Resrarch On Heavy Truck Aluminum Alloy Drive Shaft Assembly Design And Key Technology Research

With the steady advancement of the ’ Made in China 2025 ’ power strategy,the machinery manufacturing industry,especially the heavy truck industry,has ushered in vigorous development,and has been widely used in logistics transportation,engineering construction,special equipment and other fields.Since 2021,China has begun to implement the policy of comprehensive elimination of vehicles with China III emission standards and the promotion of ’double carbon ’ strategy,directly eliminating a large number of non-standard vehicles with overload and overload on the market,and also increasing the market demand for advantageous heavy trucks.With the increase of domestic sales of heavy trucks in line with national standards,while promoting the development of the industry,it also brings a series of environmental problems.With the increasingly stringent requirements of the state for energy conservation,environmental protection and fuel consumption,how to better achieve energy conservation and emission reduction has gradually become an urgent technical problem for major heavy truck manufacturers.Lightweight design of heavy trucks is currently recognized as the most widely used,most effective,practical and economical way of energy conservation and emission reduction.The lightweight design of heavy-duty trucks is the focus and hot issue that experts and scholars at home and abroad have been studying in recent years.The lightweight design of the whole vehicle is mainly realized by the lightweight of its key components.As the core product of the heavy-duty truck transmission system,the lightweight design of the transmission shaft assembly has also attracted the attention and research of many heavy-duty truck manufacturers,experts and scholars at home and abroad.In this thesis,the transmission shaft of a heavy truck is taken as the research object.A lightweight design method of transmission shaft assembly using aluminum alloy material is proposed.The design,strength check and three-dimensional model of aluminum alloy transmission shaft are established.The dynamic characteristics of aluminum alloy transmission shaft are verified by finite element simulation,and the results are verified by experiments.The main contents of this thesis are as follows :(1)The main application parts and components of the transmission shaft assembly are introduced,based on a certain 6×4 vehicle model.A design of an aluminum alloy transmission shaft assembly was carried out based on the configuration parameters of the tractor,and various components were designed through design input.Based on this,a three-dimensional model of each component and transmission shaft assembly was established.The design scheme was initially verified through theoretical verification,and the design of a lightweight aluminum alloy transmission shaft assembly was ultimately completed.(2)The established transmission shaft parts model and assembly model were imported into the finite element analysis software Ansys Workbench,and the transmission shaft assembly finite element analysis model based on aluminum alloy materials was established.After the appropriate grid was divided,the boundary conditions and constraint conditions of aluminum alloy parts and assemblies were set according to the actual operating conditions,and the key parts such as the universal joint cross shaft,spline joint,spline hub were statics simulated,Modal simulation was conducted on the established transmission shaft assembly,analyzing the strength of the transmission shaft components,as well as the vibration mode and frequency of the assembly.The reliability of the lightweight transmission shaft assembly designed based on high-strength aluminum alloy materials was verified.(3)Considering that the traditional assembly method of steel transmission shaft assembly is no longer suitable for high-strength aluminum alloy transmission shaft assembly,a new rotating friction welding process is proposed to realize the welding assembly between the shaft tube and spline hub,shaft tube and universal joint fork in the aluminum alloy transmission shaft assembly,This provides a theoretical basis for the assembly of subsequent aluminum alloy transmission shaft assemblies.(4)The designed lightweight aluminum alloy transmission shaft assembly was tested and verified,mainly four key indicators of static torsional strength,torsional fatigue,universal joint wear and sliding spline pair wear were tested,and the test process data were collected,analyzed and processed.Finally,the feasibility of the design of aluminum alloy transmission shaft assembly was verified.