| In the contemporary society,automobile had become an important means of transportation,but the increase of pollutants emitted by automobile also causes serious harm to the environment.In recent years,countries around the world were committed to energy saving and emission reduction of automobiles,and major automobile manufacturers were paying more and more attention to automobile lightweight.As a part of the automobile transmission system,the drive axle is an important part of the automobile chassis,and the axle housing is the base of the assembly of other parts of the drive axle assembly.It is not only a bearing part but also a force transfer part,and the working environment was very bad.Therefore,the axle housing should have reliable strength,stiffness and good fatigue life performance,and at the same time avoid excessive pursuit of safety leading to material waste.In this paper,the driving axle housing of a light bus was taken as the research object.The three-dimensional modeling was realized in UG software,and the finite element model was established in Hypermesh software.The whole process of the overall analysis of the performance of the axle housing was realized by combining the finite element analysis with the driving axle bench test.Four typical working conditions were considered in the static analysis of axle housing.The axle housing not only bears static stress,but also bears large dynamic stress due to the impact of uneven road surface.Therefore,based on free modal analysis,considering the influence of low order modes on the axle housing,the first six order modal parameters were extracted.In the actual working process of automobile,the axle housing may break suddenly under the action of alternating load.The nominal stress method and Miner linear cumulative damage theory were used to analyze the fatigue life of the axle housing.The results of finite element analysis showed that this type of axle housing had enough strength and stiffness,the axle housing will not resonate under the excitation of uneven road surface,and has good dynamic performance.The fatigue life of the axle housing also met the national standard.so the axle housing had a certain lightweight space.The size optimization method was used to design the light weight of the axle housing.The thickness of the sleeve was reduced from 12 mm to 9.8 mm,the thickness of the leaf spring seat was reduced from 15 mm to 8 mm,the weight of the axle housing was reduced from 65.9 kg to 58.1 kg,and the weight was reduced by 11.8%.The size parameters obtained after lightweight were given to the finite element model for recalculation.The results of finite element analysis showed that the optimized axle housing still had good static and dynamic performance.The accuracy of the modal simulation analysis of the axle housing was verified by the modal experiment of the axle housing.Finally,the bench test was carried out according to the vehicle driving bridge bench test method,the test results showed that all meet the national standards,and the reliability of the lightweight rear axle housing was verified through the vehicle driving bridge bench test. |
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