Computer-Aided Design and Simulation of Keys and Splines for 0.5-Ton Capacity Trucks (Toyota Tacoma) Optimized for Nigerian Roads Conditions

The manufacturing of keys and splines, crucial components in mechanical power transmission systems, has experienced significant growth. Various types of keys and splines have been developed using diverse techniques and procedures, influenced by factors such as application, reliability, lifespan, processing time, and manufacturing cost. Keys and splines facilitate the connection between hubs and shafts in power-transmitting devices, enabling efficient torque transmission and weight support, particularly vital for navigating challenging terrains like Nigeria roads. Existing key and spline designs may not adequately address the unique demands of Nigerian roads, potentially leading to premature failure and compromised performance. This study investigates the computer-aided design and simulation of keys and splines for 0.5-ton capacity trucks (Toyota Tacoma), tailored to Nigerian roads conditions. Utilizing Solid works models, computer-aided design and simulation were conducted. Static experimental testing analysed load-strain behaviour, while dynamic testing validated fatigue methods. Stress analysis was carried out to investigate high risk stress concentration locations and to examine the effects of spline teeth design on overall stress distribution was conducted. identified critical areas and evaluated the impact of spline teeth design on resulting stress. Maximum stress occurs at the root fillet of the splines’ drive sides. Uniform high stress distribution around the spline relief. Linear relationship between stresses and applied load with constant stress-to-load ratios. Contact stress distribution peaks at at the beginning of the face width. Analytical calculations and analysis confirm that the designed keys and splines demonstrates compactness, lightweight construction, and enhanced lifespan, rendering them suitable for Nigeria roads.