KnowledgeBase

The safety against plastic deformation and the safety against full plasticity of the inner and outer parts of the interference fit (shaft and hub) are determined in accordance with DIN 7190 by comparing the joint pressure in the interference fit with the respective limit joint pressure.

The limit joint pressure for plastic deformation (start of the elastic-plastic range) of the outer part is calculated according to equation (15) of DIN 7190-1:

$p_{PA}=\frac{1-Q_A^2}{\sqrt{3}}R_{eLA}$

The limit joint pressure for full plasticity of the outer part is calculated according to equations (27) and (28) of DIN 7190-1:

$p_{PA}=2R_{eLA}/\sqrt{3}$ für $(Q_A<e^{-1})$

$p_{PA}=-2R_{eLA}\ln Q_A$ für $(Q_A\ge e^{-1})$

The limiting joint pressure for plastic deformation (start of the elastic-plastic range) of the inner part is calculated according to equations (16) and (17) of DIN 7190-1:

$p_{PI}=(1-Q_I^2)R_{eLI}/\sqrt{3}$ für $(Q_I>0)$

$p_{PI}=2R_{eLI}/\sqrt{3}$ für $(Q_I=0)$

The limiting joint pressure for full plasticity of the inner part is calculated according to equation (2.42) in Kollmann (or according to equation (30) of DIN 7190-1 for full inner parts):

$p_{PI}=\frac{2(1-Q_I)R_{eLI}}{\sqrt{3}}$

If the calculation is performed based on the von Mises shape modification hypothesis, the safety against beginning plasticity of each part is determined by comparing the equivalent strain on the inside with the limit strain (at which the yield point is reached):

The safety against full plasticity is determined by comparing the equivalent strain on the outside with the limiting strain, and by comparing the radial stress on the inside with the yield point.

The following formulas are used to determine the maximum loads that the interference fit can transmit according to DIN 7190-1 and DIN 7190-2 (assumption: the joint pressure is completely utilized by the respective load):

Max. permissible torque (formula (17) DIN 7190-2 or (1) DIN 7190-1):

$T_{zul}=\frac{\pi}{2\cos(\beta)}l_FD_{Fm}^2p_m\nu_{ru}\sqrt{1-\left(\frac{\tan(\beta)}{\nu_{rl}}\right)^2}$

Max. permissible axial force (formula (18) DIN 7190-2 or (2) DIN 7190-1):

$F_{ax,zul}=\pi l_FD_{Fm}p_m(\nu_{rl}-\tan(\beta))$

Max. permissible bending moment for tapered interference fits (formula (27) DIN 7190-2):

$M_{b,zul}=f_Qp_mD_{Fm}l_F^2\left[0.1+0.4\frac{\nu_{ru}}{\cos(\beta)}+\nu_{rl}\left(\frac{D_{Fm}}{l_F}-0.05\pi\tan(\beta)\right)\right]$

The improved formula (33) from FVA 787 I for determining the maximum permissible bending moment for tapered interference fits has been used since FVA-Workbench 8.1:

$M_{b,zul}=f_Qp_mD_{Fm}l_F^2\left[0.12+0.3\frac{\nu_{ru}}{\cos(\beta)}+\nu_{rl}\left(\frac{D_{Fm}}{l_F}-0.05\pi\tan(\beta)\right)\right]$

The sliding safety for individual loads is determined by comparing the maximum permissible load with the transmitted loads.

In practice, there is usually a combined load on the compression joint; i.e., the joint pressure must be distributed. Applying Coulomb's law of friction to the interference fit results in an ellipsoidal relationship for the transmission range of the interference fit with combined loads (see: FVA 312-I Final Report Section 6.5). The combined sliding safety of a tapered interference fit results in:

$S_R=\sqrt{\left(\frac{1}{S_{R,F_{ax}}}\right)^2+\left(\frac{1}{S_{R,T}}\right)^2+\left(\frac{1}{S_{R,M_b}}\right)^2}$

resp.

$\frac{1}{S_R}=\sqrt{\left(\frac{F_{ax}}{F_{ax,zul}}\right)^{2}+\left(\frac{T}{T_{zul}}\right)^{2}+\left(\frac{M_b}{M_{b,zul}}\right)^{2}}$

The term with the bending moment is omitted for cylindrical interference fits.

Two calculation procedures apply when designing interference fits:

Section 4.2 of DIN 7190-1 describes the two calculation procedures for interference fits subjected to purely elastic loads. Section 4.3 then describes the calculation of elastically-plastically stressed interference fits with certain restrictions. In the FVA-Workbench, the more general approach according to Kollmann is followed when using the modified shear stress hypothesis for elastically-plastically stressed interference fits; the formulas of DIN 7190 then result as a special case. When using the shape modification hypothesis, the calculation approach from FVA 566 is used.

In the case of tapered interference fits, the fitting distance and oversize are converted into each other.

In the FVA-Workbench, the interference fit is always calculated after joining (standing at room temperature). Optionally, the user can activate the consideration of the operating temperature and/or the rotational speed of the interference fit. In this case, the change to the oversize due to the operating temperature and the reduction in joint pressure due to the centrifugal force (see DIN 7190-1 section 10.2) are also taken into account. The centrifugal force also affects the stress curve in the components. The safeties against plasticity are given for all cases. The sliding safety is determined for the worst case of all variants considered.

If the user activates consideration of the temperature, the required joining temperatures of the inner and outer part are determined for various common shrink fit thermal joining processes while maintaining the specified joining clearance. See DIN 7190-1 section 8.2.

Interference fits in which the outer hub diameter and/or the inner shaft diameter change over the joint length can be considered in the FVA-Workbench. The slice method according to DIN 7190-2 section 4.4 is used for this purpose. To do so, the interference fit is divided into slices with uniform diameters. For each slice, the (average) joint pressure occurring is determined from the oversize and the corresponding safety against plasticity is determined. The maximum permissible loads of the individual slices are then added together.

Cylindrical interference fits

The following calculation variants are available:

The joint diameter and the inner shaft diameter are determined automatically from the shaft contour.

Tapered interference fits

The following calculation variants are available:

The orientation of the cone tip and the cone ratio C of the joint must be specified:

$C=1:\frac{l_F}{D-d}=\frac{D-d}{l_F}=2\tan(\beta)$

To determine the joint diameter, either the average joint diameter is determined from the shaft contour or the maximum joint diameter is specified.

If the cone angle error is specified, the resulting diameter clearance in the center of the joint sections is determined, which reduces the effective interference.

The axial shift can be determined from the tolerances of the shaft and hub.

Additional geometry parameters

Up to 7 joint sections can be specified, each with length and corresponding hub outer diameter. In the case of tapered interference fits, the corresponding average joint diameter of each section is automatically determined from the average or maximum total joint diameter based on the cone ratio and the orientation of the cone tip.

Transmitted loads

Stress hypothesis

Cylindrical and tapered interference fits are generally calculated according to DIN 7190-1 and 2 (2017) with extensions according to Kollmann. This calculation is based on the modified shear stress hypothesis according to Kollmann. The option to select the von Mises shape modification hypothesis as an alternative stress hypothesis was added as part of FVA 985. This calculation is based on the approach from FVA 566, which also allows the consideration of a stress-strain curve; otherwise, ideal-plastic material behavior is assumed.

Surface parameters

The smoothing of roughness peaks during joining affects the effective interference after joining. The average roughness depth Rz of the joining surfaces and the smoothing factor can be specified for this purpose.

The adhesion coefficients must be specified to determine the transmittable loads and the necessary (dis)assembly forces. See DIN 7190-1 section 5.

The following procedure is recommended when designing interference fits:

The calculation of multiple interference fits goes beyond DIN 7190 and is based on FVA 566. Both elastically and elastically-plastically stressed multiple interference fits with up to 4 parts (i.e., 3 joints) can be calculated according to the von Mises shape modification energy hypothesis. Stress-strain curves can be considered in the elastic-plastic range.

The following calculation variants are available:

The outer and inner shaft diameters are automatically determined from the shaft contour. The outer diameter of all hub parts must also be specified. All hub parts have the same length (= joint length).

Transmitted loads

Surface parameters

The smoothing of roughness peaks during joining affects the effective interference after joining. The average roughness depth Rz of the joining surfaces and the smoothing factor can be specified for this purpose.

The adhesion coefficients must be specified to determine the transmittable loads and the necessary (dis)assembly forces. See DIN 7190-1 section 5.

Joining process

The joining sequence (from inside to outside or from outside to inside) must be specified. The joining clearance must be specified to determine the joining temperatures. You can select whether joining is to be done using CO2 cooling, N2 cooling, or user-defined temperatures.