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Press Fit Simulation

The document discusses press fit simulations that were verified with hand calculations. It describes types of fits and tolerances, recommends press/interference fits, provides examples, and outlines theoretical calculations for contact pressure and force required. Finite element simulations of example press fits were conducted in ANSYS, showing close agreement between simulated and theoretical contact pressure values, validating the accuracy of the simulation model.

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A2Z Mechanical Designs
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99 views16 pages

Press Fit Simulation

The document discusses press fit simulations that were verified with hand calculations. It describes types of fits and tolerances, recommends press/interference fits, provides examples, and outlines theoretical calculations for contact pressure and force required. Finite element simulations of example press fits were conducted in ANSYS, showing close agreement between simulated and theoretical contact pressure values, validating the accuracy of the simulation model.

Uploaded by

A2Z Mechanical Designs
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Press fit simulation

verified by hand calculations

aravindvijayan212
Types of fits

Fits

Clearance Interference Transition

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Types of fits and tolerance zones.

aravindvijayan212
Recommended fits

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Interference/Press fit

1. Interference fit is a mechanical assembly technique where


the inner diameter of one component is intentionally made
slightly smaller than the outer diameter of the mating
component.

2. This creates a tight, friction-based connection between the


two parts, eliminating the need for additional fasteners.

3. Interference fits provide enhanced load-bearing capacity,


improved alignment, and resistance to vibration or loosening.

4. They are commonly used in industries such as automotive,


aerospace, and manufacturing for applications like press-fit
bearings, shafts, gears, and pulleys.
aravindvijayan212
Interference/Press fit -Example 1

5 P6/h7
Hole
Designation - 5 P6
Maximum hole size - 4.991 mm
Minimum hole size - 4.983 mm

Shaft
Designation - 5h7
Maximum shaft size - 5 mm
Minimum shaft size - 4.988 mm

For maximum interference( 0.017 mm)


Hole size - 4.983 mm
Shaft size - 5 mm
aravindvijayan212
Interference/Press fit- Example 2

5 S7/h6
Hole
Designation - 5 S7
Maximum hole size - 4.985 mm
Minimum hole size - 4.973 mm

Shaft
Designation - 5h6
Maximum shaft size - 5 mm
Minimum shaft size - 4.992 mm

For maximum interference( 0.027 mm)


Hole size - 4.973 mm
Shaft size - 5 mm
aravindvijayan212
Theoretical calculations

Contact pressure

Force required to press fit


F = Force required to press fit
u= Coefficient of friction
p= contact pressure
F=uxpxA A = area of contact =

aravindvijayan212
Theoretical calculations (5 P6/h7)
5 P6/h7
Structural Steel
Elastic Modulus, E0 = Ei = 2x e11 Pa
Poisson ratio, v0 = vi = 0.3
Length of specimen,L = 50 mm ᐃ=0.017mm
So, A = Pi x d x L
Substituting in respective equations,
Contact pressure = 130 M Pa 1
Force required = 20,410 N
Aluminium alloy
Elastic Modulus, E0 = Ei = 7.1x e10 Pa
Poisson ratio, v0 = vi = 0.3
Length of specimen,L = 50 mm
So, A = Pi x d x L di =3mm
Substituting in respective equations,
m

=7mm
Contact pressure = 46.4 M Pa 2 5m
Force required = 7,284.8 N d=
aravindvijayan212
Theoretical calculations (5 S7/h6)
5 S7/h6
Structural Steel
Elastic Modulus, E0 = Ei = 2x e11 Pa
Poisson ratio, v0 = vi = 0.3
Length of specimen,L = 50 mm ᐃ=0.027mm
So, A = Pi x d x L
Substituting in respective equations,
Contact pressure = 206 M Pa 3
Force required = 32,415 N
Aluminium alloy
Elastic Modulus, E0 = Ei = 7.1x e10 Pa
Poisson ratio, v0 = vi = 0.3
Length of specimen,L = 50 mm
So, A = Pi x d x L di =3mm
Substituting in respective equations,
m

=7mm
Contact pressure = 73.71 M Pa 4 5m
Force required = 11,572 N d=
aravindvijayan212
Press fit in Ansys Mechanical

Geometry Contact

Frictional contact between the interference edges


Coeff of friction = 0.2 ,
1/4th model as 2D Plane Stress problem Pinball radius = 0.02 mm, Interface treatment = Add
offset with Ramped effect
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Press fit in Ansys Mechanical
Mesh Boundary condition

Mesh method = Quad


Element size = 0.1 mm Frictionless support at symmetry edges to constrain
Face meshing the motion normal to edges.
Note - All radial surfaces should be kept free
Press fit in Ansys Mechanical

Analysis settings

● Number of steps = 1
● Auto Time Stepping = ON
Initial substeps = 100
Minimum substeps = 10
Maximum substeps = 10,000
● Large Deflection = ON
● Output Controls> Nodal Forces = Yes

Solution
Insert Contact Tool> Contact pressure

Solve…
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Results Contact pressure- 5 P6/h7

Structural Steel Aluminium alloy

Ansys Max Value = 134.61 M Pa Ansys Max Value = 47.798 M Pa


Theoretical Value = 130 M Pa 1 Theoretical Value = 46.4 M Pa
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Results Contact pressure- 5 S7/h6

Structural Steel Aluminium alloy

Ansys Max Value = 216.5 M Pa Ansys Max Value = 76.88 M Pa


Theoretical Value = 206 M Pa 3 Theoretical Value = 73.71 M Pa
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4
Conclusion

The results obtained from the Ansys simulation demonstrate a close alignment between the
theoretically calculated contact pressure value and the contact pressure value derived from the
simulation. This close correspondence strongly indicates the accuracy and validity of the
simulation and the study conducted. The consistency between the theoretical calculations and
the simulation results reinforces the confidence in the methodology employed and supports the
conclusion that the simulation accurately represents the real-world behavior of the system under
investigation. Such robust agreement between the theoretical predictions and the simulation
outcomes reinforces the credibility and reliability of the conducted study.

Thank You

aravindvijayan212

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