Analysis of the torsional strength of hardened splined shafts

• Modeling framework to determine torsional strength of hardened splined shafts.
• Model accounts for the detailed spline geometry.
• Model accounts for the material gradation due to hardness profile.
• Numerical results agree well with experimental data in literature.
• Results reveal that there is a choice of an optimum hardness depth.

The current study presents a finite element modeling framework to determine the torsion strength of hardened splined shafts by taking into account the detailed geometry of the involute spline and the material gradation due to the hardness profile. The aim is to select a spline geometry and hardness depth that optimizes the static torsion strength. Six different spline geometries and seven different hardness profiles including non-hardened and through-hardened shafts have been considered. The results reveal that the torque causing yielding of induction hardened splined shafts is strongly dependent on the hardness depth and the geometry of the spline teeth. The results from the model agree well with experimental results found in the literature and reveal that an optimum hardness depth maximizing the torsional strength can be achieved if shafts are hardened to half their radius.