Design and Fatigue Analysis of an E-Drive Transmission System of Single-Speed Gear for Electric Vehicle

Abstract:

Design an e-drive transmission gear, it is very crucial, to understand the failure modes since gears should be sized correctly to withstand loads that will expect to act on the gear teeth and make sure that still be within reasonable load-carrying capacity, compact and lightweight. Fatigue failure can happen on gears under repeated loading due to fatigue such as tooth root bending and contact stress of gear. Materials used in this study were two candidate alloy steels of Cr-Mo and Cr-Mo-Ni and methods employed to design the e-drive transmission gear were by iteration through KISSsoft gear simulation software as well as AGMA of Matlab script, it approaches various parameters such as helix angle, face-width, and input torque. Investigations on safety factors of root bending and contact, stresses of contact and bending, weight, compactness, quiet and smooth functioning have been done by altering the variable design parameters. To conclude that by increasing face width and helix angle both safety factors were increased uniformly regardless of the input torque as we calculated by both approaches. Similarly, the results showed that by increasing the helix angle and face width it brings to reduce the contact and bending stresses of transmission gear. As we comparing the results, the KISSsoft values are a little higher than the analytical (AGMA) values as proven in all fatigue of safety factors versus variable gear design parameter. Based on the safety factor, compactness, lightweight and quiet for smooth function of the designed e-drive mating gears are proven as the face width is 24.5 mm and the helix angle is 25^o.

• Periodical: International Journal of Engineering Research in Africa (Volume 48)
• Pages: 92-107
• DOI: https://doi.org/10.4028/www.scientific.net/JERA.48.92
• Online since: May 2020
• Authors: Hailemariam Nigus Hailu*, Daniel Tilahun Redda
• Keywords: AGMA Standard, E-Drive, Face Width, Fatigue Safety Factor, Fatigue Stress, Helix Angle, KISSsoft

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