Diametral Interference Fit

Problem:
A solid steel disk of outer radius 7 in is to be bored to get an inner radius of 5.988 so that it can be shrunk fit on a steel shaft with a 12 in diameter. Both members have an axial length of 3 in. Properties of both steel members are E = 30 Mpsi, v = .29, Sy = 60 kpsi and Su = 90 kpsi. Find the maximum tangential stress in the outer disk.

Diametral Interference Fit

Overview

Anticipated time to complete this tutorial: 45 minutes

Tutorial Overview
This tutorial is divided into five parts: 1) Tutorial Basics 2) Preprocessing 3) Solution 4) Post Processing 5) Hand Calculations

Audience
This tutorial assumes familiarity of ANSYS 8.0; therefore, it does not go into step by step detail.

Prerequisites
1) ANSYS 8.0 in house Structural Tutorial 2) Completion of all Basic Machine Design Tutorials 3) Completion of three or more Guided Machine Design Tutorials

Objectives
1) Use contact elements to solve for the contact stresses 2) Use symmetry as a solution techniques to solve for interference fit stresses

Outcomes
1) Know how to solve simple geometries involving contact elements 2) Increase efficiency in problem set up and solving speed

Diametral Interference Fit

Tutorial Basics
In this tutorial: Instructions appear on the left. Visual aids corresponding to the text appear on the right. All commands on the toolbars are labeled. However, only operations applicable to the tutorial are explained. The instructions should be used as follows: Bold > Text in bold are buttons, options, or selections that the user needs to click on > Preprocessor > Element Type > Add/Edit/DeleteFile would mean to follow the options as shown to the right to get you to the Element Types window Text in italics are hints and notes Click on the left mouse button Click on the middle mouse button Click on the right mouse button

Example:

 Italics

MB1 MB2 MB3

Some basic ANSYS functions are: To rotate the models use Ctrl and MB3. To zoom use Ctrl and MB2 and move the mouse up and down. To translate the models use Ctrl and MB1.

Diametral Interference Fit

Preprocessing
1) Change the working directory, jobname, and title of your project. 2) Set Preferences to Structural. 3) Add a Solid Brick 8node 185 element. Also referred to as (SOLID185) 4) Create a Material Model. E: 30e6 PRXY: .29 5) Create the inner shaft using the Partial Annulus command. > Preprocessor > Modeling > Create > Areas > Circle > Partial Annulus
Note: To make it solid set the inner radius (Rad-1) to zero.

6) Create the outer disk again using the Partial Annulus command (see picture to the right). 7) Extrude both quarter areas 1.5 in and out of the x-y plane. 8) Add the appropriate volumes together. (i.e. add the two parts of the disk together and add the two parts of the shaft together.)

Diametral Interference Fit

Preprocessing
9) Mesh the two volumes. The mesh size is extremely important to getting a correct solution. You will need a fine mesh at the surfaces where the disk and shaft meet.
Note: The volume sweep command may be helpful here. The accuracy of your answer will depend upon the quality of your mesh. It may be necessary to define mesh attributes to some of the lines and areas to get the mesh that you desire.

10) Create a Contact pair using the Contact Wizard. > Preprocessor > Modeling > Create > Contact Pair Pick the inside of the disk as the target surface. Make sure that the areas and flexible options are selected before picking the target. Pick the outside of the shaft as the contact surface. Make sure that the areas and surface-to-surface options are selected before picking the contact surface. Specify 0.2 as the coefficient of friction and make sure that include initial penetration is selected. Click on optional settings. Specify 0.008 as the normal penalty stiffness and under the friction tab change the matrix stiffness from symmetric to unsymmetric. The contact surfaces should be similar to the one shown to the right.

Diametral Interference Fit

Solution
11) Add symmetrical boundary constraints at the interior areas where the model was sectioned. (See highlighted areas in purple in the picture shown to the right.) 12) Applying displacement constraints in the correct locations is extremely important to obtaining a correct solution. Apply displacement constraints at the keypoints and in the directions indicated below in the picture. Pay attention to the orientation of the model.

UX UZ UX UY UZ UY

Diametral Interference Fit

Post Processing
13) Change some of the solution controls. > Solution > Analysis Type > Sol'n Control Under the basic tab, make the following changes as shown to the right. 14) Solve the model 15) Plot the stress profiles. > Main Menu > General Postproc > Plot Results > Contour Plot > Nodal Solu Plot the x direction stress. Select Stress and X-direction SX under Item to be contoured. The maximum tangential stress is 50537 psi.
Note: Ansys does not have a tangential stress plotting command; however, plotting the x and y stress for problems similar to this one are understood to be the tangential stresses.

Diametral Interference Fit

Post Processing
Plot the y component of stress. Select Stress and Y-direction SY under Item to be contoured. The maximum tangential stress is 50539 psi. If you desire to see the contours of the full model: > Utility Menu > PlotCtrls > Style > Symmetry Expansion > Periodic/Cyclic Symmetry > 1/4 Dihedral Sym

Full model stress plot in X direction is shown below.

Diametral Interference Fit

Hand Calculations
Rdisk ,inner = = 5.988in Ddisk ,inner = 11.977in Dshaft = 12in 12 11.977in 2 = 0.0115in bp b 2 + a 2 bp c 2 + b 2 vi + v o+ 2 2 2 2 E0 c b Ei b a

radial = radial

radial =
Where : a=0 b=6 c=7

E0 = 30e6 psi v0 = 0.29 Ei = 30e6 psi vi = 0.29 p=

radial b b2 + a2 b c2 + b2 vi + + v o 2 2 2 2 E0 c b Ei b a p = 7647 psi

2 2 ri p ro + 1 2 2 2 ro ri ri

max =

max = 50,000 psi