An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion

A recently developed design method for circular shaft–hub connections joined using the cold-forming process of lateral extrusion allows predefined contact stress distributions to be generated on the contact surface by gradient-less shape optimization. Using contact stress results from elastic-plasti...

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Autores principales:	Daniel Ulrich, Hansgeorg Binz
Formato:	article
Lenguaje:	EN
Publicado:	Elsevier 2021
Materias:	Shaft–hub connection Shape optimization Finite element analysis Contact surface Elastic-plastic strain Lateral extrusion Engineering (General). Civil engineering (General) TA1-2040
Acceso en línea:	https://doaj.org/article/c55b63a782b24200ae9e6165fd4b30a6
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spelling	oai:doaj.org-article:c55b63a782b24200ae9e6165fd4b30a62021-12-01T05:06:05ZAn enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion2666-496810.1016/j.apples.2021.100047https://doaj.org/article/c55b63a782b24200ae9e6165fd4b30a62021-06-01T00:00:00Zhttp://www.sciencedirect.com/science/article/pii/S2666496821000133https://doaj.org/toc/2666-4968A recently developed design method for circular shaft–hub connections joined using the cold-forming process of lateral extrusion allows predefined contact stress distributions to be generated on the contact surface by gradient-less shape optimization. Using contact stress results from elastic-plastic finite-element analyses and simplified rules derived from cylindrical interference fits, the contact surface of the hub is adapted locally to the shape of the formed shaft in an iterative process. In this paper, the design method is expanded from circular to non-circular profile shapes based on complex cycloids to create optimized, polygon shaft–hub connections, minimizing sliding and fretting fatigue under dynamic loads. To enable local adaptation of non-circular contact surfaces, we introduce a suitable definition for 3D profiles, which allows simultaneous variation of the profile mean radius and eccentricity. This allows designers to create contact surface designs with complex shapes that conform to predefined contact stress distributions along the connection length. The feasibility of the method is finally demonstrated by undertaking a design adaptation study on a sample non-circular shaft–hub connection and comparing the results to the initial design. While the contact stress results for the adapted design agree very well with the specified target curves, an overall more uniform stress distribution in the hub is also achieved. Due to its combined form and friction-fit properties with high residual contact pressure, the connection is predestined for use in novel electric and hybrid drive applications, where lightweight design as well as high power density and rotational speeds are required.Daniel UlrichHansgeorg BinzElsevierarticleShaft–hub connectionShape optimizationFinite element analysisContact surfaceElastic-plastic strainLateral extrusionEngineering (General). Civil engineering (General)TA1-2040ENApplications in Engineering Science, Vol 6, Iss , Pp 100047- (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	Shaft–hub connection Shape optimization Finite element analysis Contact surface Elastic-plastic strain Lateral extrusion Engineering (General). Civil engineering (General) TA1-2040
spellingShingle	Shaft–hub connection Shape optimization Finite element analysis Contact surface Elastic-plastic strain Lateral extrusion Engineering (General). Civil engineering (General) TA1-2040 Daniel Ulrich Hansgeorg Binz An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion
description	A recently developed design method for circular shaft–hub connections joined using the cold-forming process of lateral extrusion allows predefined contact stress distributions to be generated on the contact surface by gradient-less shape optimization. Using contact stress results from elastic-plastic finite-element analyses and simplified rules derived from cylindrical interference fits, the contact surface of the hub is adapted locally to the shape of the formed shaft in an iterative process. In this paper, the design method is expanded from circular to non-circular profile shapes based on complex cycloids to create optimized, polygon shaft–hub connections, minimizing sliding and fretting fatigue under dynamic loads. To enable local adaptation of non-circular contact surfaces, we introduce a suitable definition for 3D profiles, which allows simultaneous variation of the profile mean radius and eccentricity. This allows designers to create contact surface designs with complex shapes that conform to predefined contact stress distributions along the connection length. The feasibility of the method is finally demonstrated by undertaking a design adaptation study on a sample non-circular shaft–hub connection and comparing the results to the initial design. While the contact stress results for the adapted design agree very well with the specified target curves, an overall more uniform stress distribution in the hub is also achieved. Due to its combined form and friction-fit properties with high residual contact pressure, the connection is predestined for use in novel electric and hybrid drive applications, where lightweight design as well as high power density and rotational speeds are required.
format	article
author	Daniel Ulrich Hansgeorg Binz
author_facet	Daniel Ulrich Hansgeorg Binz
author_sort	Daniel Ulrich
title	An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion
title_short	An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion
title_full	An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion
title_fullStr	An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion
title_full_unstemmed	An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion
title_sort	enhanced design method for 3d contact surfaces on shaft–hub connections joined through lateral extrusion
publisher	Elsevier
publishDate	2021
url	https://doaj.org/article/c55b63a782b24200ae9e6165fd4b30a6
work_keys_str_mv	AT danielulrich anenhanceddesignmethodfor3dcontactsurfacesonshafthubconnectionsjoinedthroughlateralextrusion AT hansgeorgbinz anenhanceddesignmethodfor3dcontactsurfacesonshafthubconnectionsjoinedthroughlateralextrusion AT danielulrich enhanceddesignmethodfor3dcontactsurfacesonshafthubconnectionsjoinedthroughlateralextrusion AT hansgeorgbinz enhanceddesignmethodfor3dcontactsurfacesonshafthubconnectionsjoinedthroughlateralextrusion
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An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion

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