CAREER EPISODE 1

Yok joint modeling and simulation

2.1 Introduction
Project Title: Yok joint modeling and simulation

Institutions: Osmania University

Location: Insert

Project type: Academic

Date: Insert

Supervisor: Insert

1.2 Background

1.2.1

Automobile is composed of thousands of parts. Among those thousands of parts of automobile,

yoke joint is the mechanical joint that joins two unparalleled intersecting shafts which rotate. It is
a positive joint and it is used to transmit power. There are two yokes in a yoke joint which are on
each shaft. They are connected utilizing a cross-shaped element between the two yokes. The
cross-shaped element is called spider. Operating angle is the angle between the two shafts of
yoke joint. It is flexible as the joint is constructed using U-shaped yokes. The yokes are
connected by cross-shaped hub. Bus and trucks usually use yoke joints. Failure of mechanical
components like yoke joints happens because of faults in design, manufacturing or material.

Design and analysis of yoke joint assembly was done in the project. Parts of yoke joint assembly
were selected. Selected parts of yoke joint assembly for designing in this project were yoke slip
and hub. Materials selected for analyzing the yoke joint assembly were SAE 1050 and SM45C
carbon steel. Mathematical calculation of design parameters of yoke joint was done. CAD model
of yoke joint was prepared in SolidWorks based on design calculation. Prepared CAD model of
yoke joint was analyzed in ANSYS using FEA. Results of analysis of yoke joint using two
materials were compared and suitable material was selected.

1.2.2 Objectives

The main objective was to design a yoke joint assembly. The other objectives were:

 To determined suitable material for yoke joint assembly.

 To increase strength of yoke joint by improving its design.
1.2.3 Organizational chart

Swathi Institute of Technology

and Sciences

Department of mechanical
engineering

HOD

Project advisors

Wasiuddin Ali
Mohammed (team Team members
leader)

Figure 1: Organizational flow

1.2.4 Duties and responsibilities

 To gather and study literatures that were relevant to yok joint designation.
 To nominate components and materials required for yok joint analysis.
 To perform design calculation in order to determine various design parameters and
dimension of yok joint assembly.
 To prepare 3D CAD modeling of yok joint assembly in SolidWorks software.
 To perform structural analysis of yok joint assembly in Ansys software.
1.3 Personal Engineering Activities

1.3.1

I collected research papers related to design and analysis of yoke joint assembly. I studied about
mechanism of power and motion transmission using a yoke joint and different applications of
yoke joint like power transmission in bus and trucks. Further, I gained information about
components of yoke joint assembly like yoke slip and hub. Then I learned to design yoke slip
and hub of yoke joint. I learned to calculate design parameters of yoke joint mathematically.
After that, I acquired skills for designing CAD model of parts of yoke joint in SolidWorks.
Further, I gained skills to analyze CAD model of yoke joint assembly in ANSYS using FEA. I
also gathered information related to properties of SAE 1050 and SM45C carbon steel materials.
1.3.2

Then I selected parts of yoke joint assembly. I selected yoke slip and hub of yoke joint assembly
for designing in this project. After that, I selected materials for designing the yoke joint assembly
based on comparison of properties of several materials. I selected SAE 1050 and SM45C carbon
steel materials for analyzing yoke joint assembly. Then I selected software for designing and
analyzing yoke joint assembly to study performance parameters of the yoke joint. I selected
SolidWorks for creating CAD model of yoke joint assembly. Also, I chose ANSYS for analyzing
the design of yoke joint assembly using FEA method to compare performance of yoke joint
assembly utilizing two materials and selecting the suitable material.

1.3.3

Then I conducted mathematical calculation of design parameters of yoke joint assembly. I

obtained dimensions of existing yoke joint to be diameter of yoke slip 70 mm, radius of yoke
slips 35 mm and hub diameter 55 mm. Assuming factor of safety to be 3, I obtained allowable
tensile stress and allowable stress for yoke joint of SAE1050 material. Then I calculated
maximum torque and maximum force at yoke joint considering maximum power, input speed
and angle of path. After that, I calculated moment of inertia of rectangular cross section, distance
from section modulus to neutral axis, bending moment and bending stress on yoke joint. Using
dimensions of yoke joint, I determined polar moment of inertia, radial distance and polar section
modulus. Then I calculated torsional moment and shear stress using force and polar section
modulus. Using maximum normal stress theory, I calculated equivalent stress. After that, I
determined allowable stress for SM45C carbon steel assuming factor of safety of 2.

Detailed calculation required????

1.3.4

I designed CAD model of yoke joint assembly in SolidWorks. I prepared 2D model of yoke slip.
After confirming dimensions of yoke slip, I converted the 2D model of yoke slip to 3D by
extruding. Similarly, I designed the second yoke of the yoke joint assembly. Then I prepared 2D
model of cross shaped hub and extruded to length of the hub. In the process of Cad modeling f
yok joint assembly and its components by using different design tools and commands such as
line command, circle command, fillet tool, tangent command and so on. After that, I assembled
the parts of yoke joint in SolidWorks. I attached hub to the first yoke of the yoke joint. Similarly,
I assembled the second yoke of the yoke joint to the hub. After completing assembly of the yoke
joint, I inspected the joint to avoid any error. After this, I saved the model of yok joint in
appropriate format for further process.

Design required???

1.3.5
Then I analyzed the design of yoke joint assembly in ANSYS. I brought the model of yoke joint
assembly to ANSYS and selected static structural analysis. Then I applied properties of
SAE1050 to yoke joint and generated mesh of the yoke joint. After that, I assigned boundary
conditions of yoke joint to meshed model; I provided fixed support to one end of a yoke and
provide torque to the other end of another yoke. Then I simulated analysis of yoke joint assembly
and studied distribution of stress and pattern of deformation of yoke joint assembly. I found
maximum equivalent stress, maximum equivalent strain and maximum deformation of yoke joint
to be 100 MPa, 0.953 mm/mm and 46.057 mm respectively. Similarly, I analyzed design of yoke
joint using SM45C carbon steel material and found maximum equivalent stress, maximum
equivalent strain and maximum deformation of yoke joint to be 200 MPa, 1.1922 mm/mm and
57.571 mm respectively. Based on the results of analysis, I found SAE1050 to be more suitable
material than SM45C carbon steel for yoke joint.

Result after analysis???

1.4 Problem and solution

1.4.1

During assembly of yoke joint in SolidWorks, I observed an error in the assembly. I found that
there was interference between the two yokes in the yoke joint. I inspected the assembly of the
yoke joint properly and found that the problem occurred due to short length of hub of yoke joint
and increasing the length of hub of yoke joint would remove the error. Then I increased length of
yoke joint slightly in all four directions. After that, I assembled modified hub with other parts of
yoke joint. Then I inspected the assembly of yoke joint closely and found that there was no error
in the assembly and all parts of yoke joint were assembled properly.

1.4.2

I found high deformation during FEA analysis of yoke joint in ANSYS. I observed that there was
high deformation near joint of yoke and hub of yoke joint on the yoke. Such high deformation
was not safe for transmitting power and motion in a vehicle which could cause failure of the joint
and cause damage to vehicle, so I optimized the design of yoke joint. For optimizing the design
of yoke joint, I studied about similar problem in research papers and scientific articles in internet.
I learned that increasing thickness of the component near joint of yoke and hub of the yoke joint
could increase strength of yoke and hence decrease the deformation of yoke at the location. So, I
increased thickness of material used near the joint of yoke and hub on the yoke. Then I
assembled the modified yoke and hub of yoke joint assembly, and analyzed the yoke joint in
ANSYS. I found deformation on yoke to be lower and within permissible limit for yoke joint.

1.5 Creative activities

I conducted theoretical design calculation of yoke joint considering its dimensions and using two
materials. I designed CAD model of yoke joint and analyzed the yoke joint in ANSYS using
FEA using SAE1050 and SM45C carbon steel, and compared the performance of yoke joint
using two materials. I increased length of yoke for avoiding interference between two yokes. I
increased thickness of yoke near joint of yoke and hub for increasing strength of the yoke.

1.6 Project management

In this research work, I performed the team leader role and conducted all the task effectively and
efficiently that came under my responsibilities. I prepared project plans in order to perform all
the project task within the limit of time. I also distributed different work of this project to the
respective project member who had skills in their respective fields. I held several meetings
within the project period to update the project members regarding the development of project. I
also managed to solve different issues raised during the time of project. I also guided as well as
monitored my team members to conduct their respective task effectively. I was also the part of
project preparation task and presented to the respective department head.

1.7 Codes

I took the referral of codes ICS 35.240.10 in order to study and carry work about yok joint
assembly design. Further, I followed each and every rule maintained by the University.

1.8 Summary

In this project work, the yoke joint assembly model was prepared and its structural analysis was
performed. Firs of all the required components and materials such as yoke slip, yoke hub, SAE
1050, SM45C and so on. Then, the design calculation was executed to determine yoke joint
assembly components design parameters and dimension. Next, the computer model of the yoke
joint assembly was prepared in SolidWorks software. After the design work, the structural
analysis of the yoke joint model was executed in Ansys software. All the deformation as well as
stress value at yoke joint assembly model was within the limit parameters. After the analysis, the
SAE1050 material was nominated as the best material. Moreover, the developed yok joint
assembly was of great mechanical strength.

From this project work, I enhanced my oral communication among the people and also
developed my presentation skills. Further, I improved significantly my leadership skills to lead a
project team to achieve its purposes.