P/M Planetary Carrier Gearset: Design Optimization with FEA

This paper describes the work performed in the design and development of a new four-wheel drive gear set with a 4:1 reduction ratio capable of carrying high torques. Close interaction between the design group and the prototype manufacturer was critical to the success of the project. FEA analyses played a crucial role in material selection and evaluation of design changes requested by component manufacturers. The validity of the models will be demonstrated by comparing test results to the predictions derived from FEA. The application of FEA allowed rapid design changes without extensive prototype testing, significantly reducing lead time on the project.