Investigation and optimization of hypoid gear micro-geometry parameters and axle deflections to improve the contact stress distribution and fatigue life of hypoid gears

Abstract

The automotive industry always demands more torque per kilogramme of weight. On the other hand, there is always a growing demand for increased warranty kilometres for customers. This puts increased pressure on the life of the drive axle, which is the major load and torque-carrying member in commercial vehicles. Drive head unit is a crucial contributor to this aim. This paper focuses on the work done towards the above targets wherein advanced tools helped to achieve them in the minimum time. Due attention is given to the hypoid gear system to sustain higher stress because of the heavy torque demanded by the application. It is accomplished by the optimum design of the gear tooth profile and system design. Gear durability is a major concern in heavily loaded axles. To have an optimum design with higher performance torque is a key challenge. The paper talks about the challenges overcome during the design, development, and validation of a single-reduction large-size gear axle to replace the hub reduction rear axle. It demands a better understanding of gear tooth and system behavior, which was analyzed by advanced software tools and measurement machines. The same is validated on the test bench, and the results are discussed.