轻量化设计的汽车零部件用高强度钢来抗凹--文献翻译.doc

KD1110型载货汽车后桥总成设计【优秀汽车后桥全套课程毕业设计含4张CAD图纸】

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KD1110型载货汽车后桥总成设计

KD1110型载货汽车后桥总成设计【优秀汽车后桥全套课程毕业设计含4张CAD图纸】

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轻量化设计的汽车零部件用高强度钢来抗凹--文献翻译.doc

KD1110型载货汽车后桥总成设计

摘要

 本设计为中型载货汽车的后桥总成设计,在本设计中后桥为驱动桥。驱动桥是汽车传动系主要总成之一,具有承载车身和驱动汽车的功用。驱动桥主要包括驱动桥壳、主减速器、差速器和两个后桥半轴。

根据本车的各项具体参数,经过必要的论证分析,确定了本次所设计的驱动桥的结构方案。驱动桥壳为非断开式驱动桥壳。主减速器为双级主减速器,双级主减速器包括一对双曲面齿轮和一对圆柱齿轮。主动双曲面齿轮和中间轴凸缘上的双曲面齿轮啮合,中间轴和第二级传动中主动圆柱齿轮做成一个整体,圆柱齿轮与固定在差速器壳上的从动圆柱齿轮啮合。差速器为对称式圆锥行星齿轮差速器,这种差速器结构简单,使用可靠。半轴采用全浮式半轴,这样半轴只承受转矩。主减速器支撑轴承选用圆锥滚子轴承。

在说明书的计算部分,说明了主要参数选择的依据,对主减速器,差速器,半轴和驱动桥壳进行了尺寸和强度计算。此外,还计算了主减速器支撑粥承的寿命。本文提供了关于以上计算的详细计算依据、步骤和计算数据。

关键词:双曲面齿轮、差速器、驱动桥、半轴

KD1110 DESIGN OF REAR AXLE FOR GOODS VEHICLE

ABSTRACT

The aim of this project is to design the rear axle for the medium goods vehicle. The rear axle acts as the driving axle in this project. The rear axle is an important component of the truck, which is used to bear the frame and drive the truck. The driving axle includes a shell of drive axle, a main decelerator, a diff, and two axle shafts.

According the specific parameters of the driving system and necessary reasoning, the structure of the driving axle is adopted: the integrated driving axle housing, two-stage main reducing gears which consist of a pair of hypoid gears and a pair of spur gears. The driving hypoid gear that is fixed to the flange of the intermediate shaft forms an integral with the 2nd-stage driving spur gear. The spur gear meshes with the driven spur gear, which is fastened to the case of the diff. The diff with the symmetric taper planetary has a relatively simple structure, and it is reliable. The diff axle is full floating type; such axle shafts are acted upon only by the torque. The bearings that the rear axle uses are both taper roller bearings

The calculation section of this paper is mainly concerning about the physical dimension of the gear of the main drive, the diff, the driving axle, the driving axle housing and the strength of them. In addition, the life of the bearing of the main drive is also calculated in this section. Majority of computations basis, the step and the estimated data for these project are advanced in paper.

KEY WORDS:  double camber gear,  differential ,driving axle ,Axle shaft

目  录

前言...............................................1

第一章 驱动桥总体设计 ...........................2

§1.1驱动概桥述.....................................2

§1.2 驱动桥总成的结构形式及选择......................2

第二章  主减速器的设计.................................3

§2.1主减速器的结构形式和选择.........................3

§2.2 主减速比的确定和分配...........................3

§2.3主减速器齿轮计算载荷的确定.....................3

§2.4 主减速器齿轮参数的确定..........................6

§2.5主减速器齿轮的强度校核.........................11

第三章  差速器的设计......................................28

§3.1差速器的结构形式的选择.........................28

§3.2 对称式圆锥行星齿轮差速器的设计...................28

第四章  驱动车轮的传动装置.............................33

§4.1半轴概述....................................33

§4.2 半轴的设计计算.............................. 33

第五章  驱动桥桥壳........................................36

§5.1驱动桥桥壳受力和强度计算..........................36

结 论.....................................................41

参考书目..................................................42

致谢...................................................43

参考文献

[1] 刘惟信编著.  汽车车桥设计. 北京:清华大学出版社. 2004.

[2] 汽车工程手册编辑员.汽车工程手册: 基础篇.北京:人民交通出版社.2001

[3] 汽车工程手册编辑员.汽车工程手册:设计篇.北京:人民交通出版社.2001

[4] 刘惟信.汽车驱动桥设计. 第三版. 北京:清华大学出版社,2004年

[5] 王望予编著.  汽车设计第4版. 北京:机械工业出版社.  2004

[6] 刘惟信.汽车设计.北京:清华大学出版社,2001

[7] 徐灏.机械设计手册.北京.机械工业出版社:2004

[8] 刘惟信主编.圆锥齿轮与双曲面齿轮传动.北京:人民交通出版社.1985

[9] 余志生编著. 汽车理论第四版.北京: 机械工业出版社.2008

[10] 陈家瑞主编.  汽车构造第二版 .北京:机械工业出版社.  1995.

[11] 成大先主编.机械设计手册第四版.北京:化学工业出版社,2002

[12] 张洪欣.汽车设计.北京:机械工业出版社, 1989

[13] 张文春主编.汽车理论.北京.机械工业出版社:2007

[14] 刘惟信.汽车驱动桥设计. 第三版. 北京:清华大学出版社,2004年

[15] 濮良贵,纪名刚主编.机械设计(第八版).北京:高等教育出版社.2006

[16] 孙恒,陈作模,葛文杰主编.机械原理.北京:高等教育出版社.2006


内容简介:
Lightweight design of automobile component using high strength steel based on dent resistanceAbstractLightweight and crashworthiness are two important aspects of auto-b-ody design. In this paper, based on the shallow shell theory,the express-ion of dent resistance stiffness of double curvatured shallow shell is obt-ained under the concentrated load condition. The critical loads resulting i-n the local trivial dent in the center of the shallow shell is regarded as the important index for the lightweight of the automobile parts. This rule is applied to the lightweight design of bumper system by using high stre-ngth steel instead of mild steel. The crashworthiness simulation of the li-ghtweight part proves the validity of the lightweighting process.Keywords: High strength steel; Lightweight; Dent resistance1. IntroductionIn recent years, the retaining number of automobiles has been incre-asing steadily, which has impacted the society and human life greatly. S-uch situation leads to many severe problems such as fuel crisis, environ-ment pollution. The international association of aluminum stated that petr-ol consumption can decrease by 810% with 10% reduction of car weig-ht 2. Thus, automobile lightweight is a basic way to fuel saving.In order to reduce the automobile weight, there are two important methods 3: One, automobile parts are redesigned to optimize the struc-ture. By using thinning, hollowing, minitype, and compound parts, car we-ight can be reduced. The other, more and more lightweight materials, s-uch as aluminum alloy, high strength steel, composite material, are wide-ly used as lightweight materials to replace the traditional materials like mild steel 4. These materials could reduce the weight remarkably. Mat-erial replacement is generally more effective in automobile lightweighting than structure modification. With the introduction of automobile safety leg-islation, crashworthiness and safety should be considered as preconditio-ns in lightweighting design of auto-body. High strength steel is widely us-ed in automobile replacing the traditional material of mild steel. High strength steel sheet can be used in auto-body to improve com-ponents_ impact energy absorption capacity and resistance to plastic def-ormation. The automobile weight can be reduced by use of high strength steel sheet of a thinner thickness to replace the mild steel sheet of bo-dy parts 1,3. Comparing with aluminum, magnesium,and composite mat-erials, high strength steel has better economy in that its raw material an-d fabrication cost are cheaper. Besides, high strength steel can be direc-tlyused in product line including forming, wielding, assembling, and painting. The operating cost can be saved since there is no need adjusting the whole lineOutside of automobile body, there are several sheet metal Panels, most of which are shallow panels. Dent resistance is the ability to retain- the shape against sunken deflection and local dent under the external force. Dent resistance of automobile panels becomes an important issue and quality criterion. Therefore, dent resistance stiffness of automobile p-anels should be tested and evaluated in the process of panel design an-d manufacture.Some reported methods of testing are listed below 68:1. Test the displacement of sunken deflection fp underfixed external forc-e2. Test the external force f to obtain fixed displacement of sunken defle-ction.3. Test the slope of forcedisplacement curve under external load.In this study, the second method will be used. The rest of this paper is organized as follows: In Section 2, the expression of dent resistance stiffness of double curvatured shallow shell is obtained under the concentrated load condition based on the shallow shell theory. The critical load resulting in the local trivial dent in the center of the shallow shell is regarded as the important evaluating index for the dent resistance of the automobile parts. This rule is applied in Section 2 to the lightweighting design of bumper system by using high strength steel instead of mild steelwith crashworthiness simulation.2. Dent resistance analysis of double curvatured shallow shell2.1. Dent resistance stiffness analysis of shallow shellShell with mid surface can be characterized into three features: thickness h, mid surface dimension L, curvature radius r, which satisfies h/r_ 1. When there exists h/L _ 1, the shell can be defined as thin shell. If L/ r _ 1 is added besides the above two conditions, the thin shell is regarded as shallow shell 10.As Fig. 1 shows, the plane xy is the projection of the mid surface of shallow shell along the z-axis. Supposing M is an arbitrary point on mid surface, two planes QMN & PMN are made paralleling to coordinate plane OYZ and OXZ, respectively. The two edges PM and QM can be regarded approximately as vertical because of mid surface_s flatness. At the same time, the line MN is normal to mid surface. Thus, MN, QM, PM can constitute a perpendicular reference frame MPQN, whose difference from orthogonal coordinate system OXYZ can be ignored. And PM and QM are denoted by a and b, the curvilineal coordinate of MPQN.Assuming the Z coordinate of the point M is z, the analytical equation of mid surface is expressed as follows: (1)The following equations can be obtained because of the flatness of the shell: (2)The curvature and torsion of mid surface can be approximated to: (3)The Lae coefficients of mid surface along a and b directions are deduced: (4)Applying concentrated force P along Z-axis and ignoring the influence of the transverse shear resultant forces, the balance differential equations of shallow shell are: (5)where d(0,0) is Dirac-d function.The compatibility equation of shallow shell isWhere (6)Expressing the moment resultants M1, M2 and M12 by the function of transverse displacement w, the basic equations of shallow shell under concentrated transverse forces are: (7)where N1 is the membrane stress resultant in X-direction; N2, the membrane resultant in Y-direction; D, the Fig. 1. Double curvature shallow shell. bending stiffness of shallow shell.It is very difficult to solve above equation. According to practical situation, sunken deflection will only concentrate on a small area around external force P, so infinite large shallow shell 5 is assumed in this study. Because w, N1, N2 are symmetric about x-, y-axis, all orders of derivatives of w, N1, N2 become to zero at infinity. The following equations can be achieved by Fourier transformation to Eq. (7): (8)Where (9)From Eq.(8), w can be obtained. Reverse Fourier transformation to w and polar coordinates transformation to n, g, w under polar coordinate system can be gained (10)Put x = 0 and y = 0 in Eq.(8), the relationship between deflection fp and concentrated force P of rectangle shallow shell can be achieved as follows: (11)Finally, dent resistance stiffness of shallow shell K is obtained (12)This equation explains synthetically the relationship between the dent resistance stiffness of double curvature shallow shell and all influencing factors including material properties, geometry parameters, which can be used to guide design, material select and manufacture.2.2. Analysis of critical load causing local trivial dentFor quantitative evaluation of critical load against local dent resistance of panels, several experience formulas have been brought forward by researchers. Based on large numbers of experiments, Dicellello 9 stated a formula that expresses minimum energy W causing visible trivial dent trace by thickness t, yield stress rs and basic dent resistance stiffness K (13)where C is proportional constant. From Eqs. (12) and (13), the critical load Pcr resulting in the local trivial dent in the center of the shallow shell can be achieved, which is defined as the evaluating index (14)From Eq. (14), there is a closely correlation between critical loads Pcr and thickness t, yield stress rs. The critical load can be a rule to carry out lightweight design of automobile parts by using high strength steel instead of mild steel.3. Example and crashworthiness analysis3.1. FE model of full car and its crash simulationA detailed finite element model has been established based on a passenger car refitted from a saloon car, which is showed in Fig. 2. To ensure the correctness and effectiveness of FE model, the following methods are adopted:1. Since the goal is to simulate the frontal impact of the car, the meshing of front car body is denser than that of the rear car body.2. Reduced integration method with hourglass control is taken for 4 noded shell element and 8 noded brick solid element to improve the efficiency of simulation.3. By using of the meshing and mass scaling technology, the characteristic length of the minimal element is ensured to improve the simulation efficiency.4. Materials constitutive with CowperSymonds strain rate item is used for steel parts.5. Automatic single surface contact algorithm is adopted in the simulation aiming at complexity of car impact simulation.6. Spot weld element with failure rule that considering the couple of normal force and shear force is used to simulate the spot weld connection between auto parts.Explicit dynamic FEM software LS-DYNA Version 950 is used to simulate the frontal impact of the car against a rigid wall at the speed of 50 km/s according to the National Crash Legislation CMVDR294. A real car crash experiment is done at Car Crash Lab settled in Tsing Hua University. By comparing the time history of acceleration of certain position on the A pillar within 0.1 s, the simulation gives a reasonable fit to the experiment results, which guarantees the correctness of FE model and gives a nicer base for the next lightweighting optimized design.3.2. Lightweighting design and crashworthiness analysisThe use of high strength steel is one of the effective ways to reduce car weight. However, the performance (such as crashworthiness, stiffness, and dent resistance) of part made of new material should be assured. For example, the front parts of a car are major energy absorption parts in the process of car crash, so energy absorption performance without affecting the safety of passengers should be assured in the design of front parts of a car. In this research, the bumper of the passenger car is studied under different materials but remaining its dent resistance.The mechanical properties of mild steel and high strength steel are listed below (see Table 1).The evaluation index of dent resistance for bumper using mild steel isWhen high strength steel is used to replace the mild steel remaining its primary shape and dent resistance performance, the new thickness t2 of high strength steel can be achievedFrom (16), the thickness of bumper that uses high strength steel is gained and updated in the full car FE model. The deformation history of bumper using new material is achieved after the car crash is re-simulated with updated part thickness (see Fig. 3).By simulation, the deformations of bumper made of two different kinds of material are similar in that plastic hinge and tensional plastic deformation appear in the middle part of bumper. And the energy absorption history is shown in the following for beam of the bumper. From Fig. 4 the difference of the energy absorption between twomaterials is small, about 4.1%for beamof the bumper,from which a conclusion can be drawn that it is feasible to reduce the thickness of the bumper panel based on the dent resistance evaluation index studied in this research.4. ConclusionDent resistance performance of small curvature shallow shell parts in automobile is studied in this paper, which enables the follows:1. Dent resistance stiffness under concentrated force is given for such parts.2. The critical load resulting in the local trivial dent in the center of the shallow shell has been deduced, which in turn becomes the index to evaluate the dentresistance of automobile parts.3. The validity of evaluating index is proven by applying the developed rule to the lightweight design of bumper system using high strength steel instead of mild steel through crashworthiness simulation.轻量化设计的汽车零部件用高强度钢来抗凹 摘要:轻巧耐撞性是汽车车身设计的两个重要因素。在这篇文章中,基于浅壳理论,表达抗凹刚度的双曲率扁壳是在集中载荷条件下取得的。该临界负荷导致当地琐碎的凹痕在该中心的浅壳被视为轻量级对汽车零部件的重要影响指数。本规则适用于轻量化设计的保险杠系统用高强度钢代替温和钢。耐撞模拟轻量级的一部分,证明了轻量化进程的有效性。关键词: 高强度钢 轻量 抗凹1、介绍近年来,由于汽车保有量的急剧增长,大大影响了社会和人们的生活,这种情况带来了很多严峻的问题比如能源危机,环境污染。国际铝组织协会声明石油的消耗可降低8-10与减少约10的汽车重量。因此,汽车轻量化是节约燃料的一个基本方式。为了减少汽车的重量,这又两个较好的方法。一种方法是重新设计汽车零部件优化其结构,通过使用细薄的、空心的、小型的和混合材料的零部件,来减轻汽车的重量。另一种是使用新的轻型材料,如今这种材料越来越多,如铝合金,高强度钢,复合材料都被广泛作为轻质材料以取代传统材料如低碳钢。这些材料可以显着的减轻汽车的重量。使汽车轻量化材料替换比优化结构更有效。根据引进的汽车安全法规,轻量化设计的车身中耐撞性和安全性被视为先决条件。高强度钢被广泛的应用于汽车上以代替传统的低碳钢。高强度钢板可用于汽车车身来提高部件碰撞能量吸收能力和耐塑性变形能力。汽车体重可减少通过使其零部件用一个更薄厚度的高强度钢板取代低碳钢板来制造。与铝相比,镁,复合材料和高强度钢具有更好的经济性因为这些材料的原料和制作费用比较便宜。此外,高强度钢可直接应用到生产线上,包括成型,焊接,装配和油漆。经营成本节省了,因为没有必要对整个线路进行调整。在车身外,有几个薄的金属板,其中大部分是浅水面板。凹痕阻力是有能力保持形状对沉没挠度和地方凹痕在外力的作用下。凹性汽车板成为汽车的一个重要方面和质量标准。因此,抗凹刚度的汽车板应在面板设计和制造过程中被测试和评估。一些报道的测试方法列举如下:1)、在外力不变的情况下,测量位移沉没挠度的fp2)、测试外力F到获得固定位移沉没偏转量3)、在外力载荷作用下测试得边坡力位移曲线在这篇文章中,第二种方法将被采用,该表达抗凹刚度双曲率浅壳是通过浅壳理论和集中负载的条件下得到的。该临界负荷导 致该中心浅壳琐碎的凹痕被视为凹性汽车零部件的重要评价指数。本规则适用于在第2条中,轻量化设计连年系统用高强度钢代替低碳钢与耐撞性仿真。2、双曲率浅壳的抗凹性分析2.1 浅壳的抗凹刚度分析壳牌与中表面特点可以分为三特征:厚度h,中面尺寸L,曲率半径r ,并满足的h / r1。当h/L1时,定义外壳为薄壳,如果在上述两条件满足的同时又满足Lr1,这个薄壳被认为是浅壳。如图1所示,平面x-y是浅壳中表面沿着z轴的投影。假设M是中表面上的任意一点,两平面QMN&PMN分别去平行OYZ和OXZ。边PM和QM可近似认为是垂直的因为中表面和平坦。同时,MN正交于中面。因此,MN,PM,QM可构成垂直参考系MPQN。其差额由正交坐标系统OXYZ可以忽略不计,同时PM和QM通过和来表示,该曲面坐标MPQN。假设M是Z轴上的一点,对中表面的详细分析方程如下:z=F(x,y) (1)由于是平坦的外壳,就有如下方程: (2)中面的曲率和挠度可近似至: (3)该中面的下载系数可沿和方向导出: (4)运用集中力P沿Z轴和忽略横向剪切力造成的影响,得到浅壳的平衡微分方程: (5)其中(0,0)是狄拉克-函数。浅壳的兼容性方程是: (6)其中 通过横向位移w来表达瞬时结果M1, M2和M12,浅壳在横向集中力下的基本方程: (7)其中N1是膜应力在X方向,N2是膜应力在Y方向,D表示浅壳的抗弯刚度。这是很难解决上述方程。据要立足现实,沉没的偏转将只集中就在小范围内左右对外力P ,所以无限大型浅水壳牌是假定在这项研究中。因为w,N1,N2关于X,Y轴对称,所有顺序衍生的w,N1,N2都无限接近于零,以下方程可通过傅立叶进行变换。 (8)其中: (9)从公
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