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| Simulation Analysis Method of Fatigue Life for Differential Housing |
| Received:April 01, 2021 Revised:May 26, 2021 |
| View Full Text View/Add Comment Download reader |
| DOI：10.7643/issn.1672-9242.2021.11.019 |
| KeyWord:differential plastic bracing FEA fatigue life |
| Author | Institution |
| TANG Tian-bao |
Zhejiang Geely Powertrain Research Institute, Powertrain Test Center, Ningbo , China |
| LUO Yi-jian |
Zhejiang Geely Powertrain Research Institute, Powertrain Test Center, Ningbo , China |
| QIN Yu-lin |
Zhejiang Geely Powertrain Research Institute, Powertrain Test Center, Ningbo , China |
| PENG Guo-min |
Zhejiang Geely Powertrain Research Institute, Powertrain Test Center, Ningbo , China |
| YU Chun-xiang |
Zhejiang Geely Powertrain Research Institute, Powertrain Test Center, Ningbo , China |
| HU Jun-feng |
Zhejiang Geely Powertrain Research Institute, Powertrain Test Center, Ningbo , China |
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| Abstract: |
| This paper is to study the fatigue life analysis method of differential housing and investigate the root cause of differential housing failure. Taking the specific testing load case as the input, support stiffness of decelerator housing as boundary condition, gear meshing force as the input load, the finite element model of the differential housing under the condition of elastic support is established, and the strength is calculated. The strength result is then input to fatigue SW FEMFAT to verify fatigue life. Considering that the analyzed conditions and loads of differential housing are complicated, Neuber formula is used to check the linear elastic stress correction method in combination with the material cyclic stress-strain curve and stress-strain hysteresis equation. At the same time, in order to better simulate the operating limit load of the differential, the load analysis adopts the alternating load of three positive and one negative. Finally, the result is judged based on the linear fatigue damage accumulated theory, Miner principle. According to the linear fatigue damage accumulated theory, Miner principle, the calculation results of the initial design scheme show that the fatigue failure occurs at the transition fillet of the housing, and the number of load cycles it can sustain is 270, which does not meet the design criterion of more than 350 times. The results are coincident with fatigue bench test and the correspondence of the failure area is good.. The differential housing is optimized by increasing the transition fillet radius of the differential housing and increasing the thickness of the housing. The optimized fatigue analysis results show that the fatigue life is increased to 417 times, which meets the design criterion of 350 times, and successfully passes the durability bench test. With comparison of simulation results and bench testing result before and after optimization, it is confirmed that this simulation analysis method can accurately predict the fatigue level of the differential housing and the analysis method is completely reliable in terms of calculation accuracy. It can be applied in the actual project development, identify and avoid risks in advance, and reduce the bench verification cost in the later stage. |
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