Abstract
A finite element method (FEM) is presented to conduct loaded tooth contact analysis and strength calculations of involute spline couplings. Special FEM software has been developed. Contact, bending and shear stresses of the spline couplings are analyzed by the developed software and they are compared with results obtained by an approximation method. It is found that "Edge loads" exist at tooth tip and root contacts and also exist at two sides of the face width when the pair of teeth has different face widths. Effects of tooth profile deviations and pitch errors on tooth contacts are also investigated by the developed software respectively. It is found that tooth contact and stresses are affected by the tooth profile deviations and pitch errors greatly. Finally, reliability of the presented method and software are discussed.