The objective of this study is to investigate the effect of torque variation on stress distributions in A-IMS module with both side tubular shaft yoke by numerically. In order to achieve this, the torque value was increased from 10Nm to 40Nm, and the results of this work were confirmed in terms of Von-mises Stress and the displacement characteristics. As the torque in module assembly was increased, the stress in tubular shaft york and splined shaft york was increased linearly. The indentation due to the steel ball was occurred in over 40N·m torque which is over the yield strength condition. The largest displacement occurred in the tubular shaft yoke 1, however, it does not exceed the yield strength and is supposed to be restored due to the elasticity. Therefore, it was concluded that there is no problem for the manufacturing of A-IMS with both side tubular shaft yoke.

The objective of this study is to find the optimal size of splined shaft in IMS module. Two methods were used in this study. One is for the investigation of effect of indentation process on the tubular shaft yoke, and another is for the investigation of effect of indentation process on splined shaft. The spline outer size of splined shaft was increased from 0.00mm to 0.20mm. The simulation results were analyzed and compared in terms of under-fill, metal flow, effective strain, Von-mises stress and load characteristics. The indentation load was increased with increasing of spline size. However, in case of 0.15mm outer diameter increasing, the separation load was decreased. The case of 0.10mm diameter increasing was the best spline size based on the low indentation load and high separation load.

The objective of this study is to investigate the effect of tubular shaft hole length on the A-IMS production process in numerically. The hole length of tubular shaft was changed from 69.5mm to 79.5mm for distribution of load and stress. Then, the tubular shaft was modeled by S20C which was referred to program library. At the same time, the results of numerical analysis were compared in terms of under-fill, metal flow, principal stress, Von-mises stress and load characteristics. In the results, the load and stress were increased at 4 stage when the hole length of tubular shaft was increased. Also, folding phenomenon was observed to intensify as increasing the hole length of tubular shaft by confirmation of metal flow.