Research on failure mechanism of final drive gears of a passenger car based on multi-condition varying-speed accelerated test
To standardize the reliability test evaluation schedule of passenger cars powertrain, a multi-condition varying-speed accelerated test criteria correlated with the statistical data of target vehicles is developed. With this test criteria, a real-vehicle test is conducted to evaluate a trial-manufact...
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| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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SAGE Publishing
2025-02-01
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| Series: | Advances in Mechanical Engineering |
| Online Access: | https://doi.org/10.1177/16878132251318171 |
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| _version_ | 1823858521427410944 |
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| author | Haibo Yu Hongyu Hu Yuzhuo Men Mingda Li Bingkui Ji Xueping Yao |
| author_facet | Haibo Yu Hongyu Hu Yuzhuo Men Mingda Li Bingkui Ji Xueping Yao |
| author_sort | Haibo Yu |
| collection | DOAJ |
| description | To standardize the reliability test evaluation schedule of passenger cars powertrain, a multi-condition varying-speed accelerated test criteria correlated with the statistical data of target vehicles is developed. With this test criteria, a real-vehicle test is conducted to evaluate a trial-manufacture car equipped with a newly developed transmission. Regarding the fracture failure of the driving and driven gears of the final drive, a heat treatment quality inspection is conducted on the fractured gears. From the meshing state of the gears, it is observed that machining precision errors caused an excessively large bearing clearance of the helical gear in the differential housing, with the meshing area of the driving gear tilting to one side and generating eccentric loads under uneven stress. The fatigue damage of the gears is calculated by the rainflow cycle matrix of the gears obtained with the rotating rainflow counting method. The calculation results show that largest loads transmitted by the final drive gears in varying-speed test condition 2, which was the main condition for fractures of the driven gear. Under this condition, the driving gear also produced bending fatigue failure due to the significant-amplitude cyclic loading caused by the eccentric loads. |
| format | Article |
| id | doaj-art-e93511553b2e4d20ad9317904c0cbd6a |
| institution | Kabale University |
| issn | 1687-8140 |
| language | English |
| publishDate | 2025-02-01 |
| publisher | SAGE Publishing |
| record_format | Article |
| series | Advances in Mechanical Engineering |
| spelling | doaj-art-e93511553b2e4d20ad9317904c0cbd6a2025-02-11T11:03:34ZengSAGE PublishingAdvances in Mechanical Engineering1687-81402025-02-011710.1177/16878132251318171Research on failure mechanism of final drive gears of a passenger car based on multi-condition varying-speed accelerated testHaibo Yu0Hongyu Hu1Yuzhuo Men2Mingda Li3Bingkui Ji4Xueping Yao5School of Mechanical and Electrical Engineering, Suqian University, Suqian, ChinaNational Key Laboratory of Automotive Chassis Integration and Bionics, Jilin University, Changchun, ChinaSchool of Mechanical and Electrical Engineering, Suqian University, Suqian, ChinaSchool of Mechanical and Electrical Engineering, Suqian University, Suqian, ChinaSchool of Mechanical and Electrical Engineering, Suqian University, Suqian, ChinaSchool of Mechanical and Electrical Engineering, Suqian University, Suqian, ChinaTo standardize the reliability test evaluation schedule of passenger cars powertrain, a multi-condition varying-speed accelerated test criteria correlated with the statistical data of target vehicles is developed. With this test criteria, a real-vehicle test is conducted to evaluate a trial-manufacture car equipped with a newly developed transmission. Regarding the fracture failure of the driving and driven gears of the final drive, a heat treatment quality inspection is conducted on the fractured gears. From the meshing state of the gears, it is observed that machining precision errors caused an excessively large bearing clearance of the helical gear in the differential housing, with the meshing area of the driving gear tilting to one side and generating eccentric loads under uneven stress. The fatigue damage of the gears is calculated by the rainflow cycle matrix of the gears obtained with the rotating rainflow counting method. The calculation results show that largest loads transmitted by the final drive gears in varying-speed test condition 2, which was the main condition for fractures of the driven gear. Under this condition, the driving gear also produced bending fatigue failure due to the significant-amplitude cyclic loading caused by the eccentric loads.https://doi.org/10.1177/16878132251318171 |
| spellingShingle | Haibo Yu Hongyu Hu Yuzhuo Men Mingda Li Bingkui Ji Xueping Yao Research on failure mechanism of final drive gears of a passenger car based on multi-condition varying-speed accelerated test Advances in Mechanical Engineering |
| title | Research on failure mechanism of final drive gears of a passenger car based on multi-condition varying-speed accelerated test |
| title_full | Research on failure mechanism of final drive gears of a passenger car based on multi-condition varying-speed accelerated test |
| title_fullStr | Research on failure mechanism of final drive gears of a passenger car based on multi-condition varying-speed accelerated test |
| title_full_unstemmed | Research on failure mechanism of final drive gears of a passenger car based on multi-condition varying-speed accelerated test |
| title_short | Research on failure mechanism of final drive gears of a passenger car based on multi-condition varying-speed accelerated test |
| title_sort | research on failure mechanism of final drive gears of a passenger car based on multi condition varying speed accelerated test |
| url | https://doi.org/10.1177/16878132251318171 |
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