Computational analysis of interlocking joints with different geometries under tensile loads

Advances in modelling and simulation are driving innovation in mechanical joint design. However, the lack of standardized evaluation criteria hinders meaningful comparison across geometries, rendering the rational design and improvement difficult. To address this, we studied three representative joint shapes—trapezoid, circle, and ellipse. Finite element analysis (FEA) was employed to evaluate their tensile performance within the elastic regime. The elliptical joint showed the highest stiffness, while the circular joint exhibited the greatest load capability and resilience. Joint performance was also influenced by friction coefficient, yield strength, and blade number. Applying edge constraints notably enhanced performance, especially for single-blade joints, with up to 7.6 × increase in load capability and 5.4 × in resilience for circular joints, and 11.2 × in stiffness for trapezoidal joints. An Ashby-type plot was developed to support the comparative selection of joint designs. These results provide a foundation for establishing standardized evaluation criteria for tensile joint performance.