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ISSN 1974-9821 June 2016
N. Laghzale1, A. Bouzid2
Abstract – The interference fit is a widely process, used to produce a joint assembly of two parts
achieved by friction. It is a popular type of joint in machine elements and it is found in many field
applications related to the automotive, aerospace, oil and gas and shipbuilding industries.
Consequently, a better understanding of its limit behavior together with an accurate evaluation of
the residual stresses generated by this process are very important for the design of mechanical
components requiring high optimized performance. This work focuses on the analytical
development of the residual stresses when the two assembled parts are circular cylinders and
deform elasto-plastically under plane strain condition. The constitutive law that governs their
material strain hardening behavior is assumed to follow a general power law which also covers
the particular cases of elastic perfectly plastic and bilinear hardening. To validate the developed
analytical model (AM), the finite element method (FEM) was used and the results showed good
agreement between the two approaches.
The obtained results show that the stresses increase when the interference value increases causing
maximum stress intensity at the inner surface of the two assembled parts to exceed their material
yield stress. After hollow shaft plastic collapse, any increase in interference results in a small
increase in residual contact pressure with a large increase of the equivalent stresses localized at
the hollow shaft inner surface. The method could be used to determine the maximum value of the
interference in order to prevent assembly failure. Copyright © 2016 Praise Worthy Prize S.r.l. -
All rights reserved.
Copyright © 2016 Praise Worthy Prize S.r.l. - All rights reserved DOI: 10.15866/iremos.v9i3.8703
191
N. Laghzale, A. Bouzid
The main advantage of an interference fit is that no The analysis of the results shows that a judicious
additional components such as screws, welds or choice of the notch geometric parameters can
adhesives are needed to hold the assembled parts significantly reduce stress concentration that generates on
together. The amount of the interference imposed to the edge of the hub. Other authors have studied the
create the joint is the main parameter that controls the influence of the surface quality on the work conditions of
strength and the tightness of the bond. The exact amount interference fit joints. Vekateswara et al. [13] studied the
of interference is sometimes difficult to accomplish with influence of contact surfaces and heat treatments on the
a tight tolerance causing the parts to be rejected. interference fitted assemblies.
In the case of higher interference the assembled parts Although in the past the stresses and deformations
can deform elasto-plastically. The interference fit, as an generated by interference fits have been the subject of
assembly process, received considerable attention in the several analytical and experimental studies [14], [15], the
literature. The theory of elasticity is generally used to elasto-plastic characterization of the assembled parts still
treat this problem [1], [2] when the deformations remain remains a subject of focus. This paper focuses on the
elastic. Gamer and Lance [3] analyzed the stresses and effect of interference on the distribution of residual stress
strains in a shrink fit assembly under a plane stress state. beyond the elastic limit. An analytical model of an
The effect of strain hardening was taken into axisymmetric interference fit composed by two cylinders
consideration by using a bilinear material behavior. under a plain strain condition and based on Hencky
Tresca yield criterion was assumed and the geometric deformation theory is developed. The material strain
model was taken as a disk mounted on a solid shaft. The hardening behavior is considered to follow a power law.
authors concluded that the residual contact pressure To validate the analytic approach, the results of the
increases with the increase of the tangent modulus and developed model were confronted to those obtained
remains constant and independent of the joint geometry using finite element analysis.
for small values of the interference. Giiven [4] developed
an analytical solution for an elasto-plastic assembly with
a linear strain hardening material behavior for a disk II. Analytical Model
varying thickness mounted on a solid shaft. II.1. Material Behavior and Geometry Characteristics
Zhang et al. [5] analyzed a shrink fit assembly using
FEM. They observed a different state of stress as It is well established that for low values of the
compared to the theoretical model in the vicinity of the interference , deformations in the assembly remain in
edges of the contact area. Özel et al. [6] analyzed the the elastic range. However for sufficiently large values of
distribution of stresses and strains of a shrink fit and according to the geometrical and mechanical
assembly and came to the same conclusion. In their characteristics of the materials, both joint parts can
study, the variation of the geometry of the joint was undergo plastic deformations. In describing the material
considered. A significant effect of the gear geometry on behavior of the interference fit assembly parts, Eqs (1)
the stress distribution was observed in particular in the and (2) for the hollow shaft and cylinder respectively will
vicinity of the edges of the gears contact surface. Lewis be adopted [16]. Fig. 1 shows the geometrical
et al. [7] developed an experimental technique based on characteristics of the interference fit assembly. The
the propagation of ultrasound waves to measure contact material behavior laws are given by Eq. (1) and (2)
forces. They evaluated the interface contact pressure for below:
a number of different interference fit cases. Their results
showed a significant increase in the radial stress at the i Es i if i ys
edges of the interference fits. (1)
The case of a shrink fit with a solid inclusion has been i As Bs i m if i ys
investigated [8], [9]. Sen and Aksakal [10] studied the
stress state throughout the contact zone between shaft
and hub for different interference fits considering plastic
i Ec i if i yc
(2)
strains. They analyzed the stress distributions obtained i Ac Bc i n if i yc
by FEM as a function of a dimensionless parameter
useful for designers. This parameter is the ratio between
contact length and shaft diameter. Yang et al. [11] used
Ro
Copyright © 2016 Praise Worthy Prize S.r.l. - All rights reserved International Review on Modelling and Simulations, Vol. 9, N. 3
192
N. Laghzale, A. Bouzid
II.2. Assumptions and Basic Equations Substituting Eq. (14) into Eq. (13) and then into Eq.
(10), gives:
An element of the hollow shaft or cylinder is
identified by its polar coordinates and the stress intensity
3 i
expression according to the three main components r , r r (15)
4 i
and z is given by:
Substituting Eqs. (5) and (6) into Eq. (15), gives:
1
i r 2 z 2 z r 2 (3)
2 3 i
r (16)
4 i
while strain intensity i for an incompressible material
is defined as: Substituting Eq. (14) into Eq. (3), gives:
2 3
i r 2 z 2 z r 2 (4) i r (17)
3 2
d r r r r 2 dr
dr
r
0 (7) r d r r
i i 3
A B
s
r
s i
m
(19)
The geometrical compatibility equations are given as: Eqs. (5) and (6) into Eq. (4), gives:
dur 2
r (8) i (20)
dr 3
Copyright © 2016 Praise Worthy Prize S.r.l. - All rights reserved International Review on Modelling and Simulations, Vol. 9, N. 3
193
N. Laghzale, A. Bouzid
Knowing r and substituting for i in Eq. (17) using II.3.1. Elastic Deformation of the Hollow Shaft
Eq. (1) gives the tangential stresses as: and Cylinder
For low values of the interference the residual
2 r contact pressure is given by considering the radial
As ln 1 displacement compatibility equation urc urs such
3 ri
(25) that:
m
Bs 2Cs 2 m
ri r 2 m 2m 1 Pc (26)
2m 3 K
1 c Ri
K 1 2 c Yc2
1
Ec Yc2
(27)
1 s ro
1 2 s Ys2 1
Es Ys 1
2
Plastic collaps
of the shaft
ys rc2 3
Cs (29)
2 Es
Copyright © 2016 Praise Worthy Prize S.r.l. - All rights reserved International Review on Modelling and Simulations, Vol. 9, N. 3
194
N. Laghzale, A. Bouzid
displacement of the cylinder and the hollow shaft elastic elastically. The stresses in the hollow shaft are given by
zone at the interference radius. The elastic part of the Eqs. (24) and (25).
cylinder is considered to be under inside and outside The constant of integration Cs can be obtained by
pressures while reaching yield at its inside radius; considering the compatibility equation that combines the
therefore: hollow shaft displacement given by Eq. (22) and the
elastic displacement of the cylinder and noting that the
Pi Pc
ys Ysc2 1 (31)
latter is subjected to a contact pressure that is equal to the
radial stress of the hollow shaft the expression of which
3Ysc2
is given by Eq. (24) replacing r by ro ;
Therefore:
Considering the above and noting that the inside
pressure Pi at the elastic-plastic interface is equal to the
2 1 c Ri r
radial stress of the plastic zone given by Eq. (24) for 1 2 c
Yc2 As ln o
r rc , the interface elastic-plastic radius rc is obtained 1
3Ec Yc2 ri
(35)
by: m C
B 2C
m
s s
2m 3
ri
2 m
ro2 m s 0
ro
2
2 r B ys rc
3
As ln c s
r
i 2 m E
ri2 m rc2 m
The stresses in the cylinder are given by the Lamé
s
(32) equations
K
2 1 c2 ro Y 2 1
K ys sc
0
c E Y 2 1 c
3Ysc2 II.3.4. Plastic Deformation of the Shaft with
s sc Elasto-Plastic Deformation of the Cylinder
1 c Ri 3 ys ro
yc Yc2 1
pcs 1 2 c
Yc2 Pcpcs (34) 3Yc2
1
Ec Yc2 2 Es
Copyright © 2016 Praise Worthy Prize S.r.l. - All rights reserved International Review on Modelling and Simulations, Vol. 9, N. 3
195
N. Laghzale, A. Bouzid
TABLE I
2 r GEOMETRICAL AND MECHANICAL CHARACTERISTICS
r Pc Ac ln
3 Ri Cylinder yc MPa Ec MPa Ac Bc m
n
(38) SA-556M 362 210000 362 3512.5 1.299
Ac 2Cc
2 n 2 n
Ri r
2n 3 Shaft ys MPa Es MPa As Bs n
SA-350FL2 328 210000 328 13055 1,539
2 r
Pc Ac ln 1 Isoparametric 8-nodes plane strain elements were used
3 Ri to model the hollow shaft and the cylinder. Because of
(39) symmetry only a quarter of the assembly was modelled.
n
B 2C Special contact and target elements were employed to
c c Ri2 n r 2 n 2n 1
2n 3 model the contact surfaces of the assembly. The friction
between the mating surfaces was not considered as a
previous study on a similar work [17] showed that
where the constants Cc is given by Eq. (29) applied to friction has no significant impact on the final results
the cylinder while constant Cs is obtained using the A mesh convergence criterion was used to validate the
compatibility equation at the interface radius: FE model mesh refinement. In fact, the meshing was
refined until the change in the contact pressure was less
2 than 1%. The other parameters such as the stresses and
3 yc Rc
Cc (40) displacements have been found relatively less sensitive to
2 Ec the mesh refinement. The characteristics given in Table I
were used for both the analytical and finite element
2
3 yc Rc simulations. The residual contact pressure analysis, as
Cs ro (41) well as the radial, tangential and equivalent stresses were
2 Ec plotted against the radial position for different values of
the interference .
and the cylinder interface radius Rc is obtained as
follows. First the contact pressure is obtained by noting
that the radial stress of Eq.(38) at the interface radius is
equal to the pressure required to start yield and is given
by an equation similar to Eq. (31) with no external
pressure for the cylinder.
Then the contact pressure is made equal to the radial
stress in the hollow shaft given by Eq. (24) at the
interface contact radius such that:
2 n
A ln Rc Bc yc Rc
c Ri
2n Ec
Ri2 n Rc2 n
Fig. 4. FE model
yc Ycc2 1 A ln r o
s (42) IV. Results and Discussion
2Ycc2 ri
m Figs. 5, 6 and 7 show the distribution of the radial,
2
B 2 ro yc Rc tangential and equivalent stress a function of radial
s
2m 3
Ec
r i
2 m
ro2 m 0
position for various values of the interference .
Four cases were considered with both the analytical
and FE methods: 0.02 mm, 0.06 mm, 0.2
The stresses in the elastic zone of the cylinder are mm and 0.8 mm. The analytical results agree very
given by Lamé equations. well with the FE counterparts which put confidence on
the developed approach.
The selected interferences produce, respectively, an
III. Numerical FE Model Validation elastic deformation of the hollow shaft and the cylinder,
The developed analytical approach was validated an elasto-plastic deformation of the hollow shaft with
using the finite element model shown in Fig. 4 that runs elastic deformation of the cylinder, a plastic deformation
under ANSYS software. of the hollow shaft with elastic deformation of the
The geometrical and mechanical characteristics of the cylinder and a full plastic deformation of the hollow shaft
joint are shown in Table I below. with an elasto-plastic deformation of the cylinder.
Copyright © 2016 Praise Worthy Prize S.r.l. - All rights reserved International Review on Modelling and Simulations, Vol. 9, N. 3
196
N. Laghzale, A. Bouzid
120
Radial position (mm)
100
Fig. 6. Tangential stress distribution
80
500 Analytical model
0.02 mm Solid lines : Predicted byFE
present
modelmodel
60
0.06 mm Dashed lines : FEM
400 0.2 mm
Equivalent stress (MPa)
40
0.8 mm
20
300
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
200 Interference (mm)
Solid lines : FEM
Dashed lines : Predicted by present model Fig. 8. Residual contact pressure vs. interference
100
0.55
Pc / y s
0 0.5
20 25 30 35 40
0.06 mm
Radial position (mm) 0.07 mm
0.45
0.1 mm
Fig. 7. Equivalent stress distribution 0.2 mm
0.4
The three interference values which give the limits
between the different cases shown in Fig. 3 are obtained 0.35
from Eqs. (28), (34) and (36) are respectively and are
ys 0.0554 mm, pcs 0.0676 mm and yc 0.612 0.3
mm. The graphs show that the radial, tangential and 1 1.5 2 2.5
equivalent stresses increase with the increase of the m, n 1.299
interference. The rate of increase remains significant
Fig. 9. Residual contact pressure vs. strain hardening exponent
until the hollow shaft undergoes plastic collapse after
Copyright © 2016 Praise Worthy Prize S.r.l. - All rights reserved International Review on Modelling and Simulations, Vol. 9, N. 3
197
N. Laghzale, A. Bouzid
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198
N. Laghzale, A. Bouzid
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