Akademik Veri Yönetim Sistemi
8. Bilsel International Truva Scientific Researches and Innovation Congress, Çanakkale, Türkiye, 27 - 28 Aralık 2025, ss.712-725, (Tam Metin Bildiri)
Involute spline connections play a critical role in machine element design due to their high torque transmission capacity and ability to provide precise angular alignment. The design and selection of such connections are defined within the framework of international standards such as DIN 5480 and, in particular, ANSI B92.1, which is adopted in this study. This research investigates the static strength behavior of involute spline connections defined according to the ANSI B92.1 standard using a systematic experimental design approach based on the Taguchi L8 orthogonal array. Within the experimental design, the combined effects of three fundamental geometric parameters at two levels each were evaluated. These parameters were identified as contact face width (10 mm and 20 mm), spline root type (flat and fillet), and the diametral pitch–number of teeth combination (16/32” DP – 8 teeth and 32/64” DP – 16 teeth). The static strength of each spline configuration was estimated through numerical analyses based on the Niemann/Winter analytical approach using KISSsoft engineering software. In addition to the numerical analyses, destructive static torsion tests under increasing torque were conducted on spline specimens manufactured from Ck 45 steel. Manufacturing tolerances and experimental conditions were kept constant throughout all tests to ensure the comparability of the results. For each experimental configuration, the primary output parameters were defined as KISSsoft-based analytical static strength values, experimentally measured fracture torques, and the associated manufacturing costs. The experimental findings revealed that, for all specimens, failure occurred in the form of torsional fracture of the spline cross-section prior to any tooth contact or tooth root damage. Post-test examinations indicated no significant damage on the spline teeth, demonstrating that the failure mechanism was governed by the torsional load-carrying capacity of the spline cross-section rather than the tooth load capacity. This result emphasizes that, in static strength evaluations of spline connections, not only the tooth load capacity but also the torsional strength of the spline cross-section must be taken into account. Overall, this study aims to identify the optimum involute spline configuration in terms of both strength and manufacturability by integrating analytical predictions, experimental results, and manufacturing-related considerations.