Int. J. Mech. Eng. & Rob. Res.
2014 S G Solanke and A S Bharule, 2014
ISSN 2278 – 0149 www.ijmerr.com
Vol. 3, No. 2, April 2014
© 2014 IJMERR. All Rights Reserved
Research Paper
AN INVESTIGATION ON STRESS DISTRIBUTION
FOR OPTIMIZATION OF YOKE IN UNIVERSAL
JOINT UNDER VARIABLE TORQUE CONDITION:
A REVIEW
S G Solanke1* and A S Bharule1
*Corresponding Author: S G Solanke, [email protected]
An increased demand for greater performance of universal joint of steering column of passenger
car has prompted the development of joints capable of long life at high torque, high angles and
high loads. This can be easily achieved by investigating or evaluating the torsion loading and its
effect over yoke by FEM. New variations of Universal joint have shown the ability to increase
universal joint performance. As Yoke generally subjected to torsional and bending stresses due
to wt of components also susceptible fatigue by nature of functioning. The purpose of this paper
is an Investigation on Stress Distribution for Optimization of Yoke in Universal Joint under Variable
Torque Condition. Yoke is analysed under torque load from steering rod observing hot spot
location/Stress concentration region, hot area potentially carrying load, scope to optimize/improve
part by eliminating/adjusting density in order to maximize area of hot region with reducing in
dead region.
Keywords: Steering rod, Universal joint, Failure kit, FEA, Photoelasticity, Optimization
INTRODUCTION positive, mechanical connection between
The universal joint consists of two forged-steel rotating shafts, which are usually not parallel
yokes joined to the two shafts being coupled but intersecting. They are used to transmit
and situated at right angles to each other. motion, power or both. The research work
Comprised of three main component-two deals with an Investigation on Stress
Yokes and cross trunnion a universal joint is Distribution for Optimization of Yoke in
linkage used to transmit rotational motion from Universal Joint under Variable Torque
one shaft to another when the axis are coplanar, Condition. The analysis will be carried out
but not coinciding. A universal joint is a under steady state conditions using FEM by
1
Department of Mechanical, SSGMCE, Shegaon 444203, MH, India.
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Int. J. Mech. Eng. & Rob. Res. 2014 S G Solanke and A S Bharule, 2014
applying the boundary condition and stresses joint, by simultaneously considering
is visualized in the model by experiment manufacturing cost, drivable joint angle and
method such as photo elasticity method. The part volume. In this research, universal joint
highest stresses are occurred at the crack is analyzed and compared through the use of
beginning location of the yoke. A possible a Pareto frontier using Adaptive Weight Sum
surface fault could have started the crack technique. Two cases of fatigue failures of
propagation period at the highly stressed point components in the power transmission
of area. After a crack propagation period, the system of passenger cars are considered in
arm had completely fractured. Bayrakceken et al. (2007) study both failures
are occurred as a result of fatigue process.
Heyes (1998) studied the common failure
Some modification on the initial design of the
types in automobiles and revealed that the
joint may be considered for prevention of later
failures in the transmission system elements
failures. Veloso et al. (2009) shows Failure
cover 25% of all the automobile failures. The
of longitudinal stringer of vehicle was
crack beginning location of the joint yoke
reported. Plastic deformation and cracks
corresponds to highest stress points. Hummel
were observed during durability tests of
and Chassapis (1998) revelled that internal
prototype vehicle. Stress analysis was
interference in the input and output Yoke which
performed using FEM. Reinforced models
will cause the large internal force which cause
were proposed and a combination of high
binding and failure of component it can be strength and production costs were the reason
eliminated by changing the design variable. of the choice of the best solution. The FEM of
Hummel and Chassapis (2000) develop the several different models lead to a reduction
methodology and derive the relationships of physical and expensive tests.
necessary to optimize the geometry of Consequently, it was not necessary the
universal joint with manufacturing tolerances production of several prototypes.
and shows that the strength of joint is adversely Compression tests were performed to
affected manufacturing tolerances. Dong-Kyun compare with numerical results. Vehicles
Min and Min-Eung Kim (2003) explains or were produced with the reinforced stringer
revealed that the manufacturing productivity and failures were not observed. Siraj (2012)
and mechanical properties an united steering focus the relationship between manufacturing
yoke largely depends upon the manufacturing cost and joint angle performance measure of
process such as forging, however, the an automotive universal joint, the result
precision cold forging process for the steering illustrate that joint angle is directly
yoke of an automobile has been analyzed by proportional to the manufacturing cost an
using a rigid-plastic finite-element analysis. increase in the drivable joint angle requires
The rigid-plastic finite-element method for corresponding increase in manufacturing
precision cold forging has been used in order cost. However for both the flange and weld
to reduce development time and die cost. Nick yoke, a substantial reduction in manufacturing
Cristello and II Yong Kim (2006) represents cost may be realized by restricting the joint
shape optimization of an automotive universal angle to less than 30°. Farzad Vesali et al.
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Int. J. Mech. Eng. & Rob. Res. 2014 S G Solanke and A S Bharule, 2014
(2012) focuses on increased the performance Figure 1: Universal Joint with Torque
and improve the life expectancy of the cardan
joint. The used of the intermediate spring and
damper increasing the torque arm, increasing
the degree of freedom in order to remove the
regularity in the impact load, installing rigid ring
over cardan joint arm to act as the inner ring.
Chr. Seherr-Thoss et al. (2005) author of
“Universal joint and Driveshaft analysis, Design
and Application” explain the non uniformity of
the transmission in the rotational motion of
single universal joint can eliminated by putting
the intermediate shaft between two
appropriately phased universal joint therefore
The statistical data obtained from a survey
transmitting a constant angular velocity
of broken universal joint carried out by Able
between shafts.
tech central Lab. It has shown that the
In this research Calculation of stress simulation results confirm the causes for the
distribution and element density distribution in frequent failure of universal joint as cited in
Yoke of universal joint to reduce stress below Table 1.
concentration in affected region by iteration
Table 1: Comparative Analysis of Failure
shape optimization and weight reduction per Year in Percent (%)
.Identify and study failure region of Yoke in
Year 2012 2011 2010
Universal Joint under Variable Torque
Name of Part Failure in percent (%)
Condition, compare stress distribution of Von
Yoke Part 66 69 71.5
Misses stress values by using FEM and failed
Spider 28 26 25
yoke stress analysis result by experiments on
Steering Rod 6 6 3.5
it for possible improvement in design of Yoke
in Universal Joint reduce stress levels below
Figure 2: PIE Chart of % Failure in 2012
yield limit by modifying existing geometry
without increasing deflection.
PROBLEM STATEMENT
The universal joint which has failed before their
life have been inspected and found to be
broken in three key main regions: (1) Yoke part
region (2) Spider region (3) Steering rod
region as shown in Figure 1 shows the stress
concentration and highly stresses region
developed by the torque.
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Int. J. Mech. Eng. & Rob. Res. 2014 S G Solanke and A S Bharule, 2014
PIE chart demonstrating percent (%) of by the engine/trans combination. Check to
failure in 2012 at different location in steering make sure the drive shaft series is not too small
rod of Universal joint. for the application.
Typical Universal joint kit failure history Improper Assembly Procedures: Striking
the bearing plate with a hammer can cock it
Brinelling: Brinelling is when needle marks
on the bearing and may cause the bearing to
appear on the surface of the U-joint cross,
be pulled down crooked in the yoke. Cocking
which is usually caused by excessive torque,
the bearing in the bore of the yoke may put
driveline angle. It can also be caused by a
undue loads on the cross, its bearings and the
seized slip yoke or by a sprung or bent yoke.
seals inside those bearings, which may cause
Spalling: Spalling looks like the bearing premature failures and make proper
surface of the U-joint has been “scraped lubrication difficult.
“away. Spalling is usually caused by water or
Bent or Deflected End Fitting: Bent yokes
dirt contamination for avoidance of Spalling
will put abnormal loading on the U-joint
failure Check the U-joint kit seals for damage
bearings and lead to premature failure. A yoke
and replace as necessary and Check to make
can be bent by a shock load or by over torquing
sure the service technician is using the proper
the yoke.
lube type.
Mixing Incompatible Greases: All greases
Burned U-Joint Cross Trunnions:
are a mixture of different additives and
Improper lube procedures, where
thickeners. Mixing greases from different
recommended purging is not accomplished,
manufacturers can lead to a mixture with a
can cause one or more bearings to be starved
lower service performance than either of the
for grease to avoid this type of failure always
original grease products.
make sure new, fresh grease is evident at all
four U-joint seals. Using the wrong lube can U-Joint Cross Broken at a Bearing
result in burned Trunnions unless otherwise Surface: U-joints seldom break off at the
recommended, use a high quality E.P. bearing surface. It takes a very large shock
(extreme pressure) grease to service most load to cause this type of failure. It is also very
vehicular, industrial and auxiliary drive shaft difficult to inspect for this type of failure
applications. because they, many times, start as a small
crack and progress into a complete failure
End Galling/Galling: The end of the trunnion
some time further down the road. The
(of the U-joint cross) looks like material has
Universal Joint Kit Failure Shown in Figure 3
been gouged out. Usual cause for this failure
below.
operating angles is too large.
U-joint Fractures: U-joint fractures are usually OBJECTIVE FUNCTION
caused by a shock load, but can also be When optimizing the systems, one might focus
caused by an improper application to avoid on costs, Weight, service levels, environmental
U-joint failure Calculate the torque transmitted impact, safety, fatigue life, etc. The
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Int. J. Mech. Eng. & Rob. Res. 2014 S G Solanke and A S Bharule, 2014
Figure 3: Universal Joint Kit Failure
Universal Joint Brinelling Universal Joint Spalling Burned U-Joint
Trunnion
Industrial Joint Galling Universal Joint Fracture Weld Yoke Failure
minimization of the stress developed in the developed in the experimental photoelastic
joint, costs and weight is most common in this method of prepared model same dimension.
type of problem. In this research try to study
the basic working principal of universal joint FUTURE METHODOLOGY
and try to identify and study failure of yoke of Finite Element Method (FEM)
universal joint under variable torque condition. FEM simulates a FEM is a numerical
At the stress region to determine the stress technique for solving problems, which are
distribution and possible design improvement described by partial differential equations or
to enhancing the life would be the objective of can be formulated as functional minimization.
this research a static stress analysis is carried FEM are predominantly used to perform
out by entering the obtained mechanical analysis of structural, thermal, and fluid flow
properties of the material for the solid model, situation. They are used to when hand
finite element mesh, distribution of von Misses calculation cannot provide accurate results and
stress values and a comparison of failed yoke geometry is so complex. A domain of interest
and stress analysis result with stresses is represented as an assembly of finite
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Int. J. Mech. Eng. & Rob. Res. 2014 S G Solanke and A S Bharule, 2014
elements. Approximating functions in finite photo elastic material, finding the stresses
element are determined in terms of nodal developed in a model and scaling model to
values of physical field, which is sought. A prototype. As the accuracy of photoelastic
continuous physical problem is transferred in model has got the major effects on the results
to a discretized finite element problem with obtained, the preparation of the model bears
unknown nodal values. its own importance in the whole problem of
Photoelasticity photo elastic stress analysis.
The photoelastic method for investigation of CONCLUSION
stresses in model should preferable because
The main objective of this work is to take an
It should be free from all residual stresses
account of previous work carried out on a
used of photoelastic material model should be
Universal joint. From the review, it can be
transparent possess required dimensional
noted that failure of component is occur due
accuracy. The model should exhibit all
properties of good photo elastic material. manufacturing and design fault, raw material
While the materials used as photoelastic faults, maintains faults, material processing
model materials are epoxy resins, faults, drivable joint angle, cyclic load to avoid
polymethacrylate, polycarbonate, cellulose this problems various method such as a
nitrate, etc. The choice of materials will then topology optimization method, Weight
depend on the objective of the experiment to reduction method, Shape optimization
be performed. The physical arrangement of method, manufacturing method etc are
photo elasticity experiment shown in Figure 4. implemented in the previous research paper
for designing a Universal joint by this method
Figure 4: Photo Elasticity Experiment utilizes or used to find out the best design of
joint with considering the all the factor such
as weight, cost, Fatigue life, stress
distribution, stiffness, etc. The investigation
of stress in the joint can give engineer an
efficient and easy way to design a Universal
joint. FEM analysis and experiments are
included in study research paper to validate
the feasibility of the proposed approach in
the paper.
ACKNOWLEDGMENT
Photoelasticity can be used to determine The authors wish to express their appreciation
the stress intensity factor of a stable crack in a Prof R D Palhade for his valuable assistance
specimen experiencing failure. Experimental and commets during this review and all
results and analysis includes finding the teaching staff of Mechanical Department,
stresses distribution in the model to calibrate SSGMCE, Shegaon 444203 (MH).
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Int. J. Mech. Eng. & Rob. Res. 2014 S G Solanke and A S Bharule, 2014
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