42 Tooth Sprocket Design
Custom sprocket design for high-torque racing applications
Role
Designer & Engineer
Year
2023
Tools
SOLIDWORKS
Project Overview
This project involved designing a custom 42-tooth sprocket for the UTFR racing vehicle's drivetrain system. The sprocket needed to meet specific gear ratios while maintaining structural integrity under high-torque racing conditions.
Design Specifications
- 42 teeth configuration for optimal gear ratio
- Lightweight design using material optimization
- High-strength construction for racing applications
- Precision tooth profile for smooth power transmission
- Optimized weight distribution and balance
Engineering Process
The design process began with calculating the required specifications based on the vehicle's performance targets. Using SOLIDWORKS, I created detailed 3D models with precise tooth geometry following industry standards. The design underwent multiple iterations to optimize weight while maintaining structural integrity.
Technical Challenges
Key challenges included balancing weight reduction with strength requirements, ensuring precise tooth profile for minimal wear, and integrating the sprocket with existing drivetrain components. FEA analysis was conducted to verify stress distribution and factor of safety under racing loads.
Manufacturing
The sprocket was manufactured using CNC machining to ensure precise tolerances. Material selection focused on high-strength alloys suitable for racing applications. Post-manufacturing, the component was tested for dimensional accuracy and surface finish quality.
Results
The final sprocket met all design specifications and successfully integrated into the vehicle's drivetrain system. The design demonstrated excellent performance under testing conditions and contributed to the overall efficiency of the power transmission system.