Influence of form defect on the mechanical behavior and stress intensity factor of shrink-fitted thick-walled cylinders

In this research work, the finite element software, ABAQUS is used to study by simulations the influence of form defect on mechanical behavior of a shrink-fitted assembly presenting internal radial cracks. Under the action of contact pressure induced by the tightening between two cylinders, these cracks resulting from incorrect assembly operations or materials elaboration defect, can be harmful to the assembly. Various simulations were carried out in two modeling cases, taking into account the geometric parameters of defect (amplitude Df), of cylinders (thickness t) and of cracks (length a, ratio a/t). Another important parameter such as the tightening was also considered in the modeling. The first modeling relates to the case with defect, external cylinder presents an oval (elliptical) form defect and internal radial cracks. The other concerns the perfect equivalent case (without form defect). The comparison of results obtained by two models shows that form defect modifies the uniformity of equivalent stresses distribution in cylinders and increases the value of stress intensity factor (SIF) KI in cracks. Defect amplitude and tightening significantly influence the value of equivalent stress and that of stress intensity factor (SIF) KI.