| Through analyzing fractures of the automotive drive axle final drive gear carriage, most of those fractures are related to fatigue failure of the gear carriage system. Therefore, the analysis of fatigue resistance of the drive axle final drive gear carriage and the life evaluate the rest life of the drive axle final drive carriage, which are important both theoretically and practically.On the basis of the current research on test rig for the automotive drive axle final drive gear carriage system, a new fatigue test rig is proposed in the form of a alternating current frequency conversion closed loading project. And the test specification could be established, and then the fatigue lives of a concrete final drive have been obtained by using this fatigue test rig. The paper briefly describes the theoretical knowledge and the fatigue analysis methods, combined with the inherent characteristics of meshing bevel gears, presented the specific method of calculation of fatigue life. And the theoretical value of bevel gear fatigue life is calculated by the nominal stress method. Specifically, 3-D solid modeling of a concrete bevel gear is established and then its virtual assembly is fulfilled, using Pro/ENGINEER software. Moreover, its FE modeling for analysis is built in different working conditions by MSC.PATRAN software. Eventually, fatigue resistance of the bevel gear is calculated by the resolver of MSC.MARC, based on which its fatigue life is forecasted by MSC.FATIGUE software. Comparing simulation results with the theoretical result, it obtains that the two results are basically the same, in order to verify the theoretical modeling and finite element analysis. It provides the theoretical basis for the further research on the analysis of fatigue life and its life evaluation in practical work conditions. By analyzing the failure of bevel gears involved experiment, it concludes bevel gear failure. The reason for that failure has taken measures to prevent premature failure of gears.
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