Manufacturing Processes

Project :
Automotive Differential
Group 3:
150100003 ACHARYA PRATIK BHASMANG
150100005 BRAHMBHATT SIDDHARTH RAJESH
150100002 ADITYA P KADMAWALA
150040083 KANUSH AGRAWAL
150040084 PRAKHAR JAIN
 Use Why and Where

Inautomobilesand other wheeled

vehicles, the differential allows the outer
drive wheel to rotate faster than the inner
drive wheel during a turn. This is
necessary when the vehicle turns, making
the wheel that is traveling around the
outside of the turning curve roll farther and
faster than the other. The average of the
rotational speed of the two driving wheels
equals the input rotational speed of the
drive shaft. An increase in the speed of one
wheel is balanced by a decrease in the
speed of the other.
When used in this way, a differential
couples the input shaft (or prop shaft) to
thepinion, which in turn runs on thering
gearof the differential. This also works as
reduction gearing.
Scale of production: Medium Quantity
Production(~10000) Also known as Batch
production.
 Design and material selection
The main characteristics considered in
the design of gears are:
Surface fatigue limit (Ssf)-
Root bending fatigue limit (Sbf)
Wear resistance of tooths flank
Good Machinability
Final selection-EN24T steel is a
popular grade of through hardening
alloy steel due to its excellent
machinability in the "T" condition.
EN24T is used in components such as
gears, shafts, studs and bolts, its
hardness is in the range 248-302 HB.
EN24T can be further surface-
hardened to create components with
enhanced wear resistance by The tooth fails under a cyclic load
induction or nitriding processing
with an amplitude equal to Rm
Manufacturing and Casting process
CASTING MANUFACTURING:

Differential Cage and cover:

Expendable shell moulding

The greater dimensional accuracy offered by shell molding (as

compared with conventional green sand molding) can reduce
the amount of machining required for completion of the part

Differential Gears:

Non expendable die casting and investment casting is used

here

Complicated gear shapes, quite costly to machine, can be

made quickly and at low cost by the die casting process. The
main disadvantage of the process is that the low-melting point
metals suitable for die castingaluminum, zinc, and copper
do not have high enough hardness for high load-carrying
capacity.

Pinion and axle shafts:

 Casting Process contd.
Pouring temp: Sand and ceramic can withstand
temperatures as high as 1650-1820c.
Riser with an insulating compound or exothermic
mixture is used.
Microstructure: The incavity solidified grain size in
DC can be as low as 10 m, but externally
solidified crystals (ESCs) as large as 200 m are
often also present. The eutectic microstructure is
very fine with an interlamellar spacing around 500
nm. Bands of positive macrosegregation and
sometimes with cracks/porosity, so-called defect
bands, are also often observed.
Injection:The molten metal, which is maintained at a set
temperature in the furnace, is next transferred into a
chamber where it can be injected into the die. The molten
metal is injected at high pressures into the die. Typical
injection pressure ranges from 1,000 to 20,000 psi. This
pressure holds the molten metal in the dies during
solidification. The amount of metal that is injected into the
die is referred to as the shot. The injection time is the
time required for the molten metal to fill all of the
channels and cavities in the die. This time is very short,
typically less than 0.1 seconds
Cooling:- The die can not be opened until the cooling time
has elapsed and the casting is solidified. The cooling time
can be estimated from several thermodynamic properties
of the metal, the maximum wall thickness of the casting,
and the complexity of the die. A greater wall thickness will
require a longer cooling time. The geometric complexity of
the die also requires a longer cooling time because the
additional resistance to the flow of heat.
Casting Defects and Improving gating system and mould

Typical Defects:

Die-casting of gears: In die casting the most common defects are misruns and coldshuts. These
defects can be caused by cold dies, low metal temperature, dirty metal, lack of venting, or too much
lubricant. Other possible defects are gas porosity, shrinkage porosity, hot tears, and flow marks.
Flow marks are marks left on the surface of the casting due to poor gating, sharp corners, or
excessive lubricant

Shell moulding of cover: Blowhole is a kind of cavities defect, which is also divided into pinhole and
subsurface blowhole. Caused by inadequate venting. Provide venting channels ensure core prints
are free of dressing reduce binder quantity and use coarse sand. Dry out cores and store dry. Reduce
sand temperature. Sand Burning thin sand crusts firmly adhering to casting caused due to mould
compaction and presence of low melting substance in high concentration. A run out is when the
liquid metal leaks out of the mold because of a faulty mold or flask. Scabs are a thin layer of metal
that sits proud of the casting. They are easy to remove and always reveal a buckle underneath,
which is an indentation in the casting surface.