The trochoidal contours for positive shaft-hub connections in drive technology

• Applicant: Professor Dr.-Ing. Masoud Ziaei
• Subject Area: Engineering Design, Machine Elements, Product Development
• Term: from 2019 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 419852403

The focal points of the project are:1) Extension of the existing results from the preceding DFG project based on a concrete practical application of SEW-EURODRIVE GmbH & Co. under pure torsional loading conditions is the main focal point of the project. Here, an optimal connection based on a complex trochoid with a shouldered form is determined for the given application. The geometric design is based on the available assembly space. In connection with the space-constrained design, the influences of the variable geometry parameters such as the teeth number z and the main eccentricity e0 on the load-bearing capacity of the connection are numerically investigated. The optimized complex trochoid can be used for the experimental specimen tests. In order to be able to demonstrate the potential of the complex trochoid in terms of its transmission capacity, a standard key connection according to [DIN 6885], which serves as a standard reference compound, will be experimentally tested and compared to the trochoidal profile.2) The characterization of the contour properties is investigated for the rotational bending loads. The trochoidal contour determined in the first step is mainly numerically examined in this step on bending and combined load conditions. The geometric parameters teeth number z and the main eccentricity e0 can be varied and optimized as the most important parameters of the profile. In addition, random experiments are carried out to validate the numerical tendencies. Furthermore, an experimentally based comparison to the standard key connections is intended.3) An economic analysis is intended for the manufacturing of the trochoidal optimal profile. Possible manufacturing technologies, which are suitable for a future industrial mass production of the novel profiles, are investigated with regard to the achievable profile quality, the tolerances and the process times. In particular, the profile manufacturing costs of a required accuracy should be evaluated. Possible manufacturing processes are the roll forming and roll milling used in the field of splines. Furthermore, in the field of polygon connection two-spindle rotating and oscillating methods are nowadays used. The manufacturing costs of the trochoidal profile is finally compared with the known costs of the key connections.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: SEW-EURODRIVE GmbH & Co KG