| Citation: | ZHAO Qingyan, ZHAO Zhihao, LU Tingting, et al. Load distribution and reliability analysis of splines under multiple errors[J]. Journal of Aerospace Power, 2026, 41（6）：20240771 doi: 10.13224/j.cnki.jasp.20240771
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Machining errors, parallel misalignment, and angular misalignment lead to uneven load distribution on spline teeth, significantly impacting their life and reliability. To address these issues, a spline load distribution model and reliability analysis method accounting for multiple errors were proposed. First, the effects of different errors on the shape and position of spline teeth were analyzed, and the uneven tooth clearance was derived. Based on this, a model for uneven torque distribution along the axial direction was developed, which incorporated the effects of torque on the torsional deformation of the spline shaft and the elastic deformation of the teeth. The accuracy of the proposed model was validated through finite element analysis. Finally, a spline fatigue reliability model was developed using classical fatigue damage criteria. Case analysis showed that after 106 cycles of load, when the tolerance class decreased from 4 to 6, the spline reliability decreased by 0.011; when the parallel misalignment increased from 0.01 mm to 0.03 mm, the spline reliability decreased by 0.054; and when the angular misalignment increased from 0.01° to 0.03°, the spline reliability decreased by 0.935. The influence of misalignment on spline reliability was significant, especially the increase of angular misalignment led to a significant decrease in spline reliability.
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