Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train using Simulation Tool

Dr. Shıvakumar Nagareddy; Ravi Subramanyam; Vijay Govindarasu

doi:10.30939/ijastech..1673182

Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train using Simulation Tool

Abstract

The complex geometry with sliding contact surfaces of hypoid gear pair with differential unit in automotive vehicles results in increased frictional losses and reduced mechanical efficiency. This study focuses on the influence of shaft offset, spiral angle of hypoid gears, shaft rotational speed of shaft and torque transmitted on the efficiency and power losses of hypoid gears with differential units used in automotive vehicles. AMESim simulation tool was used to optimize the key parameters towards maximum efficiency, and lower power losses through bearings as well as gear pair. The geometry of hypoid gear train with differential unit including forces (ra-dial, axial and tangential) consideration was modeled and tested for gear efficiency and power losses at various values of shaft offset, spiral angle, shaft rotational speed and torque. From the simulation results, it is observed that the maximum increment in total power loss achieved from 10 mm to 25mm shaft offset was 81%. The global efficiency of the gear system showed maximum when the shaft offset was small and the spiral angle was small. The maximum efficiency drop from 40° to 50° spiral angle was about 51% and the total efficiency drop from 30° to 50° spiral angle was 81%. The global efficiency of the gear system was increased gradually with the increase of rotational speed. The maximum percentage increase in total power losses from 1000 rpm to 2000 rpm speed was 102.6%. The significant power losses and maximum increase in ef-ficiency happen between 200 Nm to 300 Nm and its total power loss increase was 51%. This study serves as a valuable resource for gear manufacturers to improve the efficiency of the hypoid gear train with differential units through optimizing the input key parameters with reduced power losses.

Keywords

Supporting Institution

Chennai Institute of Technology, Chennai, India.

Ethical Statement

Authors declare that the submitted research article is original one and is not submitted to any other journals or elsewhere.

Thanks

We thank the management of the supporting institute for providing the facility available in the campus to conduct this research study.

References

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Details

Primary Language

English

Subjects

Vehicle Technique and Dynamics, Automotive Engineering (Other)

Journal Section

Research Article

Authors

Dr. Shıvakumar Nagareddy ^*
0000-0001-9084-9101
India

Ravi Subramanyam
0000-0003-1778-6516
India

Vijay Govindarasu
0009-0000-3220-8947
India

Publication Date

September 30, 2025

Submission Date

April 10, 2025

Acceptance Date

August 26, 2025

Published in Issue

Year 2025 Volume: 9 Number: 3

DOI

https://doi.org/10.30939/ijastech..1673182

IZ

https://izlik.org/JA94YR66DX

Cite

RIS / Bibtex

APA

Nagareddy, D. S., Subramanyam, R., & Govindarasu, V. (2025). Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train using Simulation Tool. International Journal of Automotive Science And Technology, 9(3), 374-381. https://doi.org/10.30939/ijastech..1673182

AMA

1.Nagareddy DS, Subramanyam R, Govindarasu V. Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train using Simulation Tool. IJASTECH. 2025;9(3):374-381. doi:10.30939/ijastech.1673182

Chicago

Nagareddy, Dr. Shıvakumar, Ravi Subramanyam, and Vijay Govindarasu. 2025. “Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train Using Simulation Tool”. International Journal of Automotive Science And Technology 9 (3): 374-81. https://doi.org/10.30939/ijastech. 1673182.

EndNote

Nagareddy DS, Subramanyam R, Govindarasu V (September 1, 2025) Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train using Simulation Tool. International Journal of Automotive Science And Technology 9 3 374–381.

IEEE

[1]D. S. Nagareddy, R. Subramanyam, and V. Govindarasu, “Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train using Simulation Tool”, IJASTECH, vol. 9, no. 3, pp. 374–381, Sept. 2025, doi: 10.30939/ijastech..1673182.

ISNAD

Nagareddy, Dr. Shıvakumar - Subramanyam, Ravi - Govindarasu, Vijay. “Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train Using Simulation Tool”. International Journal of Automotive Science And Technology 9/3 (September 1, 2025): 374-381. https://doi.org/10.30939/ijastech. 1673182.

JAMA

1.Nagareddy DS, Subramanyam R, Govindarasu V. Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train using Simulation Tool. IJASTECH. 2025;9:374–381.

MLA

Nagareddy, Dr. Shıvakumar, et al. “Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train Using Simulation Tool”. International Journal of Automotive Science And Technology, vol. 9, no. 3, Sept. 2025, pp. 374-81, doi:10.30939/ijastech. 1673182.

Vancouver

1.Dr. Shıvakumar Nagareddy, Ravi Subramanyam, Vijay Govindarasu. Influence of Shaft Offset, Rotational Speed, Spiral Angle and Torque on Efficiency and Power Losses in Automotive Hypoid Gear Train using Simulation Tool. IJASTECH. 2025 Sep. 1;9(3):374-81. doi:10.30939/ijastech. 1673182