Advanced Materials Research Online: 2013-09-04

ISSN: 1662-8985, Vols. 765-767, pp 370-373

doi:10.4028/www.scientific.net/AMR.765-767.370
© 2013 Trans Tech Publications, Switzerland

Finite element analysis of Automobile transmission shaft

Yin Jie , He Jun , Zhou Suping , Huang Wei

College of Mechanical Engineering, Shantou University, Shantou, China
yinjie.11@163.com
Keywords: Finite element analysis, transmission shaft, modal, fatigue, harmonic response

Abstract. Transmission shaft is an important component of automotive transmission, parts of which

are facing the problem of fatigue failure. This paper mainly analyzed the performance of the
transmission shaft based on finite element method. Firstly, stress contour is obtained of the shaft.
secondly, get the fatigue performance according to material S-N curve. Finally, The dynamic
characteristics including vibration modal and frequency response are analyzed. The results can
provide reference for dynamic design of transmission shaft , as well as the structure optimization
design of the transmission shaft .

1. Introduction
Transmission shaft is a key component of automotive transmission. The shaft assembly consists of a
helical gear and a multiple jawed coupling that are secured to the shaft with multiple spline teeth,
parts of which are facing the problem of prematurely resulting in fatigue failure[1]. During the
vehicle’s running, the transmission shaft working in fast rotation and huge torque conditions,
combined with changes of speed and ups and downs, As a result, the shafts are susceptible to
fatigue failure. Fig.1 shows the Transmission system of vehicle .Many factors influencing the
dynamic characteristics and the life of transmission shaft, Therefore set up a finite element model to
analyze the dynamic characteristics and stress distribution of transmission shaft and study the
intrinsic characteristics are necessary. In this paper, using the ANSYS Workbench to analyse the
dynamic character and structure resonance of the transmission shaft, get the low-order natural
frequencies and corresponding vibration mode. According to the results,we can specify the location
of failure fatigue on transmission shaft and provide reference to avoid structure resonance.

Fig.1 Transmission system of vehicle Fig.2 Finite element model of transmission shaft

2. Finite Element Modeling

A finite element stress analysis was carried out to determine the stress distribution of the shaft.
Shown in Fig. 2 is the finite element model of the spline shaft created with hexahedral elements.
This model consists of 46505 elements and 137368 nodes. Boundary conditions were applied at the
bearing supported position and the ends of the helical gear . The shaft loadings were applied on the
finite element model: a twisting torque was simulated by applying on spline.

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 Advanced Materials Research Vols. 765-767 371

3. Results of Stress Analysis

Figure 3 shows the distribution of the von Mises stress of the shaft subject to a steady transmitted
load under normal operation. As seen from this figure, the highest stresses occur at the bottom of
the spline where the maximum torque is produced. surface treatment Should be considered in the
process of machining, in order to avoid the occurrence of machining microcracks[2]. It is noted that
the location of the stress peak agrees with the fractured region as revealed by examination of the
failed shaft. The maxi-mum tensile stress at this region is 130.77 MPa, Fig.4 shows the strain is very
small .The stress levels, however, are significantly below the yield strength of the shaft material.

Fig.3 The distribution of stress on Fig.4 The strain of transmission shaft

transmission shaft
4. Fatigue strength analysis
The S-N curve is one of the basic performance data of material fatigue reliability life estimation,
When you input the material limit tensile strength and modulus of elasticity, The ANSYS soft will
produce the S-N curve according relevant data[3]. The shaft was manufactured from 20Cr with
elastic modulus of 210 GPa, Poisson’s ratio of 0.3. Typical mechanical properties are given
approximately as: 835 MPa for ultimate strength,and 460 MPa for fatigue strength [3,4].The S-N
curve of 20Cr is shown in Fig.5, When the fatigue life up to 107, the fatigue limit is 460 MPa , thus,
spline shaft meet the requirements of fatigue strength.

Fig.5 The S-N curve of 20Cr

5. Dynamic Characteristics Analysis

According to vibration theory, the dynamic matrix differential equation is as Eq. (1):

[M ]{u}+ [C ]{u}+ [ K ]{u} = {F (t )} (1)

in the formula, [M], [C], [K] respectively represents the system quality, the damping and the
stiffness matrix, {x} represents each displacement respond vector of the system, respectively, and
F(t) is the global excitation force vector.
372 Advanced Information and Computer Technology in Engineering and
Manufacturing, Environmental Engineering

5.1 Modal Analysis

As to modal analysis, there is no excitation force and the affect of damping can be ignored, so that
Eq. (1) can be simplified into the following form:

([ K ] − w [ M ]){u} = {0}
2
(2)

This type is called frequency equation, Such a determinant will, generally, given values of w2 , w
is the structure natural frequency, While the solution of Eq. (2) can not determine the actual values
of u , the vectors u j ( j = 1, 2 ,...,n ) can be found, which gives the proportions of the various
terms. Such vectors are known as the natural modes of the system and are generally normalized[5].
the transmission shaft calculated six order modal frequency is shown in Table 1:

Among them, the second and third order natural vibration frequency can be see as equal , its
vibration mode characterized by orthogonal , according to the literature they are the double root [6].
The first order and the sixth constraint modal shown in Fig.6 and Fig.7.

Fig.6 The first order modes Fig.7 The sixth order modes
Through the analysis of its first six order animation, one step natural frequency of the
transmission shaft was 876 Hz. All meshing frequency in all conditions were under the natural
frequency. Both of them don’t affect mutually.
Seen from the first order modes, the transmission shaft bending deformation occurs; for The sixth
order frequency, torsional deformation was happened. The modal analysis points out the weak area
of the transmission shaft, it is necessary to strengthening spline part, the transmission shaft modal
analysis provides a theoretical basis for its structure optimization.
5.2 Harmonic response analysis
We make the excitation force equal to F0 cos wt and neglect the damping,Thus, the structure
dynamic matrix differential equation expressed as follows:

[M ]{u}+ [K ]{u} = F0 cos wt (3)

If we make w02 = [ M ]−1[ K ] , f 0 = [ M ]−1 F0

The equation (3) can be simplified as follows:

{u}+ w02 {u} = f 0 cos wt (4)

By solving Eqs.(4), then neglect the transient value, the steady state response will be obtained.

u (t ) = A0 cos( wt + ϕ )
(5)
 Advanced Materials Research Vols. 765-767 373

The purpose of harmonic analysis is to obtain its frequency response state, to test the
transmission characteristic under excitation force, to study vibration displacement in each frequency,
and to acquire natural frequency and band in distortion measuring condition. In the harmonic
response analysis[7]. it’s frequency range is generally 0 to 5000 Hz, this is selected based on the
testing data from the laboratory. The place of applying load are selected in the side face of spline,
the frequency-displacement curve of vibration in X direction is shown in Fig.8.

Fig.8 The frequency displacement curve of vibration in X direction

It is drawn from the figure 8 that when the frequency reached about 4300~ 4600, the transmission
shaft is likely to produce harmonic resonance response. the largest vibration displacement in X
direction is 2.92 mm under frequency of 4438 Hz, so it is better to avoid transmission shaft work
under this frequency.

6. Conclusions
The transmission shaft of automotive transmission has been analyzed by finite element analysis.
Some conclusions are summarized as follows:
The root of the spline teeth is the weakest regions, surface treatment is needed to increase fatigue
strength of the transmission shaft. To design a transmitted shaft with high service durability,
mechanical characteristics such as fatigue strength, stress distribution,natural frequency, harmonic
response are important properties that should be considered at design stage.

References
[1] Kang Huang, Jiawei Li. Fatigue life prediction of vehicle transmission shaft assembly without
intermediate support: Applied Mechanic and materials,Vols.246-247(2013),p.108-112.
[2] ChunYuan Lin, Juipin Hung:J Fail. Anal. and Preven. (2008) 8:75–80.
[3] Wang Yanyun.Finite element analysis of key part of hybrid electric vehicle drivetrain:
Machinery design and manufacture.2010(3),p.6-7 (in Chinese)
[4] Dimarogonas, D.: Machine Design—A CAD Approach. John Wiley & Sons (2001).
[5] Duan Nengquan, Cai Xuanming, in:2011 Cross Strait Quad-Regional Radio Science and
Wireless Technology Conference .
[6] Chen,K.F,Jiao,Q,Y.,A parsimonious mass spring system Capable of being tuned for arbitrary
repeated natural frequencies[J].Mech,Res,Common,2008,doi:10.1016/j.mesh re-sc-om.2008.
[7] Fang Ren,Zhengyan Liu .Harmonic Response Analysis On Cutting Part of Shearer Physical
Simulation System Paper Title:ICSP2010 Proceeding.
Advanced Information and Computer Technology in Engineering and Manufacturing, Environmental
Engineering
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Finite Element Analysis of Automobile Transmission Shaft

10.4028/www.scientific.net/AMR.765-767.370