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Splined joints are commonly used to transmit rotary motion from a shaft to machine elements such as gears. While computationally efficient spline load distribution models have recently been proposed, there is no validated load distribution model of a splined joint due to lack of high-fidelity experimental data. Accordingly, this study aims to establish an extensive experimental database on load distributions of splined joints subject to both spur and helical gear loading conditions. A quasi-static, spline-specific test setup is developed and instrumented. A test matrix covering various loading conditions is executed in order to form a spline load distribution database. The experimental data illustrates the cyclic nature of loads and resultant stresses on spline teeth caused by rotation of the spline teeth in relation to the gear mesh that loads the splined joint. A nonlinear relationship between torque applied and resultant stress is revealed, as well as the relationship between the location of maximum stress along the face width and the amount of lead crown modification applied. Lastly, simulation results from the model of Hong et al. (2014b) are compared to the experimental data under spur and helical gear loading conditions to assess the premise of such models.

An experimental investigation of the load distribution of splined joints under gear loading conditions