Study On Lightweight Drive Axle Shell And Reliability Verification

As one of the key technologies in the automobile industry at present, lightweightdesign of vehicle has been more and more valued by all the major automobilemanufacturers. The implementation of lightweight can not only reduce energyconsumption and reduce automobile exhaust emissions, but also can improve thevehicle’s comprehensive competition ability. As part of the unsprung, lightweightoptimization design of the rear axle shell assembly can enhance the vehicle’sacceleration, stability and controllability. It is more significant than other parts of thevehicle weight, and the effect is more obvious.Combined with the function of speed reducer assembly and half shaft assembly,the corresponding lightweight ideas and methods are put forward based on thestructure of rear axle shell. We adopt high strength materials on shaft tube and theupper and lower plate, and change the size of its shape. We also do theoreticalcalculation and check if it meets the criteria.Based on the design results, we carry out vertical bending fatigue bench test,vertical bending rigidity bench test, and vertical bending static strength bench test.Reliability verification is done of the test result.The results show that the rear axle housing assembly is7kg lighter than theoriginal rear axle assembly after the lightweight optimization design. We do fatiguesimulation analysis of the optimized model. The theoretical check and verificationtests show that after lightweight, all aspects of axle housing’s performance meet therequirements of evaluation indicators of national standards. It can be used instead ofthe original one.