Design of an aluminum differential housing and driveline components for high performance applications

Abstract

The purpose of the study was to design a lightweight aluminum differential housing to replace the cast-iron housing used in the Torsen® T-1. The redesigned housing was destined for use in the 2004 MIT Formula SAE vehicle, a small high-performance formula-style car. FEA analysis was used to create a two-piece design that was significantly lighter than the original Torsen housing. Bearing mounts used to attach the unit to the FSAE chassis as well as inboard driveline joints were also designed and fabricated. The remainder of the driveline system was outlined and sourced. Additionally, a second design incorporating the original cast-iron housing was created for the FSAE vehicle to use in competition while the original design undergoes testing. TORSEN® is a registered trademark of Toyoda-Koki Automotive Torsen North America Inc.