Material-independent Dimensioning of Knurled Interference Fits of arbitrary Shape

轴-轮毂连接经常用于传递动态力和扭矩。在大多数情况下，使用摩擦啮合或形式闭合连接。滚花干涉配合(KIF)代表摩擦和模板闭合的组合。基于连接过程，在轴向发生摩擦闭合。此外，由于滚花形状形成了相关的补体(轮毂或轴)，因此在切线方向上会出现形状闭合。KIFs的重要性不断增加。但是，由于没有像DIN 7190那样的圆柱形压装通用指南，因此在尺寸和设计方面存在相当大的不安全性。因此，该项目的主要目标是对任意形状的KIFs进行与材料无关的尺寸标注。将首次提供用于连续数值模拟以及KIF的(半)分析计算的有效设计算法。对于汽车轻量化设计概念，将研究具有滚花轴的钢/铝组合压力铸造材料。此外，还将对齿轮用滚花轮毂钢/钢组合材料进行分析。基于对过去项目的了解，结合计划的材料组合42CrMo4/EN AC-46000和C45/16MnCr5，给出了所需目标的具体材料和几何基础。在这一点上，任意形状是指后刀节距、节距角度和滚花位置的变化。对于可靠的静态和动态设计以及对KIFS连续数值模拟的验证，获取知识是必要的。另一个目的是增强和推广连接力和扭矩的分析计算方法。基于上述特定的材料和几何基础，通过以下策略确保预期的商业可用性：解析式：用解析法设计夹具数值：任意形状的轴向联接夹具与材料无关尺寸的连续数值模拟导则

Shaft-Hub-Connections are frequently used for the transmission of dynamic forces and torques. In most cases, frictionally engaged or form closed connections are used. The Knurled-Interference-Fit (KIF) represents a combination of friction and form closure. Based on the joining process a friction closure occurs in the axial direction. Additionally, a form closure occurs in the tangential direction, because of the knurled shape which is formed into the relevant complement (hub or shaft). The importance of KIFs continuously increases. But there is a considerably insecurity regarding the dimensioning and the design of KIFs, because there is no general guideline like DIN 7190 for cylindrical press-fits. Therefore, the primary aim of the project is the material-independent dimensioning of KIFs with arbitrary shape. For the first time a validated design-algorithm for the continuous numerical simulation as well as for the (semi)analytical computation of KIFs will be available. For automotive lightweight design concepts the material combination steel/aluminum pressure die casting, with knurled shafts, will be investigated. Furthermore, the material combination steel/steel with knurled hubs, for gear wheel applications, will be analyzed. Based on the knowledge of the things past project in conjunction with the planned material combinations 42CrMo4 / EN AC-46000 and C45 / 16MnCr5 the specific material and the geometry-specific basis, for the desired target is given.The arbitrary shape refers at this point to the variation of the flank pitch, the pitch angle and the position of the knurls. For a reliable static and dynamic design as well as for the validation of the continuous numerical simulation of KIFs gaining of knowledge is necessary. Another aim is the enhancement and the generalization of analytical computation approaches for the joining-force and the torque.Based on the mentioned material and geometry-specific base the prospective commercial usability is ensured by the following strategies:Analytical: Design of KIFs with analytical approachesNumerical: Guideline for the continuous numerical simulation for the material-independent dimensioning of axial joint KIFs, of arbitrary shape