The vibration and noise performance of passenger car rear axle drive which be used to meet user comfort requirement depends on the product design and production process control. The objective of this study was to determine methods and specifications for Hypoid Gear Optimization, production control and assembly quality improvement. Based on major gear design parameters determined, the gear noise performance optimization can be achieved by improving gear meshing contact ratio, and reducing motion transmission error. The gear durability optimization can be achieved by selecting manufacture method, reasonable cutter radius, cutter edge radius and strength balance, doing tooth contact analysis and adjustment, surface topography ease-off and stress calculations in GLEASON software. High-precision gear production can be achieved by stabilizing material specification, improving gear blanks accuracy, developing work hold equipment structure and optimizing cutting process. The axle drive noise performance can be improved by controlling the assembly for keeping correct hypoid gear positions. Bearing pre-load and variation control will be used for best load capacity and quietness.


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