Lightweight Design And Fatigue Life Analysis Of Wheel Edge Reducer Housing

As the energy problem continues to be prominent,energy saving and environmental protection are getting more and more attention in the automotive industry,and new energy vehicles are also developing rapidly.As one of the important components of new energy vehicles,the strength of the housing of the wheelside reducer is crucial to the reducer,so the performance of the reducer housing has a direct link to the performance of the whole vehicle.For new energy vehicles,lightweighting can reduce the manufacturing cost and improve its acceleration performance.Therefore,when designing the shell structure,it is an important step to reasonably design the reducer shell so that its strength and stiffness meet the design requirements of the shell and verify the performance of the reducer shell through finite element analysis.This for the use of finite element analysis method,the reducer shell for static analysis,dynamic characteristics analysis,and finally through the fatigue strength analysis to verify the performance of the shell,through the topology optimization of the reducer shell to optimize the design,the main content of this paper is as follows:(1)The three-dimensional model of the reducer shell is established,and the force analysis of the reducer shell is carried out to get the force situation of the reducer shell under the peak torque working condition and rated torque working condition,and the force is applied to the shell to get the stress and deformation cloud diagram of the reducer shell under the two working conditions,and it is found that the shell structure is relatively rich and there is some space for light weighting,so as to prepare for the subsequent light weighting design of the reducer shell.(2)The modal analysis of the shell was carried out by finite element software,and fixed constraints were applied to extract the first six orders of inherent frequencies and vibration diagrams of the reducer shell,which were compared with the external excitation frequencies and the rotation and meshing frequencies of the gears to avoid resonance phenomena.On this basis,harmonic response analysis of the reducer shell is carried out,and the inherent frequency of the reducer shell structure is obtained between 1500 Hz and 3000 Hz,so the displacement and stress in this frequency range are analyzed,and the displacement-frequency curve and stress-frequency curve are obtained to provide reference for the subsequent optimization design.(3)Based on the static analysis,the topology optimization analysis of the reducer shell is carried out with the minimum mass as the constraint target,and the lightweight design of the reducer shell is carried out by changing the local structure of the reducer shell and adjusting the thickness of the reducer shell to satisfy the strength and stiffness,and the mass is reduced from 5.13 kg to 4.80 kg,which is about 6.4%,and the material cost is reduced,and the optimized The results show that the strength and stiffness of the optimized housing meet the design requirements.(4)Using the finite element software to analyze the fatigue strength of the shell,on the basis of the static analysis,combined with the road load spectrum and the S-N curve of the material to analyze the fatigue strength of the reducer shell,we get that the fatigue life of the reducer shell can reach 1.46x104 cycles,which meets the fatigue life design requirements of the reducer shell.