差速器半轴齿轮齿根断裂失效分析与优化

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中图分类号：U463.218 文献标识码：A 文章编号：1003-8639（2026）01-0128-03

Analysis and Optimization of Root Fracture Failure of Differential Half Shaft Gear

Yan Huanli， Cheng Xixi，Li Xiaoyu，Peng Cheng （China Automotive Engineering Research Institute Co.，Ltd.， Chongqing 4O1122， China）

【Abstract】Inorder to improve the durabilityand service lifeof differential half shaft gears，afailure mechanism study and manufacturing processimprovement were cariedoutto address the problemof gear rootfracture.Through static loadtorsiontesting，reliabilitytesting，and impact testinganalysis，itwasconfirmedthatthestress concentrationcaused bytoothrotfolding defects is the main cause offracture.Byutilizing ANSYS stress simulation and microstructure testing， a mold improvement plan was developed to unifythe filet size parameters of hot forging dies and cold finishing dies， significantlyreducing thedepthof toothroot defects; Simultaneously innovating gearconfigurationdesign，implementing optimization measures such as large end closure treatment，toth root arc transition，and increasing backconethickness. Testdata confirms that，afterprocessimprovement，thedepthof toothrootfolding defects iscontrolledbelow O.O2 mm， significantlyimproving thestructuralintegrityofthetoothrootareaandsignificantlyenhancingthebendingstrengthand fatigue life of the gear.

【Key words】differential half shaft gear;root defects；stress concentration;failure analysis

0 引言

差速器作为车辆传动系统的核心部件之一，在保证汽车行驶稳定性和转向灵活性方面发挥着不可替代的作用。（剩余3842字）