FEM-Based Analysis of Interference Fit for High-Precision Mechanical Assemblies

This study presents an interference fit study that supports the design and evaluation of press-fit assemblies. The simulation model is based on the Thick-Walled Cylinder Theory (TCT) to accurately predict contact pressure, pressing force, and stress distribution during assembly and disassembly. The shaft-bearing assembly is machined with high precision for experimentation. The results show good agreement between the FEM simulation and the theoretical stress distribution, confirming the mechanical behavior of the interference fit. Experimental verification of the pressing force is also performed and compared with the simulation, showing consistent trends. The simulation model helps evaluate the assembly performance in different tolerance and coefficient of friction domains, providing a practical solution for high-precision mechanical assemblies.