Failure analysis and optimization design of suspension support holes for gearbox cases

The suspension hole of a gearbox case was cracked after the mining test vehicle has covered 7000 km. In order to analyze and solve this problem, in this paper, based on the modal analysis of the suspension system and failure analysis of the faulty parts, the finite ele- ment model of the powertrain system was established using Ansys, and strength analysis of the gearbox case was carried out. According to the analysis results, improvement and optimization measures were proposed. The analysis results show that the maximum stress of the optimized gearbox case was reduced by 6.9%, and the test vehicle could operate for 50 000 km without failure after the improvement, which verified the effectiveness of those measures. Accumulating experience in the gearbox case design and simulation, modal anal- ysis and finite element analysis were combined to quickly identify the failure causes of the suspension support hole, and targeted improvement measures were taken, which effectively shortened the research and development cycle and saved production costs.