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Design Improvement of a CV Joint Boot to Increase Product Life Using Simulation
ㆍProduct: CV Joint Boot
ㆍAnalysis Goal: Reproduce the structural failure of the CV joint boot and provide design guidance
Download PDF File 'CV Joint Boot Simulation' (Click)
The Mistequay Group, a manufacturer of Constant Velocity (CV) joints had a client who requested a half-shaft that could operate at an increased transmission angle, but the existing boot for the CV joint was already at its operating limit, exhibiting reduced product life at higher transmission angles.
Traditional Finite Element Analysis (FEA) was not sufficient for modeling the flexible CV boot in motion because the CV joint boot undergoes complex nonlinear deformation during the combined rotation and bending of the CV joint, and it also makes contact with itself and potentially other half-shaft components during the motion. Because of this, the manufacturer decided to use RecurDyn (Multi Flexible Body Dynamics, or MFBD technology) for the CV joint boot simulation, successfully reproduced the structural failure, and obtained helpful design guidance.
Process for a CV joint boot simulation
① Created a MFBD model that consists of a rigid CV joint model and flexible boot
② Configured the boots of the CV joint into its installation positions with respect to the bell and driveshaft
③ Defined flexible body contacts between the folds of the boots and other locations (including Self-contact)
④ Ran the CV joint boot simulations through transmission angles and rotational speeds of interest
Key Technologies for Analysis
ㆍ MFBD modeling which consists of rigid bodies and flexible bodies
ㆍ Self-contact among the folds of the boots
ㆍ Contact between rigid bodies and flexible bodies
Comparison between CV joint boot simulation and experiments
Toolkits for CV joint boot simulation
ㆍRecurDyn/Professional
ㆍRecurDyn/FFlex
Customer Challenges
• Structural failure of the CV joint boot under the new operating conditions
• Need to evaluate the dynamic motion at an increased transmission angle
• The complex nonlinearity which is not reproduced with traditional FEA
• Need to improve the design with reasonable time and cost
Solutions
• Modeling and simulation time reduction by MFBD technology which can simulate rigid bodies and flexible bodies together
• Successful reproduction of the structural failure with the nonlinear flexible body and contact algorithm
• Simulation of various designs of the CV joint boot using an intuitive user interface
Rigid model of the boot on the CV half-shaft Boot mesh to be used for MFBD simulation
Outcome of the CV joint boot simulation
• RecurDyn could correctly recreate the behavior of the existing CV joint boot design
• The new CV joint boot design does not exhibit the problematic dimpling effect found in the existing design
• Simulation results provided additional guidance for further design improvements for the new boot
Other Applications
ㆍDynamic analysis of gears that are represented as exible bodies
ㆍAnalysis of transmission to check contact force as a function of the shape of gear teeth
ㆍAnalyze the characteristics of the vibration that occurs on the vehicle lower frame when it runs on a rough road
ㆍEvaluation of the load applied to the arm and vehicle upper frame during excavating to improve product durability
