Differential Sprocket

Objective:

Update previous Differential Sprocket design. Create a 33-teeth differential sprocket with a focus on reducing mass compared to the previous design. Maintain a deformation of no more than 0.003 inches, a factor of safety above two. Parts must be manufactured with the use of a CNC.



Process:

Started with a differential sprocket template with no cutoffs. First, run a topology study on SolidWorks to get design insight on mass removal. After running topology I implemented the various cutouts suggested. After the preliminary design, I ran static studies to check deformation, and factors of safety were within design specifications. I kept on modifying various cutouts until reached the desired mass removal while maintaining the design factor of safety and deformation.

Result:

Reached a design with a similar factor of safety and deformation compared to the previous year's sprocket design. The previous year's sprocket weighed .33 pounds while my design came in at .23 pounds achieving a weight reduction of 30%. This weight reduction might not be as significant, but it adds to the vehicle's overall weight reduction making it lighter and allowing it to achieve higher speeds much faster at lower stresses.