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CASE STUDY

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Finite Element Analysis to Locate & Analyse

Fracture in a Universal Joint
Case Study Highlights
The Solution:

The Client
Industry

: Agriculture Purpose Vehicle Manufacturer

Location

: Asia

The Objective:
Predicting fracture locations in universal joint and
modifying design accordingly using FEA.
The Solution:
A CAD model for simulation was developed and boundary
conditions in the form of loads were applied to the
universal joint model. The analysis revealed regions with
critical stresses, predicting the possibility of fracture.
Design modification was suggested based on analysis
results to overcome fracture issue, which was confirmed
with subsequent structural analysis.

An assembly of the parts was created using Pro/E & the

assembled model was imported to ANSYS for analysis. The
analysis was done by using different boundary conditions
and selecting the SOLID-92 tetrahedral element. The
stress, strain and deformation on the ANSYS model of
universal joint were checked for varying loading conditions.
The analysis revealed that the maximum stress was
occurring at both the yokes of universal joint at the middle
span. The beginning location of crack corresponds to the
point of highest stress. A modification of the design, by a
slight increase in dimension was suggested after analyzing
the parameters for different boundary conditions.

The Challenges:
?
Developing accurate CAD model for universal joint with

required features to record complete physical behavior

during simulation
?
Determining and applying suitable boundary conditions

to capture accurate stress strain information

?
Suggesting design modifications based on material

knowledge, physics behavior and FEA results

Benefits:
?
The finite element analysis revealed the exact location

where the maximum stress and the maximum

deformation were occurring in the part.
?
The client was able to examine the exact crack

propagation by the point of highest stress.

?
The downtime and associated costs in physical tests

and design modifications reduced considerably.

One of the leading special purpose vehicle manufacturers
approached Hi-Tech to obtain design solution for their
existing universal joint model. Due to frequent static
fractures in the existing universal joint design, the
manufacturer suffered from costly downtime and needed
corrective measures to prevent fracture conditions. They
also needed our engineering team to work on design
modification part to improve the design.

About Hi-Tech

Author: Gaurang Trivedi

Hi-Tech Outsourcing Services is a specialist firm providing engineering solutions to organizations across the globe.
We have extensive experience in providing concept to manufacturing and post-manufacturing solutions to clients with
a team of expert design engineers, CAD professionals and simulation analysts. We are based in India and USA,
serving 24x6, with a world-class infrastructure, hardware and software capabilities to address complex engineering
problems with least turn around time.

Outsourcing
Services

Phone: +1-408-338-8047
Email: info@hitechcaddservices.com

Your Trusted Outsourcing Partner

Hi-Tech Outsourcing Services

547 Moreland Way
Santa Clara, CA 95054

USA
California
547 Moreland Way
Santa Clara, CA 95054
Phone: +1-408-338-8047
E-Mail: sales@hitechos.com

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New York, NY 10024
USA
E-Mail: info@hitechos.com

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Copyright 2015 Hi-Tech Outsourcing Services All Rights Reserved

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