Finite Element Analysis and Simulation of Keys and Splines for 1-Ton Capacity Truck (Toyota Hilux) on Nigerian Roads

Keys and splines, crucial machinery components positioned at the interface between shafts and hubs of power transmitting elements, play a vital role in ensuring the reliability and efficiency of vehicles. The poor condition of Nigeria’s road network, characterized by potholes, uneven surfaces, and inadequate maintenance, poses significant challenges to vehicle durability, necessitating the optimization of key and spline design for off-road vehicles to ensure reliable performance and extended lifespan. This study investigates the finite analysis and simulation of keys and splines for a 1 Ton capacity truck (Toyota Hilux) designed to navigate Nigeria road’s demanding road conditions. Utilizing Creo 3.0, 3D CAD models for spline contact were created. Finite element analysis of spline hub connections was performed with ANSYS 14.5 for static pure twists. The spline shaft and hub were designed with Creo Parametric 3.0, incorporating material properties of EN19.3.5.2 for defining contact properties. Solid part modules modeled male and female spline shafts. Stress analysis of Toyota Hilux real-world model splines was conducted for various operating torques. Results show a mean error of 7.77% for torque 86.6 Nm, 8.03% for torque 111.1 Nm, 7.50 for a torque of 135.63 Nm and 18.65% for a torque of 184.68 Nm between experimental and finite element analyses. Notably, an average stress reduction of 10.82 % at spline entry point and 64.60 % at the midpoint was observed. This research demonstrates the effectiveness of optimized key and spline design for off-road vehicles, enhancing their ability to withstand the harsh conditions of Nigeria’s road network. The findings provide valuable insights for automotive engineers and manufacturers seeking to improve vehicle durability and performance in challenging environment.