DEPARTMENT OF AUTOMOBILE ENGINEERING

DESIGN, MODELING, AND ANIMATION OF LIMITED SLIP DIFFERENTIAL IN TATA TIAGO

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ATB4343-PROJECT AND VIVA VOCE

GUIDED BY

Mr. V. Ramanathan, Asst. Professor

Automobile Engineering Department

Hindustan Institute of Technology & Science

BY

NADIPUDI MEGHA SHYAM – 18104069

GOURU SAI SANTHOSH - 18104070

GONUGUNTLA VAMSI KRISHNA - 18104060

CONTENTS

ABSTRACT

• This project deals with the design, modelling, and animation of limited-slip differential in Tata Tiago.
• In vehicle differential is responsible for distribution of torque to the wheels. The proper distribution of torque between wheels is necessary during different scenarios like cornering on different surfaces such as ice, mud etc.
• The torque distribution by mechanical limited slip differential is not accurate, so for better control clutch pack limited slip differential was been used
•  To provide good traction performance with different road surfaces and to maintain overall stability of a vehicle.
• This type of LSD has all of the same components as an open differential, but it adds a pre load spring and a set of clutches.
• Clutch-style limited slip differential that improves traction and performance. It complements brake-based traction control systems to increase torque transfer and improve brake durability.

INTRODUCTION

• Field of the Invention The present invention relates to limited-slip differentials suited for use in automotive drivelines. Description of the Prior Art Such a limited-slip differential is known in the art that includes friction clutches which are urged to its engagement condition by the difference in torque on the differential gears and spring preload.
• A former type is that the spring preload applied to the clutches is constant and cannot be set large enough to improve the directional stability of the associated vehicle at high speed since a large spring preload will inevitably disable the differential from affecting the desired differential action upon turning.
• In automobile and other wheeled vehicles, the differential allows each of the driving wheels to rotate at different speeds, while supplying equal torque to each of them.
• In this situation, a limited-slip differential prevents excessive power from being allocated to one wheel, and thereby keeping both wheels in powered rotation.

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There are different types different types of limited slip differentials� 1. clutch LSD � 2. Viscous coupling LSD � 3. Locking LSD � 4. Torsion LSD

Mechanical Clutch LSDs are also further split into subtypes which behave in slightly different ways and alter when the pressure on the clutch plates and pressure rings is exerted:

• In a one-way LSD, the pressure is only exerted under acceleration. This means that when cornering and off the power the diff behaves as an open type, allowing them to turn independently – but under acceleration the forced rotation of the differential creates friction in the clutch plates, locking them in place in order to gain more traction.
• A Two-way LSD takes it a step further and exerts pressure on the clutch plates under deceleration too, in an effort to improve stability under braking on variable road surfaces.
• The one and half way again tries to combine the best of both subtypes, by exerting a greater amount of pressure under acceleration and lesser amount under deceleration.

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LITERATURE REVIEW

OBJECTIVES

• The main objectives of this project is to Design, Modelling, Assembly and Animation of components of a limited slip differential of a Tata Tiago Vehicle.
• The first objective is to Design the components of a Limited Slip Differential.
• The second objective is to Model the components of a Limited Slip Differential.
• The third objective is to Assembly the components of a Limited Slip Differential.
• The Fourth objective is to make an animation of working of the components of a Limited Slip Differential.

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METHODOLOGY

DESIGN

• Crown Wheel and Side Gears.
• Bevel Gears and pre - load spring.
• Friction Disc and Steel plate.

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MODELING

• Crown Wheel and Side Gears.
• Bevel Gears and pre - load spring.
• Friction Disc and Steel plate.

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ASSEMBLY

• Crown Wheel and Side Gears.
• Bevel Gears and pre - load spring.
• Friction Disc and Steel plate.

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ANIMATION

By assembling all the components of a limited slip differential together. A small animation was done using Solidworks software

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DESIGN

DESIGN OF BEVEL GEAR AND BEVEL PINION GEAR

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Calculations for Bevel Gear & Bevel Pinion Gear: -

For Bevel Gear: No. of Teeth(z1) = 26

Module: - (M)= 2.375mm

M = (Dbg/z1) {Dbg = Dia. Of Bevel Gear}

Dbg = M*Z

= 2.375*26 = 61.75mm

For Bevel Pinion Gear: No. of Teeth(z2) = 16

Module: -(M)= 2.375mm

M = (Db/z2) {Db = Dia. Of Bevel Pinion Gear}

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DESIGN OF CROWN WHEEL AND PINION GEAR:

Dimensions:

Diameter 95mm for crown wheel and Dia. 26.125mm for pinion gear

No. of teeth for crown wheel(z1) = 40

No. of teeth for pinion gear(z2) = 11

Calculations: -

• For Crown Wheel: No. of Teeth(z1) = 40
• Diameter of Crown Wheel(d1) = 95mm
• Module = (d1/z1) = (95/40) = 2.375mm
• For Pinion Gear: No. of Teeth(z2) = 11
• Diameter of Pinion Gear(d2) = 26.125mm
• Module = (d2/z2) = (26.125/11) = 2.375mm
• Pressure angle (α) = 20⁰
• Face Width (b) = 5mm
• Bottom Clearance (c) = 0.25mm

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DESIGN OF FRICTION DISC AND STEEL PLATES:

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Material used: - steel plates is made up of hot rolled mild steel, Friction disc consists of metal plate bonded with Friction material.

Dimensions: -

Inner dia. Of friction discs and steel plates are 13mm

Outer dia. Of friction discs and steel plates are 21mm

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MODELING

1.CROWN WHEEL

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• According to our calculation we did modelled some of the components with its accurate dimensions using solidworks software.
• Components that we modelled are bevel gears, side gear, crown wheel, friction disc, steel plate, pre load spring, case housing.

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2.SIDE GEAR

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3.BEVEL GEAR

4.FRICTION DISC

5.STEEL PLATE

6.PRE-LOAD SPRING

7.CASE HOUSING

ASSEMBLY

Assembly of the limited slip differential: -

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• As we modelled the components, we have to fit in all the components as a single unit. So, according to our calculation the module of the components should be equal in order to mesh the teeth. we assembled the components using Solidworks software.

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• Assembly of Limited slip differential with case housing. To assemble the case housing the values should accurate otherwise it wont fit in, where the assembly was done in solidworks software.

ANIMATION

RESULT

• In this project we designed the components of the limited slip differential.
• The components that we designed are crown wheel, pinion gear, bevel gears, friction disc, steel plate, pre load spring using our reference.
• And we modelled some of the components of the limited slip differential they are: - Crown Wheel, Side Gear, Bevel Gears, Friction Discs, Steel Plates, Pre-Load Spring, Case Housing with accurate dimensions using solidworks software.
• And assembled all the components using our calculations in order to get the components teeth meshed with each other in solid works software.
• Finally, we also done a small animation of our limited slip differential in order to show how the gears are rotated in the limited slip differential.

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CONCLUSION

• This project deals with the design of the components. As we have chosen to design a limited slip differential of a car.
• We had chosen Tata Tiago because it has a simple construction and the torque that transmitted to the rear wheels was an effective manner.
• As we all know that a wheel can be pulled out of a slippery surface when it has required amount of torque and the job gets done in this limited slip differential mechanism rather than in an open differential.
• In limited slip differential it consists of clutch pack assembly where it can transfer the torque to the required wheels in required amount. Since it has advantages and disadvantages.
• This working principle is not 100% effective but rather than an open differential it can save some of the torque of the desired vehicle.

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FUTURE SCOPE

• In modern electronically controlled limited-slip differentials the clutch packs are controlled electro-hydraulically. The clutches can be controlled individually to vector torque from one side of the axle to the other, creating torque vectoring system. 
• A variation of that is the Twinster system, used in the Ford Focus RS, for example. In a Twinster rear axle, there’s no central gear cluster at all, just the clutch packs. The differential effect is controlled by slipping the clutch on the inside wheel, allowing it to rotate more slowly, and it can also decouple the wheels completely to improve fuel economy. It’s made possible by advances in materials and clutches that are claimed not to wear out. It’s clever stuff, even if it lacks the elegant appeal of the original, mechanical, infernal machine.

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REFERENCES:

• Ina, H. (1994). Development of a new limited slip differential. JSAE Review, 15(3), 209–214. doi:10.1016/0389-4304(94)90036-1 
• Rubin D, Arogeti S A, (2015). Vehicle yaw stability control using active limited-slip differential via model predictive control methods. Vehicle SystemDynamics,53(9),13151330. doi:10.1080/00423114.2015.1046461 
• Russo R, Strano S & Terzo M, (2016). Enhancement of vehicle dynamics via an innovative magnetorheological fluid limited slip differential. Mechanical Systems and Signal Processing, 70-71, 1193–1208. doi: 10.1016/j.ymssp.2015.09.029 
• Forstinger M, Bauer R & Hofer A (2015). Modelling and Simulation of Passive Limited-slip Differentials. IFAC-Papers Online, 48(1), 502–507. doi: 10.1016/j.ifacol.2015.05.057
• Berglund K, Marklund P, Larsson R & Olsson R. (2013). Evaluating lifetime performance of limited slip differentials. Lubrication Science, 26(3), 189–201. doi:10.1002/ls.124

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• Sneha Gandhi C, Nayak G & Shanthigrama M. (2019). Electronically controlled limited slip differential for two-wheel drive for a vehicle network with AUTOSAR. 2019 4th International Conference on Recent Trends on Electronics, Information, Communication & Technology (RTEICT). doi:10.1109/rteict46194.2019.9016984
• A Study on Vehicle Differential system. Chandrakant Singh, Lalit Kumar, Bhumesh Kumar dewangan, Prakash Kumar Sen, Shailendra Kumar bohidar. International Journal of scientific research and management (IJSRM) ||Volume||2||Issue||11||Pages||1680-1683||2014|| Website: www.ijsrm.in ISSN (e): 2321-3418.
• https://en.m.wikipedia.org/wiki/Limited-slip_differential
• https://www.autoexpress.co.uk/car-news/103829/what-is-a-limited-slip-differential

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THANK YOU