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This paper presents an improvement in the design of the transfer case helical gear for a 3.5 ton commercial vehicle. Helical gear has been used increasingly as a power transmitting gear due to its relatively smooth and silent operation, large load carrying capacity, and high-speed operation. The bending stress is a key parameter in gear design. Theoretical equation and FEM analysis were used to determine the bending stress of the helical gear. The major factors in a theoretical equation were based on AGMA standards, and a simplified finite element model was created. The results obtained from the FEM were compared with the theoretical equation, and the difference in the maximum bending stress was discussed.
This paper discussed the development of the transfer case involving a 3.5-ton commercial vehicle. A transfer case is mainly used as a power distribution system between the transmission and the front/rear axle. In this paper, the main parts of the transfer case, such as power transfer shaft, helical gear, bearing, etc., were verified through CAE simulation and performance tests. A developed transfer case is not damaged, not even a crack and fracture, after the strength and durability tests. Finally, a transfer case meeting the requirements of a 3.5-ton front axle driven commercial vehicle was developed. The results of the development would be used as an alternate to the existing transfer case after the vehicle test.
This paper suggests how to improve the fatigue strength of an axle shaft, which is the vulnerable part of an axle shaft system for a 3.5-ton commercial vehicle. The axle shaft is composed of a universal joint with a spider and yoke, yoke shaft, and so on. Structural analysis of the initial axle shaft was conducted to select the exact area for structural strength fatigue improvement, and as a result, the inner/outer yoke shaft and spider were selected. Four cases considered design variables, such as length and thickness, to verify the enhanced durability of the axle shaft, and fatigue analysis was conducted. Finally, we suggest that the axle shaft system satisfied the working conditions for a 3.5-ton commercial vehicle.
Disc brake fixed to the axle with disc brakes and brake lining is a part of braking systems in commercial vehicle and is a tool to stop rotating squeezed. Specifications of the vehicle brake system, brake conditions, environmental conditions and the geometry of the disk and the pad, material properties and cooling conditions, etc. are made in the form of very complex. So there are many constraints on the theoretical approach. In addition, the actual analysis to verify these systems caused by a lot of trial and error must occur is difficult . The purpose of this study is to grasp the parameter affected to design of disc brake through analysis of heat stress applied to the temperature distribution, direction and scale of heat flow, analysis of heat trasnfer.
This paper represents the structural design of the light weight axle beam for medium duty commercial vehicle using hot press. To reduce the weight of the axle, axle beam of solid type was replaced by hollow type which was made by hot press. According to the change of axle beam structure and manufacturing method, we have to investigate the structural strength and fatigue performance. To verify the axle beam performance, the structural analysis was carried out by simplified axle beam model and various design parameters that are axle beam height, thickness and width. From the analysis results, the light weight axle beam structure was founded and applied the full model analysis. This study will be used as a guidance in development of the light weight axle for medium duty commercial vehicle.