Load distribution in the axial direction in a spline coupling

A finite element model has been made of a spline coupling between a shaft a nd a sleeve. The stress concentration factor is calculated and compared to analytical calculations. An analytical model for the load distribution in t he axial direction and the torque transfer between shaft and sleeve is pres ented and compared to finite element results. Methods to uniform the load d istribution and thereby decrease the stress concentration factor are tested with the analytical model. The induction hardened shafts with splines are fatigue tested and the lives are presented. The residual stress on the shaf t surface is measured. The analytical model shows that the best way uniform the load is to vary the thickness of the spline tooth in the axial directi on. Different shapes and sizes of the tooth thickness variation are also in vestigated. It is probably possible to extend the fatigue life at least two times for this spline, by uniforming the load distribution. (C) 2001 Elsev ier Science Ltd. All rights reserved.