汽车变速器输出轴齿座限位花键轴向断裂失效分析与试验研究

Failure Analysis and Experimental Study on the Axial Fracture of Spline for the Limit of the Hub of Vehicle Transmission Output Shaft

针对某汽车变速器输出轴齿座限位花键轴向频繁断裂的失效现象,从断口形貌、材料成分、力学性能、受力状态以及样件拆检等方面对输出轴齿座限位花键进行了详细分析。应用感压纸测试技术和有限元计算分析,确定输出轴齿座限位花键异常受力是导致其轴向断裂的根本原因,并通过控制输出轴定位、改进花键配合等措施,避免该花键承受异常载荷,解决了断裂失效问题。

Axial fracture occurred frequently to output shaft limit spline of a vehicle transmission, to solve this problem, the fracture morphology, material composition, mechanical property, stress state and sample part inspection of the output shaft limit spline were analyzed in details. By using pressure sensitive paper testing technology and finite element analysis, It was found that the abnormal stress to the output shaft limit spline was the root cause of axial fracture. By controlling the output shaft position and improving the spline fit, the spline abnormal under load is avoided, and the axial fracture of output shaft limit spline of a vehicle transmission is solved successfully.