Analysis of Automotive Axis Carrier Assembly and Comparison with Test Results

This paper describes the analysis of an axle carrier manufactured by Borg Warner Australia for the Pontiac Firebird. The aims of the analysis were to model the separation of the crown and pinion gears under drive and coast load and to produce reasonably accurate stress information for the axle carrier shell. It was also intended to gain confidence in the modelling techniques so that they could be used in the design of future components. Deflection test data was available for the actual carrier. The paper shows that good correlation (within the accuracy of the test) was achieved between the model and the test results. This paper also discusses several other points of interest in the analysis. These include the use of solid modelling to define complex surface geometry, the use of inclined planes to model gear tooth interaction, modelling of bearing stiffness and support conditions and the use of thermal expansion to model an interference fit.