A number of key aspects of the three-dimensional finite element (FE) modelling of spline couplings for fretting and fatigue assessment are discussed. The primary issue addressed is the development of an efficient and accurate modelling technique for non-symmetric shaft loading of the couplings, which is an important mode of loading for fretting fatigue assessment. An improved method is presented for implementing an axial modification of the contact geometry, commonly referred to as barrelling, which is also important for fretting fatigue assessment of splines.
LeikinA. S.Vasil'evaG. A.Stress concentration and distribution in straight-sided splined shafts in torsionVestnik Mashinostroeniya, 1974, 54 (3), 41–45.
VolfsonB. P.Stress sources and critical stress combinations for splined shaftJ. Mech. Des., July 1982, 104, 551–556.
4.
LevinaZ. M.Friction and wear in spline connectionsMachines and Tooling, 1966, 37 (11), 14–21.
5.
LevinaZ. M.ReshetovD. N.Cyclic sliding in spur gear splined joints and nominal calculation of their wear-resistanceRussian Engng J., 1974, 54 (7), 11–17.
6.
McFarlaneC. W. R.WilliamsE. J.HydeT. H.The comparison of the boundary element analysis of a high performance spline coupling with experimental measurements In IMechE One Day Seminar on Coupling and shaft technology for aerospace transmissions, Soli-hull, June 1999.
7.
MedinaS.OlverA. V.An analysis of misaligned spline couplingsProc. Instn Mech. Engrs, Part J: J. Engineering Tribology, 2002, 216 (J5), 269–279.
8.
SumW. S.WilliamsE. J.LeenS. B.Finite element, critical-plane, fatigue life prediction of simple and complex contact configurationsInt. J. Fatigue, 2005, 27, 403–416.
9.
ANSI B92.1: 1996 Involute splines and inspection (Society of Automotive Engineers, New York).
10.
SumW. S.FE-based multiaxial fatigue life prediction of spline couplings undergoing fretting. PhD Thesis, University of Nottingham, 2004.
11.
ShigleyJ. E.UickerJ. J.Theory of machines and mechanisms, 2nd edition, 1995 (McGraw-Hill, New York).
12.
ABAQUS user's and theory manuals, Version 6.4, 2004 (Hibbit, Karlsson and Sorensen, Pawtucket, Rhode Island).
13.
WaterhouseR. B.Fretting corrosion, 1972, p. 139 (Per-gamon, Oxford).
14.
VincentL.BerthierY.DubourgM. C.GodetM.Mechanics and materials in frettingWear, 1992, 153, 135–148.
15.
RatsimbaC. H. H.McCollI. R.WilliamsE. J.LeenS. B.SohH. P.Measurement, analysis and prediction of fretting wear damage in a representative aeroengine spline couplingWear, 2004, 257, 1193–1206.
16.
LeenS. B.HydeT. R.WilliamsE. J.BeckerA. A.McCollI. R.HydeT. H.TaylorJ. W.Development of a representative test specimen for frictional contact in spline joint couplingsJ. Strain Analysis, 2000, 35 (6), 521–544.
17.
LeenS. B.RichardsonI. J.McCollI. R.WilliamsE. J.HydeT. R.Macroscopic fretting variables in a splined coupling under combined torque and axial loadJ. Strain Analysis, 2001, 36 (5), 481–497.
18.
LeenS. B.HydeT. H.RatsimbaC. H. H.WilliamsE. J.McCollI. R.An investigation of the fatigue and fretting performance of a representative aeroengine splined couplingJ. Strain Analysis, Special Issue on Fretting Fatigue, November 2002, 37 (6), 565–583.
19.
LeenS. B.McCollI. R.RatsimbaC. H. H.WilliamsE. J.Fatigue life prediction for a barrelled spline coupling under torque overloadProc. Instn Mech. Engrs, Part G: J. Aerospace Engineering, 2003, 217 (G3), 123–142.
20.
LimmerL.NowellD.HillsD. A.A combined testing and modelling approach to the prediction of fretting fatigue performance of splined shaftsProc. Instn Mech. Engrs, Part G: J. Aerospace Engineering, 2001, 215 (G2), 105–112.
21.
MugaduA.HillsD. A.A generalised stress intensity approach to characterising the process zone in complete fretting contactsInt. J. Solids Structs, 2002, 39 (5), 1327–1335.
22.
DingJ.LeenS. B.McCollI. R.The effect of slip regime on fretting wear-induced stress evolutionInt. J. Fatigue, May 2004, 26 (5), 521–531.
23.
ZienkiewiczO. C.The finite element method, Vol. 1: Basic formulation and linear problems, 1989 ((McGraw-Hill International UK), Maidenhead).
24.
IyerK.MallS.Analyses of contact pressure and stress amplitude effects on fretting fatigue lifeJ. Engng Mater. Technol., 2001, 123, 85–93.
