SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA...

Page 1 of 12

SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT

Rul Lesso Arroyo,

Instituto Tecnológico De Celaya & SSC De México S.A. De C.V., Celaya, Guanajuato, Mexico

Fernando Balderas Lopez,

SSC De Mexico S.A. De C.V., San Miguel De Allende, Guanajuato, México

Antonio Angmen Vigil

VELCON S.A De C.V, Grupo UNIK, Celaya, Guanajuato, Mexico

ABSTRACT

The application of the finite element method is a useful and important tool when the classic theory is
difficult to use or apply. Furthermore, if we have a highly nonlinear problem with large displacement,
large deformations and also contact effects. The rubber boot is a very important element of a
constant velocity joint. To be able to simulate it’s behavior we used ANSYS as our finite element
analysis tool. In the past, this problem had already been tried to solve using another FEA code, The
FEA module of IDEAS was not able to calculate the contacts within the rubber boot. We decided to
use ANSYS for it’s outstanding nonlinear and contact generation capabilities. We want to analyze
the contact stresses and strains due to the operation conditions of the rubber boot. Special interest
is to be able to predict where the contact occurs versus the angle of rotation of the shaft axis.
Finally, in this paper we present a validation of the ANSYS strains results against X-rays tests in the
physical prototype.

INTRODUCTION

NOMENCLATURE

ANSYS Software of finite element analysis

The finite element method is a dominant technique to solve systems of linear differential equations and nonlinear.
The use of special and general finite elements permits a math approximation of the continuous mechanics of a
structure or a mechanical element. On the other hand, upon speaking of nonlinear analysis, there exist very few
finite element programs that are reliable to solve models in which the linear behaviors are not sufficient and
adequate. Farthermore, upon applying this technique to the analysis of a rubber boot (element of the constant
velocity joint), in which the classic theory is difficult to use. The figure 1, shows a constant velocity joint, this
element is a mechanical component manufactured by Velcon S.A. de C.V. as member of the Automotive Parts
Division (UNIK) of Grupo Desc. One of the largest manufacturers of original and spare parts for the automotive

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA... Page 2 of 12

industry in Mexico. The system consists of several elements such as shafts, cv-joints, rubber boots, etc. This
system is used in front wheel drive vehicles. One of the most critical elements in a CV-Joint mechanism is the
rubber boot, if this element fails it will probably be just a matter of time before the whole system start to have
serious noise and even structural problems.

Figure 1. Application of the CV-Joint

The importance of the rubber boot is given by the fact that it covers mechanical components with very precise
finished surfaces from humidity, mud, dust, etc. These components are bearings, housings and shafts that are
found always in continuous contact in motion. Because of this, is not permitted the entry of abrasive particles
found in mud and dust is essential for a good operation. Though this element is very economic and easy to repair,
it is very common the driver of the vehicle does not notice the failure of the rubber boot, and as the time goes by a
major breakdown of the entire CV-Joint may occur.

ANALYSIS OF THE PROBLEM

To know the displacement of contacts behavior, the stress level, strains and to locate the contact points between
the external and internal plaits of the rubber boot with the steel shaft is the objective of the analysis. With this goal
in mind it was only needed to model the steel shaft and the rubber boot, also the applied load, in this case a
maximum allowed rotation for the shaft in the CV-Joint (extreme operation condition). The simulation consists of
carrying the shaft and the boot to a maximum angle of rotation, that it is the opening angle of the direction system
in the vehicles.

STAGE OF PREPROCESS

The first step of the analysis by finite element is the preprocess, where it was created a 3D solid model of the
shaft and boot. Starting with a flat profile of the boot and shaft and extruded around an axle of rotation.

Figure 2. Boot and Shaft profile

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA... Page 3 of 12

In this same phase of preprocess the physical properties of the material are defined. In the model two materials
are used, the steel for the shaft and a hyperelastic material (neoprene) for the boot (in this case the properties are
input through a stress-deformation curve). Another important detail in the modeling, is to simulate the
phenomenon of contact between the shaft-boot elements and boot-boot. To create the 3D mesh we start by
meshing the 2D profile with PLANE 42 elements and then extruding them in 3D to get a mesh with HYPER 58
elements (see figure 3).

Figure 3. Element type used

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA... Page 4 of 12

In order that the different surfaces of the rubber boot can come in contact with each other and also the inner part
of the boot with the shaft (see figure 4) we have to create Contact Elements. To save modeling and solution time,
these elements were generated only at the surfaces that for experience were known to come in contact with each
other. These elements have the capability to calculate where the surfaces will be in contact and allow them to
penetrate only at given user input value. The meshed model is presented in the figure 4.

Figure 4. Finite element model

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA... Page 5 of 12

In finite element analysis the used mesh density is critical to get precise results. This size and number of
elements is controlled by the user using some of the tools ANSYS has for this purpose. To get a good mesh it is
always of much help that the Engineer visualize and anticipate where in the model will be greater deformation and
stress gradient. It is in these parts of the model where we need greater mesh density. The number of degrees of
freedom used in the FEA model directly influences the precision of the results and computational solution time.

STAGE OF SOLUTION

In the processor of solution, the loads are applied to the finite element model. Also known as boundary conditions,
these loads have to be as real and faithful as possible to the actual loads applied to the physical model (see figure
5 ).

The union of the boot with the homokinetic joint was simulated with the zero displacement constraint. To simulate
the rotation of the model a node in the center axis of the shaft end (pivot) constraints in all directions were
applied. And to make the model rotate, at the node located in the other end of the shaft and in the axis center,
input values of displacements in X and Y directions were applied in order to get the same equivalent angle of
rotation.

Figure 5. Boundary conditions

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA... Page 6 of 12

This is an analysis highly nonlinear due to large displacement, large deformations and contact elements (which
change of status). To complete a nonlinear analysis in ANSYS, only a few menu command options need to be
changed in relation to a linear analysis. This type of analysis and three-dimensional model requires of very large
running times. Computers of big capacity are recommended in terms not only of floating point processing
performance but also in graphics capabilities. This particular analysis was solved using an Octane Workstation of
Silicon Graphics with 1 MIPS R10000 processor and 256 MB of RAM. The solution time was 6 hours.

STAGE OF POSTPROCESS

Once the analysis is solved the results are available in the Postprocessor ready to be judge and interpreted by the
analyst. In this phase one can visualize and understand how the model behaves at different load levels. Therefore
we can see not just the final solution but a big number of steps in between, which give the analyst a lot of
information to be able to understand how the model behaves through all the load history. The graphic capabilities
of the software permit visualize very realistic animations of how the different surfaces are coming in contact and at

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA... Page 7 of 12

what degrees of rotation. In the figure 6 is presented the displacement positions of the rubber boot at the
maximum draft angle.

Figure 6. Maximum displacement of the boot

The graphics of the figure 7 show the deformation results for three instants of the draft angle position of the
system. Figure 7 shows us when the first contact is presented in the internal plaits of the boot.

Figure 7. Total Strain given at the instant of the first contact (between the plaits of the rubber boot)

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA... Page 8 of 12

Figure 8 shows us when the second contact occurs between the external plaits of the boot. Furthermore, the first
contact between the interior part of the boot and the shaft has started. We can also see the stretching between
the zone of the first contact.

Figure 8. Total Strain for a position with 2 plaits in contact

In the figure 9 can see that a third type of contact occurs between the internal plaits of the boot and the steel
shaft.

Figure 9. Total Strain at maximum angle of rotation

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SHA... Page 9 of 12

The stress results are presented in the figure 8. Here we can see the location of the critical zones of the model for
the maximum draft angle.

Figure 10. Maximum Von Misses Stress in the Rubber Boot

The previous results, show the zone where the maximum stress occurs in spite of the fact it is low. But
considering the fatigue effects of the material after a given number of cycles, it is clear that these areas are the
most likely to fail under fatigue loads. It is convenient to mention that values or exact data of the results are not
given by secrecy issues with VELCON S.A. de C.V.

CONCLUSIONS

In the design and analysis of mechanical components the experience in this case tell us that it was a good
practice to use ANSYS in terms of getting better designs in less time and with less money invested in prototypes
and tests. The results are very much in concordance with experimental data obtained from physical prototypes as
you can see in the X-ray pictures in the APPENDIX. For this application in particular, it can be summarized, that
the use of this type of software will help us to know the behavior of the displacement of the joint shaft - boot
mechanism. Furthermore, the advantage of obtaining better design parameters that for future developments will

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SH... Page 10 of 12

be of great use in the design of rubber boots, and therefore higher quality CV-Joints. For the validation of the
results, in this analysis in particular was counted on X-rays taken in test laboratories of the real boot. The
agreement indicates the accuracy of the numerical solutions obtained by ANSYS (see appendix 1).

REFERENCES

R. D. Cook., 1993, "Concepts and Application of Finite Element Analysis", John Wiley & Son, New York.

Robert D. Cook., 1995, "Finite Element Modeling for Stress Analysis", John Wiley & Son, New York.

Constantine C. Spyrakos, 1994, "Finite Element Modeling", WVU press, West Virginia.

ANSYS Inc., 1998, Analysis Guides Manual 5.5(help in line), ANSYS Inc, Canonburg, PH.

ANSYS Inc., 1998, Element Manual 5.5(help in line), ANSYS Inc, Canonburg, PH.

ANSYS Inc., 1998, Structural nonlinearrities Seminar (User’s Guide for 5.5, ANSYS Inc, Canonburg, PH.

M.Glaenzer, 1997, General Theory Experimental of Homokinetic Join, Spicer, France .

R. Lesso-Arroyo, F. Balderas_Lopez, 1999, Analysis the stress of contact in element highly nonlinear, Fifth
International Meeting of Mechanical Engineering, San Luis Potosi, Mexico.

APPENDIX

In this appendix 4 Pictures taken from X-ray plates are shown for the positions of 17.5 , 24 , 32 and 40 . The X-
rays were taken upon submitting the joints to a maximum displacement during a laboratory test, these results
validate the result obtained in ANSYS

Figure 11. X-ray for position of 17.5

Figure 12. X-ray for position of 24

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SH... Page 11 of 12

Figure 13. X-ray for position of 32

Figure 14. X-ray for position of 40

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002
SOLUTION OF PROBLEMS HIGHLY NONLINEAR IN A CONSTANT SPEED SH... Page 12 of 12

file://C:\Documents%20and%20Settings\beh\Local%20Settings\Temp\~hh18F5.htm 7/9/2002