Role Overview 

• Responsible for end-to-end design of differential systems used in Transmission and e-Axle architectures  

• Deliver robust designs meeting torque capacity, durability, NVH and efficiency targets within package and cost constraints. 

Differential Gearset Design Responsibility 

• Bevel gear macro-geometry sizing and micro-geometry optimization using KISSsoft/HyGears; contact pattern and backlash tuning. 

• Differential Housing/case design (FE-cast), bearing setting (preload/back-to-back), and shim strategy. 

• Differential Seizure & Differential Spline & Lockring calculation  

• DFM for forged bevel gears; heat treatment specs and inspection (Gleason/Klingelnberg charts). 

• 3D/2D in UG-NX with full GD&T and tolerance stack-up; release assemblies/BOMs in Teamcenter and SAP. 

• Coordinate with FEA for structural, thermal and NVH; plan test correlation; conduct DFMEA and root-cause analyses for failures (bending, pitting, scuffing, carrier cracks). 

Required Skills 

• Software: KISSsoft, HyGears(Optional), BECAL(Optional) , MASTA, UG-NX, Teamcenter, SAP. 

• Manufacturing knowledge: bevel cutting/grinding, casting/forging, heat treatment; inspection methods and acceptance criteria. 

• Materials and surface treatments for bevel gears, shafts, thrust washers and pins; lubrication fundamentals. 

• Excellent communication and cross-functional coordination skills