Executive Summary
In this group project, our trio of mechanical engineering students faced the challenge of designing and creating a fully functional differential gearbox that adhered to pre-established size constraints. Our journey from concept to reality involved meticulous planning, detailed calculations, and innovative design, all converging towards the production of a 3D-printed prototype. The project was a comprehensive exercise in mechanical design, demanding a blend of theoretical knowledge and practical skills. We focused on delivering a model that not only met the spatial limitations but also accurately emulated the complex motions found in vehicular power distribution systems. Through collaborative effort and a dedication to practical application, we achieved a working differential, illustrating the power of teamwork in engineering solutions.
Project Overview
The differential's core function was to enable differential speeds between two powered wheels, a critical component in automotive engineering. A thorough analysis was conducted to select appropriate gear ratios, materials, and design specifications that would lead to an efficient and smooth operation (Fig 1. Specification table).
Design Process
We adopted an iterative design approach using 3D CAD models to simulate the working conditions of the differential. This allowed for pre-emptive identification of potential issues and adjustments before fabrication. The design was also optimized for 3D printing, considering the limitations and capabilities of the printing materials and technology.
3D Printing and Assembly
The culmination of our design efforts was the 3D printing of the differential gearbox components. Each piece was meticulously printed, with attention to the integrity and precision necessary for the gears to mesh correctly. The technical drawing of the sun gear (Fig 3. Technical drawing of sun gear) and the crown (Fig 2. Technical drawing of crown) provided a detailed blueprint for production and assembly.
Aesthetic Engineering: The Wheel Design
A unique element of our differential gearbox project was the emphasis on aesthetics alongside functionality. In mechanical engineering, the efficacy of a design is often the primary focus, but the visual aspect can play a significant role in the overall impact of a product. Understanding this, our professor incentivized us with the prospect of extra credit for a wheel design that was not only functional but also exhibited a high level of aesthetic appeal. I embraced this challenge and dedicated myself to creating a wheel that would stand out for its elegance and intricate details (Fig 7. Isometric view of wheel v2). The resulting design was a sophisticated fusion of art and engineering, which not only met our functional requirements but also captured the attention and appreciation of our professor, earning us the extra credit for our project.
Results and Testing
The assembled differential (Fig 5. 3D printed crown and sun gears) was a success, exhibiting the intended function with the application of a hand crankshaft. This component was instrumental in demonstrating the differential action, showcasing our design's efficacy.
Challenges and Solutions
A key challenge was ensuring smooth gear operation. The initial assembly revealed friction points that were mitigated by strategic adjustments in gear alignment and the addition of washers for better spacing. Ensuring the precision of these components was critical and required multiple iterations and refinements.
Conclusion
Our project not only achieved the functionality required but also provided insights into the complexities of mechanical systems in motion. Through collaborative effort and innovative problem-solving, we delivered a working model that stands as a testament to our practical engineering skills and our capacity to overcome design and manufacturing obstacles.
Personal Contribution
I focused on the design and fabrication of the sun gears and half-shaft components, which were central to the differential's operation. I also designed the wheels for the gearbox.
This included detailed work on the CAD models, overseeing the 3D printing process, and ensuring the compatibility and functionality of the final assembly.
