Effect Of Half-shaft Bushing Process Parameters On Strength, Stiffness And Fatigue Life Of Bulging-crushing Deforming Axle Housing

Drive axle housing is one of the most important load-bearing and power transmission parts of automobile, which performance directly affects the service life of the automobile. With the new technology manufacturing of bulging-pressing deforming automobile housing, which advantages are high material utilization, reasonable thickness distribution, long life, etc. Half-shaft bushing connection welds as the main axle weld and weak performance area of bulging-pressing deforming automobile housing. Half-shaft bushing assembly tolerances and fitting length have influence on the strength but uncertain. Therefore, reveals the influence law of half-shaft bushing assembly process parameters on strength, stiffness and fatigue life of bulging-crushing deforming axle housing and puts forward a better process scheme. Then provide a reference for the production that will produce a great economic benefit and practical significance.This article takes the bulging-crushing deforming axle housing as research object which standard load is 5ton. The static bending stress of the axle housing is calculated in the maximum vertical force condition and reveals three dangerous section areas. Establish and analyze deformation and stress model of half-shaft bushing connecting seam. Then the influence law of half-shaft bushing assembly process parameters on stress of connecting weld zone is revealed.The bulging-crushing deforming process is simulated with the software UG, ABAQUS. Then get result of the axle housing body with residual stress and deformation strengthening. Establish five groups finite element model of the bulging-crushing deforming axle housing and then get the axle housing strength stiffness finite element analysis results from the maximum vertical force of static analysis. The influence law of half-shaft bushing assembly process parameters on strength, stiffness and the key parts stress of the bulging-crushing deforming axle housing are revealed by analysis.According to the strength, stiffness of axle housing analysis result, the fatigue life of the axle housing is analyzed by MSC.FATIGUE software, then focuses on the changes in fatigue life of three fatigue damage area which are inside leaf spring, arm transition zone, half-shaft bushing weld zone, then get relationship between the fatigue life values S of connection welds and half-shaft bushing assembly tolerances a, fitting length of b. Finally, the influence law of half-shaft bushing assembly process parameters on fatigue of bulging-crushing deforming axle housing is revealed.The assembly stress and axial force is obtained by numerical simulation of the half-shaft bushing and axle housing body assembly process. Then combine with performance analysis results, this paper make a better half-shaft bushing assembly and welding process scheme. Finally, half-shaft bushing and axle housing assemble with loose fit is carried a fatigue bench, verify the reliability of the research methods.