Modeling and analysis of an EV-specific Differential Gearbox and its Casing

The rapid advancement of electric vehicles (EVs) demands innovative transmission systems that prioritize performance, efficiency, and weight reduction. One critical component is the differential gearbox, which must transmit torque effectively while adapting to speed variations during turning. Traditional cast iron or steel differential housings significantly increase vehicle weight, reducing energy efficiency and limiting range. This study focuses on the design, modeling, and finite element analysis (FEA) of a lightweight differential gearbox and its casing specifically tailored for EV applications. 3D modeling and ANSYS 14.5 for structural and modal analysis, the project investigates stress distribution, displacement, and natural frequencies under various torque conditions. Modal analysis identifies critical vibration modes to prevent resonance-induced failures. The primary goal is to ensure structural integrity, reduce gearbox weight, and maintain thermal and acoustic performance. Statistical and dynamic simulations help optimize the gearbox casing, ensuring it meets strength and vibration control standards. This research ultimately contributes to enhancing EV efficiency, safety, and reliability by introducing lightweight materials and a robust gearbox design.