Press-fit for gear blanks

Rigid connection with defined preload displacements is a good way to model press fit but when we look at the deflections between the two gear blanks, they seem to go out of the plane (the gear blanks overlap each other by a significant amount) an alternative and a much effective way is to model the press fit condition using the thermal expansion effect. 

Method - convert the required gear blank to FE and supply it a different temperature which is higher than other components (from 'Loading' tab > 'Temperature'). Now, include thermal expansion in static analysis - 'Calculate thermal expansion' for 'Thermal solver:', the amount of pressfit depends on: 

Change in shaft outer radius= R x α x ΔT 

Where,

R = Outer Radius

α = Coefficient of thermal expansion

ΔT = Temperature difference

This helps to calculate the input temperature value required to model the amount of press fit.

Now check the radial displacement: Double click on the respective FE gear blank > 'Run' Static analysis > in the 'Statics' result worksheet > click on 'Model' > select the required load case > 'Solve' > now select 'Show only thermal expansion' for your load case > select 'Results on:' as 'Displacement' and 'Available values:' as 'Radial Displacement'

To know more on what caution to maintain while modelling press fit by this approach, have a read to article - How to model press fit for gear blanks?