Design and manufacture of a rear driveline package including limited slip differential for Formula SAE applications

Abstract

This document describes the design and manufacture of a lightweight rear driveline package for a Formula SAE race car. The design focuses on all components needed to transfer power from the chain driven Honda CBR600 F4i to the rear drive wheels, and includes a custom limited slip differential housing, drive shafts, hubs, and wheels. The design is centered on a custom aluminum housing for Torsen@ T1 gears, which provides limited slip and torque biasing between the two drive wheels. This type of differential has proven itself in the world of motorsports, especially in the Formula SAE series. This document demonstrates the design concepts and justifications, as well as the manufacturing processes needed to fabricate the designs. This work on the driveline package was developed with the hopes that it will be used in future years as a stepping stone for improved designs. Design choices and justifications have been explained, and manufacturing processes have been thoroughly described through the use of both text and figures to aid in the manufacture of future components. TORSEN® is a registered trademark of Toyoda-Koki Automotive Torsen North America Inc.