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1、wFailureanalysisofanautomobiledifferentialpinionshaftAbstractDifferentialisusedtodecreasethespeedandtoprovidemomentincreasefortransmittingthemovementcomingfromtheenginetothewheelsbyturningitaccordingtothesuitableangleinvehiclesandtoprovidethatinnerandouterwheelsturndifferently.Piniong

2、earandshaftattheentrancearemanufacturedasasinglepartwhereastheyareindifferentformsaccordingtoautomobiletypes.Mirrorgearwhichwillworkwiththisgearshouldbecomefamiliarbeforetheassembly.Incaseofanybreakdowntheyshouldbechangedasapair.Generallyinthesesystemsthereareweardamagesingears.Thegea

3、rinspectedinthisstudyhasdamageasaformofshaftfracture.Inthisstudyfailureanalysisofthedifferentialpinionshaftiscarriedout.Mechanicalcharacteristicsofthematerialareobtainedfirst.Thenthemicrostructureandchemicalcompositionsaredetermined.Somefractographicstudiesarecarriedouttoassesthefatig

4、ueandfractureconditions.Keywords:DifferentialFracturePowertransferPinionshaft1.IntroductionThefinal-drivegearsmaybedirectlyorindirectlydrivenfromtheoutputgearingofthegearbox.Directlydrivenfinaldrivesareusedwhentheengineandtransmissionunitsarecombinedtogethertoformanintegralconstructio

5、n.Indirectlydrivenfinaldrivesareusedattherearofthevehiclebeingeithersprungandattachedtothebodystructureorunsprungandincorporatedintherear-axlecasing.Thefinal-drivegearsareusedinthetransmissionsystemforthefollowingreasons1:atoredirectthedrivefromthegearboxorpropellershaftthrough90°andb

6、toprovideapermanentgearreductionbetweentheengineandthedrivingroad-wheels.Invehiclesdifferentialisthemainpartwhichtransmitsthemovementcomingfromtheenginetothewheels.Onasmoothroadthemovementcomestobothwheelsevenly.Theinnerwheelshouldturnlessandtheouterwheelshouldturnmoretodotheturningwi

7、thoutlateralslippingandbeingflung.Differentialwhichisgenerallyplacedinthemiddlepartoftherearbridgeconsistsofpiniongearmirrorgeardifferentialboxtwoaxlegearandtwopinionspidergears.AschematicillustrationofadifferentialisgiveninFig.1.Thetechnicaldrawingofthefracturedpinionshaftisalsogiven

8、inFig