Differential Sprocket Adapter
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Sep 2024 - June 2025 | Northwestern Formula Racing
Designed and manufactured a drivetrain-critical differential sprocket adapter (DSA) as part of my freshman project for the Formula SAE Electric team — a part the team had unsuccessfully attempted for the past 3 years.
CAD
Previous Design
Version 1
Version 5
Version 7 (Final)
The original design supported only one-directional torque. We redesigned it to handle bidirectional loads while accommodating a new sprocket and differential. After 7 design iterations guided by FEA, we finalized a 4-spoke geometry, validating that 8 spokes (matching the 8 sprocket bores) were structurally unnecessary.
Assembly with differential and sprocket
FEA
We optimized the part through multiple FEA iterations under peak drivetrain torque to meet a ≥1.25 Factor of Safety and survive over 450,000 peak torque drivetrain cycles, all while minimizing mass.
Von-Mises Stress Simulation
FoS Simulation - Achieved FoS of 2.9
Fatigue Simulation - Part withstands >950,000 drivetrain cycles
Manufacturing
Machined the DSA using 7075-T6 Aluminum on a 3-axis CNC mill using Fusion 360 CAM in two operations. Included fillets and chamfers to reduce stress concentrations. Centered from the spline geometry to avoid tolerance stack-up.
Results
Successfully manufactured on the first attempt, one month ahead of our rolling chassis deadline as the first drivetrain component completed. Achieved a 12% mass reduction from the 2023–24 design and exceeded mechanical requirements by over 2× (Factor of Safety, fatigue life). Contributed to the 2024–25 team’s leap from a non-driving car at the ’24 competition to placing 23rd out of 86 teams in ’25.
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