The Application of Modern FE Simulation Methods in the Product Development of Transmission Components

The design of transmission components and systems begins nowadays in the early stages of the product development process by means of numerical methods such as Finite Element Analysis (FEA). By using virtual prototypes for optimization, time- and cost-consuming iterations in design and testing may be reduced. The constantly increasing efficiency features of hardware and software allow simulation to approach reality. Complex partial systems can be investigated under consideration of relevant interaction with adjacent components of the transmission. This offers the condition for a complete system understanding and a further increased reliability of the dimensioning.

The paper presents the use of modern calculation methods in typical examples of transmission applications at INA-Schaeffler KG, a global automotive supplier. The range comprises linear FE analyses of shifting components to non-linear investigations of rotational behavior of a synchronization unit including constant mesh gear and constant mesh gear bearing, as well as the simulation of highly dynamic cage stresses in a planetary gear bearing.