Structural Analysis of a Flanged Shaft Under Torsional Loading

A flanged shaft component was assessed to evaluate its structural performance under torsional loading conditions. The component is designed to transmit torque while maintaining alignment between connected systems, making its structural integrity critical to overall system reliability.

Finite element analysis was conducted to investigate stress distribution and identify potential failure points under operational loads.

Challenge

Shaft components with flanged connections are particularly susceptible to stress concentrations at geometric transitions, especially where the shaft meets the flange. Under torsional loading, these regions can experience elevated stresses that may lead to fatigue or failure over time.

The objectives of the analysis were to:

• Evaluate stress distribution under applied torque

• Identify critical stress concentrations

• Assess the integrity of the shaft-to-flange interface

• Ensure the design was suitable for operational loading conditions

Solution

A detailed finite element model of the shaft was developed, incorporating realistic boundary conditions and applied torque to replicate service conditions.

The analysis:

• Applied torsional loading along the shaft axis

• Evaluated von Mises stress distribution throughout the component

• Identified peak stress concentration at the shaft–flange transition

• Assessed load transfer through the flange and bolt interface

The results showed a clear concentration of stress at the transition region, consistent with expected behaviour under torsional loading.

Outcome

The analysis provided a clear understanding of how the component responds to torsional loads and highlighted key areas for improvement.

Key outcomes included:

• Identification of critical stress concentration at the shaft–flange interface

• Validation of overall load-carrying capability

• Improved understanding of stress distribution under torque

• Recommendations for design refinement to enhance durability

Suggested improvements included increasing the fillet radius at the transition, refining local geometry, and optimising load distribution across the flange.

Testimonial

“The analysis highlighted exactly where the highest stresses were occurring and gave us clear direction on how to improve the design. It provided the confidence we needed before progressing further.”

— Senior Design Engineer