Differential Gears

Interactive Lecture

Torque Distribution, Speed Kinematics, and Cornering Behaviour in Automotive Drivetrains

by Dr Arnaldo Delli Carri

The Differential: Allowing Wheels to Turn at Different Speeds

When a car turns a corner, the outer wheel traces a longer arc than the inner wheel. If both driven wheels were locked to the same shaft, one would be forced to slip — wasting energy and causing tyre wear. The differential solves this by allowing the two output shafts to rotate at different speeds while still transmitting engine torque to both wheels.

The open differential uses a set of bevel gears arranged so that the speed of the two output shafts averages to the speed of the input (ring gear). The planet gears — the small bevel gears that sit on the spider — are the key: they are free to rotate about their own axes, which lets one output speed up as the other slows down, without disturbing the sum.

The fundamental rule of the open differential: the average output speed equals the input speed. Torque is always split equally between the two outputs, regardless of the speed difference. This is both its strength and its limitation.

Kinematic Equations

Label the ring gear (carrier) angular velocity \(\omega_c\), and the two output shafts (left and right axles) \(\omega_L\) and \(\omega_R\). The differential imposes the constraint:

\[\omega_c = \frac{\omega_L + \omega_R}{2}\]

Where:

Rearranging, the speed difference between the outputs is:

\[\omega_R - \omega_L = 2(\omega_R - \omega_c)\]

When the vehicle travels straight, \(\omega_L = \omega_R = \omega_c\) and the planet gears do not spin about their own axes. In a corner, they begin to rotate, allowing the speed difference to develop.

Planet Gear Self-Rotation

The planet gears mesh with the side (output) gears at the pitch-line, so in the carrier's rotating frame the two gears' surface speeds must match at that mesh. Writing the planet's pitch radius as \(r_p\) and the side gear's as \(r_s\) gives the planet's own spin rate:

\[\omega_p = \frac{\omega_R - \omega_L}{2} \cdot \frac{r_s}{r_p}\]

Where:

Driving straight gives \(\omega_R = \omega_L\), so \(\omega_p = 0\) — the planets orbit with the carrier but do not spin on their own axes. Cornering makes them spin at a rate set by the speed difference and the gear ratio \(r_s / r_p\).

Cornering Kinematics

For a vehicle of track width \(2w\) (distance between tyre contact patches) turning with radius \(R\) measured to the vehicle centreline, the required speed ratio is:

\[\frac{\omega_R}{\omega_L} = \frac{R + w}{R - w}\]

Where:

The carrier runs at the average: \(\omega_c = \frac{\omega_L + \omega_R}{2}\).

Torque Distribution

In an open differential, the planet gears are in static equilibrium on the spider. Summing torques about the spider axis shows that the driving torque \(T_c\) delivered to the carrier splits equally:

\[T_L = T_R = \frac{T_c}{2}\]

This equal split is the defining property of the open differential. It is independent of the speed difference between the outputs. The torque available at each wheel is limited by whichever side has the least traction — the Achilles' heel of the open design.

Limited-Slip Differentials

A limited-slip differential (LSD) adds a mechanism — friction clutch packs, viscous coupling, or Torsen worm gears — that introduces a torque bias ratio \(k\):

\[T_{\text{high}} = k \cdot T_{\text{low}}\]

Where:

Simulation 1 — Cornering Kinematics

The left panel shows a top-down view of the driveshaft, differential, and two driven wheels. The right panel shows the differential internals — ring gear, planet bevel gears on the spider, and side gears. Press the buttons to steer; adjust the turning radius to see how the inner/outer speed ratio depends on the corner geometry. The sim runs at a fixed display speed, so try \(R = 8\) m to reproduce Problem 1's turning radius and 1.222 speed ratio — not its 200 rpm carrier speed; try \(R = 3\) m for a tight roundabout.

8.0

Simulation 2 — Torque Distribution and Limited-Slip

Select a road scenario. The width of the torque arrow on each axle reflects how much drive reaches that wheel. A wheel spinning freely (red) is receiving torque it cannot use. Notice how the LSD scenario recovers drive that the open differential wastes. Wheel speeds animate at a fixed schematic rate for legibility, not to any real vehicle speed — the rpm and kW readouts show how power (torque × angular speed) splits between useful drive and slip losses, not an actual drivetrain's numbers.

Engineering Applications

Summary of Key Equations

Concept Equation Description
Differential constraint \(\omega_c = \dfrac{\omega_L + \omega_R}{2}\) Carrier speed equals the average of the two output speeds
Speed difference \(\Delta\omega = \omega_R - \omega_L\) Proportional to how fast planet gears spin on their own axes
Cornering speed ratio \(\dfrac{\omega_R}{\omega_L} = \dfrac{R + w}{R - w}\) Required ratio for smooth rolling; outer wheel faster than inner
Open diff torque split \(T_L = T_R = \dfrac{T_c}{2}\) Equal torque to both outputs regardless of speed difference
LSD torque bias \(T_{\text{high}} = k \cdot T_{\text{low}}\) Higher-traction side receives \(k\) times more torque than the slipping side
Total input torque (LSD at bias) \(T_c = T_{\text{low}}(1 + k)\) Only when the low-traction side has reached its grip limit and the LSD is at its bias ratio; below that, the diff acts as open

Practice Problems

Problem 1: Cornering Wheel Speeds

A rear-wheel-drive car has a track width of 1.6 m (so \(w = 0.8\) m). The rear axle carrier rotates at 200 rpm. The car turns a corner with a turning radius of 8 m measured to the vehicle centreline.

Find: (a) the required speed ratio \(\omega_R / \omega_L\), and (b) the angular speeds of the inner and outer rear wheels.

Show Solution

Problem 2: Open Differential on a Slippery Surface

A vehicle's rear differential receives 400 N·m of input torque. The right rear wheel sits on ice and can transmit a maximum of 30 N·m before spinning. The vehicle has an open differential.

Find: (a) the torque delivered to each wheel, and (b) the total forward thrust force available, given a tyre rolling radius of 0.32 m.

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Problem 3: Limited-Slip Differential Torque Distribution

The same vehicle from Problem 2 (400 N·m input, ice-side traction limit 30 N·m, \(r = 0.32\) m) is now fitted with an LSD having a torque bias ratio of \(k = 3\).

Find: (a) the torque at each wheel, and (b) the total forward thrust, and compare with the open differential result.

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Problem 4: Planet Gear Angular Velocity

In a bevel differential, the ring gear (carrier) rotates at \(\omega_c = 120\) rpm. The left output shaft rotates at \(\omega_L = 90\) rpm. The bevel planet gears have a pitch circle radius of \(r_p = 40\) mm, and the side gear (output bevel) has a pitch circle radius of \(r_s = 80\) mm.

Find: (a) the right output shaft speed, and (b) the angular velocity of a planet gear about its own axis relative to the carrier.

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Knowledge Check Quiz

Question 1: A vehicle's open differential receives 500 N·m of input torque. How much torque reaches each output shaft?

Question 2: A car with \(w = 0.7\) m turns with \(R = 7\) m. What is the ratio of outer to inner rear wheel speeds?

Question 3: An open differential has one wheel on ice (max traction 20 N·m) and one on tarmac. What is the maximum forward thrust if tyre radius is 0.3 m?

Question 4: What happens to the planet gears when the vehicle travels in a straight line at constant speed?

Question 5: A Torsen-type LSD has a bias ratio of \(k = 4\). The low-traction wheel receives 40 N·m. What torque does the high-traction wheel receive?

Question 6: Why is the open differential described as having an "equal torque" constraint rather than an "equal speed" constraint?