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1、FailureanalysisofanautomobiledifferentialpinionshaftAbstractDifferentialisusedtodecreasethespeedandtoprovidemomentincreasefortransmittingthemovementcomingfromtheenginetothewheelsbyturningitaccordingtothesuitableangleinvehiclesandtoprovidethatinnerandouterwheelsturndifferently
2、.Piniongearandshaftattheentrancearemanufacturedasasinglepartwhereastheyareindifferentformsaccordingtoautomobiletypes.Mirrorgearwhichwillworkwiththisgearshouldbecomefamiliarbeforetheassembly.Incaseofanybreakdown,theyshouldbechangedasapair.Generally,inthesesystemstherearewearda
3、magesingears.Thegearinspectedinthisstudyhasdamageasaformofshaftfracture.Inthisstudy,failureanalysisofthedifferentialpinionshaftiscarriedout.Mechanicalcharacteristicsofthematerialareobtainedfirst.Then,themicrostructureandchemicalcompositionsaredetermined.Somefractographicstudi
4、esarecarriedouttoassesthefatigueandfractureconditions.Keywords:Differential;Fracture;Powertransfer;Pinionshaft1.IntroductionThefinal-drivegearsmaybedirectlyorindirectlydrivenfromtheoutputgearingofthegearbox.Directlydrivenfinaldrivesareusedwhentheengineandtransmissionunitsarec
5、ombinedtogethertoformanintegralconstruction.Indirectlydrivenfinaldrivesareusedattherearofthevehiclebeingeithersprungandattachedtothebodystructureorunsprungandincorporatedintherear-axlecasing.Thefinal-drivegearsareusedinthetransmissionsystemforthefollowingreasons[1]:(a)toredir
6、ectthedrivefromthegearboxorpropellershaftthrough90°and,(b)toprovideapermanentgearreductionbetweentheengineandthedrivingroad-wheels.Invehicles,differentialisthemainpartwhichtransmitsthemovementcomingfromtheenginetothewheels.Onasmoothroad,themovementcomestobothwheelsevenly.Thei
7、nnerwheelshouldturnlessandtheouterwheelshouldturnmoretodotheturningwithoutlateralslippingandbeingflung.Differential,whichisgenerallyplacedinthemiddlepartoftherearbridge,consistsofpiniongear,mirrorgear,differentialbox,twoaxlegearandtwopinionspidergears.Aschematicillustrationof
8、adifferentialisgiveninFig.1.Thetechnicaldrawingofthefracturedpinions
