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  • Composite Driveshaft: MEEN 4263/4264

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    The document summarizes the design, fabrication, testing, and results of a composite carbon fiber driveshaft project. Key points: - The driveshaft was designed to be lighter and more efficient than a steel one while maintaining strength and safety standards. - Filament winding was used to fabricate the driveshaft from carbon fiber, epoxy resin, and aluminum yokes. - Dynamometer testing found the composite driveshaft held the same horsepower and torque as the steel one but weighed less. - While initially more expensive to produce, composite driveshafts could achieve cost reductions through mass production.

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    The document summarizes the design, fabrication, testing, and results of a composite carbon fiber driveshaft project. Key points: - The driveshaft was designed to be lighter and more efficient than a steel one while maintaining strength and safety standards. - Filament winding was used to fabricate the driveshaft from carbon fiber, epoxy resin, and aluminum yokes. - Dynamometer testing found the composite driveshaft held the same horsepower and torque as the steel one but weighed less. - While initially more expensive to produce, composite driveshafts could achieve cost reductions through mass production.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    28 views31 pages

    Composite Driveshaft: MEEN 4263/4264

    Uploaded by

    api-61200414
    The document summarizes the design, fabrication, testing, and results of a composite carbon fiber driveshaft project. Key points: - The driveshaft was designed to be lighter and more efficient than a steel one while maintaining strength and safety standards. - Filament winding was used to fabricate the driveshaft from carbon fiber, epoxy resin, and aluminum yokes. - Dynamometer testing found the composite driveshaft held the same horsepower and torque as the steel one but weighed less. - While initially more expensive to produce, composite driveshafts could achieve cost reductions through mass production.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    of 31

    Composite Driveshaft

    MEEN 4263/4264

    Wesley Kinkler Chad Keys Alex Santiago

    Composite Driveshaft
    Introduction Design Criteria Design Material Properties Fabrication Testing Results Cost Conclusions

    Introduction
    Purpose
    Create a more efficient, lightweight driveshaft

    Objectives
    Construct a useable driveshaft Lessen amount of rotating mass Improve performance of vehicle Maintain adequate safety standards

    Introduction
    Advantages
    Overall increase in vehicle efficiency Made to be interchangeable with OEM parts Safer than a metal driveshaft Vibration dampening qualities

    Disadvantages
    High costs Fragile Unfavorable in shock loading conditions

    Design Criteria
    Operating Conditions
    Loading Torque 550 ft-lbs Horse power 576 HP RPM 7000

    Design
    Qcr = 2 2r t D22 Qcr = 2r kcr 2 l
    2 2

    kcr = 0.925Z i
    2 i

    4 2 12 4

    ( A11 A22 A )l Z = 2 12 A22 D22 r

    Design
    Shear

    ro = J
    Polar Moment of Inertia

    J =

    32

    (d

    4 o

    d )
    4 i

    Design
    Tested several wind pattern lay-ups in Laminated Design Software to
    achieve high stiffness achieve high natural frequency

    Additional 45s increase stiffness Additional 15s increase natural frequency Lay-up thickness
    0.091 inches

    Design
    Driveshaft Properties

    E1 = E x = Q11 (1 12 21 ) E1 = 9.65 *10 psi


    6

    E2 = E y = Q22 (1 12 21 ) E2 = 6.15 *10 psi


    6

    A66 6 G12 = = 4.05 *10 psi t

    Design
    Driveshaft Properties

    A11 Q11 = t A11 12 = A22

    A22 Q22 = t

    12
    E1

    21
    E2

    Design
    Driveshaft Properties
    Inplane Modulus from Laminate Design Software

    A11 A22 A66


    Flexural Modulus

    946.0*106 lb/in 602.6*106 lb/in 397.2*106 lb/in

    D66

    718.0 lb-in

    Design
    Moment of Inertia Isteel=0.599 in4 Icomposite=0.390 in4 Mass Moment of Inertia Im steel=36.837 lb in4 Im composite=6.829 lb in4

    d d I = 64
    4 o

    4 i

    Im

    m ( r + ri ) = 2
    2 o 2

    Design

    Design
    Finite Element Analysis Results
    Max Stress at 3500 ft-lbf 50,000-60,000 psi Natural Frequency 329 Hz (19,740 RPM)

    Material Properties
    IM7 6K Carbon Fiber
    Tensile Strength 835,000 psi Aerospace Quality

    Epolam 2015 Resin


    Viscosity 6080 mPa*sec Pot Life 125 155 min Elongation at Break 6%

    Hysol EA9394 Adhesive


    Lap Tensile Shear Strength - 29 MPa @ 25 C 20 MPa @ 93 C

    Fabrication
    Filament Winding

    Fabrication
    Filament Winding

    Fabrication
    Yokes After Machine Work

    Before Machine Work

    Fabrication
    Driveshaft Assembly

    Fabrication
    Carbon Fiber Shaft
    4.77 lbs.
    16 14 12 10 8 6 4 2 0 Weight Steel Carbon Fiber

    Steel Shaft
    14.10 lbs

    Testing
    Chassis Dynamometer

    Testing
    Chassis Dynamometer Horse Power
    402 401 400 399 398 397 396 395 394 393 Run 1 Run 2 Run 3
    Steel Carbon Fiber

    Testing
    Chassis Dynamometer - Torque
    395 390 385 380 375 370 365 360 355 Run 1 Run 2 Run 3 Steel Carbon Fiber

    Testing

    Steel Drive Shaft

    Composite Drive Shaft

    Cost
    Construction Materials
    Carbon fiber - $114 Epoxy resin = $157 Aluminum tubing = $117 Yokes = $112 Adhesive = $220 U-joints = $30

    Cost
    Freebies
    Machine work and welding approx. 15 hrs. $900 3 aluminum bar stock = $100 Miscellaneous costs = $150 Balancing = $80 Dynamometer = $75

    Our cost = $750 Total Estimated Cost = $1905

    Cost
    Cost Reduction
    Mass production
    Mandrel and jig costs dispersed Less waste to testing patterns Have yokes forged to specs
    Decrease machining time

    Decrease in shipping costs


    No overnight delivery

    Conclusions
    Held up to loading conditions No discernable change in horsepower or torque
    Driveshaft has the smallest effect on the efficiency of the driveline Most power lost in transmission and differential

    Special Thanks
    We would like to thank the following people for their help in the making of this project: Dr. Larry Peel Dr. Hector Estrada Dr. Yousri Elkassabgi Victor DeLeon Larry Keys Jody Keys Ronnie Santhuff Chassis Dyno Services Keltons Truck Parts, Inc.

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