Cracking Failure Analysis And Improvement Measures Of Automobile Drive Axle Housing

Drive axle housing's function is support, protection, fixed bearing, power transmission and so on. In the process of car moving, drive axle housing bears and transmits the power and torque of wheel, and transmits them to car body by suspension. In many parts of the domestic, because of complex terrain and overload, drive axle housing can be dehiscent on the wearing occasion.Drive axle housing is intricately shaped and in the system of rear suspension. System of rear suspension have lots of parts and have a complicate strained condition, so that it is difficult to calculate the strained condition and plastic strain of rear suspension system clearly.The topic is from Chang an automobile company, one automobile type of Chang an broke down when it was road test. In this essay, we analysis the drive axle housing in the rear suspension system and study its plastic strain under the vertical stress to find the reason of cracking. Then optimize the structure of drive axle housing to improve the plastic strain property. The main work of this essay as follow:Chapter one, introducing the composition and function of drive axle housing, the current study situation in china and abroad and the background of research.Chapter two, introducing the theory of Failure Analysis and Fracture Analysis, the feature and classification of fracture, studying metallographic phase of drive axle housing, fracture morphology and chemical composition. Analysis the crack reason of drive axle housing to analysis the drive axle housing by finite element software.Chapter three, introducing the theory and development of finite element software, using CATIA sets up the finite element model of drive axle housing and rear suspension system, then using HyperMesh does mesh generation to analysis plastic strain of drive axle.applying load and constraint to the finite element model of rear suspension, improving mesh generation, then calculate the plastic strain result of drive axle housing out. In addition, introducing the stiffness experience of drive axle housing and rear suspension system, analyzing the accuracy of CAE result.Chapter four, improving the structure of drive axle housing, presenting five ways to improve the structure, and analyzing weather it meets requirements or not one by one.Through the analysis of essay, we find the crack reason of drive axle housing out, and present two efficient ways to decline the plastic strain of drive axle housing, they meet requirements of plastic strain property, and it is beneficial to subsequent study.