, displacement and Maximum Shear

Elastic Strain for tangential loading at 6400 rpm. Figure

9.1 to Figure 9.3 show the Von-Misses stress,

displacement and Maximum Shear Elastic Strain for

tangential loading at 5000 rpm. Figure 10.1 to Figure

10.3 show the Von-Misses stress, displacement and Maximum Shear Elastic Strain for Direct loading at

2400 rpm. Figure 11.1 to Figure 11.3 show the Von-

Misses stress, displacement and Maximum Shear

Elastic Strain for direct loading at 6400 rpm. Figure

12.1 to Figure 12.3 show the Von-Misses stress,

displacement and Maximum Shear Elastic Strain for

direct loading at 5000 rpm. Table 6(a), (b) & (c) gives

the comparison chart of Von-Misses Stress,

Displacement (total Deformation) and Maximum Shear

Elastic Strain for a different revolution i.e. 2400 rpm,

5000 rpm and 7500 rpm under static conditions at different Loading conditions (i.e. Tangential Load and

Static Load) for different Material Differential Gear box

(Nickel chrome Steel, Aluminium alloy, Cast Iron and

Glass Filled Polyamide (composite Material)). The

stress produced in composite material is found lower than metallic material gearbox.

1. Tangential Loading

For2400 rpm

Von-Misses stress, Displacement (Total

Deformation) and Maximum Shear Elastic Strain

for Glass Filled Polyamide Differential Gear box

Figure 7.1 Von-Misses Stress

Figure 7.2 Displacement (Total Deformation)

Figure 7.3 Maximum Shear Elastic Strain


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For 6400 rpm


Deformation) and Maximum Shear Elastic

Strain for Glass Filled Polyamide Differential

Gear box




For 5000 rpm




Gear box




For Direct Loading

For 2400 rpm




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Gear box

Figure 10.1Von-Misses Stress



For 6400 rpm




Gear box




For 5000 rpm

Von-Misses stress, Displacement (Total deformation)

and Maximum Shear Elastic Strain for Glass Filled

Polyamide Differential Gear box


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Table 6 (a), (b) & (c) gives the comparison chart of Von-

Misses Stress, Displacement (total Deformation) and

Maximum Shear Elastic Strain for a different revolution

i.e. 2400 rpm, 6400 rpm and 5000 rpm under static

conditions at different Loading conditions (i.e. Tangential

Load and Direct Load) of Glass Filled Polyamide

(composite Material) for Differential Gearbox.

(a) for 2400rpm

(b) For 6400rpm

Tangential Ni Cr Alloy

Steel Aluminum Cast Iron

Glass Filled

Polyamide

Load (N) 1818.54 1595.22 1770.24 1635.17

Displacement

(m) 2.8762 x10-8 7.2692 x10-8 2.9412 x10-8 .00088049

Stress (Pa) 214.29 185.33 209.3 190.74

Strain 1.4638 x10-9 3.8277 x10-9 1.4877 x10-9 4.5829 x10-5

Static Ni Cr Alloy

Steel Aluminum Cast Iron

Glass Filled

Polyamide

Load (N) 56141.9 18143.3 37933.7 13243

Displacement

(m) 2.2318 x10-6 8.2677 x10-7 6.3025 x10-7 .008215

Stress (Pa) 6521.8 2107.9 4485 1779.6

Strain 1.3468 x10-7 4.353 x10-8 3.1878 x10-8 0.00042758

Tangential Ni Cr Alloy Steel Aluminum Cast Iron Glass Filled

Polyamide

Load (N) 915.177 1276.18 1416.19 825.35

Displacement

(m) 2.3529x10-8 5.8154x10-8 2.3529x10-8 .00044443

Stress (Pa) 167.44 148.27 167.44 96.275

Strain 1.1901x10-9 3.0169 x10-9 1.1901x10-9 2.3132x10-5

Static Ni Cr Alloy Steel Aluminum Cast Iron Glass Filled

Polyamide

Load (N) 56141.9 18143.3 37933.7 13243

Displacement

(m) 8.8793 x10-7 8.2677 x10-7 6.3025 x10-7 .007131

Stress (Pa) 6615.7 2107.9 4485 1544.8

Strain 4.519 x10-8 4.353 x10-8 3.18178 x10-8 0.00037116


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(c) For 5000 rpm

6 CONCLUSIONS

The present work relates to composite material

differential gear box as an effective alternative to

existing metallic differential gearbox. Computer aided

engineering is found to be useful tool for various design

stages. Reference model of Differential gear box is

selected and CATIA is used to develop various

parametric models. Glass filled polyamide composite

material is used for gears and are analysed using

ANSYS for equivalent (Von-Misses) stress,

displacement (total deformation) and maximum shear

elastic strain for different revolutions (2500 rpm, 5000

rpm and 7500 rpm) under static conditions.

Comparisons of various stress and strain results with

Glass filled polyamide composite and metallic materials

(Aluminium alloy, Alloy Steel and Cast Iron) are also

being performed and found to be lower for composite

material. By observing these analysis results, Glass

Filled Polyamide composite material is selected as a

best material for Differential gear box which in turn

increases the overall mechanical efficiency of the

system.

7 REFERENCES

[1] Prof. Dr.Ing. Constantine ISPAS, „Computer Aided

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[7] Riccardo Morselli a , Roberto Zanasi a

&GermanoSandoni, 2006, „Detailed and reduced

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Tangential Ni Cr

Alloy Steel Aluminum Cast Iron

Glass Filled

Polyamide

Load (N) 2093.8 29922.51 3243.08 2425.31

Displacement

(mm) 3.3115x10-5 0.00013318 5.3882x10-5 1.306

Stress (Mpa) 0.00024673 0.00033954 0.00038344 0.00028291

Strain 1.6853 x10-

9 7.0118x10-9 2.7254x10-9 6.7973x10-5

Static Ni Cr

Alloy Steel Aluminum Cast Iron

Glass Filled

Polyamide

Load (N) 56141.9 18143.3 37933.7 13243

Displacement

(mm) 0.00088793 0.00082677 0.00063025 7.131

Stress (Mpa) 0.00066157 0.0021079 0.004485 0.0015448

Strain 4.519x10-8 4.353 x10-8 3.1878 x10-8 0.00037116


1894


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BIOGRAPHIES

Nitin Kapoor received his B.

Tech. Degree in Mechanical

Engineering from Jind Institute

of Engineering and Technology,

Jind under Kurukshetra

University, in 2005, C-DAC from

Pune University in 2008, Pune

(Maharashtra), M.B.A in HR

from Guru Jambeshwar

University in 2008 and M. Tech.

Degree in Mechanical Engg.

From Guru Jambeshwar

University of Science and

Technology, Hisar, (Haryana) in

2013. Nitin Kapoor worked in

industry for 5 years in Production

in THAI Sumit Pvt. Ltd &

AirLink Engineers, Bristlecone,

Mahindra base company as SAP

Administrator and is working as

an Assistant Professor, with

Department of Mechanical Engg.

in Panipat Institute of

Engineering and Technology,

Samalkha Near Panipat (Haryana)

Virender Upneja received his B.

Tech. Degree in Mechanical

Engineering from JMIT, Radaur

under Kurukshetra University, in

2006, and M. Tech.Degree in

Mechanical Engg. From Thapar

University, (Punjab) in 2013.

Virender Upneja has total 7.5 years

of experience. He worked in

Haryana Engg. College, Kalpna

Institute (Ambala), Asian Institute

(Yamuna nagar) and Globel

Research (Radaur). Virender Upneja

is an Assistant Professor, with

Department of Mechanical Engg. in

Panipat Institute of Engineering and

Technology, Samalkha Near Panipat

(Haryana)

Ram Bhool received his B. Tech.

Degree in Mechanical Engineering

from Shree Ram Mulkh Institute


Naraingarh (Ambala) under

Kurukshetra University, in 2011, and

M. Tech.Degree in Mechanical

Engg. From Deenbandhu Chhotu

Ram University of Science and

Technology, Sonipat, (Haryana) in


1895


2013. Ram Bhool is an Assistant

Professor, with Department of

Mechanical Engg. in Panipat

Institute of Engineering and


(Haryana

Ram Bhool received his B. Tech.

Degree in Mechanical Engineering

from Shree Ram Mulkh Institute


Naraingarh (Ambala) under

Kurukshetra University, in 2011, and

M. Tech.Degree in Mechanical

Engg. From Deenbandhu Chhotu

Ram University of Science and

Technology, Sonipat, (Haryana) in

2013. Ram Bhool is an Assistant

Professor, with Department of

Mechanical Engg. in Panipat

Institute of Engineering and


(Haryana)

Documents

design and stress strain analysis of composite differential gear box