CHAPTER 1

INTRODUCTION

The differential is a very important part in a vehicle, as a component transfer,

the engine power is transmitted to the wheels. Engine power is transferred by a rear
propeller shaft to the wheel first changed direction by differential rotation are then
referred to rear axle shafts after that to the rear wheel. A differential is a device that
capable of transmitting torque and rotation through three shaft, 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 input to create an
output that is the sum, differential, or average, of the input.
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 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 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 in 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.
On an FWD car or truck, the differential is normally an integral part of the
transaxle assembly located at the front of the vehicle. Transaxle design and operation
depends on whether the engine is mounted transversely or longitudinally. With a
transversely mounted engine, the crankshaft centerline and drive axle are on the same
plane. With a longitudinally mounted power plant, the differential must change the
power flow 90 degrees.
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On RWD vehicles, the differential is located in the rear axle housing or

carrier. The drive shaft connects the transmission with the rear axle gearing. Four-
wheel-drive vehicles have differential on both their front and rear axles.

1.2. Aim and Objectives

The main aim of this thesis is to analyze design of the differential components.
The objectives of this thesis are:
1. To study the components of differential system and different types of
differential system
2. To study the working principle of differential system of a vehicle
3. To calculate the design of crown gear and drive pinion for differential unit
4. To calculate the design of spider gear and side gear for differential unit
5. To calculate the contact stress of bevel gear
6. To analyze the contact stress of bevel gear by using SolidWorks software

1.3. Scope of the Thesis

In this thesis, the differential unit and the related parts for differential system
are discussed. Design calculation of ring gear and pinion of differential unit for
Toyota Hilux (N-LN30-CDSY) are presented.

1.4. Implementation Program

The implementation program of this thesis is carried out by the following
procedures:
1. Studying types of differential system and their function for automobiles
2. Measuring the necessary components for differential system of Toyota
Hilux (N-LN30-CDSY)
3. Collecting the data from differential system of Toyota Hilux (N-LN30-
CDSY)
4. Calculating the design of the ring gear, pinion gear, spider gear and side
gear of differential system
5. Calculating the contact stress of the bevel gear by theoretically
6. Analyzing the contact stress of bevel gear with different face width and
different materials by using SolidWorks software
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7. Comparing the theoretical result and simulation result of the bevel gear

1.5. Outline of the Thesis

In this thesis, five chapters can be found. Chapter one describes introduction to
differential system. Chapter two consists of literature reviews of the differential
system. Methodology and design theory of the differential unit is expressed in chapter
three. Chapter four describes design calculation of differential unit. Chapter five
includes the discussions, conclusions and recommendations.