• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.5
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• pp.128-134
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• 2021

A press-fitted shaft is an essential part used in industrial machines, and it is generally used to transmit large quantities of power. Very high contact pressure occurs at the end parts of the contact between the shaft and boss, which are press-fitted shaft components. Such contact pressure not only damages the contact surface of a press-fitted shaft but also reduces its fatigue strength. To improve a press-fitted shaft's fatigue strength, the contact pressure on the contact surface, which directly affects the fatigue strength, should be minimized. Thus, in this study, the design configuration optimization of the end part of the boss was based on the approximate optimization method and was aimed at minimizing the contact pressure at the end of a press-fitted shaft. Comparison of the contact pressure and the contact stress of a conventional press-fitted shaft with those of the optimized press-fitted shaft showed that the boss design of the optimized press-fitted shaft effectively improved the fatigue life.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.11
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• pp.1083-1092
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• 2007

The objective of the present paper is to evaluate the effect of the evolution of contact surface profile caused by fretting wear on fatigue life of press-fitted shaft by means of an analytical method based on experimental data. A finite element analysis was performed to analyze the stress states of press-fitted shaft, considering the worn contact profiles of shaft. The fatigue lives of the press-fitted shaft reflecting the evolution of contact stress induced by fretting wear were evaluated by stress-life approach using fatigue notch factor. It is found that the stress concentration of contact edge in press-fitted shaft decreases rapidly at the initial stage of total fatigue life, and its location shifts from the contact edge to the inside with increasing number of fatigue cycles. Thus the change of crack nucleation position in press-fitted shaft is mainly caused by the stress change of contact edge due to the evolution of contact surface profile by fretting wear. Furthermore, the estimated fatigue lives by stress-life approach at the end of running-in period of the fretting wear process corresponded well to the experimental results. It is thus suggested that the effect of fretting wear on fatigue life in press fits is strongly related to the evolution of surface profile at the initial stage of total fatigue life.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.3
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• pp.85-91
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• 2015

The press-fit shaft is an important part used in automobiles, vessels, and trains. This study proposes an optimized design method to reduce damage that may occur in the press-fitted shaft by modifying the shape of the boss step of the press-fitted shaft. To reduce the time and cost of running the optimized design method, an approximate design optimization is applied and an optimized algorithm is generated using a genetic algorithm that is widely used in engineering fields and an approximate model using a response surface method. The planned experiments for the data that are needed to generate the approximate model use a central composite design (CCD) and Latin hypercube sampling (LHS), and the results of the approximate optimization using the above two design of experiments are to be compared.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.1
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• pp.54-62
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• 2008

In this paper the fretting wear of press-fitted specimens subjected to a cyclic bending load was simulated using finite element analysis and numerical method. The amount of microslip and contact variable at press-fitted and bending load condition in a press-fitted shaft was analysed by applying finite element method. With the finite element analysis result, a numerical approach was applied to predict fretting wear based on modified Archard's equation and updating the change of contact pressure caused by local wear with influence function method. The predicted wear profiles of press-fitted specimens at the contact edge were compared with the experimental results obtained by rotating bending fatigue tests. It is shown that the depth of fretting wear by repeated slip between shaft and boss reaches the maximum value at the contact edge. The initial surface profile is continuously changed by the wear at the contact edge, and then the corresponding contact variables are redistributed. The work establishes a basis for numerical simulation of fretting wear on press fits.

• Proceedings of the KSR Conference
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• 2004.06a
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• pp.632-637
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• 2004

In the shrink or press fitted shaft such as railway axle, fretting can occur by cyclic stress and micro-slippage due to local movement between the shaft and the hub. When the fretting occurs in the press fitted shaft, the fatigue strength remarkably decreases compared with that of without fretting. In this paper, the analysis of contact stresses in a press fitted shaft in contact with a hub was conducted by finite element method and the micro-slip according to the bending load was analyzed. It is found that the largest stress concentration and maximum slip amplitude of shrink fitted shaft are found at the edge of the interface and the distribution of contact stresses at the contact edge has largely influenced and coefficient of friction.

• Journal of the Korean Society for Railway
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• v.10 no.5
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• pp.546-553
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• 2007

The objective of the present paper is to evaluate the effect of the evolution of contact surface profile by fretting wear on the contact stress distribution and fatigue crack initiation site of press-fitted shaft by means of an analytical method based on experimental data. A finite element analysis was performed to analyze the stress states of press-fitted shaft, considering the worn contact surface profiles of shaft. The evolutions of contact stress as wearing of contact surface were analyzed by finite element analysis and fatigue crack nucleation sites were evaluated by fretting fatigue damage parameter (FFDP) md multiaxial fatigue criteria. It is found that the stress concentration of a contact edge in press-fitted sha손 decreases rapidly at the initial stage of total fatigue life, and its location shifts from the contact edge to the inside due to fretting wear as increasing of fatigue cycles. Thus the transition of crack nucleation position in press-fitted shaft is mainly caused by stress change of a contact edge due to the evolution of contact surface profile by fretting wear. Therefore, it is suggested that the nucleation of multiple cracks on fretted surface of press fits is strongly related to the evolution of surface profile at the initial stage of total fatigue life.

• Journal of the Korean Society for Precision Engineering
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• v.33 no.7
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• pp.559-564
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• 2016

The objectives of this paper are to develop a finite element analysis model to analyze press-fitted and bending load conditions in a press-fitted assembly, and propose a hub shape optimization method to minimize contact pressure near the shaft contact edge. Numerical asymmetric-axisymmetric finite element models have been developed to predict contact stress on press-fitted shafts. The global optimization method, genetic algorithm, local optimization method, and sequential quadratic programming were applied to a press-fitted assembly to optimize the hub contact edge geometry. The results showed that the maximum contact pressure with the optimized hub shape decreased more than 60 % compared to conventional hubs and the maximum contact stress affecting fatigue life was reduced about 47 %. Hub shape optimization can be useful to increase the load capability of press fits in terms of wear and fatigue behavior.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.1097-1098
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• 2009

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.6 s.261
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• pp.701-709
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• 2007

To clarify the characteristics of surface damage due to fretting in press-fitted shaft, experimental methods were applied to small scale specimen with different bending load condition. Fatigue tests and interrupted fatigue tests of press-fitted specimen were carried out by rotate bending fatigue test. Macroscopic and microscopic characteristics were examined using scanning electron microscope (SEM), optical microscope or profilometer. It is found that small fatigue cracks are nucleated early in life regardless of bending stress, and thus the most portion of fatigue life on press fits can be considered to be crack propagation process. Most of surface cracks are initiated near the contact edge, and multiple cracks are nucleated and interconnected. Furthermore, the fretting wear rates at the contact edge are increased rapidly at the initial stage of total fatigue life. It is thus suggested that the fatigue crack nucleation and propagation process is strongly related to the evolution of surface profile by fretting wear in press fits.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.8
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• pp.42-47
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• 2010

In this paper, the characteristics of contact surface damage due to fretting in a press-fitted shaft below the fretting fatigue limit are proposed by experimental methods. A series of fatigue tests and interrupted fatigue tests of small scale press-fitted specimen were carried out by using rotating bending fatigue test machine. Macroscopic and microscopic characteristics were examined using scanning electron microscope (SEM), optical microscope or profilometer. It is found that fretting fatigue cracks were initiated even under the fretting fatigue limit on the press-fitted shafts by fretting damage. The fatigue cracks of press-fitted shafts were initiated from the edge of contact surface and propagated inward in a semi-elliptical shape. Furthermore, the fretting wear rates at the contact edge are increased rapidly at the initial stage of total fatigue life. After steep increasing, the increase of wear rate is nearly constant under the load condition below the fretting fatigue limit. It is thus suggested that the fretting wear must be considered on the fatigue life evaluation because the fatigue crack nucleation and propagation process is strongly related to the evolution of surface profile by fretting wear in the press-fitted structures.