Initial Crack Analysis on 175 Nm Torque Differential Helical Gear Using Finite Element Method for Structural Failure Prediction
DOI:
https://doi.org/10.29103/mjmst.v9i1.21607Abstract
Differential helical gears are critical components in power transmission systems of vehicles, responsible for transmitting torque from the engine to the drive wheels. These components operate under continuous high torque loads and are susceptible to failure due to material fatigue and the presence of initial cracks. This study aims to predict the initial crack location and evaluate the potential failure of a differential helical gear subjected to a 175 Nm torque using the Finite Element Method (FEM). The gear was modeled with actual dimensions and simulated using ANSYS software under two conditions: without cracks and with an initial crack. The simulation results show that the maximum shear stress without a crack is 45.82 MPa, while with an initial crack, it increases to 66.14 MPa, exceeding the allowable shear stress of ASTM A36 material at 45.45 MPa. This significant increase in stress due to the crack indicates a high risk of structural failure. Therefore, finite element analysis proves to be an effective tool for early crack detection and stress distribution evaluation, which is essential for improving the reliability of gear design and material selection.References
S. Netpu and P. Thanakijkasem, Failure Analysis of Helical Gear Shaft in Hot Rolling Mill, Tube Hydroforming Technology, 2017, pp. 233-237.
U.A. Patil, V.J. Savant, R.S. Bharamgonda and P.N. Gore, Recent Advances in Differential Drive Systems for Automobile Propulsion, International Research Journal of Engineering and Technology (IRJET), 5 (2018) 3244-3249.
J. Ruztamreen, N. Atiqah, M.D. Reduan, M. Nor Salim, A.R. Mohd Nazim, I.A. Ibrahim, M.Z. Nurul Hilwa and I.N. Hidayah, Failure Prediction of Helical Gear Using Wear Debris Analysis, Australian Journal of Basic and Applied Sciences, 8 (2014) 309-312.
H. Husaini, F. Fauzan, N. Ali and A. Arhami, Failure Analysis of the Rear Driveshaft Using Experimental and Analytical Methods, AIP Conference Proceedings, 2613 (2023) 020004.
H. Sutanto, Analisis Tegangan Roda Gigi Miring pada Transmisi Kendaraan Roda Empat berdasarkan AGMA dan ANSYS, Media Teknika Jurnal Teknologi, 12 (2017) 17-25.
F. Fauzan, H. Husaini and N. Ali, Fracture: The Finite Element Method Simulation of Rear Driveshaft Failure in Trucks, in: Lecture Notes in Mechanical Engineering, (2024) 211-219.
J. Ruztamreen, N. Atiqah, M.D. Reduan, M. Nor Salim, A.R. Mohd Nazim, I. Asriana Ibrahim, M.Z. Nurul Hilwa and I. Nur Hidayah, Failure Prediction of Helical Gear Using Wear Debris Analysis, Australian Journal of Basic and Applied Sciences, 8 (2014) 309-312.
A. Kanagaraj, S.M. Pandurangan, S. Durai and A. Gopi, The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer, International Journal of Mechanical Engineering and Applications, 12 (2024) 71-80
S. Netpu and P. Srichandr, Failure Analysis of a Helical Gear in a Gearbox Used in a Steel Rolling Mill, Journal of Materials Science and Engineering B, 2 (2012) 289-294.
A. Kanagaraj, S.M. Pandurangan, S. Durai and A. Gopi, The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer, International Journal of Mechanical Engineering and Applications, 12 (2024) 71-80
S. Senthilkumar, S. Manivannan, R. Venkatesh and M. Karthikeyan, Influence of Heat Input on the Mechanical Characteristics, Corrosion and Microstructure of ASTM A36 Steel Welded by GTAW Technique, Heliyon, 9 (2023) e19708.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 Fauzan Fauzan, Amalia Harmin, Muhammad Isra, Akbar Rizqullah, Muhammad Nuzan Rizki
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.
