Numerical and analytical investigation of steel-aluminum knurled interference fits: Joining process and load characteristics

This paper describes a verified numerical investigation of the joining process and the axial strength of steel/aluminum knurled interference fits (100Cr6/AlMgSi1). Knurled interference fits have huge potential, as demonstrated by their increasing industrial use. However, as is characteristic of state of the art of knurled interference fits, current research lacks generality and makes comparison difficult between results, especially in relation to geometry-, material- and load-specific results. The work in this paper provides detailed investigation results for the influence of shaft-chamfer angle, hub-diameter ratio and geometric interference on knurled interference fits. This includes the type of joining process as well as joining force and axial strength. The joining process is essential for axial strength as well as for the transmission behavior of the connection. Finally, a new approach for the analytical computation of the joining force is presented.