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Modeling and Finite Element Analysis of Universal Joint

  • March 2021
DOI:10.5281/zenodo.4624800
Authors:
Kanishk Yadav at Delhi Technological University
Kanishk Yadav
Harshit Jain at Delhi Technological University
Harshit Jain
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Abstract and Figures

A universal joint, also known as a Hooke's joint, is a joint or coupling that connects rigid rods with angled axes. It's commonly found in rotary motion transmission shafts. It consists of a cross shaft linking two hinges that are close together and oriented at 90 degrees to each other. The objective of this project is to design and understand the working of the universal joint. Also, to determine the stresses, strains and element displacement in the existing design of the universal joint. If the existing design shows some failure, then suggest a minimum factor of safety for the joint. In this project, only the static FEA of the universal joint has been performed by the use of the Fusion 360 software. The simulation was carried out in the Static structural analysis module in the Fusion.
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HBRP Publication Page 1-4 2021. All Rights Reserved Page 1
Advancement in Mechanical Engineering and Technology
Volume 4 Issue 1
DOI: http://doi.org/10.5281/zenodo.4624800
Modeling and Finite Element Analysis of Universal Joint
Kanishk Yadav1*, Harshit Jain2
B.Tech. Student, Department of Mechanical Engineering, Delhi Technological University,
Shahbad Daulatpur, Rohini, Delhi
*Corresponding Author
E-mail Id:- kanishkyadav_2k18me107@dtu.ac.in
ABSTRACT
A universal joint, also known as a Hooke's joint, is a joint or coupling that connects rigid rods
with angled axes. It's commonly found in rotary motion transmission shafts. It consists of a
cross shaft linking two hinges that are close together and oriented at 90 degrees to each other.
The objective of this project is to design and understand the working of the universal joint.
Also, to determine the stresses, strains and element displacement in the existing design of the
universal joint. If the existing design shows some failure, then suggest a minimum factor of
safety for the joint. In this project, only the static FEA of the universal joint has been performed
by the use of the Fusion 360 software. The simulation was carried out in the Static structural
analysis module in the Fusion.
Keywords:- Universal joint, Autodesk Fusion 360, modelling, static structural analysis, CAD-
Computer Aided Designing, Meshing, FEA- Finite Element Analysis
INTRODUCTION
Universal joints are a part of the power
transmission system. They are commonly
used when there needs to be angular
deviations in the rotating shafts [1]. The
main components of the universal joint as
shown in Figure 2 are:
1. Two fork pins that are connected to the
perpendicular arms of the centre block
2. Pin and collar assembly, which allows
the fork to rotate along the axis of the centre
block.
3. The forks allow the assembly to rotate
along their respective shaft axes thus
transmitting torque.
After a long period of use, the universal
joint can develop faults such as looseness,
wear, and torsional deformation of the
intermediate shaft. It could compromise the
universal joint's protection, which is one of
the most important components of a
vehicle's engine and transmission systems.
[2]
Fig.1:-Dimensions used in designing the universal joint
Fig.2:-Modelling of different parts in Fusion 360
HBRP Publication Page 1-4 2021. All Rights Reserved Page 2
Advancement in Mechanical Engineering and Technology
Volume 4 Issue 1
DOI: http://doi.org/10.5281/zenodo.4624800
MODELING
Fig.3:-Universal joint assembly
Autodesk Fusion 360 was used to build the
universal joint model as shown in Figure 3.
We have used dimensions as shown in
Figure 1 for modelling. Fusion 360 is a
collaborative product creation cloud-based
CAD/CAM platform. It allows for product
concept discovery and iteration, as well as
collaboration within a distributed product
development team. Figure 4 shows the top-
view of our Universal joint assembly.
Rendered image of universal joint is shown
in Figure 5.
Fig.4:- Universal joint assembly top-view Fig.5:- Rendered Image of Universal joint
FINITE ELEMENT ANALYSIS
The simulation was carried out in Fusion
360 to observe the stresses and strains
developed on the universal joint by static
structural analysis.
The boundary conditions were given such
that one end of the universal joint was kept
fixed while the other end of the joint was
given a torque of 6400 Nm. The material
used in the analysis of universal joints was
structural steel. The result of Stress
analysis, Strain analysis and Displacement
analysis is shown in Figure 6, 7 and 8
respectively.
Fig.6:- Stress Analysis
HBRP Publication Page 1-4 2021. All Rights Reserved Page 3
Advancement in Mechanical Engineering and Technology
Volume 4 Issue 1
DOI: http://doi.org/10.5281/zenodo.4624800
Fig.7:- Strain Analysis
Fig.8:- Displacement Analysis
RESULTS AND DISCUSSION
S. No.
PARAMETERS
VALUES
1
Maximum Stress (Von-mises)
6.132 MPa
2
Maximum Principal stress
(Maximum Tensile stress)
8.945 MPa
3
Minimum Principal Stress
(Maximum compressive stress)
2.717 MPa
4
Maximum shear stress
1.911 MPa
5
Maximum Equivalent strain
4.61 * 10^(-5)
6.
Maximum Principal strain
5.022*10^(-5)
7.
Maximum deformation
0.002435 mm
8.
Recommended factor of safety
15
LITERATURE REVIEW
[3] Mills, control devices, gadgets,
instrumentation, medical and optical
gadgets, arms radio sewing machines,
material hardware, and computer drives all
use universal joints.
When the FEA findings were compared to
the current results, they were found to be
quite similar. As a result, FEA is a feasible
tool for evaluating the stresses and failure
points of a joint.
[4] The stresses which generally develop in
the universal joint because of power
transmission include bending stress in
yoke, shear stresses in yoke, crushing
stresses between pin and hole of yoke,
shearing stress in hole of yoke and bending
stress in spider assembly.
[5] The stresses were obtained by applying
similar boundary conditions as in our paper,
that is keeping one end constrained and
applying torque on the other end. Since the
stresses obtained were well within the yield
HBRP Publication Page 1-4 2021. All Rights Reserved Page 4
Advancement in Mechanical Engineering and Technology
Volume 4 Issue 1
DOI: http://doi.org/10.5281/zenodo.4624800
stresses of the material, hence weight
optimisation approach was also applied to
the transmission yoke
[6] Java, an object-oriented and high-level
programming language, is used to measure
the different stresses in flange coupling
components. This offers an alternative
approach for precisely computing stresses
in a short period of time.
.
[7] A comparison is made between the
existing design and a new design by making
small modifications to the existing design.
In the new design the stresses obtained (i.e.
Von mises stress and shear stress) are
significantly reduced and are evenly
distributed.
CONCLUSION
1. The modelling of the universal joint
was carried out in Fusion 360 to better
understand its design, working and the
failure points.
2. From the simulation, it was observed
that considerable compressive stresses
were induced at the point of contact
between the fork pin and the fork
which causes premature wearing of the
fork pin, resulting in failure of the
universal joint.
3. High amounts of stresses were also
observed at the intersection of the
centre block, which could also result in
failure of the universal joint.
4. The factor of safety obtained by the
FEA software for the joint was 15.
5. The Von-mises Stress and maximum
shear stress were found to be 6.13 MPa
and 8.94 MPa respectively.
6. The part was found to be safe under
given load conditions
REFERENCES
1. Vesali, F., Rezvani, M. A., & Kashfi,
M. (2012). Dynamics of universal
joints, its failures and some
propositions for practically improving
its performance and life
expectancy. Journal of mechanical
science and technology, 26(8), 2439-
2449.
2. An, K., & Wang, W. (2017).
Transmission performance and fault
analysis of a vehicle universal
joint. Advances in Mechanical
Engineering, 9(5),
1687814017707478.
3. Arora, R. Modeling and Failure
Analysis of Universal Joint using
ANSYS.
4. Mahajan, S., Khamankar, S.,D. Finite
Element Analysis of Universal Joint.
Journal of Emerging Technologies and
Innovative Research. 2349-5162.
5. Kolekar, D., Kalje, A., Kulkarni, S.
Design, Development and Structural
Analysis of Universal joint.
International Journal of Advanced
Engineering Research and Studies.
2249–8974
6. Vardhan, D. H., HariPrasad, M., Rafi,
D. M., & Ravuri, M. Java for
Mechanical Design Computation:
Dimensions of the Various Flange
Couplings.
7. Shah, P., & Patil, A. (2016). Modeling
and FEA of universal coupling of an
automobile truck. International
Journal for Innovative Research in
Science and Technology, 3(2), 131-6.
Cite as
Kanishk Yadav, & Harshit Jain. (2021).
Modeling and Finite Element Analysis of
Universal Joint. Advancement in
Mechanical Engineering and
Technology, 4(1), 1–4.
http://doi.org/10.5281/zenodo.4624800
Modeling, Analysis, and Comparison of Two Materials for Universal Joint by Using Ansys Software
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  • Aug 2023
In this paper, the study has been done for modeling of universal joints and analysis by using Ansys software for structural steel and titanium alloy as materials used. After that performed meshing and gives three possible solutions which are total deformation, equivalent stress, and safety factor. Finite elements analysis is done in the universal joint by considering and applying the average load on it. The analysis confirms the successful design of the universal joint. The study is done by providing real data for the experiments. The safety factor and equivalent stress are more, and total deformation is less in Universal joint-2. So, according to analysis, titanium alloy is the best material for the universal joint and is long-lasting. Because it is lightweight as compared to other materials used for automobile parts manufacturing.KeywordsUniversal jointAnsys softwareStructural steelTitanium alloyTotal deformationEquivalent stress
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Modeling and Failure Analysis of Universal Joint using ANSYS
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Full-text available
  • Aug 2017
Vehicle transmission framework comprises a few parts which in some cases experience the ill effects of various burdens (disappointments). An all inclusive joint comprise of two yokes, one on each pole, associated by cross-molded middle of the road part i.e. creepy crawly. Yoke get together are constantly subjected to torsion and shear. Era of stress, removal and strain in a general coupling has been broke down. Yoke get together are turning part and here and there experience the ill effects of weakness by use of variable torque. In this paper limited component investigation of the part is done to discover the stress and deformation of the last item. For demonstrating of the segment Solidworks CAD software is utilized. Pre-handling work like cross section and examination work is done in ANSYS CAE software. Utilizing FEA investigation, we can recognize the nature and qualities of stresses following up on the Yoke and evaluate the impact of the load/mass geometry/boundary limit conditions over the yoke. Index Terms-FEA: Finite Element Analysis.
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Transmission performance and fault analysis of a vehicle universal joint
Article
Full-text available
  • May 2017
The universal joint is one of the most critical parts of both the engine and the transmission system of a vehicle. After long-term use, however, some vibration and abnormal noise might occur in it, which may lessen safety while driving. In this article, we investigate faults associated with the double cross universal joint, including looseness, wear, and intermediate shaft torsional deformation. First, we propose a transmission model and a new fault model for this joint. Then, the model parameters of the optimal transmission performance are analyzed. Finally, the main contribution of this article is in discussing the transmission performance as related to looseness, wear, and the intermediate shaft torsional deformation. Our results show that when the angle of the two universal joints is consistent, the phase angle equals 90 and the angular velocity of the output shaft becomes constant, which indicates an optimal transmission performance. When the universal joint is exhibiting looseness, the performance of the angular velocity of the output shaft and the transmission becomes worse as the looseness increases. For both wear and the intermediate shaft torsional deformation, the output angular velocity is also unstable. If looseness occurs at the same time as one of these two faults, the instability will be superimposed and the transmission performance will be even worse. This article provides reference for analysis of faults of the universal joint and its diagnosis; for example, it provides suggestions for when the universal joint should be inspected for repairs or replaced.
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Dynamics of universal joints, its failures and some propositions for practically improving its performance and life expectancy
Article
Full-text available
  • Aug 2012
A universal joint also known as universal coupling, U joint, Cardan joint, Hardy-Spicer joint, or Hooke’s joint is a joint or coupling in a rigid rod that allows the rod to ‘bend’ in any direction, and is commonly used in shafts that transmit rotary motion. It consists of a pair of hinges located close together, oriented at 90° to each other, connected by a cross shaft. The Cardan joint suffers from one major problem: even when the input drive shaft rotates at a constant speed, the output drive shaft rotates at a variable speed, thus causing vibration and wear. The variation in the speed of the driven shaft depends on the configuration of the joint. Such configuration can be specified by three variables. The universal (Cardan) joints are associated with power transmission systems. They are commonly used when there needs to be angular deviations in the rotating shafts. It is the purpose of this research to study the dynamics of the universal joints and to propose some practical methods for improving their performance. The task is performed by initially deriving the motion equations associated to the universal joints. That is followed by elaborating on the oscillatory behavior in the rotational speed and the torque that transmits through the intermediary shaft. The forces in the joint bearings are calculated by using an analytical method that is also supported by the numerical modeling. Such models are also used in order to calculate the rhythm and the amount of the excess loads on the joint. This is suggested as a systematic procedure in the search for the causes of the failures in these popular bearings. With the same purpose in mind some defected bearings with deformed sections were selected for the laboratory examinations. By analyzing the loading behavior and the surface conditions of the defected bearings and by comparison with the known fatigue theories attempts are made in order to dig into the causes for the failures in these joints and their bearing surfaces. With the aim of improving the performance and the life expectancy of these popular elements of the machineries, some practical recommendations are also suggested.
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Java for Mechanical Design Computation: Dimensions of the Various Flange Couplings
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Coupling is most commonly used machine element it is required to do computation of dimensions for each and every application separately and it consumes time for every set of calculation. Java is most emerging programming language in scientific computing. Since java is Object oriented and high level programming language leads to use that for computation. The current work deals with the dimensional computing of various types of flange coupling by considering the various stresses in all elements. In current work we considered standard materials for the elements and also provision given to change the material and stresses in the machine members. With help of java we can compute the couplings in shorter duration with precise values.
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Finite Element Analysis of Universal Joint
  • 2349-5162
  • S Mahajan
  • S Khamankar
Mahajan, S., Khamankar, S.,D. Finite Element Analysis of Universal Joint. Journal of Emerging Technologies and Innovative Research. 2349-5162.
Development and Structural Analysis of Universal joint
  • 2249-8974
  • D Kolekar
  • A Kalje
  • S Kulkarni
  • Design
Kolekar, D., Kalje, A., Kulkarni, S. Design, Development and Structural Analysis of Universal joint. International Journal of Advanced Engineering Research and Studies. 2249-8974
Modeling and FEA of universal coupling of an automobile truck
  • Jan 2016
  • 131-136
  • P Shah
  • A Patil
Shah, P., & Patil, A. (2016). Modeling and FEA of universal coupling of an automobile truck. International Journal for Innovative Research in Science and Technology, 3(2), 131-6.