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Helical gears in manual transmission are designed based on static loading. Sometimes these gears are subjected to impact during misuse events such as sudden engagement and disengagement of clutches, inappropriate shifting of gears, while vehicle is negotiating different maneuvers. These misuse events call for the need to consider the study the gear strength under impact loading in design phase. In this paper, attempt is made to evaluate stresses in the gear root under impact using the dynamic implicit algorithm available with commercial Finite element analysis (FEA) software Abaqus. Dynamic analysis is run for duration of few milliseconds to capture both impact and rebounding events. First gear pair, which is generally heavy loaded among all gear pairs, is considered for simulation. Initially, static analysis is performed for different pitch positions of one mesh to find out the most critical pitch position in which stresses in fillets reach their peak values.

Bevel planetary in the differential helps the vehicle in negotiating a turn and splitting the torque between the axles. The bevel gear differential assembly consists of two bevel pinions, two side gears, differential shaft and washers, enclosed in differential housing. Bevel pinions mounted on the differential shaft act as idlers for power transfer from carrier to side gears which are splined to axles. This paper is aimed at evaluation of stress cycles in fillets of bevel pinion in a differential. Generally analysis of bevel pinion is carried out using specialized codes. These codes ignore the stiffness of differential housing and differential shaft and effect of surface hardness on the gear tooth. Hence, in this work, a method has been proposed to simulate the complex mechanism of differential assembly with simple static analysis using commercial Finite Element Analysis Software ABAQUS/STANDARD.