Survey on non-conventional methods for large elasto-plastic deformations and their applicability to structured shaft-hub connections

Shaft-hub connections are essential components in many engineering applications. A relatively new type of shaft-hub connections is the knurled interference fit. In order to determine the stiffness and deformation behavior of this type of connection numerically, simulations where shaft and hub are pulled apart are necessary. However, in such simulations, large plastic deformations can occur, which pose significant challenges due to the severe mesh distortions when using the classical finite element method. Therefore, in this thesis, non-conventional methods are investigated and compared in typical problems characterized by large elasto-plastic deformations. These methods include the Coupled Eulerian Lagrangian (CEL) finite element method and the Smoothed Particle Hydrodynamics (SPH) method in Abaqus/Explicit, which are compared to the geometrically nonlinear finite element method (FEM) in Abaqus/Standard. Furthermore, a rotational and an axial pull-off test of a structured shaft-hub connection geometry similar to a knurled interference fit are performed and assessed in terms of the general deformation behavior and the determined reaction forces. In general, it can be stated that if the geometry is not too complex, the obtained results for the CEL and the SPH method align well with the FEM solution for not too severe deformations. Regarding the pull-off process of a structured shaft-hub connection geometry, the CEL and the SPH method can be considered suitable, particularly when an approximation of the plastic deformations is required in deformation states where the classical FEM fails due to the severe mesh distortions. However, to capture geometric details and to obtain more accurate results, a very fine Eulerian mesh or a large number of particles is required. Furthermore, it should be noted that the results of the SPH simulation are significantly influenced by specific simulation parameters.