Abstract: Based on the finite element model of drive axle assembly, the transmission error of hypoid gear is analyzed by simulation, and a test rig is also built to measure the transmission error of hypoid gear under different working conditions. The results of simulation show that the curve of hypoid gear transmission error moves down as the loading torque increases, while the amplitude of the transmission error reduces first and then increases. At light load, the amplitude of the transmission error curve decreases as the loading torque rises due to the deformation compensation of hypoid gear. But when the loading torque further increases to an extent that the transmission error curve is below the lowest end of the designed transmission error curve, the tooth edge contact of gears happens, making the amplitude of transmission error become larger. The results of test exhibit the same law as those of simulation do.

Key words: drive axle, hypoid gear, transmission error, finite element analysis, bench test