Fatigue Life Estimation And Research Of A Gearbox Housing Based On Finite Element Method

The paper makes on fatigue life estimation of a gearbox housing，what is a part of aproject named “the research and the production exploitation of the structural topologyoptimization of the gearbox housing. The project is supported by Changchun Science andTechnology Bureau。Facing the problem that the gearbox became heavy because of thematerial of it is changed, the lightweight processing of the gearbox housing is done by usingtopological optimization. In this course，the fatigue life of the gearbox housing is estimatedby using multi-body dynamics and finite element method, which is used to verify whethertopological optimization is reasonable or not.This paper is relate to the model analysis by using finite element method andexperiment. the enhancement tests of the vehicle on the proving ground, the simulation byusing four-post test rig，the stress analysis of the finite elements model, the fatigue lifeestimation and so on.First of all，the both results of the model analysis by using both finite element methodand experiment are used to verify the final element model of the gearbox housing to bereasonable. Then, The acceleration signal of wheel centre is collected in the enhancementtests of the vehicle on the proving ground by using LMS.Test.Lab. The anomalies of the testdata are removed by using Matlab. Subsequently, four-post test rig is built by using therigid-flexible vehicle model, which is built by using ADAMS/Car and HyperMesh. Takethe acceleration signal which are got from the enhancement tests of the vehicle on theproving ground as the drive signal of the four-post test rig. Then Dynamics simulationanalysis is carried on, the load time histories of the connections between the gearboxhousing and.the frame are gained. At last, the S-N curve work out, with load time history,the fatigue lifes of the two gearbox housings, one is before topology optimization and theother is after optimization are estimated by using Nominal stress method and the softwareMSC.Fatigue. the fatigue lifes of the two are meet the requirements of work. And，it effects well that multichannel peak-valley extraction with setting a gate and no is used tomake the acceleration of the fatigue course.