Numerical Modelling and Analysis of Analytical Limits in Large Interference-Fit Coaxial Cylinders
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This study presents a detailed investigation into the insertion mechanics of press-fit bushing joints using advanced numerical modelling. The primary objective is to analyse the evolution of insertion forces and determine how initial contact and localized impacts govern the subsequent deformation response of the assembly. Contrary to conventional design intuition, the results demonstrate that increasing nominal interference does not monotonically raise the insertion force; once a critical interference threshold is exceeded, the required force actually decreases. The research identifies the cylinder thickness ratio as a vital, yet frequently overlooked, parameter for predicting both global mechanical behaviour and peak insertion forces. A critical comparison is performed between analytical solutions derived from thick-walled cylinder theory and Finite Element Method (FEM) simulations. The findings show that while analytical models lose predictive accuracy and yield unrealistic estimates once plasticity develops, FEM simulations successfully reproduce the process with errors below 15%. These results establish clear validity limits for classical analytical formulas and provide a robust mechanistic basis for selecting interference levels and wall thickness combinations in assemblies undergoing plastic deformation