Modelling and 3D Printing of Differential Gear Box

International Journal of Trend in Scientific Research and Development (IJTSRD)
Volume: 3 | Issue: 3 | Mar-Apr 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 - 6470
@ IJTSRD | Unique Paper ID – IJTSRD23287 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1163
Modelling and 3D Printing of Differential Gear Box
Yogesh Avula, Vanga Rajeev Narayana Reddy, VojaAnand Swaroop, Varikuppala Srisailam
Department of Mechanical Engineering, Guru Nanak Institute of Technology,
affiliated to JNTUH, Hyderabad, Telangana, India
How to cite this paper: Yogesh Avula |
Vanga Rajeev Narayana Reddy |
VojaAnand Swaroop | Varikuppala
Srisailam "Modelling and 3D Printing of
Differential Gear Box" Published in
International Journal of Trend in
Scientific Research and Development
(ijtsrd), ISSN: 2456-
6470, Volume-3 |
Issue-3, April 2019,
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ABSTRACT
The main aim of the project is to focus on the modeling and 3D printing of
differential gear box. Differential permit each of the driving wheels to rotate at
different speeds, while for most vehicles supplying equaltorqueto eachofthem.
A vehicle's wheels rotate at divergent speeds, mainly when turningcorners. The
differential is designed to operate a pair of wheels with same torque while
permit them to rotate at different speeds. Differential gear box is designed in
CATIA V5 software and manufactured using additive manufacturing (3D
printing). The function of gear is to protect and provide a platform for gear
transmission. It also provides supports for moving parts and protection from
outside environmental condition.
KEYWORDS: Differential gear box, CATIA V5R20 software; PLA (Poly lactic Acid)
materials; 3D printing
1. INTRODUCTION
DIFFERENTIAL GEAR BOX
In automobiles and other wheeled vehicles, the differential
permit each of the driving wheels to rotate at different
speeds, while for most vehicles supplying equal torque to
each of them. A vehicle's wheels rotate at divergent speeds,
mainly when turning corners. The differential is designed to
operate a pair of wheels with same torque while permit
them to rotate at different speeds. In vehicles without a
differential, such as karts, both driving wheels are forced to
rotate at the equal speed, generally a commonaxledriven by
a simple chain drive mechanism. When cornering, the inner
wheel needs to travel a shorter distance than the outer
wheel, so with no differential, the result is the inner wheel
spinning and/or the outer wheeldragging,andthisresultsin
difficult and unpredictable handling, damage to tires and
roads, and strain on the entire drive train. The Differential
transmits mechanical energy from a prime mover to an
output device. It also varies the speed, direction of
mechanical energy. Differential gearbox is used when high
speed, large power transmission where noise reduction is
important.[1]
Principle
The Differential transmits mechanical energy from a prime
mover to an output device. It also varies the speed, direction
of mechanical energy. Differentialgearboxisused when high
speed, large power transmission where noise reduction is
important.[2]
3D PRINITING
3D printing or additive manufacturing (AM) is a process for
making a 3D object of any shape from a 3D model or other
electronic data sources through additive processes in which
successive layers of material are laid down under computer
controls. Hideo Kodama of Nayoga Municipal Industrial
Research Institute is generally regarded to have printed the
first solid object from a digital design. However, the credit
for the first 3D printer generally goes to Charles Hull, who in
1984 designed it while working forthecompanyhefounded,
3D Systems Corp. Charles a Hull was a pioneer of the solid
imaging process known as stereo lithography and the
STL(stereo lithographic) file format which is still the most
widely used format used today in 3D printing. He is also
regarded to have started commercial rapid prototyping that
was concurrent with his development of 3D printing. He
initially used photo polymers heated by ultraviolet light to
achieve the melting and solidification effect.[7]
CATIA
CATIA an acronym for Computer Aided Three-dimensional
Interactive Application. It is one of the leading 3D software
IJTSRD23287

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used by organizations in multiple industries ranging from
aerospace, automobile to consumer products.
CATIA is a multiplatform 3D software suite developed by
Dassault Systems, encompassing CAD, CAM as well as CAE.
Dassault is a French engineering giant active in the field of
aviation, 3D design, 3D digital mock-ups, and product
lifecycle management (PLM) software. CATIA is a solid
modelling tool that unites the 3D parametric features with
2D tools and also addresses every design-to-manufacturing
process. In addition to creating solid models andassemblies,
CATIA also provides generating orthographic, section,
auxiliary, isometric or detailed 2D drawing views. It is also
possible to generate model dimensions and createreference
dimensions in the drawing views. The bi-directionally
associative property of CATIAensuresthatthemodifications
made in the model are reflected in the drawing views and
vice-versa.
The first release of CATIA was way back in 1977, and the
software suite is still going strong more than 30 years later.
While CATIA V6 is just being released, the most popular
version of CATIA is V5 which was introduced in 1998. That
said, it is important to note that each version of CATIA
introduces considerable additional functionality. For
example, V4 (introduced in 1192) offered enhancements to
the Assembly Modeling Product including easy-to-use
graphical tree-based assembly management. V5 and V6 saw
changes in the way data is handled. Dassault Systems
typically offers new updates, releases and bug fixes for each
version.
2. LITERATURE REVIEW
The idea of printing 3D objects conceptualized and was
patented by Chuck Hull of 3D Systems Inc. in 1986. Sachs et
al. at MIT obtained a patent for making a component by
depositing a first layer of a fluent porous material, such as a
powder, in a confined region and then depositing a binder
material to selected regions of the layer of powder material
to produce a layer of bonded powder material attheselected
regions. Such steps are repeated a selected number of times
to produce successive layers of selected regions of bonded
powder material so as to form the desired component. The
un-bonded powder material is then removed.
In some cases the component may be further processed, for
example, by heating it to further strengthen the bonding
thereof. MIT's DPTM process laboratory lead the way in 3D
printing process research in the area of gradient index
lenses, tooling for low cast casting, fine ceramiccomponents
for electronic application, tungstencarbide cuttingtools, and
metal matrix composites.
D. A. Roberson et al. evaluated the capability of five desktop
additive manufacturing (AM) machines based on the ability
to produce a standard component. This workalsodeveloped
a model/method forevaluatingand rankingAMtechnologies
based on select criteria that can facilitate purchasing
decisions. A standard part was designed and printedoneach
machine, and evaluated based on dimensional accuracy and
surface finish. Additionally, the machines were compared
based on build time for single and multiple parts as well as
material consumption and unit cost. The ranking system
presented in this paper has demonstrated the ability to
discriminate between differentAMprocessesandrank these
systems based on quantitative measures.[3]
Lee and Kim analyzed the trend of 3D printing-related
patents for the last 10 years to investigatepatent application
trends by country, by year, by assignee and by technology.
Furthermore, the paper analyzed the patent trend on 3D
printers and materials used to secure original technologies
and a portfolio of application technologies in medium and
long terms.[4]
Utela et al. presented a paper organizing the process of 3DP
implementation into five steps (powder formulation,binder
method selection, binder formulation and testing, printing
process specification, andpost-processingspecification) and
presented a review of the literature relevant to each step in
3DP implementation. Huang et al. reviewed the societal
impact of additive manufacturing in
1. Customized healthcare products to improve population
health and quality of life,
2. Reduced environmental impact for manufacturing
sustainability, and
3. Simplified supply chain to increase efficiency and
responsiveness in demand fulfillment.Their reviewalso
identified the need for further research in the areas of
life-cycle energy consumption evaluation and potential
occupation hazard assessment for additive
manufacturing.
Berman in his paper examined the characteristics and
applications of 3D printing for mass customization. He
argued that there are a number of promising applications
exist in the production of replacement parts, dental crowns,
and artificial limbs, as well as in bridge manufacturing. 3D
printing market allow firms to profitably servesmallmarket
segments, and enable companies to operate with little or no
inventory and significantly reduce the need for factory
workers.[5]
Thompson et al. provided an overview of the major
advancements, challenges and physical attributes related to
Direct Laser Deposition (DLD) process.ThePartI focused on
the thermal/fluidic phenomena during the powder-fed DLD
process, which directly influence the solidification heat
transfer, which thus affects the part’s microstructure and
associated thermo-mechanical properties. In Part II
Shamsaei et al. focused on the mechanical properties,
characteristics, behavior and microstructure of parts
manufactured via DLD and post DLD process parameters
(e.g. heat treatment, machining). Methods for
controlling/optimizing the DLD process for targeted part
design discussed – with an emphasis on monitored part
temperature and/or melt pool morphology.
Singh et al. reviewed the recent technological advancements
in materials and in technological aspects of 3D printing,
identified future challenges and potential applications in
engineering, manufacturing and tissue engineering. Also
provided number of patents filed in materials, their
applications and industry-wise patent filing trends.
3. METHODOLOGY
GENERAL PRINCIPLES
Modeling
3D printable models can be created with the help of CATIA
design packages or via 3D scanner. The manual modeling
process of preparing geometric data for 3D computer
graphics is similar to method sculpting. 3D modeling is a
process of analyzing and collecting data on the shape and

appearance of an object. Based on this data,3Dmodelsofthe
scanned object can be produced. Bothmanualand automatic
creations of 3Dprinted models are very difficult foraverage
consumers. That is why severalmarket-placeshave emerged
over the last years among the world. The most popular are
Shape ways, Thing verse, My Mini Factory, and Threading.
Printing
Before printing a 3D model from .STL file, it must be
processed by a piece of software called a "slicer" which
converts the 3D model into a series of thin layers and
produces a G-code file from .STL file containing instructions
to a printer. There are several open source slicer programs
exist, including, Slic3r, KISSlicer, and Cura. The 3D printer
follows the G-code instructions to put down successive
layers of liquid, powder, or sheet material to build a model
from a series of cross-sections of a model. These layers,
which correspond to the virtual cross sections from the CAD
model, are joined or fused to create the final shape of a
model. The main advantage of this technique is its ability to
create almost any shape or geometricmodel. Construction of
a model with existing methods can take anywhere from
several hours today’s, depending on the method used and
the size and complexity of the model. Additive systems can
typically reduce this time to very few hours; it varies widely
depending on the type of machine used and the size and
number of models being produced.
Finishing
Although the printer-produced resolution is sufficient for
many applications, printing a slightly oversized version of
the object in standard resolution andthen removingmaterial
with a higher-resolution process can achieve greater
precision. As with the AccurateiD-20 and other machines
Press Release. International Manufacturing Technology
shows some additive manufacturing techniques are capable
of using multiple materials in the course of constructing
parts.
4. 3D PRINTING TECHNIQUE
FUSED DEPOSITION MODELING
Fused deposition modeling(FDM)methodwasdeveloped by
S. Scott Crump in the late 1980s and was designed in 1990
by Strata sys. After the patent on this technology expired, a
large open source development community developed and
commercial variants utilizing this type of 3D printer
appeared. As a result, the price of FDM technology has
dropped by two orders of magnitude since its creation. In
this technique, the model is produced by extruding small
beads of material which harden to form layers. A
thermoplastic filament or wire that is wound into a coil is
unwinding to supply material to an extrusion nozzle head.
The nozzle head heats the material up to the certain
temperature and turns the flow on and off. Typically the
stepper motors are employed to move the extrusion head in
the z-direction and adjust the flow according to the
requirements. The head can bemoved inboth horizontaland
vertical directions, and control of the mechanism is done by
a computer-aided manufacturing (CAM) software package
running on a microcontroller.
Figure 17. Fused deposition method
MATERIALS USED
Poly Lactic Acid [PLA]
Poly lactic acid (PLA) (is derived from corn and is
biodegradable) is another well-spread material among
3Dprinting enthusiasts. It is a biodegradable thermoplastic
that is derived from renewable resources. As a result PLA
materials are more environmentally friendly among other
plastic materials. The other great feature of PLA is its
biocompatibility with a human body. The structure of PLAis
harder than the one of ABS and material meltsat180 –220°C
which is lower than ABS. PLA glass transition temperature is
between 60 – 65 ° C, so PLA together with ABS could be
some good options for any of your projects.[6]
Technical Specifications
Density - 1.3 g/cm³ (81 lb/ft³)
Elastic (Young's, Tensile) Modulus - 2.0 to 2.6 GPa(0.29
to 0.38 x 10³ psi)
Elongation at Break - 6.0 %
Flexural Modulus - 4.0 GPa (0.58 x 10⁶ psi)
Flexural Strength - 80 MPa (12 x 10³ psi)
Glass Transition Temperature - 60 °C (140 °F)
Heat Deflection Temperature At 455 kPa (66 psi) -65 °C
(150 °F)
Melting Onset (Solidus) - 160 °C (320 °F)
Shear Modulus- 2.4 GPa (0.35 x 10⁶ psi)
Specific Heat Capacity - 1800 J/kg-K
Strength to Weight Ratio - 38 kN-m/kg
Tensile Strength : Ultimate (UTS) - 50 MPa (7.3 x 10³
psi)
Thermal Conductivity - 0.13 W/m-K
Thermal Diffusivity - 0.056
Material Properties of Poly Lactic Acid [PLA]
Temperature - 180°C
Flow Tweak - 0.95
Bed Temperature - 60°C
Bed Preparation - apply glue stick 2 layer
5. EXPERIMENTATION
MODELLING OF DIFFERENTIAL GEAR BOX

PROCEDURE FOR SLICING AND 3D PRINTING
Adding and Repairing Your Model
To add your model, click on the plus icon in the middle.
Choose your file and it will be loaded onto the screen. Use
the “Pan”, “Move” and “Rotate” tools to look around. You can
also use the shortcuts.
One thing you might notice is an orange warning sign. This
means your models are “Invalid” and that they need to be
repaired. If you unselect them, they will be colored red.
Repairing is a very smooth and efficient process in Idea
Maker. Here’s how to do it:
1. Select the model.
2. Click “Repair” on the toolbar
Transforming Your Model
With Idea Maker, it’s also possible to transform your model.
The tools are basic but often enough to get the job done.
You can move, rotate and scale your model usingthetools in
the toolbar. Here’s how to transform your object:
1. Select your model, and then choose the tool you want.
2. 3D axes will appear on your model — lines for “Move”
and “Scale” or circles for “Rotate”. Click and drag the
lines to transform your model.
3. Alternatively, you can insert manual values for the
transformations in the window that pops open on the
left.
4. If you want to print the model as big as your printer
allows, you can use the “Max Fit” tool. This scales the
model to precisely fit your printer.
Setting up the Print Settings
The settings are abundant and you can adjust almost
anything you can think of in Idea Maker’s settings tab.
From “Coasting Distance” to “Infill Acceleration”, there are
settings present in Idea Maker that usually aren’t present in
other 3D Slicers.
Once you’re done adjusting the settings, click “Okay” and
then “Save and Close”.
Slicing and Printing
After setting up the print settings, it’s time to finally slice
it into g-code:
1. Click on the play icon labeled “Start Slicing” or use Ctrl+
P. It might take some time to slice the model.
2. Once the slicing is finished, you’ll see a window
indicating the estimated price, print duration, etc.
3. If you’ve connected your printer, you can print directly
from Idea Maker by clicking “Export”. However, if you
don’t have your printer connected, it will export the g-
code file.
4. Selecting “Upload” will upload the g-code to the printer
wirelessly. This is the case for Raise3D printers.
5. If you want to preview your g-code, click on “Preview”.
The preview screen itself will take some time to load.
Temperature maintains
Right Nozzle 240oC
Left Nozzle 0oC
Heat Bed 109oC
3D printing the differential gear box by FDM

6. RESULTS AND DISCUSSION
Differential Gear Box is designed and 3D printed by using
fused deposition modeling
7. CONCLUSION
In this journal modelling of a DIFFERENTIAL GEAR BOX is
carried out with the of CATIA v5 Software by using of
machine design. After creating model we save the
component in stl.file. Import the component into the 3D
Printing machine. And then we apply the G-CODES to the
component. And then we get the component.
8. REFERENCES
[1] Shashank pandey, Nikhilesh N. sing&Dr. rabhatkumar
sinha,2017,”Modelling and design of differential gear
box through FEM, SOLIDWORKS WORKBENCH”,
International Journal of Engineering Sciences and
Research Technology.
[2] T. Loknadh, DR. P. S. S. Vasu , Design a crown wheel
gear of differential gear box used in heavy vehicles for
structural loads, International Journal of Science,
Engineering and Technology Research (IJSETR),
Volume 4, Issue 7, July 2015
[3] Roberson, D. A., Espalin, D., & Wicker, R. B., "3D printer
selection: A decision making evaluation and ranking
model", Virtual and Physical Prototyping, 2013, 8:3,
201-212
[4] Lee, I. and Kim, Y., "The Recent Patent Analysis and
Industrial Trend of 3DPrinting", Indian Journal of
Science and Technology, Vol 8(S8), 70-73, April 2015
[5] Thompson S. M., Bianc, L., Shamsaei, N.,&Yadollahia,A.,
" An overview of Direct Laser Deposition for additive
manufacturing;PartI:Transportphenomena,modeling
and diagnostics", Additive Manufacturing8 (2015)36–
62, http://dx.doi.org/10.1016/j.addma.2015.07.001
[6] Shamsaei, N., Yadollahia, A., Bianc, L., & Thompson
S.M.," An overview of Direct Laser Deposition for
additive manufacturing; Part II: Mechanical behavior,
process parameter optimization and control",Additive
Manufacturing 8 (2015) 12–
35,http://dx.doi.org/10.1016/j.addma.2015.07.002
[7] Berman, B., "3-D printing: The new industrial
revolution", Business Horizons(2012) 55, 155—162
[8] https://www.stratasysdirect.com/manufacturing-
services/3d-printing
[9] https://www.designtechcadacademy.com/knowledge-
base/catia-training
[10] https://grabcad.com/tutorials/catia-v5-basic-tutorial--
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