FEM numerical simulation of contact stresses between driving shaft and hub impeller of fuel pump

Purpose: The aim of the work was to test the contact stresses in the model system of the turbine hub cooperating with the fuel pump drive shaft. The hypothesis of the work was that, by means of FEA, it is possible to assess the contact stresses in the materials of the turbine hub and the fuel pump shaft during torque transmission. Design/methodology/approach: A turbine with fibre-reinforced polyphenylene sulphide (PPS) composite cooperating with a stainless steel shaft (X46Cr13/1.4034) in a commonly used D-flat shape joint was selected for the experimental research. To assess contact stresses, the CAD model (NX, Siemens) of the entire turbine was limited to the hub area. The drive shaft is supported in accordance with the bearing in the fuel pump, and the possibility of rotation about the axis along the length of the torque-producing magnet is taken away. The system was loaded with a torque of 200 Nmm on the turbine. The turbine hub and shaft were calculated, taking into account the phenomenon of contact detachment or slip at the value of the friction coefficient of 0.1. Findings: The pressure transmission area was found in the area at the edge of the flat surface D-flat and on the opposite side of the D-convexity. The contact stresses on the D-flat side reached values close to the composite strength. Research limitations/implications: The studies did not take into account the technological inaccuracies, thermal deformation, local material properties, and wear. The value of the friction coefficient was not measured in realistic conditions with fuel lubrication. Practical implications: FEA has been achieved, which allows to reduce the cost of experimental research. Originality/value: The proposed model allows for further studies of the influence of elasticity of various materials and structures on contact stresses in order to assess wear resistance.