The research object is a light truck drive axle, which is mainly composed of main reducer, axle housing, axle shaft, hub and bearing, as shown in Figure 1. When the drive axle works, the transmission shaft is connected with the flange plate of the input shaft of the drive axle through bolts, and the flange plate of the drive axle is connected with the spline in the hypoid gear of the main reducer. When the drive axle works, the input flange plate of the drive axle rotates and drives the hypoid gear to rotate. The hypoid gear small wheel meshes with the hypoid gear big wheel. The hypoid gear big wheel is bolted to the differential housing, and the differential housing rotates with the hypoid gear big wheel. When the vehicle runs in a straight line, the differential gear of the drive axle does not rotate, and the left and right half axles of the drive axle rotate at a constant speed. One end of the half axle of the drive axle is connected with the hub bolt to drive the hub to rotate. Finally, the engine power drives the hub to rotate through the transmission system, so that the vehicle can overcome the road resistance and drive forward. The drive axle can also be regarded as a kind of hypoid gear transmission system. For the convenience of modeling, the drive axle components are divided into four categories according to the hypoid gear train: input shaft, intermediate shaft, output shaft and support housing.
1. Input shaft
The drive axle input shaft contains parts, as shown in Figure 2, mainly including drive axle input flange, gear pinion, gear pinion bearing and other components. The input flange is connected with the input hypoid gear pinion by splines. The drive axle pinion is supported by horse riding. The two large bearings at the rear end of the hypoid gear pinion shaft are tapered roller bearings, which mainly bear the axial and radial forces generated in the meshing process of the hypoid gear. The front end of the hypoid gear pinion is a deep groove ball bearing, which mainly plays a guiding role. The inner surface of the inner ring of the bearing is interference fit with the pinion shaft, and its outer ring is supported on the differential housing.
2. Intermediate shaft
As shown in Figure 3, the intermediate shaft of the large hypoid gear includes the large hypoid gear wheel, the left and right differential housings, bearings and other components. The left and right axle housings of the differential housing are firmly connected by bolts. The main reducer hypoid gear wheel is bolted to the differential housing. The bearing of the differential is also two tapered roller bearings, which mainly bear the axial and radial forces generated during the meshing of the hypoid gear. Its bearing inner ring is matched with the bearing seat on the differential housing, and the bearing outer ring is installed on the main reducer housing.
3. Output shaft
As shown in Figure 4, the output shaft mainly includes differential gear, spider, halfshaft, hub, bearing and other components. The output shaft is fixedly connected with the differential housing on the intermediate shaft through the spider. The connection relationship between differential gear and spider is shown in Figure 5. The inner spline of the axle shaft gear is connected with the outer spline of the axle shaft. The perspective view of the hub is shown in Figure 6. The end of the halfshaft is connected with the hub bearing seat by bolts. There are two tapered roller bearings at each end of the hub, which mainly bear the impact load generated by the wheel movement. The inner ring of the hub bearing is supported on the axle housing, and its outer ring is supported on the hub bearing seat.
4. Support shell
The support housing mainly includes drive axle housing, main reducer housing and other components. The main reducer housing is connected with the axle housing through bolts, which is mainly used to support other parts of the drive axle. The installation positions of the input shaft hypoid gear pinion bearing and the output shaft differential housing bearing relative to the main reducer housing are shown in Figure 7. The installation position of the hub bearing and the opposite axle housing is shown in Figure 8
