Numerical Design of a Low Mass Differential Housing

Lawrence Technological University's 1998 SAE Formula car needed a high performance differential assembly. The performance requirements of a competitive SAE Formula car differential are as follows:

• Torque sensing capabilities
• Perfect reliability
• High strength
• Low mass
• Ability to withstand inertia and shock loading
• Small package
• Leak proof housing
• Ability to support numerous components

With these requirements in mind an existing differential was selected with the capability for torque sensing. This differential lacked the desired low mass, support, internal drive splines, and proper gearing protection. The differential was re-engineered to remedy the deficiencies. The internal gearing from the selected differential was used in an improved casing. This casing and it's position in the car, reduce the number of side-specific parts required as well as improving the performance. The new design significantly reduces the size and mass of the assembly. This design improves reliability while reducing manufacturing time and cost.