| As an important part of automobile transmission system, transfer case is located in thetransmission chain between the gearbox and drive axle, in order to increase thetransmission torque, expanding the scope of the variable speed, and distribute torque to thedrive axle reasonable. Since it is especially important for military off-road vehicles whichusually run under the poor road conditions, the design of transfer case directly affect theperformance of vehicle transmission system. However, in order to ensure the intensity ofthe gear box, designers always take higher safety factor to increase the body wall thicknessbase on traditional design experience, although the strength was improved, the weight alsoimproved and materials was wasted, and the vehicle driving performance was badlyaffected. With the high development of automobile industry, the traditional experiencedesign is difficult to meet the people’s high requirements of automobile design, and theautomobile lightweight research will have a far-reaching significance by using advancedFEA and topology optimization method to optimize structure.In this paper, aimed at the performance characteristics of a military off-road vehiclestransfer case, a FEA model was built with finite element method, on this basis, the modeland strength analysis of gear box was taken, the natural frequency and vibration of box, aswell as the stress and displacement distribution under the specific conditions: climbing,obstacle crossing, skidding was gained. Based on the analysis of the gear box, a topologyoptimization was taken by using of the variable density method, which set minimumweighted strain energy for optimal object, displacement, volume fraction and stress foroptimal constraints, then the optimal design was taken according to density contours, theweight of modified gear box is reduced by8%. Analysis results showed that overallperformance of the optimized box was improved, the lightweight design is realized. |
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