Sprocket Design and FEA Testing
I designed and FEA-tested this sprocket to help transfer torque from the motor to the differential. The sprocket was implemented with a safety factor of ~2 and was designed with waterjet cutting in mind. The analysis included deformation and stress results from ANSYS, along with a load cases spreadsheet for further verification.
FEA stress of Sprocket
Load Cases Spreadsheet
Key Features
- ANSYS FEA Simulations: Performed deformation and stress analyses to ensure the sprocket's structural integrity.
- Safety Factor: Implemented a safety factor of ~2 to account for potential operational stresses.
- Waterjet Design: Designed the sprocket with waterjet cutting in mind for precise manufacturing.
- Load Case Analysis: A detailed load cases spreadsheet was used to verify the sprocket's performance under various conditions.
Applications and Benefits
This sprocket is a key component in the drivetrain system, transferring torque efficiently from the motor to the differential. The FEA testing ensures that the sprocket can handle the required loads while maintaining structural integrity and longevity. By using a safety factor of ~2 and optimizing for waterjet cutting, the sprocket is both durable and manufacturable, making it a reliable solution for high-performance vehicle applications.
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