An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion
An enhanced design method for 3D contact surfaces on shaft–hub connections joined through lateral extrusion
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DOI：
10.1016/j.apples.2021.100047
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发表时间：
2021-04
期刊：
影响因子：
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通讯作者：
D. Ulrich;H. Binz
中科院分区：
文献类型：
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作者：
D. Ulrich;H. Binz
最近开发的一种设计方法，用于圆形轴毂连接使用横向挤压的冷成型工艺，允许通过无梯度形状优化在接触表面上产生预定义的接触应力分布。使用从弹塑性有限元分析得到的接触应力结果和从圆柱形过盈配合得到的简化规则，轮毂的接触表面在迭代过程中局部地适应成形轴的形状。在本文中，设计方法从圆形扩展到非圆形轮廓形状的基础上复杂的摆线创建优化，多边形轴毂连接，最大限度地减少滑动和微动疲劳下的动态负载。为了使非圆形接触表面的局部适应，我们引入了一个合适的定义为三维轮廓，它允许同时变化的轮廓平均半径和偏心率。这允许设计人员创建具有复杂形状的接触表面设计，这些形状符合沿着连接长度的预定义接触应力分布。最后，通过对一个非圆轴毂连接的设计适应性研究，并将结果与初始设计进行比较，证明了该方法的可行性。虽然调整设计的接触应力结果与指定的目标曲线非常一致，但也实现了轮毂中总体上更均匀的应力分布。由于其组合形式和摩擦配合特性以及高残余接触压力，该连接注定用于新型电动和混合动力驱动应用，这些应用需要轻量化设计以及高功率密度和转速。
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.