| Drive axle housing is one of the most important load-bearing parts of automobile, its performance directly affects the overall performance of the automobile. Bulging-pressing deforming axle housing relative to traditional processes(stamping and welding) axle housing has the advantages of integrity, no welds, reasonable thickness distribution, light weight, non-polluting, high stiffness strength and long life, etc. But in the actual using condition, the actual stress state of the axle housing is complex. At present, most researches are static state analysis of axle housing that contains stiffness static strength and fatigue life under the maximum vertical force conditions, but no overall force model of axle housing in the car real driving conditions. The overall force model of the driving axle which make the bulging-pressing deforming axle housing as the housing body will be established in the actual movement condition of automobile. Then Finite element analysis and bench test are used to verify the model, which will provide a reference for the later axle manufacturing.In the paper, aimed to the actual movement condition of the automobile, the theoretical analysis model of axle housing is established and the dangerous parts of the axle housing body is predicted. In the model, the load of internal reducer gears is converted to the housing, and driving axle assembly is simplified the assembly of axle housing, main reducer shell, half-shaft bushing and spring seat. Finally the bending stress at left and right spring seat of Dong feng DFA1080S12D3 driving axle which loads 5t is calculated.The three-dimensional model of the drive axle’s accessories are established by UG software, and the bulging-crushing deforming process is simulated by ABAQUS. According to the theoretical model of the force, the Finite Element Mode of the drive axle housing assembly is established and analyzed by ABAQUS under the maximum vertical force conditions and maximum traction conditions. Then finite element analysis results of the stiffness strength are get under maximum vertical force conditions. And the influence of force that gears produce in driving axle on the stress of axle housing key parts(Spring Seat zone, transition zone, rear casing zone) is comparative analyzed under the maximum traction conditions.Aimed to the bulging-pressing deforming axle housing, the bench test is made. And according to the strength, stiffness of axle housing analysis result, the fatigue life of the axle housing which contains the small casing and residual stresses is analyzed by MSC.FATIGUE software under the maximum vertical force conditions. The fatigue life of three key parts(spring seat zone, transition zone, axle casing) are shown respectively, and zone of the minimum fatigue life is transition zone which is between the arm and axle casing, and the minimum fatigue life is 121 million times. The results agree with the bench test. |
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