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  4. Vol 11, Issue 1, 2026

Process-Route Optimization of a Solid Intermediate Shaft for Constant-Velocity Universal Transmission

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DOI: 10.23977/jemm.2026.110108 | Downloads: 4 | Views: 75

Author(s)

Jiajun Tang 1

Affiliation(s)

1 School of Mechanical Engineering, University of Shanghai for Science and Technology, Shanghai, China

Corresponding Author

Jiajun Tang

ABSTRACT

This study optimizes the process route of a constant-velocity (CV) universal transmission intermediate solid shaft under specified static-torque and fatigue constraints. A combined analytical-FEA workflow was established for pure torsion and bending-torsion conditions based on assembly test specifications. The critical zone was identified at the spline-root fillet transition. Radial hardness data after induction hardening were converted into a local static-strength field and compared with an ideal demand field derived from equivalent stress and safety-factor requirements. The original route exhibited a subsurface strength depression overlapping with the high-stress region, resulting in the minimum local safety margin. After increasing the lower bound of effective case depth and smoothing the hardness gradient, negative local margins were eliminated and stress-strength matching improved significantly. Modal analysis identified slender low-stiffness sections and vibration-sensitive locations, providing guidance for support placement and spindle-speed window planning. Bench tests showed failure concentration near spline run-out regions, consistent with predictions, while meeting specified performance targets. The proposed stress field-static-strength field-modal coupling framework enables section-wise process control and provides a practical route for reliability-oriented optimization of similar splined shaft components.

KEYWORDS

CV Universal Transmission Intermediate Solid Shaft, Equivalent Stress Field, Static-Strength Field, Modal Analysis, Process-Route Optimization

CITE THIS PAPER

Jiajun Tang. Process-Route Optimization of a Solid Intermediate Shaft for Constant-Velocity Universal Transmission. Journal of Engineering Mechanics and Machinery (2026). Vol. 11, No. 1, 75-85. DOI: http://dx.doi.org/10.23977/jemm.2026.110108.

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