某轻型卡车变速器壳体的开发

发布时间：2018-08-07 07:14

【摘要】：变速器总成是汽车零部件中关键的部件之一,要求具有一定的承载能力以及抵抗外力冲击的能力,具有足够的刚度和强度。而变速器壳体是变速器总成中的重要组成部分,承载着型腔内所有齿轮、轴、同步器组件和内部操纵机构等众多零件。本文根据新车型的需要,开发了某轻型卡车变速器壳体,运用有限元方法对其结构进行了静力学和模态分析,在此基础上进行了壳体的改进设计,并开展了相关的试验研究。首先,基于CATIA软件建立了变速器壳体三维实体模型,运用HyperMesh软件进行了网格划分,模拟壳体所承受的载荷分布,施加边界条件的约束,建立了有限元模型。根据变速器壳体静止状态和工作状态下正向制动和反向制动4个工况,分别进行了壳体的有限元分析,获得了相应的应力和应变分布云图,针对应力集中部位,采用在壳体薄弱点增加加强筋等方法进行改进。其次,对壳体进行了有限元模态分析,得出各阶模态频率与振型,通过改进前后的对比评价,确定了最优方案。最后通过模态试验和实物台架试验,进行模拟与实际试验的双重验证。在模态试验中,获取壳体自由状态下的机械固有频率、阻尼比、振型等固有特性参数,并与计算结果进行比较。在扭矩试验机上对实物进行静扭台架试验,通过试验所测数据,验证是否符合设计要求。结果表明：该轻卡变速器壳体的结构设计满足整车提出的强度要求。通过在薄弱部位增加加强筋并优化设计,是有效的方法。本文较系统的讨论了壳体强度分析的整个过程和基本思路,以及增加壳体强度的有效方法,为变速器壳体的优化设计提供了理论依据和实践经验。
[Abstract]:Transmission assembly is one of the key parts in automobile parts. It requires a certain bearing capacity and the ability to resist external force impact, and has sufficient stiffness and strength. The transmission housing is an important part of the transmission assembly, carrying all the gears, shafts, synchronizer components and internal manipulators in the cavity. In this paper, according to the needs of the new type of vehicle, the shell of a light truck transmission is developed, and the static and modal analysis of the structure is carried out by using the finite element method. On this basis, the improved design of the shell is carried out, and the relevant experimental research is carried out. Firstly, the three-dimensional solid model of the transmission shell is established based on CATIA software, and the finite element model is established by using HyperMesh software to divide the mesh, simulate the load distribution of the shell and impose the constraint of the boundary condition. According to the four working conditions of forward braking and reverse braking in the static state and working state of the transmission shell, the finite element analysis of the shell is carried out, and the corresponding stress and strain distribution cloud diagram is obtained, aiming at the stress concentration position. The method is improved by adding stiffeners to the thin weakness of the shell. Secondly, the finite element modal analysis of the shell is carried out, and the modal frequencies and modes of each order are obtained, and the optimal scheme is determined through the comparative evaluation before and after the improvement. At last, both simulation and actual test are carried out through modal test and physical bench test. In the modal test, the mechanical natural frequency, damping ratio and mode shape are obtained under the free state of the shell, and the results are compared with the calculated results. The static torsion bench test is carried out on the torque testing machine, and the test data are used to verify whether it meets the design requirements. The results show that the structural design of the light truck transmission housing meets the strength requirements of the whole vehicle. It is an effective method to increase reinforcement and optimize design in weak position. This paper systematically discusses the whole process and basic idea of shell strength analysis, as well as the effective method of increasing shell strength, which provides the theoretical basis and practical experience for the optimum design of transmission shell.
【学位授予单位】：南京理工大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：U463.212

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