Published Paper Details:

This project focuses on designing a differential gearbox for a small commercial vehicle, taking the TATA ACE as a reference. The main goal was to design a gearbox that allows the rear wheels to rotate at different speeds while smoothly transferring power from the engine. The considered data such as engine power, torque, and material properties were collected from reliable sources like Tata Motors official website and research papers. The gearbox components were designed using standard formulas for strength, wear, and load capacity. The material 20MnCr5 was chosen because it offers good strength and resistance to wear. A 3D model of the gearbox was created in SolidWorks 2025 to check dimensions and assembly. The design was further verified through static structural analysis in ANSYS, which showed that the maximum stress and deformation values were well within safe limit, confirming the strength and stiffness of the gearbox. The results showed that the design is safe and slightly overdesigned, which adds to its reliability. In the future, the design can be improved by performing static and thermal analysis, using 3D printing (additive manufacturing), and modifying it for electric and hybrid vehicles to make it more efficient and modern.