The input shaft of gearbox usually bears a cyclic variation of torque, which may lead to the risk of experiencing a fatigue fracture. To evaluate the fatigue life accurately and identify the weak parts, the ANSYS is used to simulate the torsional fatigue of the input shaft for the gearbox, and the fatigue life of the weak part is obtained, which is then tested and verified by the torsional fatigue testing in the MTS torsional fatigue test rig. The test results show that the maximum difference is 14% between the calculated life and the testing results, indicating that the simulation value can reflect the actual fatigue life accurately. Notably, the cracks appear in the large oil holes, and its life is mainly concentrated in the crack initiation stage, accounting for 99.2% of the total life. The analysis results show that the fatigue life of the software simulation has the guiding significance for the life evaluation. The fatigue life of the shaft can be quickly calculated by the simulation to reduce the number of fatigue tests and achieve cost-effectiveness.
Noise, Vibration and Harshness (NVH) is a comprehensive issue of manufacturing quality that gives the purchaser a superficial feeling. The NVH performance of the vehicle has undoubtedly become an important factor and basis for consumers. When the internal combustion engine is working, it generates a strong noise thus making it necessary to reduce the vibration and noise. The noise of diesel engine is divided into acoustic and structural radiation noise according to different radiation paths. The structure radiated noise is mainly caused by the combustion noise and mechanical transmission noise, while mechanical transmission noise is mainly generated by the meshing gears in the diesel. This paper aims to solve the problem of a diesel engine abnormal gear whine noise under idling conditions with a combination of simulation and experiment. By gear micro-modification, the gear train whine noise is reduced by minimizing the PPTE of the gear train. The comparison of the simulation to benching testing shows a good correlation. It provides an optional solution to the modification proposal of the engine gear train, which uses the similar structure for the engine. Future work will dwell on a better understanding of the gear rattle noise, which will be discussed later.
Gears are rotating mechanical parts with excellent power transmission efficiency and are widely used in machine tools, automobile, industrial machinery, and aviation industries. To enhance the performance of the gear, optimized design of the gear geometry is paramount. In this paper, we optimize the geometric tooth profile of helical gears which are among the gears of the transfer case gearbox by using the finite element program, Romax Designer to model and analyze the load and gear teeth of the gearbox power transmission system. The optimized gears were fabricated and compared to the results of the gear tests.
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Nowadays, noise, vibration, and harshness (NVH) is a comprehensive issue related to manufacturing quality, it gives the purchaser the most direct and superficial feeling. Following economic development, the improvement of people’s living standards, and the expansion of the export market, it has become urgent to develop and produce some better NVH performance motorcycles. In this paper, the transmission of a scooter gearbox is modeled and analyzed by software. Then, the first helical gear pair of the gearbox was investigated through static analysis. Lastly, optimized modification was verified using B&K testing equipment in the semi-anechoic room. The comparison of the simulation to prototype during testing showed a good correlation, which means simulation optimization can greatly improve the research and development efficiency of the transmission system.
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The aim of this study is to design the gearbox of an electric vehicle using the rear-wheel drive. The gearbox is a set of revolving gears and shafts based on programmed torque and rotations per minute (rpm). In this case, safety, strength and durability of gears and shafts was considered. In the narrow vehicle, a light case is used. In addition to gear safety and deflection, the weight of the vehicle was reduced. The electric vehicle reducer gearbox was modeled according to the vehicle room. The strength analysis was conducted using finite element method (FEM). After analyzing the strength using FEM to verify stress distribution, the design was modified, and compared with the results of altered design using FEM. As a result, the reducer gearbox of electric vehicle was designed according to incorporate gear safety, deflection of each gear, durability, and analysis of finite elements followed by test assessment, vehicle installation and the production of real parts.
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