The manufacturing of differential gears went away from the Revacycle broaching process to forging more than 30 years ago. Today, where electric vehicles create a peak torque which are a multiple higher than in vehicles with internal combustion engines, the strength and the Noise Vibration Harshness (NVH) advantages of cut differential gears are revisited. The newly developed Coniflex Pro straight bevel gears combine several new features which make them stronger and quieter than past straight bevel gears and far superior to the forged version.
In modern automotive vehicles, gear noise becomes more and more of an issue. The main reason is the reduced masking noise of the engine, which vanishes completely in the case of an electric driveline. Improved gear quality unfortunately does not correlate with a better noise performance in any case. High gear quality makes sure that the gear flanks are inside tight tolerances and that all teeth are nearly identical. Even if the running behavior of such gear sets shows a very low sound pressure level, the noise perception for human ears may be annoying.