Lightweight forged differential

Differentials are found in all vehicles – in four-wheel drives there are even two of them. They are mostly designed as a hypoid-toothed ring gear or as an input gear with helical teeth on the outside. Both types are connected to a cast housing. This can lead to geometry duplications (e.g. for fastening) which increase the system mass. Hirschvogel opts for a forged component area which can be designed very thin due to the high Young’s modulus and the high strength of the steel. Welding the part to a ring gear or speed gear (whose central area then forms the cover of the differential housing) leads to significant weight savings compared to conventional solutions.

 

Technical specifications

Application Area Differential, powertrain
Material Case-hardening steel for toothed part, bainitic or dispersion-hardening steel for housing component; both materials have good weldability
Porduction process Forged, machined, heat treatment, joined
Characteristics Lightweight solution beyond conventional approaches