Crack Fault Analysis And Improvement Of A Commercial Vehicle Drive Axle Housing

As one of the key components of truck chassis,the drive axle housing plays a very important role.In the process of truck running,the drive axle housing protects the internal transmission system and carries the load on the frame.If it fails,the driving function of the vehicle will be affected.At present,the road conditions of large mining areas in China are bad and the phenomenon of overload is serious.The driving axle housing bears repeated torsion pendulum and impact under heavy load and is prone to cracking,fracture and other failure forms.The failure of the axle housing brings huge losses to enterprises and customers every year.In this paper,the cast steel axle housing used for mining dump truck in an enterprise is taken as the research object.The cracking fault of the axle housing occurs frequently in the market,and the cracking part mainly concentrates on the transition area between the disk surface and the axle shoulder and the plate spring mounting seat.In this paper,the finite element model of axle housing was established by using Hyper Mesh,and the dynamics model of mining dump truck and D-class random virtual road surface were established by using ADAMS/CAR software.The wheel core load spectrum of rear axle housing was obtained by simulating the road conditions of the whole vehicle under the virtual environment.Through the load spectrum as boundary condition is loaded into the bridge shell finite element model of fatigue life of the bridge shell simulation analysis,combined with the finite element analysis results and bridge housing market failure mode,analysis disk and bridge abutment and bridge shell plate spring installation transition region have stress concentration phenomenon,fatigue life can not reach the anticipated conditions of use.Therefore,the life value under the fatigue test condition was taken as the constraint condition,combined with the design experience of the enterprise,the local structure optimization design of the disc surface of the axle housing was carried out by using the topology optimization tool,and the key parameters of the disc surface and the stiffening position of the shoulder of the axle housing were determined by using the multi-objective optimization tool.Finally,the performance of the improved rear axle housing was verified by bench test,field road test and small batch user test.In this paper,the fatigue life of the axle housing is taken as the optimization objective for optimization analysis,and topological optimization and multi-objective optimization are combined to carry out local reinforcement design for the axle housing.Finally,the rationality of the improved method is verified by experiments.