Spline optimization tool using finite element analysis

Abstract

The current method for spline design at the Driveline department consists of several steps. First the initial design is established using analytical calculations, then a 3-dimensional CADmodel is created based on the analytically derived geometrical data. If deemed necessary this model is then manually discretisized with necessary boundary conditions introduced and solved using the Finite Element Method. If needed additional changes are made to the CADmodel and the final design is obtained by through iteration. The main goal of this thesis is to create a program that can automate the pre-processing process and act as an intermediate tool between the analytical calculations and the full Finite Element models during spline design. This report covers the steps taken in order to create a standalone application with a graphical user interface that can generate meshed models of two and three component spline couplings, with all necessary boundary conditions and setup parameters, ready to be solved in the Finite Element program Abaqus. This report also includes a parameter study that investigates the effects different geometrical parameters have on the strength of spline couplings. Lastly the effects of manufacturing tolerances and assembling deviations are studied.