Drive Axle – Spiral Bevel Gear Set Design

Designed the rear axle spiral bevel ring-and-pinion for a Nissan X-Trail–based vehicle. Using MATLAB, I calculated the weighted input torque from the duty cycle over all gears and vehicle lifetime, then used this torque as input to a KISSsoft bevel gear calculation according to ISO 10300/23509. I selected case hardened steel, defined geometry, materials and lubrication, verified tooth root and flank safety factors and service life, and created fully dimensioned manufacturing drawings for both gears.