Abstract
This paper presents an approach for physical/virtual coupled product development and validation. A method for studying the influence of tooth geometry on the efficiency and acoustics of an electric vehicle’s powertrain will be presented. To achieve improved acoustic characteristics the micro geometry of the teeth will be optimized. The modified gears were analysed on a gear test rig under load and at high speeds and evaluated with regard to their acoustic properties. Established analytical models are used to describe the influence of profile modifications on the gear stiffness of helical gears. The authors’ approach is to calculate the dynamic system behaviour of the gearbox using a 1D simulation. Based on this, studies of the entire gear box will be performed. For this, the results of the 1D simulation are coupled with 3D FEA analyses. This enables acoustic calculations (structure-borne and airborne sound) to be carried out.
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