Design and Analysis of Two Stage Reduction Gear Box for Formula EV

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 11 Issue: 07 | July 2024

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p-ISSN: 2395-0072

Design and Analysis of Two Stage Reduction Gear Box for Formula EV Ajay

B. Tech Student, Dept. of Mechanical Engineering, SAE NIT Kurukshetra National Institute of Technology Kurukshetra, Haryana, India ---------------------------------------------------------------------***--------------------------------------------------------------------Abstract - This paper presents the design and analysis of a two-stage reduction gearbox for a Formula Electric Vehicle (FEV). The gearbox is designed to meet the specific performance requirements of the FEV, focusing on efficiency, weight reduction, and compactness. The design process includes selecting appropriate gear ratios to optimize torque and speed based on the vehicle's electric motor characteristics. A detailed analysis using Finite Element Analysis (FEA) is conducted to evaluate the structural integrity and durability of the gearbox components under operational loads. Additionally, material selection is performed to ensure lightweight construction without compromising strength. The gearbox's thermal performance is also assessed to ensure reliable operation under varying conditions. The final design demonstrates a significant improvement in power transmission efficiency and vehicle performance. Results indicate that the two-stage reduction gearbox effectively balances the trade-offs between torque amplification and speed reduction, contributing to the overall enhancement of the FEV's dynamic performance. This study provides a comprehensive approach to gearbox design in electric vehicles, offering insights into achieving high efficiency and robustness in high-performance applications.

operational conditions. This study also addresses thermal management to ensure consistent performance. The resulting gearbox design aims to significantly enhance the FEV’s dynamic performance, providing a comprehensive approach to efficient and robust gearbox design in highperformance electric vehicles.

1. DESIGN PARAMETER

1.1 Material Selection Material selection focuses on lightweight yet strong materials, such as high-strength aluminum alloys and advanced composites, to reduce the gearbox's overall weight without compromising durability. These materials provide excellent mechanical properties, including high strength-to-weight ratios and good thermal conductivity, ensuring the gearbox can withstand the demanding operational conditions of Formula Electric Vehicles (FEVs). TABLE: MATERIAL PROPERTY

Key Words: FEV, Gears, Gear ratios, shaft, Bearing, Power transmission efficiency

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Impact Factor value: 8.226

VALUE

Material selected

EN24

Young’s Modulus

207Gpa

BHN

INTRODUCTION The rapid evolution of Formula Electric Vehicles (FEVs) has necessitated advancements in powertrain components to enhance performance, efficiency, and reliability. A critical component in this evolution is the gearbox, which must efficiently translate the high-speed, low-torque output of electric motors into the optimal torque and speed required by the vehicle's wheels. This paper focuses on the design and analysis of a two-stage reduction gearbox tailored for FEVs. The primary objective is to develop a gearbox that maximizes power transmission efficiency while minimizing weight and spatial footprint, essential for the competitive edge in FEV racing. The design process begins with selecting appropriate gear ratios to achieve the desired balance between torque amplification and speed reduction, considering the specific characteristics of the electric motor used in the FEV. Advanced computational tools, including Finite Element Analysis (FEA), are employed to assess the structural integrity and durability of the gearbox under dynamic loads. Material selection is critical, aiming for lightweight yet robust components to withstand the demanding

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PROPERTIES

650

Tensile strength

1300Mpa

Yield strength

1100Mpa

In this paper, we choose EN24 material for the gearbox components due to its optimal balance of strength, toughness, and wear resistance, crucial for the demanding conditions of Formula Electric Vehicles (FEVs). EN24 offers high tensile strength and excellent fatigue resistance, ensuring the gearbox can withstand substantial operational stresses while maintaining reliability and performance. This material selection enhances the gearbox's capability, significantly improving the overall efficiency and competitive edge of the FEV. 1.2 Input Parameter input parameters for the design and analysis of the twostage reduction gearbox for a Formula Electric Vehicle (FEV):

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