Hypoid Gear Modeling And Contact Fatigue Analysis

This article is an important part of the work of SAIC-GM-Wuling Project "research to reliability of rear axle assembly and optimization of noise performance". In this paper, we use the method of rain-flow counting on statistics of measured load time history to the micro-car's all kinds of conditions, so that formulating the rear axle assembly's input torque load spectrum; then we establish hypoid gear's three-dimensional model, and convert torque spectrum into stress spectrum through the contact Finite Element Analysis. At last we use the method of fatigue analysis conducting Hypoid gear's contact fatigue life analysis. Main contents and characteristics of this paper are:(1) Analysis the hypoid gear's processing, study Hypoid Gear's Cutting parameters, solve equation of the hypoid gear's tooth surface; establish the hypoid gear's three-dimensional model.(2) Carry on rain-flow counting to various of condition's input torque measured load spectrum of micro-car Rear axle assembly's active and passive gear(Hypoid gear pair),use probability statistics analyzing distribution regular of working conditions load spectrum's peak and mean value.(3) Adopt knowledge of fuzzy comprehensive evaluation and comprehensively considering conditions of hardware, conditions of laboratory equipment, laboratory material properties, load spectrum types and other factors to load-spectrum-preparation giving full play to experience strength of the experts, establish a new way to a small load cutting.(4) Study the load spectrum types of roads at all levels, achieve load grading base on the preparation method of traditional eight level load spectrum, give full consideration to the location of the load cycle, so that prepared load spectrum take consideration in the effect of load order.(5) Finite element method is used for numerical simulation of hypoid gear tooth surface contact stress, comparing differences between the results of theoretical calculation and finite element calculation to determine analysis accuracy of the three-dimensional model that created. Set up the stress spectrum of fatigue life analysis.(6) Basing on P-S-N fatigue curve of material, considering life curve of stress concentration coefficient, the size coefficient, the lateral surface coefficient and other Horizontal factors'effecting and combining, we fit P-Sa-Sm-N fatigue curve surface equation; using the method of two-dimensional fuzzy-Miner, predict contact fatigue life of hypoid gears. Study effect of hypoid gear's installation Technology (install bias, coaxiality, opening volume) to the prediction results of the fatigue life.