Simulation Analysis and Lightweight Design of Automotive Transmission Shafts Based on Optistruct

Abstract The transmission shaft is an important power transmission assembly in the automotive transmission system. Its structural mechanical performance is crucial for the comfort and safety of the vehicle. For this purpose, the transmission shaft of commercial vehicles is taken as the research object. Mechanical simulation analysis is conducted based on the finite element analysis software of Optistruct to investigate the stress and displacement distribution of various components on the transmission shaft under maximum torque and to verify its strength and stiffness. In addition, based on the stress distribution and manufacturing process requirements of the transmission shaft, a lightweight design is carried out for the transmission shaft components. The research results indicate that using simulation analysis methods can quickly obtain the force transmission path of the transmission shaft assembly and introducing manufacturing process requirements for lightweight design not only meets the manufacturing requirements but also has a more uniform stress distribution. The overall structure of the transmission shaft has been reduced from 23.8 kg to 16.8 kg with a weight reduction of 30%. The lightweight design method described in this article can quickly achieve weight reduction goals while meeting the structural strength of the transmission shaft.