@twetzel2 I have given this some more thought and think I now better understand the kinematic relationship between the various components. As I'm sure you understand, a single U-joint will yield an output shaft rotation that varies sinusoidally from an input of constant rotational velocity. If that non-constant rotation is appropriately fed into a second U-joint then the final output will have constant angular velocity. Hence the CV (constant velocity) joint.
The attached file does a pretty good job in showing the action of the double U joint. The two joints do show some distortion as the tube rotates. I determined that this could be fixed by relating the rotation of the x vector of the tube to the y direction vector of the joint. For example, if the angle of the rotation of the tube is 0° or 180° then the flange axis direction should be parallel to the Y direction vector of the joint. However, if the angle of the rotation of the tube is 90° or 270° then the y direction vector of the joint should be parallel to a vector that is the angle bisector of the flange axis and the tube axis. If you think that you would use the results I will try to make that correlation.
Let me know what you think. Just click PLAY in the attached file.
It was not clear to me how to use the file you posted.
Lee
lee.minardi