Design and Analysis of an Open Differential

A transmission or gearbox provides speed and torque conversions from a rotating power source to another device using gear ratios. The most common use is in motor vehicles, where the transmission adapts the output of the internal combustion engine to the drive wheels. Such engines need to operate at a relatively high rotational speed, which is inappropriate for starting, stopping, and slower travel. The transmission reduces the higher engine speed to the slower wheel speed, increasing torque in the process. We have designed a differential gearbox and tried to create the frictional contact between two mating gears. And we have performed the structural analysis on gear box by providing the torque to the assembly of crown gear and pinion gear, assembly of inner gears- spider gears and side gears and crown gear with the cage to attach spider gears. We have selected two kinds of alloy steel and have compared the factor of safety and structural analysis of the both.

Analisis Kerusakan Differential Pada Kendaraan HINO 260 FM (SH17) : Studi Kasus di PT. Hudaya Maju Mandiri

Differential or often known as the axle is a component in a car that functions to transmit engine power to the wheel axle that previously passed through the transmission and propeller shaft. Problems or damage to the differential varies, ranging from a buzzing sound in the differential, damage to the gear pinion, worn gear pinion, oil leakage in the differential. In this case, finding the differential is damaged in the pinion gear, the pinion teeth are worn and damaged so that the vehicle cannot run or the torque from the engine cannot be continued due to damage to the differential. The differential on the HINO 260 FM vehicle has a lot of damage to the differential, because the overload. Overload capacity or weight of the vehicle's payload exceed the standard limits and there is a differential damage in the pinion gear. Differential atau sering dikenal dengan nama gardan adalah komponen pada mobil yang berfungsi untuk meneruskan tenaga mesin ke poros roda yang sebelumnya melewati transmisi dan propeller shaft. Problem atau kerusakan pada differential bermacam-macam, mulai dari bunyi berdengung pada bagian differential, kerusakan pada gear pinion, gear pinion aus, kebocoran oli pada differential. Pada kasus kali ini, menemukan kerusakan differential pada bagian pinion gear, gigi pinion aus dan rusak sehingga membuat kendaraan tidak bisa berjalan atau tenaga putaran dari mesin tidak bisa diteruskan keroda akibat kerusakan pada differential. Differential pada kendaraan Hino 260 FM sering sekali rusak, dikarenakan daya angkut yang melebihi kapasitas. Dan hal inilah yang biasanya menjadi penyebab kerusakan differential pada bagian pinion gear.

Experimental verification of methods for calculation of the distribution of forces in planetary pin gearboxes

Various models are considered for calculating the forces at the areas of contact of the satellite with the pinion gears of the planetary pinion gear (PPG). The distributions of forces along the pins for each model are given and an experiment is performed to check the reliability of the analytical dependences for different models. The applicability of these models for calculating the PPG is analyzed. Keywords: planetary pinion gearbox, load distribution, experiment. [email protected]

Die Design Architecture for Enhancing Tool Life Via Manipulation of the Elastic Strain Field of the Dies During Extrusion Processes

Forging and extrusion tools are often subjected to a combination of cyclic thermo-mechanical, chemical, and tribological loads. Strategies for minimizing these loads are critical for preventing premature tool failure and increasing productivity. A die design architecture for extrusion that minimizes the residual contact pressure at the die-workpiece interface during the ejection stroke is proposed. The underlying principle of this die design is that during the extrusion stroke, a tapered die can move in the direction of the extrusion load, thus inducing negative radial elastic strain on the die. When the extrusion load is removed, the elastic strain energy stored in the die is released, thus repositioning the die to its initial state. With this design architecture, the workpiece can be ejected at no load. The process was validated using finite element (FE) warm forging/extrusion simulations for a constant velocity (CV) joint and pinion gear shaft. These simulations showed that in addition to reducing residual contact pressure, which enhances tribological conditions, the new die design can easily lower die stresses, thus increasing die fatigue life. The FE simulations for CV joint and pinion gear shaft demonstrated residual pressure in certain locations of the die ranging from 30% to 100% of the pressure induced during the extrusion stroke. The case studies simulated showed that a total energy saving of up to 15% can be achieved with the proposed die setup.

ANALISIS PENGARUH RASIO FINAL GEAR TERHADAP KECEPATAN DAN KONSUMSI BAHAN BAKAR MOBIL HYBRID URBAN KMHE 2018

In automotive world, differential ratio also known as final gear ratio. It consist of pinion gear and ring gear. Final gear ratio will be affecting car speed and fuel consumption that can be achieved. Research will be performed by experiment and data collection will be displayed through descriptive methode. Research began by selecting 2 kind of final gear ratio which are 1,27 and 2,53. Those ratios have been achieved by selecting pinion gear 15 and 30 teeth and ring gear 38 teeth, which are common and easy to find on the market. Testing performed by running the car on the tarmac testing track, 2800 meters (4 lap @700 meters), from stop until reached finish line with limited the speed test by 30 km/h and 40 km/h. Each test will be performed 5 times and the data collection will be displayed by tabulation and chart. The test results shown pinion gear with 30 teeth have less travelling time, less engine rotation and better fuel efficiency compare with pinion gear 15 teeth. Pinion gear 30 teeth have 8,9% better fuel consumption on 30 km/h speed and 4,7% better fuel consumption on 40 km/h.

ANALISA KEGAGALAN KOMPONEN DRIVE PINION GEAR PADA SWING MOTOR EXCAVATOR CATERPILLAR 349D

Penelitian ini bertujuan untuk mengetahui alasan fraktur yang terjadi pada drive pinion gear unit motor swing Excavator Caterpillar 349 d. Dalam penelitian ini dilakukan beberapa tahapan yaitu pengamatan visual dan pengamatan makro, pengujian komposisi struktur logam, dan pemodelan load and latch menggunakan Autodesk Inventor 2014 sebelum mendapatkan hasil akhir. Hasil yang diperoleh dari penelitian ini adalah bahwa ada kurangnya presisi antara pinion drive dan planetary gear karena pin planet yang tidak dapat berfungsi sebagai pemegang planetary gear sehingga rotasi planet rentan terhadap tabrakan sebagai pemicu yang mengakibatkan cacat. Pada proses analisis tegangan menggunakan software autodesk inventor 2014 versi mahasiswa, hasil analisis nilai von misses adalah 9,798 Mpa jauh lebih kecil dari batas elastisitas material 790 MPa sehingga faktor pembebanan tidak menyebabkan sebuah kesalahan. This research is purpose to knowing the reason of the fracture that happen in drive pinion gear of the swing motor unit Excavator Caterpillar 349 d. In this research is doing by several stage it is visual observation and macro observation, testing of metal structure composition, and load and latch modeling using Autodesk Inventor 2014 before getting the final result. The results obtained from this study are that there is a lack of precision between drive pinion gear and planetary gear due to planetary pins that cannot function as planetary gear holders so that planetary rotations are prone to hilarious triggering collisions resulting in defects. In the process of stress analysis using the student version of autodesk inventor 2014 software, the results of the analysis of the value of von misses is 9.798 Mpa are much smaller than the limit of material elasticity of 790 MPa so that the loading factor does not cause a fault.

Improvement in Quenching Uniformity through Flow Conditioning

Historically, the design of liquid quenching systems has relied on providing a set amount of agitation power for the size of the tank (horsepower/gallon). With the advent of computer flow analysis tools, it has been increasingly possible to refine the quench system design to ensure that the flow created by the agitation system is effectively delivered to the load, resulting in an increase in quench performance.The current paper considers the effect of one element of a quench system design, an egg-crate flow straightener, on the uniformity of quenching a production intent differential pinion gear load. Size change data is combined with CFD analyses of two variations of a single quench system to determine the flow attributes that result in improved quench performance.

Calibration Experiments on a Visual Measurement System for Pinion Gears

Visual measurement is one of the important measurement methods for pinion gears. The measurement principle and the systematic structure of a pinion gear visual measuring system were given. Pixel equivalent is the key parameter in the visual measurement system, which needs to be calibrated before dimensions evaluation. A glass dot calibration plate was applied in the system calibration. Pixel equivalent calibration experiment, LED brightness experiment, edge compensation experiment and multiposition edge compensation experiment was carried out. The parameter pixel equivalent is determined by the comparison between the physical size of center distance of adjacent mark circle in the glass dot calibration plate and its pixels number obtained by the visual system. The center distance of adjacent mark circle was chosen to avoid the affection of the brightness of light source and the sub-pixel technology was used. The proper brightness condition of LED light was selected in the LED brightness experiment. Under this condition, the compensation of edge deviation was obtained by analyzing the edge position deviation in the diameter measurement of the mark circle of the calibration plate. The experimental results show that the pixel equivalent is 5.59522μm/Pixel, and the compensation of edge deviation is 0.54μm. 49 diameters of the circular marker were measured in edge compensation experiment, the largest difference between the measured diameter in central vision after compensation and its physical dimensions is 0.3μm, which is 0.2μm in muti-position edge compensation experiment. The calibration methods and the experimental research are important for the designed visual measurement system for pinion gears.