Analysis of the influence of fillet geometry on stress concentration in keyway by the finite element method

Abstract

Machines play a pivotal role in the modern world, as they streamline various activities by virtue of their capacity to convert energy, such as transforming electrical energy into mechanical energy. In this context, the mechanical shaft assumes significant importance, as it enables the transmission of power to a wide range of applications. Being a solid component, the shaft is subjected to mechanical stresses, and the keyway groove, present in the shaft, is a feature that exacerbates stress concentrations in its geometry, which is undesirable as it increases the risk of failure due to rupture. Therefore, this research aimed to investigate the influence of the keyway groove geometry on stress concentration in shafts under bending loads, using simulations based on the finite element method. The study compares elliptical keyways with circular keyways and assesses how variations in parameters impact stress concentration, employing the Ansys tool for the analysis. The results demonstrate that slight modifications in the keyway groove geometry can significantly reduce stress concentrations, thereby contributing to the optimized design of mechanical components and providing valuable insights for engineers working in this field.