Numerical Strength Analysis of Laser-Welded Differential Housing and Gear Considering Residual Stress

Author:

Wang Liuping1,Ni Zhengshun1,Xiao Yingang1,Li Yongqiang1,Liu Xianghuan2,Chen Yongzhi2,Cui Shuanghao2,Zhang Dejun2,Mi Chengji12,He Quanguo1ORCID

Affiliation:

1. College of Mechanical Engineering, Hunan University of Technology, Zhuzhou 412007, China

2. Laser Welding Department, Zhuzhou Gear Co., Ltd., Zhuzhou 412007, China

Abstract

In order to avoid slackening of differential housing and gear joined by bolts, the laser-welding process is proposed in this paper, and the strength of a connecting joint was estimated by numerical analysis with consideration of welding residual stress. The process parameters of laser welding for dissimilar materials QT600 cast iron and 20MnCr5 structural alloy steel were introduced, and chemical composition analysis and microstructure analysis were conducted on the welded joints. The finite element model of laser-welded differential housing and gear was established to obtain the welding residual stress by applying a moving heat source. To verify the accuracy of the simulated result, static pressing tests were employed. The maximum tensile residual stress was 319.4 MPa, located at the same point as the maximum temperature. The simulated stress agreed well with the experimental data. Finally, the dynamic strength of laser-welded differential housing and gear under forward, reverse, and start-up conditions was assessed by regarding welding residual stress as the initial stress field, which showed that all safety factors were greater than 1.4.

Funder

Natural Science Foundation of Hunan Province

Postgraduate Research Innovation Project of Hunan Province

Scientific Research Project of Hunan Provincial Education Department

Publisher

MDPI AG

Subject

General Materials Science

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