Analysis Of A Differential Gear Dynamic Engagement With The Fatigue Life

Gear transmission has the advantages of high efficiency, stable transmission, reliable structure. So the gears are widely used in the automotive industry. Tooth fracture failure is the most common form of gear failures. This paper focuses on the straight bevel gear’s dynamic meshing and fatigue life analysis.(1) First of all, the gears were designed parameterized in the GSD and knowledge engineering modules of CATIA software. A design table was created associated with the gear model. Once the parameter was changed, the gear model would recreated accordingly. The method would save much time in the design of the same series products.(2) Secondly, the gear model was imported into HyperMesh software and meshed. Then all the contact, constraints and load were established in Abaqus/Explicit. Simulated the dynamic meshing of the gears in the maximal loading torque location. Analyzed the impacting performance, the numerical value and distribution of contacting stress and bending stress. Ensured the pinion’s risk position of to be loaded. Contacted the two gears on pinion’s dangerous loading position and verified pinion’s bending strength.(3) This paper analyzed of the influences of inertial load, damping and load factors on the characteristics of dynamic meshing process and reached conclusions as follows:Damping is greater, the initial angular velocity of side gear is greater and tooth contact stress is larger, but the contact area is almost unchanged; The side gear’s inertia is larger, the amplitude of angular velocity is smaller, the corresponding contacting stress and area are greater; The pinion’s rotate speed is higher, the amplitude of angular velocity, contacting stress and area are larger. With the load increases, the amplitude of side gear’s angular velocity inc eases, and the contact force would also increase linearly.(4) Computed pinion’s fatigue life based on the bending stress of dynamic meshing finite element results. The life analysis was be done in nCode software. Differential gears’ bench test were also been done. Compare the fatigue life analysis and test to verify the feasibility of the method of finite element fatigue life analysis.