DESIGN OF AN AUTOMOTIVE DIFFERENTIAL WITH REDUCTION RATIO GREATER THAN 6

Sumair Sunny, Siddhesh Ozarkar, Sunny Pawar

Abstract: Commonly found automobile differentials have a reduction ratio of 6 at max. This is because designing an automotive differential with a reduction ratio greater than 6 may lead to a bulky design which isn’t feasible to position with the limited space available. Furthermore, increasing the size of the differential may lead to excessive undesired weight. Most on-road vehicles have differentials with reductions of 3 or 4. Commercially speaking, finding a differential with a reduction greater than 6 is close to impossible. Most manufacturers would introduce an additional single speed gearbox however this would over complicate the design and increase servicing costs. The aim of this paper is to design a differential with a reduction ratio greater than 6. The paper includes all the calculations as well as a strength based analysis performed on Altair-Hypermesh, to prove the success of the design.

Keywords: Worm, differential, over-running, self-locking, bevel, gear, bearing, reduction ratio

DOI: https://doi.org/10.15623/ijret.2014.0307013