Discrete Profile Approximation in Contact Elements of Mechanical Assemblies

The article examines three types of approximation used for the discretization of contact surface profiles. The assembly under study corresponds to a hub-shaft connection, which is commonly used for the transmission of rotational motion. The profiles that are analyzed are 2D axisymmetric and represent the surfaces of the mechanical elements. The analysis process consists of: a) simulating the ideal nominal geometry without clearances in the contact region, b) obtaining a convergence of contact stresses for the nominal geometry ring-shaft interface, and c) adding clearances to the geometry and changes in the profile contact, at the surface waviness level. The variations of the profile are obtained from measurements of the diameter of the connecting elements within the regions of interest. The study focuses on the analysis of variations of contact stresses generated by different representations of the discrete surfaces. For this analysis, variations in diameter measurements are considered, as are Bezier and spline curve fitted to these variations. The influence of the approximations on the discretization of the contact zones of the finite element models is indicated.