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Split Clamping Hub on Hollow Drive Shaft Assembly (3 Bodies)
Nonlinear 3-body Mortar contact analysis of a two-piece EN-GJS-500-7 split clamping hub squeezing a hollow 42CrMo4 steel shaft under 65 MPa bolt flange preload.
Split clamping hubs transmit high torque without keyways by squeezing two ductile-iron saddle halves directly onto a hollow drive shaft across a 4 mm split gap. Using 3 disconnected B-Rep meshes (bonding = 0, mesh components = 3), this model captures the flexural wrapping of the clamping ears under 65 MPa bolt preload, the radial contact pressure distribution around the Ø50 mm shaft seat, and the hoop compression inside the hollow shaft bore.
1. Geometry & FEA Mesh
- •3 disconnected B-Rep solids (mesh components = 3): hollow drive shaft (OD = 50 mm, ID = 20 mm, L = 60 mm) and two symmetric split clamping hub halves (OD = 96 mm, flange span 136 mm, width 36 mm, 4 mm split gap).
- •Materials: 42CrMo4 alloy steel shaft (E = 210 GPa, ν = 0.29) and EN-GJS-500-7 ductile iron clamping halves (E = 170 GPa, ν = 0.28).
- •Independent tetrahedral volume meshes: 31,685 elements, 8,038 nodes, and 24,114 DOFs.
- •Unilateral frictionless Mortar contact across both semicylindrical R = 25 mm shaft-to-hub interfaces.
2. Loads & Boundary Conditions
- •End faces of the hollow drive shaft (z = ±30 mm) fixed in all directions (Ux = Uy = Uz = 0), leaving the central clamping span (z = -18..+18 mm) free to deform radially.
- •Lateral and axial symmetry guide constraints (Ux = 0 on outer ear flanks x = ±68 mm, Uz = 0 on rear hub face z = -18 mm) guiding both hub halves strictly along the vertical clamping axis Y.
- •Opposing 65.0 MPa bolt clamping pressure applied across the four horizontal flange bosses at y = ±18 mm.
3. Simulation Results & Findings
- ✓Peak contact pressure p_contact = 922.1 MPa along the clamping pinch edges where the split hub ears transition into the Ø50 mm cylindrical seat.
- ✓Peak equivalent von Mises stress σ_vm = 608.5 MPa in the fillet root of the clamping flange ears and hollow shaft wall.
- ✓Maximum clamping displacement |u| = 0.1685 mm at the outer bolt flanges as the two hub halves wrap around the shaft.
Machinery designers use WebCAE to size split clamping hubs, check ear bending stresses, and predict radial grip pressure without keyway stress concentrations.
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