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1、FailureanalysisofanautomobiledifferentialpinionshaftAbstractDifferentialisusedtodecreasethespeedandtoprovidemomentincreasefortransmittingthemovementcomingfromtheenginetothewheelsbyturningitaccordingtothesuitableangleinvehiclesandtoprovidethatinnerandouterwheelsturndiffer
2、ently.Piniongearandshaftattheentrancearemanufacturedasasinglepartwhereastheyareindifferentformsaccordingtoautomobiletypes.Mirrorgearwhichwillworkwiththisgearshouldbecomefamiliarbeforetheassembly.Incaseofanybreakdown,theyshouldbechangedasapair.Generally,inthesesystemsther
3、eareweardamagesingears.Thegearinspectedinthisstudyhasdamageasaformofshaftfracture.Inthisstudy,failureanalysisofthedifferentialpinionshaftiscarriedout.Mechanicalcharacteristicsofthematerialareobtainedfirst.Then,themicrostructureandchemicalcompositionsaredetermined.Somefra
4、ctographicstudiesarecarriedouttoassesthefatigueandfractureconditions.Keywords:Differential;Fracture;Powertransfer;Pinionshaft1.IntroductionThefinal-drivegearsmaybedirectlyorindirectlydrivenfromtheoutputgearingofthegearbox.Directlydrivenfinaldrivesareusedwhentheengineandt
5、ransmissionunitsarecombinedtogethertoformanintegralconstruction.Indirectlydrivenfinaldrivesareusedattherearofthevehiclebeingeithersprungandattachedtothebodystructureorunsprungandincorporatedintherear-axlecasing.Thefinal-drivegearsareusedinthetransmissionsystemforthefollo
6、wingreasons[1]:(a)toredirectthedrivefromthegearboxorpropellershaftthrough90°and,(b)toprovideapermanentgearreductionbetweentheengineandthedrivingroad-wheels.Invehicles,differentialisthemainpartwhichtransmitsthemovementcomingfromtheenginetothewheels.Onasmoothroad,themoveme
7、ntcomestobothwheelsevenly.Theinnerwheelshouldturnlessandtheouterwheelshouldturnmoretodotheturningwithoutlateralslippingandbeingflung.Differential,whichisgenerallyplacedinthemiddlepartoftherearbridge,consistsofpiniongear,mirrorgear,differentialbox,twoaxlegearandtwopinions
8、pidergears.AschematicillustrationofadifferentialisgiveninFig.1.Thetechnicaldrawingofthefracturedpinions
