Creation of a general mathematical model of Torsen T-2 differential units for kinematical analysis, geometric design and CAD modelling

Abstract The power can be taken from the ICE crankshaft is a function of the continuously changing adhesion coefficient between the tire and the road surface and the normal force of the wheel. In order to maximize vehicle dynamic performance, Torsen differentials were developed change the power transmission ratio between the wheels or axles depending on the tractive force can be transmitted. The Torsen T-2 differential having internal kinematic ratio i = −1, can be used both as a front and rear as well as a central differential. The torque ratio between the axles connected via Torsen T-2 differential is ensured by the high internal mechanical friction, can be derived from the axial tooth force component of the helical gear drive applied. The aim of this study is to create a general mathematical model of the Torsen T-2 standard construction. Using this model enables to perform a detailed kinematic analysis of the operation of the entire mechanism. This model will be created by the motion of the gears since coordinate systems are ordered to each moving gears. Based on the Connection I statement the conjugated gear profiles of the gear pairs can be determined by mathematical and computational ways. After that, the CAD models of the gears can be created using 3D software for further finite element analysis. These CAD models are also required for computer-aided manufacturing (CAM) and CNC programming. We prove the usefulness of the model in the case of creating a concrete geometric facility produced by 3D printing.