Search Results (21)

In this study, an innovative approach to torque transmission mechanisms within the context of hub–shaft connections is introduced by exploring the viability of a transverse key configuration. Unlike traditional longitudinal key placements, the proposed method positions the key perpendicularly to the rotational axis, resembling a pin joint at the interface of the shaft and the hub. This research primarily aims to elucidate the maximum torque capacity of such a connection, juxtaposed against conventional methodologies. Employing a rigorous analytical framework, equations originally designed for pin connections are adapted to suit the unique geometric and loading conditions presented by the transverse key. This adaptation is essential in quantifying the resultant torque that the connection could sustain without failure. The study meticulously accounts for the variations in key dimensions and the inherent limitations posed by the method’s reliance on the end-face connection strategy. Comparative analyses underscore the manufacturing advantages of the proposed method, notably its reduced machinery requirements, by leveraging standard milling processes over more complex machining operations that are traditionally associated with keyway or keyseat creation. However, the findings also highlight the compromised torque transmission capability due to the reduced contact area, a significant consideration for designers. This research contributes to the broader discourse on mechanical connection innovations, offering a novel perspective on torque transmission solutions. It provides a foundation for future exploration into alternative key configurations, potentially revolutionizing hub–shaft connection designs in applications constrained by manufacturing capabilities or cost considerations. Full article

In the field of modern drive technology, conventional form-fit shaft-hub connections, such as the standardized keyway connection, are reaching their mechanical limits due to the space-saving design. The trochoidal profiles are elegant modern shaft-hub connections with a compact design for high-power transmission. This article deals with an analytical approach to determining the stress state in trochoidal profiles under shear bending. The solution completes the existing analytical attempts at the load cases of pure bending and torsion. Similar to the torsional loading case, a conformal mapping must be found that can completely transform the unit circle to the non-circle profile area. The conformal mapping function is deduced from the contour equation of the profile. To check the analytical results, in addition, numerical investigations were carried out. The results of the complementary numerical studies show very good agreement with the analytical solutions. The equations derived for the maximum stresses enable a reliable and cost-effective design of the profile shafts subjected to shear force loading. Full article

The wheel hub is an important component of the wheel, and a good hub design can significantly improve vehicle handling, stability, and braking performance, ensuring safe driving. This article optimized the hub structure through morphological aspects, where reducing the hub weight contributed to enhanced fuel efficiency and overall vehicle performance. By referencing honeycombed structures, a bionic hub design is numerically simulated using finite element analysis and response surface optimization. The results showed that under the optimization of the response surface analytical model, the maximum stress of the optimized bionic hub was 109.34 MPa, compared to 119.77 MPa for the standard hub, representing an 8.7% reduction in maximum stress. The standard hub weighs 34.02 kg, while the optimized hub weight was reduced to 29.89 kg, a decrease of 12.13%. A fatigue analysis on the optimized hub indicated that at a stress of 109.34 MPa, the minimum load cycles were 4.217 × 10⁵ at the connection point with the half-shaft, meeting the fatigue life requirements for commercial vehicle hubs outlined in the national standard GB/T 5334-2021. Full article

A well-known phenomenon in machinery systems is the easing of a blocked connection of mechanical parts after an impact hit close to the connection. Such impact hits may also arise in shaft–hub connections such as gears, crankshafts, or other parts. The objective of this study is to investigate the influence of local impact loads on the transmittable torque of smooth shaft–hub connections. In a specially designed test rig, it was demonstrated that the transmittable torque of the shaft–hub connection is reduced as a consequence of the impact, resulting in a reduction in the frictional force and slippage of the hub. Increasing the impact load leads to an increase in the reduction in the frictional force as well as the slippage and reduces the transmittable torque. By carrying out a modal analysis of the relevant parts and FE simulations of the impact, two possible reasons have been identified: (i) the impact load excites a vibration mode in the connection which reduces the frictional force and the transmittable torque; and (ii) the impact causes local deformation of the shaft, which results in local slip. Full article

Drive systems are an important part of general mechanical engineering, automotive engineering, and various other fields, with shaft–hub connections being an important part of such systems. Decisive aspects in the development of such systems today are, for example, high transmittable forces and torques, low masses, and the cheapest possible production of components. A possibly threefold increase in the force and torque transmission capacity can be achieved by using press–fit connections with an elastic–plastic design as opposed to regular elastically designed alternatives. An elastic–plastic design of the press–fit connection is achieved by using a large interference. A large transition geometry on the shaft (which replaces the conventional chamfer) is required to join such an interference. The material and space requirements have a negative impact on lightweight applications and limited building spaces. Therefore, the objective of the research presented in this paper is to design and analyze a detachable joining device that substitutes this geometry. A simulation study was conducted to determine the geometry of the joining device that improves the stress state and consequently the force and torque transmission capacity of the connection. Moreover, the influence of manufacturing tolerances of the joining device and the shaft, corresponding risks, and measures to mitigate them are analyzed using finite element analysis. The results show that large transition radii, enabled by using a joining device, lead to a homogenous distribution of plastic strain and pressure in the press–fit connection, even for large interferences ξ and soft hub materials like wrought aluminum alloys. The influence of manufacturing tolerances on the stress state was quantified, leading to design guidelines that minimize the risk of, e.g., the front face collision of a shaft and hub, while maximizing the power transmission of the connection. The results show the capability of a detachable joining device to enable elastic–plastic press–fit connections and the corresponding threefold increase in the force and torque transmission capacity in lightweight applications, resulting from the substitution of the installation space consuming and mass increasing the transition geometry of the shaft. Full article

Shafts with a stepped shoulder are particularly well known in the field of drive technology. In combination with a form-fit shaft–hub connection, the shaft shoulder fixes the hub on the shaft as well as being responsible for the absorption of the axial forces. With profiled shafts, there is a notch overlay in the shaft shoulder, involving the shaft shoulder and profile. If the hub is also connected with the profiled shaft, the hub edge acts as an additional notch in the shaft shoulder area. The multiple resulting notches have not previously been part of research activities in the field of innovative trochoidal profile connections. Compared to conventional positive-locking connections, such as the keyway connection or the involute splined shaft profile, the favourable features of trochoidal profiles have only been based on connections with stepless shafts without a shoulder in previous studies. Accordingly, this article addresses numerical and experimental investigations of trochoidal profile connections with offset shafts for pure torsional loading. Focusing on a hybrid trochoid with four eccentricities and six drivers, a well-founded numerical and experimental investigation was carried out with numerous fatigue tests. In addition, the influence of a shaft shoulder was also demonstrated on simple epitrochoidal and hypotrochoidal profiles. Full article

Interference fits are very common shaft–hub connections due to their low manufacturing costs and excellent technical properties. The Plastic Conditioning of this machine element is a new and not very well-known method. During the development of this method, it was discovered that Reverse Yielding occurs in certain applications and has a negative impact on the result. This paper examines the effects of Reverse Yielding on the technology of Plastic Conditioning of interference fits in Power Transmission Engineering. Based on the Shear Stress Hypothesis (SH), the Plane Stress State (PSS), and the ideal plastic behavior of materials, established stress–mechanical relationships are used to find the influencing parameters of Reverse Yielding on the technology of Plastic Conditioning and their limits. As a result, a new computational concept is developed that allows the user to maximize Plastic Conditioning while avoiding Reverse Yielding. Analytical calculation suggestions and diagrams for practical application are provided. Furthermore, the deviations in the obtained results, taking into account other material models such as the Von Mises Yield Criterion (VMYC) and material hardening, as well as the Bauschinger effect, are examined in comparison with our own numerical results from the development of Plastic Conditioning, and the resulting need for further research is defined. In addition, the method of Plastic Conditioning of interference fits is introduced and its basic principles are briefly explained. Full article

Mechanical couplings in engineering usually use interference fits to connect the shaft and hub. A railway wheel axle is a press fit that is connected by interference and can be subjected to bending stress. In loaded press fits, a high concentration of contact stresses can be generated in the area of the axle-fillet beam, which in most cases leads to the failure of the axle due to fatigue and fretting fatigues. Therefore, it is crucial to determine the ability of the press-fitted joints to provide sufficient frictional resistance that can withstand the loads and torques by evaluating the safety factor, especially when the mechanical or structural system is loaded. In this paper, the contact pressure and stress distribution along the radius of the wheel axle are studied using the analytical calculation of Lame’s equation, and the numerical method used is by ANSYS software. It was found that interference fits have a great influence on the connection strength of interference fits, which are directly related to the contact pressure. Increasing the interference increases the contact pressure, which allows higher torque and load capacity to be transmitted. The finite element analysis showed good agreement for the highest interference value of 230 µm with a relative error of 1.4%, while this error increased to the maximum relative error of 14.33% for a minimum interference of 100 µm. Full article

This article deals with the uniformity of the distribution of axial forces between the individual bolts of the clamping sleeve. Clamping sleeves are machine components connecting the shaft to the hub using contact force. For sleeve pretension, bolts are used and positioned symmetrically with respect to the axis of the clamping sleeve. Though the bolts are placed symmetrically around the axis, the bolt axial forces are not uniformly distributed when the bolts are tightened according to the manufacturer’s catalog. First, this article describes the procedure for tightening the sleeve bolts according to the manufacturer’s catalog. In the next part of the article, an FEA simulation of sleeve tightening is performed. The FEM simulation is then compared with the values found by measurement. Full article

Hypotrochoidal profile contours have been produced in industrial applications in recent years using two-spindle processes, and they are considered effective high-quality solutions for form-fit shaft and hub connections. This study mainly concerns analytical approaches to determine the stresses and deformations in hypotrochoidal profile shafts due to pure bending loads. The formulation was developed according to bending principles using the mathematical theory of elasticity and conformal mappings. The loading was further used to investigate the rotating bending behaviour. The stress factors for the classical calculation of maximum bending stresses were also determined for all those profiles presented and compiled in the German standard DIN3689-1 for practical applications. The results were also compared with the corresponding numerical and experimental results, and very good agreement was observed. Additionally, based on previous work, the stress factor was determined for the case of torsional loading to calculate the maximum torsional stresses in the standardised profiles, and the results are listed in a table. This study contributes to the further refinement of the current DIN3689 standard. Full article

This research studied the knurled interference fits (KIF) jointing process, which involves connection via a shaft and hub. KIF are widely used in many industries and products, but the related research is limited, especially in the case of auto parts. To confirm the optimal parameters for KIF joining, two different simulations in the finite element method (FEM), two hub thicknesses, three geometry versions, and four coefficients of friction (COF) were adopted to simulate the KIF forming process in this study. All the parameters were investigated in detail and accurately referred to experimental examination outcomes. The simulations and the experimental results offered explicit explanations of the relationship between jointing force and geometry dimensions. The hub-forming shape and the simulation of hoop deformation were analyzed, and the analysis results provide useful suggestions for other related industrial research as well. Full article

This paper presents an analytical method for determining the bending stresses and deformations in prismatic, noncircular profile shafts with trochoidal cross sections. The so-called higher trochoids can be used as form-fit shaft-hub connections. Hybrid (mixed) higher trochoids (M-profiles) were developed for the special application as a profile contour for the form-fit shaft and hub connections in an earlier work by the author. M-profiles combine the advantages of the two standardised polygonal and spline contours, which are used as shaft-hub connections for the transmission of high torques. In this study, the geometric and mechanical properties of the higher hybrid trochoids were investigated using complex functions to simplify the calculations. The pure bending stress and shaft deflection were determined for M-profiles using bending theory based on the theory of mathematical elasticity. The loading cases consisted of static and rotating bends. Analytical, numerical, and experimental results agreed well. The calculation formulas developed in this work enable reliable and low-cost dimensioning with regard to the stresses and elastic deformations of profile shafts subjected to bending loads. Full article

A new method of material and lubricant testing is demonstrated with a planar contact fretting wear tribometer under typical fretting wear conditions. The usual abstraction of contact geometries with an easy-to-align point or line contacts is deliberately dispensed to do justice to the frequently flat contacts of machine elements (shaft-hub connection, bearing seats, etc.). For the study, a new method of targeted observation of the contact surfaces during the test is used, which allows a time-lapse animation of the fretting wear progress of solid lubricant mixtures. Thus, the formation of possible transfer film build-up and the type of wear mechanism occurring can be visualized. This technique represents, in conjunction with additional analytical methods such as microscopy and SEM/EDX, a powerful tool to provide a better insight into the mechanisms of solid lubricant action under fretting conditions. To demonstrate the potential of this approach, a time to damage study is performed on commercial and self-prepared pastes from solid lubricants and white oil, where calcium hydroxide is a commonly employed solid lubricant for the avoidance of fretting wear is compared to other materials. Full article

Balancing holes in single-suction centrifugal pumps are generally applied to attenuate the axial thrust caused by a pressure difference between the front side of a shroud and the rear side of a hub of an impeller. The magnetic drive pump, the subject of this study, has a leak-free airtight structure and an integrated structure of the impeller and inner magnet. To prevent the performance degradation of the magnetic drive caused by heat during operation, complex cooling flow paths connected to balancing holes have been designed so that a sufficient amount of coolant would flow around the magnetic drive. Due to this spatial characteristic, when balancing holes are applied to a magnetic drive pump, the balancing hole flow path becomes very long compared to that of balancing holes applied to conventional pumps. When the balancing hole flow path is long, the flow path loss increases, which in turn increases the adverse effect of balancing holes on the pump performance. Therefore, the design of highly efficient balancing holes to which a sufficient amount of coolant can be supplied is critical in a magnetic drive pump. To this end, two types of balancing holes were investigated in this study. First, balancing holes are drilled in the impeller that rotates during operation. Second, balancing holes are drilled in the inner shaft installed to maintain the centre of rotation of the impeller during pump operation. The results confirmed the flow characteristics of the two types of balancing holes and verified the effect of each balancing hole on the pump performance. Finally, this study found that drilling balancing holes in the shaft were appropriate for the magnetic drive pump, and this type can maintain relatively high efficiency and supply a sufficient amount of coolant to maintain the efficiency of the magnetic drive. Full article