Methodology of Virtual and Physical Verification of Symmetrical Design of Tandem Axle’s Input shaft for Mining Application. 2019-26-0028
Automotive torque transmission shafts, which delivering the maximum torque to wheel hub while transformation of torqueing through driveline components , heavy loading on shaft and possibility of failures in bending is major concerns on heavy duty trucks ( 4 x 2 ) in mining. Need to be getting maximum strength of shaft within optimized packaging of overall design in tandem axle mechanism. An attempt has been made to explore symmetrical cross-sectional shapes to improve bending as well as shear strength performance. Symmetrical shaft concept has been proposed for stiffening to improve the deflection and verification with CAE analysis. A number of design solutions have obtained from the study and a comparison has been made with unsymmetrical design.
In this paper we are representing, tandem axle input shaft design is made as symmetrical construction by which are minimizing max deflection at high torque application ( Crawler gear ), verifying with theoretical calculation and virtually validation by CAE methodology. Here are made an iteration of design a shaft with same grade of material 20MnCr5 and different cross section changes are required to align the layout with respect to gear position, bearing alignment and spline fitment are suitability match with both end of shaft to deliver high torque on mating parts.
For virtual validation and analysis, we are used an engine producing maximum torque 900Nm@1700rpm , 6 speed transmission and single gear pair (Helical Tooth) tandem axle model having 180 CD transferring torque from input shaft to axle shaft through single gear pair and set of crown wheel pinion. In tandem axle mechanism as far as concern demand torque and regarding friction changes as requirement of different road condition e.g. slip, dry, hill etc. will changes speed and torque that input to IAD actuation and will provide the split torque to both axle. In between torque deliverability acts as maximum loading, impact of road shocks, braking as well acceleration reaction on input shaft carrying out same things are considered in analysis theory. Here are reduced the high residual stresses by improved symmetrical design and analysis with simulating actual road condition in virtual static analysis with CAE hyper-mesh by applying realistic duty cycle loading.
VE Commercial Vehicles, Ltd.
Symposium on International Automotive Technology 2019