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Static and Dynamic Strength Analysis of Reduction Gears for an Automotive Shift-by-wire Actuator

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Abstract

This paper deals with the static, impact, and dynamic strength of reduction gears applied to a shift-by-wire (SBW) actuator system. A sintered material (FD-0405-60) was used for cost competitiveness and mass production. Therefore, strength verification is essential at the beginning of product development. A high-speed tensile test was conducted on the sintered material to understand the mechanical properties and stress-strain curve. After that, for detailed verification, the bending strength and contact strength of the gear were verified mathematically using modified Lewis equation and Hertz contact theory. Next, finite element method (FEM) was used to derive the static strain energy for the damage of each gear through ABAQUS. The impact strength was verified by comparing the static strain energy with the kinetic energy of each gear when the SBW actuator system was driven at the maximum speed. Flexible multibody dynamic analysis was then conducted to confirm the dynamic strength depending on the operating section (initial operation, during operation, collision stop) using ANSYS MOTION. In the future, we intend to implement frontloading by applying the process used in this study.

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Abbreviations

Z :

number of teeth

m :

module, mm

α :

pressure angle, deg

D :

pitch diameter, mm

R :

pitch radius, mm

A :

center distance, mm

b :

face width, mm

ρ :

radius of curvature, mm

F t :

tangential force, N

ω p :

gear rotation speed, rpm

v c :

circumferential speed, m/s

f v :

speed factor

f :

impact factor

p :

pitch, mm

y :

tooth shape factor based on pitch

σ b :

tooth root stress, MPa

S f_b :

safety factor for bending

σ c :

contact stress, MPa

S f_c :

safety factor for contact

v :

poisson’s ratio

E :

elastic modulus, MPa

k :

contact surface stress coefficient or non-stress factor

σ y :

yield strength, MPa

σ t :

tensile strength, MPa

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Acknowledgement

This research was supported by Yeungnam University Research Grant in 2021.

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Authors and Affiliations

  1. School of Mechanical, Mechanical Engineering, Yeungnam University, Gyeongbuk, 38541, Korea

    Ki Bum Lee & ** Ho Kim

  2. Structure CAE Team, SL Corporation, 77 Gongdan 6-ro, Jillyang-eup, Gyeongsan-si, Gyeongbuk, 38470, Korea

    Ki Bum Lee & ** Goo Lee

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  1. Ki Bum Lee
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  2. ** Goo Lee
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Correspondence to ** Ho Kim.

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Lee, K.B., Lee, J.G. & Kim, J.H. Static and Dynamic Strength Analysis of Reduction Gears for an Automotive Shift-by-wire Actuator. Int.J Automot. Technol. 23, 99–107 (2022). https://doi.org/10.1007/s12239-022-0008-z

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