Abstract
In this paper it is described a method to simulate the tensional state in a gearbox shift force assembly. The goal is to create a tool to optimise this kind of component since the earliest phases of a new project. Due to the complex geometry of the involved components and due to the specific kinematics behaviour, the usage of modern softwares, based on the finite element analysis, has been required. In addition, an active contribution was provided by our testing facilities, not only focused on the final verification of the calculation results but also supplying useful information on how to proceed in the simulation itself. During the test phases two techniques have been used: the photo-elasticity, providing an overview of the stress distribution on the component, and the strain-gauges technique providing precise informations in specific points of the structure. At the end of this document well see how the results, obtained on a single component, can be rapidly extended to other components with similar geometrical characteristics without the support of the test phase which will be reduced only to a final verification.
Keywords:Transmission, shift forks, virtual validation, physical validation, photoelasticity.