design and stress strain analysis of composite differential gear box
TRANSCRIPT
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
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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
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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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,
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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ISSN: 2278 – 7798 All Rights Reserved © 2014 IJSETR
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
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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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
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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ISSN: 2278 – 7798 All Rights Reserved © 2014 IJSETR
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
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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ISSN: 2278 – 7798 All Rights Reserved © 2014 IJSETR
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
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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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.
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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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.
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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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
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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For 6400 rpm
Von-Misses stress, Displacement (Total
Deformation) and Maximum Shear Elastic
Strain for Glass Filled Polyamide Differential
Gear box
Figure 8.1 Von-Misses Stress
Figure 8.2 Displacement (Total Deformation)
Figure 8.3 Maximum Shear Elastic Strain
For 5000 rpm
Von-Misses stress, Displacement (Total
Deformation) and Maximum Shear Elastic
Strain for Glass Filled Polyamide Differential
Gear box
Figure 9.1 Von-Misses Stress
Figure 9.2 Displacement (Total Deformation)
Figure 9.3 Maximum Shear Elastic Strain
For Direct Loading
For 2400 rpm
Von-Misses stress, Displacement (Total
Deformation) and Maximum Shear Elastic
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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Strain for Glass Filled Polyamide Differential
Gear box
Figure 10.1Von-Misses Stress
Figure 10.2 Displacement (Total Deformation)
Figure 10.3 Maximum Shear Elastic Strain
For 6400 rpm
Von-Misses stress, Displacement (Total
Deformation) and Maximum Shear Elastic
Strain for Glass Filled Polyamide Differential
Gear box
Figure 11.1Von-Misses Stress
Figure 11.2 Displacement (Total Deformation)
Figure 11.3 Maximum Shear Elastic Strain
For 5000 rpm
Von-Misses stress, Displacement (Total deformation)
and Maximum Shear Elastic Strain for Glass Filled
Polyamide Differential Gear box
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
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Figure 12.1Von-Misses Stress
Figure 12.2 Displacement (Total Deformation)
Figure 12.3 Maximum Shear Elastic Strain
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
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
1893
ISSN: 2278 – 7798 All Rights Reserved © 2014 IJSETR
(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.
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9 7.0118x10-9 2.7254x10-9 6.7973x10-5
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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
of Engineering and Technology,
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
International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 7, July 2014
1895
ISSN: 2278 – 7798 All Rights Reserved © 2014 IJSETR
2013. Ram Bhool 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
of Engineering and Technology,
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
Technology, Samalkha Near Panipat
(Haryana)