Finite element modeling and fatigue analysis of hypoid gears installed in a power transfer unit with a correlational study based on an experimental investigation
- 16 Downloads
The effective analysis modeling of a power transfer unit (PTU) with the finite element method was conducted to investigate gear-root bending fatigue. This PTU was designed for an AWD/4WD vehicle system. The hypoid gear plays an important role in PTU systems. The finite element (FE) model is useful to consider various stiffness components and is regarded as the most suitable and effective tool as computer performance increases. Without a proper introduction of system stiffness, we cannot exactly predict fatigue failure life in FE analysis. In this study, a simulation model was developed with the focus of affecting gear-mesh misalignment, such as gear-body flexibility, shafts, bearing stiffness and gearbox stiffness. To validate the results, we did a correlation study of fatigue failure life between physical test results and fatigue life analysis results. Prior to this fatigue analysis, the system torsional stiffness was correlated between physical tests and virtual analysis. Next, loaded tooth contact analysis (LTCA) was conducted to compare the experimental and simulated results. The proposed integrated FE model for predicting the fatigue life of hypoid gear roots based on the full system agrees well with the results of the physical durability test. Moreover, the developed FE model is becoming competitive in terms of computational costs.
KeywordsPower transfer unit (PTU) Hypoid gear Gear mesh misalignment Finite element method Fatigue analysis
Unable to display preview. Download preview PDF.
This work was supported by the Hyundai WIA Research Project in 2018.
- L. E. Wilcox, An exact analytical method for calculating stresses in bevel and hypoid gear teeth, Proceedings of International Symposium on Gearing and Power Transmissions, Tokyo, 2 (1981) 115–121.Google Scholar
- T. C. Lim and J. Wang, Effects of assembly errors on hypoid ear mesh and dynamic response, ASME International Design Engineering Technical Conferences and Computers and Information in Engineering Conference (2005) 801–806.Google Scholar
- Gleason Works, Method for Designing Hypoid Gear Blanks, Rochester, USA (1971).Google Scholar
- ASM Metals Handbook, Failure of gear, Failure Analysis and Prevention, 8th Ed., ASM International, 10 (1975).Google Scholar
- E. Claesson, Modelling of Roller Bearings in ABAQUS, Master’s Thesis, Chalmers University of Technology (2014).Google Scholar
- T. A. Harris, Rolling Bearing Analysis, 3rd Ed., Wiley, New York, USA (1991) 1013–1013.Google Scholar
- MSC Software Corporation, MSC Nastran Superelement User Guide, USA (2001).Google Scholar
- Altair Engineering, Inc., Altair User’s Guide, Altair HyperWorks, Troy, MI (2017).Google Scholar
- ABAQUS Inc., ABAQUS Analysis User’s Manual, Version 2016 (2016).Google Scholar
- Magna Powertrain Engineering Center Steyr GmbH&Co KG, FEMFAT Manual (2012).Google Scholar
- W. Eichlseder and B. Unger, Prediction of the fatigue life with the finite element method, SAE Technical Paper (1994) 940245.Google Scholar