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Design and Analysis of Composite Drive Shaft
Design and Analysis of Composite Drive Shaft
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transmission shafts. In heavy duty vehicles Modeling, Composite, Weight reduction,
driveshaft is one of the important ANSYS.
components. The weight reduction of the
drive shaft can have a certain role in the 1. INTRODUCTION
general weight reduction of the vehicle Drive Shaft is a rotating shaft that
and is a highly desirable goal, it can be transmits power from the engine to the
achieved without increase in cost and differential gear of a rear wheel drive
decrease in quality and reliability. The aim vehicles Driveshaft must operate through
of this work is to replace the conventional constantly changing angles between the
steel driveshaft of automobiles with an transmission and axle. Automotive drive
appropriate composite driveshaft. The Shaft is a very important component of
conventional drive shafts are made in two vehicle. The present project focuses on the
pieces for reducing the bending natural design of such an automotive driveshaft by
frequency, whereas the composite shafts composite materials. Now a day’s two
can be made as single-piece shafts, thus pieces steel shaft are used as drive shaft.
reducing the overall weight. The design However, the main advantages of the
parameters were optimized with the present design are only one piece of
objective of minimizing the weight of composite driveshaft is possible that fulfill
composite drive shaft. The composite all the requirements of drive shaft. The
drive shaft made up of high modulus basic requirements considered here are
material is designed by using CAD torsion strength, torsion buckling and
software and tested in ANSYS for bending natural frequency. An optimum
optimization of design or material check design of the draft shaft is done, which is
and providing a best material. The cheapest and lightest but meets all of the
replacement of composite materials can above high load is the most requirements.
.
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section can be determined. In the today’s
reinforced composite shaft had the highest;
days there is a heavy requirement for
glass reinforced composite had the lowest
lightweight materials vehicle. (Fig:1&2)
resistance to impact. Resistance of hybrid
composite shafts was between that of glass
and carbon [5]. H. Bayrakceken, S.
Tasgetiren, I. Yavuz, investigated about
two cases of failure in the power
transmission system on vehicles: A
universal joint yoke and a drive shaft, they
concluded that failures are occurred as a
result of fatigue process [6]. R. Srinivasa
Moorthy, Yonas Mitiku & K. Sridhar
Fig:2 3D Model of a drive shaft investigated about Design of Automobile
Driveshaft Carbon/Epoxy and
A.R. Abu Talib, Aidy Ali, Mohamed A. Kevlar/Epoxy Composites. They found
Badie , Nur Azida Che Lah, A.F. that use of Carbon/Epoxy results in a mass
Golestaneh investigated about hybrid, saving of 89.756% when compared to the
carbon/glass fiber-reinforced, epoxy conventional SM45C steel driveshaft,
composite automotive drive shaft. They Obviously, the number of plies needed for
found that changing carbon fibers winding Carbon/Epoxy is 14 with 1.82 mm wall
angle from 0⁰ to 90⁰, the loss in the natural thickness as compared to 44 plies with
frequency of the shaft is 44.5%, while, 5.72 mm wall thickness in the case of
shifting from the best to the worst stacking Kevlar/Epoxy [7]. Harshal Bankar, Viraj
sequence, the drive shaft causes a loss of Shinde, P.Baskar investigated about
46.07% in its buckling strength. The best Material Optimization and Weight
fiber orientation angle for maximum Reduction of Drive Shaft Using Composite
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composite material and decreasing with load, size & shape In addition glass/epoxy
decreasing the strength of composite with 0⁰orientation have higher strength,
materials. For oblique load on fiber [12]. R. Sino,T.N. Baranger,E. Chatelet,G.
direction, surface fatigue perpendicular on Jacquet investigated about Dynamic
fiber direction [9].Ban. Bakir and Haithem analysis of a rotating composite shaft they
. Hashem investigated about Effect of concluded that closer the fiber is oriented
Fiber Orientation for Fiber Glass to 90⁰,the greater the internal damping and
Reinforced Composite Material on the sooner instability may appear.
Mechanical Properties they found that the Equivalent rigidity decreases as a function
effect on hardness of the materials having of ply angle, whereas, the damped
different orientations of fiber and it is equivalent rigidity increases [13].
maximum in discontinuous fiber specimen,
with orientation 90°, with orientation 0°,
then with orientation 45° parallel
2. COMPOSITE MATERIAL
orientation and still constant in specimen
of angle 45 °. while for 0° fiber
A material composed of 2 or more
orientation angle of glass fibers/ epoxy
constituents is called composite material.
specimens, failure was irregular and cracks
Composites consist of two or more
propagate in the different directions [10].
materials or material phases that are
B Stanly Jones Retnam, M Sivapragash
combined to produce a material that has
and P Pradeep investigated about Effects
superior properties to those of its
of fiber orientation on mechanical
individual constituents. The constituents
properties of hybrid bamboo/glass fiber
are combined at a macroscopic level and
polymer composites they concluded that
or not soluble in each other. The main
the hybrid specimen with ±45⁰ orientation
difference between composite and an alloy
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Suggesting Technology to Improve
the Failures.
Fig:3 Methodology
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mode shapes of a structure or a machine
component. Rotational speed is limited by
Table:2 Material Selection lateral stability considerations fig (5 to8).
8. MODAL ANALYSIS
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Fig:9 STEEL
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Fig:10 E – GLASS EPOXY
9. STRESS ANALYSIS
A static analysis is used to determine the
displacements, stresses, strains and forces in Fig: 11HM CARBON EPOXY
structures or components caused by loads that
do not induce significant inertia and damping
effects. A static analysis can however include
steady inertia loads such as gravity, spinning
and time varying loads.[9] In static analysis
loading and response conditions are assumed,
that is the loads and the structure responses are
assumed to vary slowly with respect to time. If
the stress values obtained in this analysis
crosses the allowable values it will result in
the failure of the structure fig (9to12).
Fig: 12 HS CARBON EPOXY
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E-Glass / HM
HS Carbon/Epoxy
Parameter Steel Epoxy Carbon/Epoxy
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When compare to Steel, E-Glass/ High Strength Carbon / Epoxy composite
Epoxy, High Strength Carbon/Epoxy drive shaft has been proposed to design to
materials for Automobile drive shaft High replace the two piece conventional steel
Modulus Carbon/Epoxy has the high drive shaft of an automobile. The FEA
strength, less weight hence it is used as the analysis is done to validate the analytical
optimized material for automobile drive calculations of the work.
shaft (Table 3).
The results of the work are
11. CONCLUSION encouraging and suggesting to
replacement of conventional drive by
The replacement of conventional drive composite has an added advantage. The
shaft results in reduction in weight of next phase of work consists of
automobile. The finite element analysis is Optimization of shaft for the objective
used in this work to predict the function as weight and fundamental
deformation of shaft. The deflection of natural frequency.
steel, Glass Epoxy / HS Carbon and HM
12. ACKNOWLEDGEMENTS
Carbon / Epoxy shafts was 298.296,
311.945 and 397.189 mm respectively. The authors their express immense
Natural frequency using Bernoulli – Euler thanks to the Sona College of Technology,
and Timoshenko beam theories was Salem, for providing the required facilities.
compared. The frequency calculated by We wish to express our gratitude to Dr R.
Bernoulli – Euler theory is high because it Venkatesan, HOD/Mech, Sona College of
neglects the effect of rotary inertia & technology-Salem, for his constant
transverse shear. Hence the single piece encouragement and valuable guidance.
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13. REFERENCES
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ASCE Vol. 118 PP. 1233-1250 .
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Properties Bi Directional
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