Car Differential

Developed a comprehensive CAD model of a car differential based on the loading parameters of a 2021 BMW M3 projected to undergo one million cycles throughout its lifetime

Reduced project costs by selecting off-the-shelf gears and bearings, ensuring affordability and performance

Analyzed design using AGMA equations for gear tooth bending stress and calculated the R.R. Moore endurance limit, leading to a redesign that improved the differential's ability to withstand input loads

Utilized finite element analysis (FEA) to verify hand calculations, reinforcing the need for a redesign