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This paper presents a novel method for the design of purely elastic interference fits by exploiting the plastic properties of a material. In this process, the elastic potential of the material is expanded by the targeted application of residual stresses and material strengthening, in such a way that additional operational loads due to rotating bending moments, torsion, temperature changes, and centrifugal forces are absorbed by the hub in a purely elastic manner, and plastic deformations are avoided. In the ideal case, the performance shown by the connection can be almost doubled compared to conventional elastically joined interference fits. Compared with conventional elastically–plastically joined interference fits, a specifically defined additional safety against plastic deformation can be guaranteed. In addition to the prerequisites of plasticity theory, the fundamental aspects of the process are presented and investigated on the basis of two-dimensional numerical calculation models. Both ideal plastic and hardening material models were used. The results of this work showed that previous stress limits can be significantly increased up to full plastic loading and that the utilization of plastic material properties is also made possible by plastic conditioning for applications that were previously designed to be purely elastic.

Increase in Elastic Stress Limits by Plastic Conditioning: Influence of Strain Hardening on Interference Fits