1. Differential for Formula SAE Race Car
Shivana Mahes
Uber Mantovani
Alessandro Tasca
Differential for Formula SAE Race Car
EML4551 Ethics and Design Project Organization
Team 09

2. SUMMARY Problem statement Project description Motivation and goals
Division of Responsibilities
Project Timeline
Goals
Design Considerations
Design Alternatives
Standards
Global Learning
Conclusion
Questions

3. PROBLEM STATEMENT
Design differential and components for the 2016 FSAE competition
Components include housing, mounts, sprocket
Photo credit: audi-technology-portal.de

4. MOTIVATION AND GOALS Motivation
FSAE is a prestigious global competition
Top engineers attend and judge entries
Goals
Optimize differential for FIU’s car
Optimize power transfer
Photo credit: torsen.com

5. DIVISION OF RESPONSIBILTIES
Shivana Mahes
Calculation and design of housing and spacers, Solidworks modeling and simulations, written documents
Uber Mantovani
Calculation and design of sprocket, springs, and friction plates, Solidworks modeling and simulations
Alessandro Tasca
Calculation and design of gears, prototyping, and manufacturing

6. PROJECT TIMELINE

7. GOALS Reduce weight from current differential by 15%
Maintain current torque bias ratio of 4:1
Photo credit: torsen.info

8. DESIGN CONSTRAINTS 2016 FSAE rules
45° tilt test-differential cannot leak
Withstand engine specifications
Location and size of sprocket
Safety and reliability
Dimension of current drive axle shafts and CV joint angle
Costs

9. DESIGN CONSIDERATION Location of differential Engine development
Interchangeable sprocket

10. DESIGN ALTERNATIVE 1 Alternative 1 Differential using gears only
Simple design
Utilizes only mechanical parts
Photo credit: blog.keyeslexus.com

11. DESIGN ALTERNATIVE 2 Alternative 2
Differential using gears and friction plates
Added weight from friction plates is negligible over alternative 1
Friction plates can wear out
Photo credit: italiaspeed.com

12. DESIGN ALTERNATIVE 3 Alternative 3
Differential using gears and spring-loaded friction plates
Capable of achieving highest torque bias ratio of all 3 alternatives
More complex than all 3 alternatives
Increases cost of manufacturing and maintenance
Photo credit: torsen.info

13. DESIGN ALTERNATIVE 3
Photo credit: torsen.info

14. SURVEY OF STANDARDS American Society of Testing and Materials
Specific standards to be used depend on material selected
American Gear Manufacturers’ Association
Standards apply to gears, couplings, and power transmission components

15. SURVEY OF STANDARDS Society of Automotive Engineers
Bolts and viscosity of lubricants

16. GLOBAL LEARNING
Design for manufacturability in various parts of the globe
Use of universal units (SI/US)
Manual in multiple languages
Cost analysis for different regions in different currencies

17. CONCLUSION
Design, manufacture, and assemble differential for 2016 FIU Formula SAE car
Optimize drivetrain
Reduce weight
Maintain current TBR

18. QUESTIONS