Project: Targeted use of verification tools for shafts

Standards, guidelines, analytics and FEM

Project: Targeted use of verification tools for shafts - Standards, guidelines, analytics and FEM | MDESIGN Consulting Services

Problem definition

By definition a shaft. However, not everything that is constructively made possible in virtual space by CAD can actually be called a shaft in the sense of computational methods. Flanged shafts represent a concrete application case. In addition to the geometric property of large diameter deviations between the flange blade and the main body of the connecting shaft, force-related special influences such as carding moments and displacement of stress concentrations place high demands on analytical verification methods. Cracks and subsequent fatigue fractures in the component transition of the flange require detailed consideration. Here, a decision has to be made between practical tests, FEM calculations or measurements on the component from a multitude of possibilities, so that, in addition to cost variance of the respective processes, subjective knowledge often decides on the final result.



A solution is sought which basically permits a statement on the load-bearing capacity of the flange shaft geometry. The verification methods should be selected and organized in such a way that they can be used as generally as possible for similar components in series production without requiring detailed application knowledge of the methods used. Using numerical calculations, stress distributions are parameterized and automatically determined on flange shaft geometries in order to generate standard-extending influence factors. Constructive, application-specific boundary conditions should be describable by practical experience. In terms of component verification, applicability must always remain ahead of theoretical principles and be available to every department.



A practicable verification process could be created for various company locations through a targeted selection of in-depth investigation methods. While company departments with test laboratories can perform strain measurements on the component directly and at low cost, international development teams are equipped with computational tools that can take into account the same stress influence as the measuring strip on the notch. The results are comparable across components, departments and locations and enable development teams to design optimized products on a uniform basis for discussion.