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This paper presents the design procedure for a gear wheel-shaft direct frictional joint. The small difference between the operating pitch diameter of the gear and the mounting diameter of the frictional joint is the key feature of the connection. The contact surface of the frictional joint must be placed outside the bottom land of the gear, and the geometry of the joint is limited to the specific type of solutions.The strength analysis is based on the relation between the torque and statistical load intensity of the gear transmission. Several dimensionless parameters are introduced to simplify the calculations. Stress-strain verifying analysis with respect to combined loading, the condition of appropriate load-carrying capacity of the frictional joint and the fatigue strength of the shaft are applied to obtain the relations between the dimensions of the joint and other parameters. The final engineering solution may then be suggested. The approach is illustrated by a numerical example.The proposed procedure can be useful in design projects for small, high-powered modern reducers and new-generation geared motors, in particular when manufactured in various series of types.

Analysis of Gear Wheel-shaft Joint Characterized by Comparable Pitch Diameter and Mounting Diameter