1. 25/01/16 www.pro-sim.com
Design & Development of an
Integrated Transmission System
A case study of successful collaborative engineering between
AVTEC & ProSIM R&D Pvt Ltd
2. 2
PREAMBLE
Issues involved in development of a Integrated
transmission system for AWD
Optimizing the product (material, geometry for
needed performance)
Success of collaborative engineering for product
innovation and NPD
Optimizing the investments and optimization of
RoI are discussed.
3. ProSIM
- A simulation technology based collaborative
R&D company
- Inter disciplinary team of experts
- Design –materials - Manufacturing-
performance
- Multi-physics simulation capabilities
25/01/16 www.pro-sim.com
4. ProSIM
- We assist customers in
- New product development
- Innovation / R&D projects
- VA / VE
- Failure analysis
25/01/16 www.pro-sim.com
5. 5
Design of Gearbox
Product design and development
An integrated transmission for vehicle having 5 forward speeds & 1 reverse speed
within the specified torque & rpm range.
4th
Gear
3rd Gear
2nd Gear
1st Gear
Reverse Gear
5th Gear Front Output
Rear Output
6. Workflow
- Study the customer requirements
- Design specifications and conceptualisation
- Engineering design
- Digital mock up
- CAE and FEM analysis
- Durability analysis
- MBD model (flexible model)
- NVH Analysis
- Optimisation
- Physical prototype
- Testing
- Design fine tune
- Control drawing release
25/01/16 www.pro-sim.com
7. Design Validation of an Integrated Transmission
System
Automotive Noise & Vibration Congress, Pune
10. 10
7-Feb-16
It is now necessary to utilize company’s investment in design stage gate
process qualification, virtual prototyping & physical prototyping.
Development of superior design is mandatory as technology, methods,
guidelines & tools are available on finger tips.
Design is signed off for performance, quality, safety & cost so that a
higher upgraded version of the model can be achieved after passing all the
stage gates.
Business Case Feasibility
Schematic
Design
Design
Development
Pre
Construction
Construction
Introduction
14. 14
Features 7-Feb-16
This transmission is designed for a vehicle which is on-road luxurious SUV
& at the same time can run on ice covered roads too.
Demands speed & torque at different times.
The unique feature is that transfer case is directly mounted on rear cover of
transmission for compactness.
It compliment design of engine, axle, propeller shaft & tunnel of vehicle
very well.
All the designed parts were gone through design stages such as
DFMEA/PFMEA.
15. 15
7-Feb-16
All the parts of the transmission are built to sustain a temperature range of
-30 degree Celsius to 50 degree Celsius.
Material selection for all parts is done for adverse condition and considering
variations in temperature.
The B10 life for all the parts qualifies as per demanded.
Effect of all torque transfer parts such as gear, shafts, synchronizers,
bearings were analysed with respect to the manufacturing accuracies.
All the design were checked for serviceability, assembly, quality & cost
before signing off with customer.
Features continues…
20. 07/02/2016
S.no. % of total time Front Axle (% of total torque) Rear Axle (% of total torque)
1 10% 100% 100%
2 30% 120% 80%
3 30% 80% 120%
4 10% 140% 60%
5 10% 60% 140%
6 5% 200% 0%
7 5% 0% 200%
Load Cases for testing
21. Modelling and Simulation
- ABAQUS is used for finite element analysis
- FESAFE is used for fatigue damage and
durability assessment
- SIMPACK is used for flexible multi-body
dynamic simulation (order analysis, NVH, etc)
25/01/16 www.pro-sim.com
28. Drive trainMain model
Topology
Topology diagrams ease the
understandability of the
model
FE43 - Force Element Representing Bolting
FE225 - Force element representing gear pair
DOF - Degrees of Freedom
FE93 - Force Element Representing input
torque
29. MBDResult
Using MBD Bearing forces
The Bearing reaction forces are considered as an input for
Structural analysis of housing components as shown in
the figure.
By FFT (Fast Fourier Transform) converted bearing loads
it could be possible to conduct housing acoustic analysis
in FE.
Figure: Bearing reaction forces
30. Vibration analysis of gearbox
Methodology and Inputs
• Flexible gear shafts
• Switchable gears
• Bearings (Non linear stiffness and damping values)
• Synchro bodies as dummy bodies
• Rigid gearwheels with detailed macro- and micro-geometry
• Gearwheels with material data
• Gear pair contact
Figure: Nonlinear bearing stiffness value
Figure: Gear tooth modification
31. Vibration analysis of gearbox
Sensors at Probe location
on housing to extract accelerations
Figure shows the sensors location on the
housing components
The resultant housing acceleration in all
direction captured at sensors locations.
Probe locations
35. Observation
Vibration analysis of gearbox
1. In order analysis the RPM is increased from 0 to maximum, with a constant
acceleration. This is done in order to see at what RPM the system has maximum
amplitude of vibration
2. The maximum amplitude of vibration occurs because of the interaction of natural
frequencies of vibration and forcing frequencies (teeth meshing frequency of any one
of the gear pairs).
3. The natural frequencies also considerably depends on the mounting locations of the
housing. The critical RPM may change if the mounting locations and stiffness values
are varied
39. Boundarycondition
The transmission assembly is fixed in bearing locations (highlighted - six location), The
shafts are allowed to rotate along the shaft axis (rotation along X– direction).
43. Durability
Fatigue analysis is carried out taking the results of non linear static FE results.
Appropriate fatigue material properties are assigned for all the components from the
material library of the software and a cyclic half sine wave load (zero to max) is
applied to predict the fatigue life of the system.
50. Conclusions
- A integrated transmission system for SUV with AWD is
developed
- Static Stress, modal/ harmonic analysis, contact stress
analysis carried out using ABAQUS.
- Customer desired fatigue life and noise levels have been
achieved by simulation based studies (using Abaqus, Fesafe
and SIMPACK)
- Physical testing & prototyping time &effort is reduced.
- Using good collaborative practices between ProSIM and
AVTEC, a new transmission system was developed in a short
time, with minimal cost.
25/01/16 www.pro-sim.com