A three-dimensional study of frictional contact in a helical splined coupling for the assessment of macroscopic fretting variables is presented. The study is based on an experimentally validated finite element model of the coupling under combined torque and axial loads. The effect of axial profile modification for reduced contact stresses in spline teeth and the effect of friction coefficient are considered. The motivation for the work is the need for representative information about fretting variable distributions in splined couplings for the development and application of simplified fretting test configurations.
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