Reliability Analysis and Evaluation of Differential System Based on low Load Strengthening Model

The differential is an important part of a driveline, and differential performance is related to the handling and stability performance of a vehicle. Thus, a differential with sound design structure and reasonable form and size parameters could lead to satisfactory driving performance. In this work, we analyze and evaluate the reliability of the key parts of a differential system. Firstly, each of key parts is regarded as a subsystem of a differential system, so the subsystem reliability models are obtained. A system reliability model is built based on the paths of the forces from the differential system, and system reliability is calculated. Secondly, according to the result of the analysis of system reliability and the use of the six sigma method, 45 steel or 1Cr18Ni9Ti utilized as the material for the worm shaft, system reliability is analyzed and discussed separately. Then, the reliability of the key parts and the overall system reliability increase with the low load strengthening characteristic of the material. Finally, according to the analysis and discussion, the level of system reliability matches that required for differential systems, and the cost is also considerably reduced, as demonstrated using the stress–strength interference and low-load strengthening models. These results provide a theoretical basis for the improvement of the design of Torsen differentials. Similar methods can be used to develop automobile subsystems in the future. Copyright © 2015 John Wiley & Sons, Ltd.

[1]  Badih Jawad,et al.  Design of an Aluminum Differential for a Racing Style Car , 2000 .

[2]  Shaoze Yan,et al.  Reliability analysis method of a solar array by using fault tree analysis and fuzzy reasoning Petri net , 2011 .

[3]  Jing Zhang,et al.  Structural reliability analysis based on probabilistic response modelling using the Maximum Entropy Method , 2014 .

[4]  Liyang Xie,et al.  System-level load-strength interference based reliability modeling of k-out-of-n system , 2004, Reliab. Eng. Syst. Saf..

[5]  Shaoze Yan,et al.  Reliability apportionment approach for spacecraft solar array using fuzzy reasoning Petri net and fuzzy comprehensive evaluation , 2012 .

[6]  J. Christian,et al.  Fatigue in Metals , 1955, Nature.

[7]  Wu Zhixue,et al.  STUDY ON FATIGUE DAMAGE BELOW THE FATIGUE LIMIT AND THE COAXING EFFECTS , 2009 .

[8]  Lu Xi,et al.  Strengthening of transmission gear under low-amplitude loads , 2008 .

[9]  Weiwen Peng,et al.  A Bayesian Approach for System Reliability Analysis With Multilevel Pass-Fail, Lifetime and Degradation Data Sets , 2013, IEEE Transactions on Reliability.

[10]  Toshio Nishihara,et al.  Fatigue Life of Metallic Materials under Varying Repeated Stresses of Two Different Stress Waves , 1957 .

[11]  Shaoze Yan,et al.  An approach to system reliability prediction for mechanical equipment using fuzzy reasoning Petri net , 2014 .

[12]  陈铁,et al.  Reliability Reallocation for Fuel Cell Vehicles Based on Genetic Algorithm , 2015 .

[13]  Chengbin Chu,et al.  Reliability allocation problem in a series-parallel system , 2005, Reliab. Eng. Syst. Saf..

[14]  Alyson G. Wilson,et al.  Advances in Data Combination, Analysis and Collection for System Reliability Assessment. , 2006, 0708.0355.

[15]  Chris P. Tsokos,et al.  The effect of loss functions on empirical Bayes reliability analysis , 1999 .

[16]  Nisitani Hironobu,et al.  Significance of initiation, propagation and closure of microcracks in high cycle fatigue of ductile metals , 1981 .

[17]  Xianzhen Huang,et al.  A probability estimation method for reliability analysis using mapped Gegenbauer polynomials , 2014 .

[18]  Hong-Zhong Huang,et al.  A Discrete Stress-Strength Interference Model With Stress Dependent Strength , 2009, IEEE Transactions on Reliability.

[19]  Sallie Keller-McNulty,et al.  Testing the untestable: reliability in the 21st century , 2003, IEEE Trans. Reliab..

[20]  Xintian Liu,et al.  Reliability Analysis and Evaluation of Automobile Welding Structure , 2014, Qual. Reliab. Eng. Int..

[21]  Wang,et al.  Lightweight Design of Automobile Drive Shaft Based on the Characteristics of Low Amplitude Load Strengthening , 2011 .

[22]  Gao Hongyi.  A Study on Critical Load of Automotive Transmission Gears with Low Amplitude Load Strength , 2009 .

[23]  Z. Songlin,et al.  Lightweight design of vehicle components based on strengthening effects of low‐amplitude loads below fatigue limit , 2012 .

[24]  V. E. Johnson,et al.  A hierarchical model for estimating the early reliability of complex systems , 2005, IEEE Transactions on Reliability.

[25]  Zu Shi-hua.  Bending Fatigue Strength of Gear Under Random Loads , 2007 .

[26]  Bradley A. Lerch,et al.  Conducting high-cycle fatigue strength step tests on gamma TiAl , 2002 .

[27]  David W. Coit,et al.  Reliability Analysis for Multi-Component Systems Subject to Multiple Dependent Competing Failure Processes , 2014, IEEE Transactions on Reliability.

[28]  Badih Jawad,et al.  An Adjustable Aluminum Differential , 2001 .

[29]  Theodore Nicholas,et al.  Step loading for very high cycle fatigue , 2002 .

[30]  G. M. Sinclair,et al.  An Investigation of the Coaxing Effect in Fatigue of Metals , 1952 .