Simulation and Experiment Research on Shuffle and Clunk in Gear Shifting Process

The dynamics model of gear shifting process considering the state of clutch and synchronizers and the process of engagement and disengagement is established to realize the continuous simulation of the entire shifting process. The pitching dynamics module is introduced based on the coupled mechanism of torsional, longitudinal and vertical vibration of the system. The simulation reproduces the dynamic responses and states of eight analyzed phases in the whole process. The model is verified from the comparison between simulation and experimental results of four working conditions. Based on the simulation analysis of time-domain and time-frequency domain, the characteristics of shuffle and clunk phenomena are investigated and compared between four working conditions. The key influencing factors of the jerk degree and shuffle intensity are obtained through theoretical analysis, and the verification is made through the simulation comparison of the assessing metrics. The real vehicle test is also carried out focused on shuffle phenomenon. The differences of characteristic frequencies and intensities of shuffle phenomenon in different gear shifting conditions are compared and analyzed.