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<p>This study investigates the damage observed in shaft, key, and flange within gearbox assembly through a combination of visual inspection and finite element analysis (FEA). The evaluation process emphasizes achieving a clear fit between the shaft and flange, which is further analysed through a parametric study involving various interference fits. FEA simulations are conducted using NX NASTRAN software to assess the structural integrity and performance of the assembly under different interference fit conditions. By synthesizing the findings from visual inspection, FEA results, and parametric study, the study aims to gain insights into the modes of failure and propose design modifications to enhance the reliability and longevity of the shaft-key-flange assembly in gearboxes. This research contributes to a deeper understanding of failure mechanisms and offers valuable recommendations for improving the design and performance of gearbox components.</p>

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Failure Analysis Case Study and Design Improvement of Shaft-Key-Flange Connection in EV Gearbox Applications

  • 期刊论文

  • 发表日期：

    2025年4月18日

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  • K. C. Ganesh,
  • V. Karthikeyan,
  • Ramachandra Panda

摘要

This study investigates the damage observed in shaft, key, and flange within gearbox assembly through a combination of visual inspection and finite element analysis (FEA). The evaluation process emphasizes achieving a clear fit between the shaft and flange, which is further analysed through a parametric study involving various interference fits. FEA simulations are conducted using NX NASTRAN software to assess the structural integrity and performance of the assembly under different interference fit conditions. By synthesizing the findings from visual inspection, FEA results, and parametric study, the study aims to gain insights into the modes of failure and propose design modifications to enhance the reliability and longevity of the shaft-key-flange assembly in gearboxes. This research contributes to a deeper understanding of failure mechanisms and offers valuable recommendations for improving the design and performance of gearbox components.