Aiming at making the contact performance analysis of accurate conical friction coupling agree with actual conditions to precisely evaluate performance and guide design process, a theoretical formula about the relation between normal pressure of contact surface and axial pretightening load was given. A method combing experimental measurement technique with finite element simulation analysis was then proposed. In this method, the measured real contact contours of the coupling were fitted by Bezier curve. According to the fitting Bezier contact contours, finite element measured model was constructed by APDL command stream which was outputted by a Matlab program. Thus, the measured data and simulation model were coalesced. The frictional behaviors simulation results were compared to analytical solution, which demonstrated that the analytical solution underestimates the maximum torque and axial force of conical friction coupling. Furthermore, the irregularity of the measured contact contours leads to incomplete contact on interfaces of coupling. Stress distribution and maximum stress of the measured model differ remarkably from that of the ideal model. Therefore, elastic deformation and effect on transmission efficiency caused by the compatibility of interfaces of coupling have to be taken into account simultaneously in accurate conical friction coupling design process.
