Review on Design and Structural Analysis of a Differential Gearbox and Casing for Electric Vehicles

The rapid growth of electric vehicles (EVs) necessitates innovative approaches to improve power transmission efficiency, reduce weight, and enhance overall vehicle performance. A critical component in EV drivetrains is the differential gearbox, which transfers torque from the electric motor to the drive wheels while allowing differential wheel speeds during cornering. Conventional gearboxes, typically constructed from heavy cast iron or steel, significantly increase vehicle weight, adversely affecting energy efficiency and battery range. This study focuses on the design, modeling, and structural analysis of a single-speed, two-stage reduction compound differential gearbox and its casing, specifically optimized for EV applications. Finite Element Analysis (FEA) is employed to evaluate stress distribution, deformation, and thermal behavior under varying torque loads. The study explores alternative lightweight materials to replace traditional metals without compromising mechanical strength or durability. The proposed design aims to optimize structural performance, reduce overall weight, and ensure reliability under operational conditions. Results from this research provide valuable insights for developing advanced, lightweight differential gearboxes that enhance EV efficiency, improve driving range, and meet modern performance and durability requirements.