International Journal of Analytical, Experimental and Finite Element Analysis

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This work is intended to design differential cover based on existing cover. The cover is checked for structural stability by performing finite element analysis. Earlier observed issues like premature cover failure, bolt loosening (carrier to cover) and oil leakage from cover mating surface are rectified through finite element analysis. This is done by performing multiple FEA iterations by changing wall thickness, size of hole and number of holes. Fatigue life of differential cover obtained by finite element method is validated by experimental method. The model chose is that of a light commercial vehicle which has a gross axle weight rating 1050 kg. The cover material is SAPH 440 (Steel Automotive Pickled Hot-rolled and 440 MPa minimum tensile strength).
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