Failure analysis and optimization design of suspension support holes for gearbox cases
More details
Hide details
School of Materials Science and Engineering, North China University of Water Resources and Electric Power, Zhengzhou, China
Zhengzhou Yutong Bus Co., Ltd., Zhengzhou 450001, China
School of Mechanical Engineering, North China University of Water Resources and Electric Power, Zhengzhou, China
Zhengzhou Research Institute of Mechanical Engineering Co., Ltd., Zhengzhou, China
Submission date: 2023-02-17
Final revision date: 2023-05-25
Acceptance date: 2023-05-25
Online publication date: 2023-06-19
Publication date: 2023-07-31
Corresponding author
Leyu Wei   

Materials Science and Engineering, North China University of Water Resources and Electric Power, China
Journal of Theoretical and Applied Mechanics 2023;61(3):533-544
The suspension hole of a gearbox case was cracked after the mining test vehicle has covered 7000 km. In order to analyze and solve this problem, in this paper, based on the modal analysis of the suspension system and failure analysis of the faulty parts, the finite ele- ment model of the powertrain system was established using Ansys, and strength analysis of the gearbox case was carried out. According to the analysis results, improvement and optimization measures were proposed. The analysis results show that the maximum stress of the optimized gearbox case was reduced by 6.9%, and the test vehicle could operate for 50 000 km without failure after the improvement, which verified the effectiveness of those measures. Accumulating experience in the gearbox case design and simulation, modal anal- ysis and finite element analysis were combined to quickly identify the failure causes of the suspension support hole, and targeted improvement measures were taken, which effectively shortened the research and development cycle and saved production costs.
Chen D., Chen Q.SH., Deng L., et al., 2018, Optimization design analysis of a certain SUV transmission suspension bracket, Modern Manufacturing Engineering, 8, 3-5.
Dong X.L., 2011, Analysis and optimization design of transmission case cracking, Mechanical Engineering and Automation, 7, 180-182.
Fan J.D., Pan H.M., 2010, Finite element modal and experimental modal analysis of gearbox case, Coal Mining Machinery, 31, 5, 92-93.
Fu J.S., Wang J.F., Wang J., 2010, Finite element static analysis on heavy-duty truck gearbox housing, Applied Mechanics and Materials, 37-38, 491-495.
Guo M., Li B., Yang J., Liang S., 2015, Study of experimental modal analysis method of machine tool spindle system, Journal of Vibroengineering, 17, 6, 3173-3186.
Hu W.G., Liu Z.M., Liu D.K., Hai X., 2017, Fatigue failure analysis of high speed train gearbox housings, Engineering Failure Analysis, 73, 57-71.
Huang N., Chen Q., Cai G., Xu D., Zhang L., Zhao W., 2021, Fault diagnosis of bearing in wind turbine gearbox under actual operating conditions driven by limited data with noise labels, IEEE Transactions on Instrumentation and Measurement, 70, 1-10.
Jin B., Li H.P., Yan W.S., Cao M., 2021, Distributed model predictive control and optimization for linear systems with global constraints and time-varying communication, IEEE Transactions on Automatic Control, 66, 7, 3393-3400.
Korka Z.I., Gillich N., 2017, Modal analysis of helical gear pairs with various ratios and helix angles, Romanian Journal of Acoustics and Vibration, 14, 91-96.
Li J., Wang L., 2008, Finite element analysis of 1.5MW wind power gearbox housing, Acta Energiae Solaris Sinica, 29, 11, 1438-1443.
Li L.Y., Chen Y., 2017, Research and countermeasures of transmission case cracking problem, Research and Development, 8, 56-58.
Liu C., Zhao Y., Wang Y., Zhang T., Jia H., 2021, Hybrid dynamic modeling and analysis of high-speed thin-rimmed gears, Journal of Mechanical Design, 143, 12, 123401.
Liu W.G., 2018, Analysis and improvement of front shell cracking, Times Automotive, 7, 116-119.
Liu Z.H., Gao Q.H., 2017, In-plane vibration modal analysis of heavy-loaded radial tire with a larger flat ratio, Journal of Vibroengineering, 19, 7, 5327-5345.
Shen G., Xiang D., Mou P., Jiang J., Gao L., 2014, Analysis of vibration characteristics for wind turbine gearbox, Applied Mechanics and Materials, 496-500, 962-968
Son G.H., Kim B.S, Cho S.J., Park Y.J., 2020, Optimization of the housing shape design for radiated noise reduction of an agricultural electric vehicle gearbox, Applied Sciences, 10, 23, 8414.
Vilán J.A.V., Robleda A.S., Lago M.L., Ruiz E.C., 2010, Feasible geometrical configurations for split torque gearboxes with idler pinions, Journal of Mechanical Design, 132, 12, 121011-121018.
Walunj P.S., Chougule V.N., Mitra A.C., 2015, Investigation of modal parameters on planetary gearbox using finite element analysis to minimize vibration, International Journal of Analytical, Experimental and Finite Element Analysis, 2, 4, 147-152.
Wang H., Wu X., Zheng X., Yuan X., 2022, Virtual voltage vector based model predictive control for a nine-phase open-end winding PMSM with a common DC bus, IEEE Transactions on Industrial Electronics, 69, 6, 5386-5397.
Wang Z.W., Mei G.M., Zhang W.H., Cheng Y., Zou H., Huang G., Li F., 2018, Effects of polygonal wear of wheels on the dynamic performance of the gearbox housing of a high-speed train, Proceedings of the Institution of Mechanical Engineers Part F – Journal of Rail and Rapid Transit, 232, 6, 1852-1863.
Wilk A., Madej H., Figlus T., 2011, Analysis of the possibility to reduce vibroactivity of the gearbox housing, Eksploatacja i Niezawodność – Maintenance and Reliability, 42-49.
Wu H., Wu P.B., Li F.S., Shi H., Xu K., 2019, Fatigue analysis of the gearbox housing in high-speed trains under wheel polygonization using a multibody dynamics algorithm, Engineering Failure Analysis, 100, 351-364.
Xiao B., 2021, Research on the Dynamic Characteristics of the Transient Impact Conditions of the Electric Vehicle Powertrain Suspension System, Ph.D. Thesis, South China University of Technology, Guang Zhou.
Xue X.C., 2019, Analysis of the causes of fracture in automobile transmission suspension, Failure Analysis and Prevention, 14, 6, 5.
Yang J., Liu H., Ma K., Yang B., Guerrero J.M., 2022, An optimization strategy of price and conversion factor considering the coupling of electricity and gas based on three-stage game, IEEE Transactions on Automation Science and Engineering, 20, 2, 878-891.
Zhang C., Wang H., 2020, Swing vibration control of suspended structures using the Active Rotary Inertia Driver system: Theoretical modeling and experimental verification, Structural Control and Health Monitoring, 27, 6, 25-43.
Zhang Q., Du W.H., Ma W.J., et al., 2014, Finite element and experimental modal analysis of light truck transmission case, Mechanical Design and Manufacture, 7, 149-151.
Zhang X., Wang Y., Yuan X., Shen Y., Lu Z., Wang Z., 2022, Adaptive dynamic surface control with disturbance observers for battery/supercapacitor-based hybrid energy sources in electric vehicles, IEEE Transactions on Transportation Electrification.
Journals System - logo
Scroll to top