Design Modeling and Analysis for Differential Gear Box and Propeller Shaft

Abstract

Light Commercial Vehicle (LCV) is a standout amongst the most utilized business merchandise bearer vehicles in India. Because of use of overabundance stack than the required, vehicle separates. One of the significant issue clients of LCV are confronting is sudden separation of drive shaft from the pole associated with motor and differential.

Reasons of withdrawing shaft from the motor to the differential is the point at which the heap is connected on the carriage the torque and pivot speed is more from motor so the apparatuses slip and separate with contact rigging and tumble down, particularly while turning at corners .

The principle point of this proposal is to center around the mechanical plan and investigation on get together of Differential apparatuses in equip box and Propeller shaft when they transmit control at various paces i.e-2500 rpm, 5000 rpm and 7500 rpm. Examination is likewise directed by differing the materials for gears, Cast Iron, Cast Steels and Aluminum Alloy. By and by utilized materials for riggings and apparatus shafts is Cast Iron, Cast steel.

In this Thesis is to supplant the materials with Aluminum material for diminishing weight of the item and to lessen vibration. Stress, removal is broke down by considering weight decrease in the rigging box at higher speed. The examination is done in ANSYS WORKBENCH programming.

In the present work every one of the parts of differential are outlined under static condition and demonstrated. Displaying and get together is done in Solid Works. The definite illustrations of all parts are outfitted.

INTRODUCTION

Light Commercial Vehicles (LCVs) are composed for the most part for the Indian market. While different nations looked with suspicion at the smaller than normal trucks fragment, India was the ideal market for this kind of vehicles as they were modest, productive and furthermore exceptionally down to earth. With a normal length of 3800 mm and a width of 1500 mm, LCVs are exceptionally famous and are usually used to transport different sorts of products in many parts of India. In India, a portion of the LCV models are Tata Ace, Daihatsu HI stream, Piaggio Porter or Suzuki Carry. These vehicles are for the most part accessible just in drop side appearance and are fueled by a modest 700cc motor with around 1.5Ton to 2Ton limit.

The primary goal of apparatus is to ensure and to give a sheltered stage to get great rigging transmission. It is likewise gives a help for moving parts and shields them from outside conditions. The Differential couples and the propeller shaft on the pinion, which keeps running on the ring apparatus or crown rigging of the Differential apparatus and it is likewise helps in the lessening of outfitting erosion and upgrades the life of the apparatus. Henceforth when subjected to vibration, it ends up mandatory to figure the reaction of Differential apparatus lodging in various vibration conditions and in likewise finding their normal frequencies. This can be most essential apparatus in planning the Differential rigging lodging free from weariness disappointments caused by the reverberation. The outline of the rigging lodging ought to be fitting a technique for designated with factors causing vibrations and to elevate logical means and to limit the impacts of frequencies. This vibration examination is finished by utilizing ANSYS 14.0 programming as a computational strategy and approval and the demonstrating of Differential rigging box is finished by utilizing of SOLIDWORKS for Differential apparatus of LCV and to decrease the heaviness of car Propeller Shaft with the usage of composite material. Composite materials have been utilized as a part of car segments in light of their properties, for example, low weight, high particular solidness, erosion free, capacity to create complex shapes, high particular quality and high effect vitality assimilation and so on. As the car Propeller Shaft is a critical part of vehicle. The demonstrating of the Propeller Shaft gathering was finished utilizing SOLIDWORKS programming.

LITERATURE REVIEW

• Ronak P Panchal and Pratik B Umrigar (2015) talked about on the attributes of a slope adapt in unique condition including fitting firmness and different burdens deliver are examined. By utilizing numerical approach the creator has created hypothetical model of angle adapt and decided the impact of cross section equip tooth worries by taking material Nickel chromium steel (15Ni4Cr1).
• Luciana SgarbiRossinoa et al (2014) influenced an examination to decide the reasons for surface contact to exhaustion disappointment of an unfeeling pinion. The examination of the part uncovered the nearness of a solidified layer considerably thicker than that for the most part determined for pinions contrived for this application. This connect with the monstrous nearness of weak threadlike carbon-rich cementite stage (Fe3C) in earlier austenite grain limits of the pinion teeth favored surface break nucleation and spread amid cyclic stacking prompting spallation of the contact surface with the partner equip which disabled the framework's operation.
• Gregory Antony (2014) In this paper, a scientific model was exhibited for evaluating and anticipating the mechanical grating misfortunes happening in differential gearboxes. A portion of the parameters associated with this model can be resolved effortlessly (geometric parameters), while others depend straightforwardly on the sort of rubbing happening in the instrument which influences the mechanical misfortunes to a variable degree. Keeping in mind the end goal to test the impact of these parameters and decide the capacity of the model to foresee any mechanical misfortunes, an affectability examination was directed
• S H Gawande, S V Khandagale et al (2013) Spiral slant gears, in contrast with straight or zero incline gears, have extra covering tooth activity which makes a smoother equip work. As of now the bolero 14 pickup vehicle of Mahindra Company is running with a pinion introduce in the differential apparatus box having 11 quantities of teeth. So the creators did the work to outline another pinion appropriate to fit in the bolero pickup vehicle. Just the quantity of teeth were lessened by keeping every single other measurement same to fit the new pinion in a similar lodging.
• C.Veeranjaneyulu et al (2012) managed the Mechanical outline and investigation on gathering of apparatuses in adapt box is done when they transmit control at various velocities i.e-2500 rpm, 5000 rpm and 7500 rpm. Examination is likewise led by shifting the materials for gears, Cast Iron, Cast Steels and Aluminum Alloy. Supplant of the materials with Aluminum material for diminishing weight of the item. Stress, uprooting is investigated by considering weight decrease in the apparatus box

Objective of the proposed work

One of the fundamental issue clients of LCVs are confronting is sudden separation of propeller shaft from the bar associated with motor and differential rigging while at the same time turning at corners. Reasons of confining shaft from the motor to the differential apparatus is the point at which the heap is connected on the carriage, the torque and turn speed is more from motor so the riggings slip and withdraw with contact apparatus and tumble down. There is lost power from propeller shaft to differential apparatus box and transmission isn't proficiently accomplished.

To adjust this, I am proposing a material for differential apparatus and propeller shaft, to deal with the issue and give fitting arrangement. To comprehend this, rotational paces from 2500rpm to 7000rpm is shifted and reasonable material for differential apparatus box and propeller shaft is proposed from among Gray Cast Iron, Aluminum compound and Nickel-Chromium steel

Noteworthy Contributions

Chong et al explored the impacts of span of arch of root filet, the width of the base of the tooth space, the weight edge and the stacking position on the root pressure dissemination. The impacts of the state of the tooth on the root stresses and tooth avoidance of a thin rimmed gear with ribs and networks were contemplated by Syama et al [8] utilizing three dimensional limited component technique.

Bibel et al have done three-dimensional pressure examination of winding slope gears utilizing multi-tooth limited component show. Four gear teeth and three pinion teeth have been demonstrated and the surface contact pressure has been assessed utilizing hole components. The outcomes have been observed to be in great concurrence with ascertained Hertzian contact pressure.

Ramamurti et al have exhibited the utilization of cyclic symmetry idea in the limited element investigation of rotationally intermittent structures like gears. They have connected this idea for the static and dynamic examination of goad and slope gears. Static anxieties and diversion, and, the initial ten common frequencies and mode shapes have been acquired in light of their examination.

Methodology

The methodology followed in this project is as follows:

• Perform outline computations of crown wheel equip demonstrate.
• Create 3D model of the current Differential rigging parts and shafts from the 2D illustrations.
• Solid works programming is utilized to do the 3D displaying.
• Convert the 3D show into IGES/STEP configuration and import into ANSYS to do Finite component examination.
• Perform Static investigation of the crown wheel adapt by applying the transmit control at most extreme speed 2500rpm,5000rpm,7000 rpm, and record the anxieties and diversions.
• Perform Modal investigation of the crown wheel adapt and ascertain the normal frequencies in the working reach. Plot the frequencies and mode shapes.
• The examination is led to confirm the best material.

Modeling Using Solid Works

Solid Works records use the Microsoft Structured Storage archive organize. This suggests there are distinctive records embedded inside each SLDDRW, SLDPRT, SLDASM archive, including audit bitmaps and metadata sub-reports. Distinctive untouchable gadgets can be used to isolate these sub-reports, notwithstanding the way that the sub records all things considered use selective parallel record plans. In this plan distinctive parts have planned with a specific end goal to make the get together and material. A portion of the workbenches which are utilized as a part of the making of differential rigging and the propeller shaft are given underneath

• Sketcher
• Part design(features)
• Assembly
• Design resources
• Rendering

Analysis Of Differential Gear & Propeller Shaft

The Thesis is divided into two domains:

Stress Analysis 2. Modal Analysis

Stress Analysis: It is static investigation of the model by applying limit conditions and powers which are ascertained by the information given by the teacher

Modular Analysis: The characteristic frequencies of in free conditions are computed utilizing Ansys programming and by the use of limit conditions to contrast and trial and working frequencies. Modular investigation is a term used to depict any of the procedures utilized to remove a structure's modular properties (common frequencies, modular damping elements, and mode shapes) from data about the structure that is displayed in an alternate arrangement. At the point when these properties are removed from a hypothetical investigation of the dynamic conduct.

Analysis Using Ansys Workbench Software.

Ansys workbench works is a helpful programming for plan examination in mechanical building. ANSYS WORKBENCH Works is an outline investigation mechanization application completely incorporated with Solid Works. This product utilizes the Finite Element Method (FEM) to recreate the working states of your outlines and anticipate their conduct. FEM requires the arrangement of huge frameworks of conditions. Fueled by quick solvers, ANSYS WORKBENCH Works makes it feasible for fashioners to rapidly check the uprightness of their outlines and scan for the ideal arrangement

A product development cycle typically includes the following steps:

• Build your model in the Solid Works CAD system.
• Prototype the design.
• Test the prototype in the field.
• Evaluate the results of the field tests.

Modify the design based on the field test results

Expected out come

To focus on mechanical design and analysis of LCV design parameters of Differential Gears in Gear Box and Propeller Shaft housing when they transmit power at different speeds of 2500 RPM, 5000 RPM & 7000 RPM using solid works.

To find out the natural frequencies of differential gearbox and propeller shaft using ANSYS WORKBENCH.

Static Analysis and Modal analysis was done to check the differences in stress values and deformations between the different materials

To find out the deformation, stress, and strain generated in Differential Gear Box and Propeller Shaft under different conditions with different materials.

To find a suitable alternate materials for Differential Gear Box and Propeller Shaft to withstand heavy load conditions as well as weight reduction and at the same time providing strength.