08 Practical Application Press Fit
08 Practical Application Press Fit
08 Practical Application Press Fit
A spur gear is mounted by press fit on a rotating shaft. The nominal power of the transmission is 25
kW, the service factor is equal to 1.2, the rotational speed 1000 rpm.
Data:
L=40 mm
Dc=60 mm Do = 400 mm
Other data:
Coefficient of friction 𝑓 = 0.2
Safety factor against slipping 𝜙 = 1.25
Safety factor against yielding 𝜙𝑌 = 1.5
L
It is requested to determine:
1) Minimum and maximum interference
2) Coupling tolerances
3) Safety margin on the maximum transmittable torque
4) Stress state
1
2
Solution
Problem description
In this exercise, we want to design the interference fit by identifying the proper coupling tolerance
able to introduce a minimum contact pressure for torque transmission and a maximum pressure that
maintain the coupling within the elastic regime.
Minimum interference
The interference should be calculated on the base of the maximum power that is obtained by
multiplying the nominal power by the service factor:
æ 2 × p × n ö æ 2 × p ×1000 ö
w =ç = ÷ø = 104.72 [rad / s]
è 60 ÷ø çè 60
𝑃𝑚𝑎𝑥 30000
𝑇= 1000 = × 1000 = 286,479 Nmm
𝜔 104.72
The minimum contact pressure pc,min is related to the tangential action produced by T at the interface
𝑇 286479
𝜏=𝑟 = 2𝜋 302 40 = 1.267 MPa
𝑐 (2𝜋 𝑟𝑐 𝐿)
Considering the slipping safety factor, the minimum pressure that must be guaranteed in service is:
2 pc,min rc 1 2 × 7.916 × 30
imin = × = = 0.00231 [mm]
E æ rc 2 ö æ 30 2 ö
çè 1- R 2 ÷ø 210000 × çè 1- 200 2 ÷ø
o
3
Maximum interference
The maximum interference is dictated by the yielding condition on the inner surface of the hub
(maximum shear stress theory):
−1
𝑟2 𝜎
2 |𝑝𝑐,𝑚𝑎𝑥 | (1 − 𝑅𝑐2) ≤ 𝜙𝑌 𝜙𝑌 = Yielding safety factor
𝑜 𝑌
sY æ r 2 ö 450 æ 30 2 ö
pc,max = × ç 1- c2 ÷ = × ç 1- = 146.63 [MPa]
2fY è ro ø 3 è 200 2 ÷ø
Since the relation between interference and pressure is linear, we can scale the minimum interference
by the ratio between maximum and minimum pressure:
𝑝𝑐,𝑚𝑎𝑥 146.63
𝑖𝑚𝑎𝑥 = 𝑖𝑚𝑖𝑛 = 0.00231 = 0.0429 mm
𝑝𝑐,𝑚𝑖𝑛 7.916
Coupling tolerances
imin,tol =
(32 − 19) 10 −3 = 0.0065[mm]
2
45 − 0
imax,tol = 10 −3 = 0.0225 [mm]
2
The stress state depends on the value of i assumed within the tolerance range. We can therefore
determine the maximum and minimum value that the shrink pressure takes at the extremes of the
tolerance range and define an interval of possible values.
4
Radial and hoop stresses are given by
BR
r / = AR Hub r / = AA Shaft
r2
Boundary conditions:
Hub:
𝐵𝑅 𝑝 𝑟2
𝜎𝑟,(𝑟=𝑟𝑐) = −𝑝𝑐 = 𝐴𝑅 − 𝐴𝑅 = 𝑅2𝑐−𝑟𝑐 2
𝑟𝑐2 𝑜 𝑐
𝐵𝑅 𝑝𝑐 𝑅𝑜2 𝑟𝑐2
𝜎𝑟,(𝑟=𝑅𝑜 ) = 0 = 𝐴𝑅 − 𝑅2 𝐵𝑅 =
𝑜 𝑅𝑜2 −𝑟𝑐2
Shaft:
r ,( r =rc ) = − pc = AA
5
Safety margin on the transmittable torque
The safety margin on the maximum transmittable torque can be calculated on the base of the
minimum pressure produced by the selected coupling 𝑝𝑐,𝑚𝑖𝑛,𝑡𝑜𝑙 = 22.24 MPa.
𝑇𝑡𝑜𝑙
𝑓 𝑝𝑐,𝑚𝑖𝑛,𝑡𝑜𝑙 = 𝑟
𝑐 (2𝜋 𝑟𝑐 𝐿)
Ttol 440627
h= = = 3.51
T 286479
The press fit can be achieved in two ways: (i) shop press, (ii) temperature difference
(i) In this case, the friction axial load 𝐹𝑎 developed by the maximum pressure produced by the
coupling tolerances must be overcome through a shop press:
E æ rc 2 ö
pc,max,tol = imax,tol 1- = 77.0 MPa
2rc çè Ro 2 ÷ø
Fa = fpc,max,tol 2p rc L = 116 kN
(ii) The temperature difference must produce a thermal strain able to compensate the
maximum tolerance interference. A small clearance must be also produced to overcome the
roughness of the surface. Let us assume the radial clearance 𝐶𝑙 to be 1/1000 of the contact
radius and the thermal expansion coefficient a to be 𝛼 = 10−6 1/°C.