Author(s)

KangZhe Si

Affiliation(s)

School of Materials and Metallurgy, Liaoning University of Science and Technology, Anshan 114051, Liaoning, China.

Corresponding Author

KangZhe Si

ABSTRACT

With the rapid development of new energy vehicles, the noise source of its power system has changed significantly, in which the gear mesh noise of the gearbox has a direct constraint on the NVH performance of the whole vehicle. In this paper, a new energy vehicle three-in-one motor in the 7500-9000rpm speed range of the obvious gear whistling problem to carry out research, through the analysis to determine its main noise source for the first gear pair. The study used SolidWorks software to establish a three-dimensional model of the first gear, and imported into ANSYS for finite element modal analysis, and also calculated the gear meshing frequency based on the formula f=n*z/60. The analysis results show that under 8000rpm, the gear meshing frequency is very close to the first-order intrinsic frequency of the structure, which is very easy to trigger structural resonance, resulting in a stepwise increase in the noise sound pressure level. In order to suppress this resonance phenomenon, an economical and direct structural optimization scheme is proposed in this paper: the number of weight-reducing holes in the gear body is reduced from 8 to 4 to enhance the structural stiffness of the spokes. The optimized simulation results show that the first-order modal frequency of the gear is increased to about 3000 Hz, which successfully avoids the excitation frequency under the main working speed, so that the noise source under the common working conditions is transformed into the wind noise and the tire noise, and the gear meshing noise is effectively masked. The study confirms that structural optimization by adjusting the number of weight-saving holes is an effective and economical way to suppress the resonance noise of the gears in new energy vehicles, which improves the dynamic performance while taking into account the lightweight design objective. 

KEYWORDS

New energy; Vehicle gear meshing; Modal analysis; Noise

CITE THIS PAPER

KangZhe Si. Modal analysis and structural optimization of gear meshing noise in new energy vehicles. World Journal of Engineering Research. 2026, 4(1): 79-86. DOI: https://doi.org/10.61784/wjer3081.

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