Abstract

Effective analysis modeling of power take-off unit by using finite element method is developed in order to investigate gear root bending fatigue and welding fatigue. The hypoid gear plays an important role in the PTU system. Without proper information of system stiffness it is impossible to exactly predict fatigue failure life in finite element (FE) analysis. In this study, a simulation model is developed with the focus of affecting gear mesh misalignment, such as gear body flexibility, shafts, bearing stiffness and gearbox stiffness. To validate results this paper presents a correlation study of fatigue failure life between physical test results and fatigue life analysis results. The proposed integrated FE model for predicting the fatigue life of hypoid gear root and welds based on the full-system agreed well with the result of physical durability test.

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