International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 5, May 2017, pp. 10–23, Article ID: IJMET_08_05_002

Available online at http://iaeme.com/Home/issue/IJMET?Volume=8&Issue=5

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

PARAMETRIC OPTIMIZATION OF
COMPOSITE DRIVE SHAFT USING ANSYS
WORKBENCH 14.0
I.V.S. Yeswanth
P.G Student, Mechanical Engineering,
Hindustan Institute of Technology and Science, Chennai, India

A. Abraham Eben Andrews

Assistant Professor, Mechanical Engineering,
Hindustan Institute of Technology and Science, Chennai, India

ABSTRACT
This study mainly aims at replacing the conventional steel drive shaft used in
automobiles with composite material such as High Modulus carbon/ Epoxy or E glass
polyester. Conventional drive shaft has the disadvantages such as more weight, low
specific stiffness and low strength. Composite materials offer the advantage of high
specific strength, light weight and longer life compared to conventional drive shaft.
For finding the suitability of composite structures for automobile applications the
parameters such as ply thickness, number of plies for HM carbon/ Epoxy and E- glass
polyester shafts are analyzed using ANSYS tool with the object of weight reduction.
When the shaft is subjected to torque transmission and fundamental bending natural
frequency. The drive shaft, which is used in heavy automobiles like truck, was taken to
model the drive shaft assembly using CATIAV5R20 to create a shaft model and ANSYS
16 is used for predicting the results. The comparison is carried out for conventional
steel shat and composite materials. Parametric optimization is done to compare the
results of steel and composite drive shaft by varying the design variables such as inner
diameter, outer diameter and Torque of the drive shaft and the results of change in
design variables are compared.
Key words: Driveshaft, composite materials, HM carbon, Epoxy, E-glass polyester,
CATIA, ANSYS, Parametric Optimization
Cite this Article: I.V.S. Yeswanth and A. Abraham Eben Andrews, Parametric
Optimization of Composite Drive Shaft Using Ansys Workbench 14.0. International
Journal of Mechanical Engineering and Technology, 8(5), 2017, pp. 10–23.
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1. INTRODUCTION

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 I.V.S. Yeswanth and A. Abraham Eben Andrews

A shaft is an important rotating machine element which is responsible for transmitting the
power generated from source to the required part. The power is transmitted to the shaft by
tangential force and the resultant torque helps the shaft to transmit power to various parts
which are connected to it. In automobile applications the drive shafts receives power from the
engine through clutch assembly and transmission system transfers the power to rare wheels,
which is responsible for the actual movement of the vehicle. One of the desirable goals for the
design engineers is to increase the fuel efficiency of the automobile. The conventional
material used in drive shaft for automobile applications is carbon steel of grades 40C8, 45c8,
50c4 etc. The conventional materials are more weight because of high density. The thumb
rule is that around 22% of the power generated by the engine is lost because more energy is
required to rotate heavier parts. The conventional materials of drive shaft can be replaced by
composite materials as it offers the advantage of high specific strength and high modulus
without affecting the reliability of the component. The composite materials also offer the
advantage of long fatigue life when compared to conventional materials. The various types of
composite materials that can be used for automobile application are HM carbon epoxy, HS
carbon, Kevlar, E-glass polyester etc. Various other applications where drive shafts are used
is aerospace, marine application and automobile applications.
Sagar R. Dharmadhikari [1] discusses the application of optimization of drive shaft using
Genetic algorithm and substitution of conventional drive shaft with composite material. This
paper discusses about optimization of structural systems based on mathematical programming
involving gradient search and direct search. S.Mohan [2] designs a composite drive shaft for
application of drive shaft in automobile applications and carries out investigation to estimate
the stresses, deflection and natural frequency using ANSYS software and compares the result
with steel shaft to validate the results. R.P.Kumar [3] discusses about design and analysis of
composite drive shaft which is used in power transmission applications. It also discusses
about optimization of design parameters with the objective of weight reduction. It also
discusses about uses of composite drive shaft at higher critical speed with longer life.
V.S.Bhajantri [4] discusses about replacement of conventional drive shaft with composite
materials like HS carbon, HM carbon and E-glass fiber. It also discusses about the importance
of fiber angle orientation in the design of composite drive shaft which offers the advantages of
lower weight, higher strength and power consumption. Ghatage [5] discusses about replacing
metallic shafts with composite materials as the offer the advantage high specific stiffness and
high strength. This paper uses Genetic Algorithm as optimizing tool with the objective of
weight reduction which is constrained to torque transmission; fundamental natural frequency
and torsional buckling with a view of optimizing number of plies and stacking sequence are
optimized for composite materials. A.Sridhar [6] predicts the deformation of the shaft and
compares with conventional steel and composite materials like HS carbon, HM carbon and
Glass epoxy using ANSYS software and discuss the suitability of replacement of steel with
composite materials. Pankaj k.Hatwar[ 7] discuss about polymeric materials reinforced with
synthetic fibers such as glass carbon and aramid fibers which offers the advantage of high
weight strength to weight ratio when compared to conventional materials.
This paper aims at reducing the fuel consumption of automobiles by reducing the weight
of drive shaft. Replacement of steel drive shaft with composite materials reduces about 72-
82% of the drive shaft. M.R.Khoshravan [8] discuss about design method and vibration
analysis of composite drive shaft. The parameters such as torque, critical speed, fiber
orientation and adhesive joints are studied. The results reveal that the fiber orientation has
great influence on dynamic characteristics of the composite shaft. Amit Soni [9] designs a
drive shaft with a different taper angle and ANSYS software is used for doing buckling
analysis and modal analysis to study the behavior of shaft whether it can be replaced with
composite drive shaft. Belawagi Gireesh [10] this papers compares the design of conventional

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 Parametric Optimization of Composite Drive Shaft Using Ansys Workbench 14.0)

steel drive shaft with composite drive shaft by using different composite material and
concludes around 72% reduction of weight and also concludes that there is a great influence
of fiber orientations on the static and dynamic characteristics of the composite shafts.

2. PROBLEM DESCRIPTION
Conventional drive shafts used in automobile applications are made of stainless steel which
offers the advantage of high strength, but there are disadvantages like stainless steel has low
specific modulus, low specific strength. More over because of high density the weight of the
shaft is increased which also increases the fuel consumption.
The objective of the work is to replace the conventional steel drive shafts with composite
material which offers the advantages of high strength and reduces the weight of the shaft as
the density of the composite materials is low without affecting the reliability of the composite
material.

3. DESIGN METHODOLOGY
• Study the cause of failures in the conventional drive shaft
• Selection of composite materials
• Preparation of a 3-D model of drive shaft using CATIA software
• Analysis of composite drive shaft using ANSYS
• Comparing the results with conventional drive shaft to validate the project.

4. MATERIAL SELECTION
The present material used in industry for manufacturing conventional drive shafts is SM45C
SM45C: It also known as S45C which is an unalloyed carbon mechanical structural steel
belonging to ISD3752-1986 steel grade standard. It is widely used in ladder shaft, hollow
shaft, crank shaft, mould base structural applications.

Table 1 Properties of SM45C

Property Symbol value Units
Poisson’s ratio µ 0.3
Young’s modulus of E 207 GPa
elasticity
Shear modulus G 80 GPa
Density Ρ 7600 Kg/𝑚3
Yield strength 𝜎𝑦 370 MPa

4.1. Selection of Composite Materials

The composite material chosen for Analysis are HM carbon/ Epoxy and E-Glass fiber.
HM carbon Epoxy: High Modulus Carbon epoxy is a composite material which is used
where high strength and rigidity are required. HM carbon epoxy is widely used in the areas of
automotive, aeronautical, marine and civil engineering applications as it reduces the weight of
mechanical structure without affecting the reliability of the component.
The material and their properties were used in this analysis [6]

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 I.V.S. Yeswanth and A. Abraham Eben Andrews

Table 2 Properties of HM carbon epoxy

Property Symbol Value units
Young’s Modulus of E 𝐸𝑥 =190, GPa
Elasticity 𝐸𝑦 =7.7,
𝐸𝑧 =7.7
Poisson’s ratio µ µ𝑥 =0.3,
µ𝑦 =0.3,
µ𝑧 =0.3

Shear modulus G 4.2 GPa

Density Ρ 1600 Kg/𝑚3
E Glass polyester: The E Glass fiber is a high glass fiber which is used in almost all
automobile applications which offers the advantage of low cost, high chemical resistance and
good electrical properties.

Table 3 Properties of E Glass polyester

Property Symbol Value units
Young’s Modulus of E 𝐸𝑥 =34, GPa
Elasticity 𝐸𝑦 =6.5,
𝐸𝑧 =6.5
Poisson’s ratio µ µ𝑥 =0.217,
µ𝑦 =0.366,
µ𝑧 =0.217

Shear modulus G 𝐺𝑥𝑦 =2.4, GPa

𝐺𝑦𝑧 =1.6,
𝐺𝑧𝑥 =24
Density Ρ 2100 Kg/𝑚3

5. DESIGN CALCULATIONS OFDRIVESHAFT

Specification of Engine: H series Ashok Leyland Engine Truck Model: 6DT120
Maximum Power [P] =132KW
Speed [N] =1200rpm
Length [L] =1800mm
DESIGN OF STEEL SHAFT
2∗𝜋∗𝑁∗𝑇
P=
60
2∗𝜋∗1200∗𝑇
132*10^3=
60
T= 1050.42 N-m
𝑑𝑜
= 1.25 (from PSG data book)
𝑑𝑖
Ʈ = 50N/𝑚𝑚2
Based on stiffness equation equation
𝐺𝜃 𝑇
= 𝜋
𝐿 (𝑑 4 −𝑑𝑖4 )
32 𝑜

G= shear modulus

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 Parametric Optimization of Composite Drive Shaft Using Ansys Workbench 14.0)

𝐺𝜃 𝑇
𝜋=
𝐿 (𝑑 4 −𝑑𝑖4 )
32 𝑜
80∗103 ∗1.5 1050.42
= 𝜋
1800 (1.25𝑑𝑖4 −𝑑𝑖4 )
32

𝑑𝑖 = 56mm
𝑑0 =70mm
For long shafts torsional buckling ( 𝑇𝑏 )
𝑇𝑏 = 𝑇𝑐𝑟 ∗ (2 ∗ 𝜋 ∗ 𝑡 ∗ 𝑟 2 )
Where
𝑇𝑐𝑟 = critical stress
3
𝐸
𝑇𝑐𝑟 = 3 *(𝑡/𝑟)2
3√2(1−𝜇 2 )4
3
207
𝑇𝑐 = 3 *(7/31.5)2
𝑟 3√2(1−0.32 )4
𝑇𝑐𝑟 = 5485.7281 N/𝑚𝑚2
𝑇𝑏 =239.405 KN-m
Mass of steel drive shaft
m=ρAL
𝜋
m=ρ* (𝑑02 − 𝑑𝑖2 ) ∗ 𝐿
4
𝜋
m= 7600* (0.072 − 0.0562 )*1.8
4
m= 18.93kg
Fundamental bending frequency

𝜋 𝐸∗𝐼
𝑓𝑛𝑏 = ∗√ 4
2 𝐿 ∗𝑚
𝑓𝑛𝑏 = Fundamental natural frequency (Hertz)

𝜋 207 ∗ 109 ∗ 6.95 ∗ 10^ − 7

𝑓𝑛𝑏 = ∗√
2 1.8^4 ∗ 10.52
𝑓𝑛𝑏 = 56.66 HZ

5.1. Design of Composite Drive Shaft

HM carbon epoxy
𝑇𝑏 = 𝑇𝑐𝑟 ∗ (2 ∗ 𝜋 ∗ 𝑡 ∗ 𝑟 2 )
3
𝐸
𝑇𝑐𝑟 = 3 *(𝑡/𝑟)2
3√2(1−𝜇 2 )4
3
190∗10^3
𝑇𝑐𝑟 = 3 *(7/31.5)2
3√2(1−0.32 )4
𝑇𝑐𝑟 = 5035.20 N/𝑚𝑚2
𝑇𝑏 = 5035.20∗ (2 ∗ 𝜋 ∗ 7 ∗ 31.52 )
𝑇𝑏 = 219.74 KN-m
Mass of HM carbon epoxy drive shaft

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 I.V.S. Yeswanth and A. Abraham Eben Andrews

m=ρAL
𝜋
m=ρ* (𝑑02 − 𝑑𝑖2 ) ∗ 𝐿
4
𝜋
m= 1600* (0.072 − 0.0562 )*1.8
4
m= 3.99 Kg
Fundamental bending frequency

𝜋 𝐸∗𝐼
𝑓𝑛𝑏 = ∗√ 4
2 𝐿 ∗𝑚

𝜋 190 ∗ 109 ∗ 6.95 ∗ 10^ − 7

𝑓𝑛𝑏 = ∗ √
2 1.8^4 ∗ 2.21
𝑓𝑛𝑏 = 118.50 Hz

Design of E-Glass polyester

𝑇𝑏 = 𝑇𝑐𝑟 ∗ (2 ∗ 𝜋 ∗ 𝑡 ∗ 𝑟 2 )
3
34000
𝑇𝑐𝑟 = 3 *(𝑡/𝑟)2
3√2(1−𝜇 2 )4
3
34000
𝑇𝑐𝑟 = 3 *(7/31.5)2
3√2(1−0.32 )4
𝑇𝑐𝑟 = 870.43 N/𝑚𝑚2
𝑇𝑏 = 870.43∗ (2 ∗ 𝜋 ∗ 7 ∗ 31.52 )
𝑇𝑏 = 37.98 KN-m
Mass of steel drive shaft
𝜋
m=ρ* (𝑑02 − 𝑑𝑖2 ) ∗ 𝐿
4
𝜋
m= 2100* (0.072 − 0.0562 )*1.8
4
m= 5.23Kg
Fundamental bending frequency

𝜋 𝐸∗𝐼
𝑓𝑛𝑏 = ∗√ 4
2 𝐿 ∗𝑚

𝜋 34 ∗ 109 ∗ 6.95 ∗ 10^ − 7

𝑓𝑛𝑏 = ∗√
2 1.8^4 ∗ 2.90
𝑓𝑛𝑏 = 43.76 Hz

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 Parametric Optimization of Composite Drive Shaft Using Ansys Workbench 14.0)

6. DESIGN AND ANALYSIS OF DRIVESHAFT

Table 4 Design Specification of the drive shaft
Parameter Symbol Value Unit
Outer diameter of 𝑑𝑜 70 mm
shaft
Inner diameter of 𝑑𝑖 56 mm
shaft
Length of shaft L 1800 mm
Thickness of shaft T 7 mm
The design of drive shaft is done using CATIAV5 as per the design specification
mentioned in the above table.
The composite drive shaft is designed by considering number of layers as 3 and the
stacking sequence 0/45/45 because at this stacking sequence more shear load will be applied
on the shaft.

Figure 1 Drive shaft modeled using CATIA V5

ANALYSIS OF DRIVE SHAFT: The modeled drive shaft in CATIAV5 is imported into
ANSYS.
MESHING ELEMENT: The mesh element chosen is SHELL181. SHELL 181has the
advantage of adding up to 250 layers and has six degrees of freedom. It also helps us to give
different mechanical properties in X, Y and Z directions.
BOUNDARY CONDITION: One end of the shaft is fixed and 3000M-m load us applied on other end.

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 I.V.S. Yeswanth and A. Abraham Eben Andrews

Figure 2 Meshing

Types of Analysis
STATIC ANALYSIS: A static analysis is used to calculate the effects of steady loading
conditions ignoring the effects of inertia and damping. In static analysis loading and response
conditions doesn’t vary with time. The input loading conditions that can be given in a static
analysis are moment, applied force and pressure and the output can by displacement, forces in
a structure, stress and strain. If the values obtained in static analysis crosses the allowable
values it will result in the failure of structure.
MODAL ANALYSIS: Modal analysis is a type of dynamic analysis which is used to
determine natural frequency and mode shape of a component. Mode shape and natural
frequency is an important parameter in the design of the component for dynamic loading.
PARAMETRIC OPTIMIZATION: A parametric tool is an useful element is a useful tool for
evaluating design sensitivity from a variety of levels. Input quantities consists of geometric
dimension, material coefficients and boundary conditions, whereas the output quantities
include post processing entities such as reaction forces, displacement forces and stresses etc.

Analysis Results
Static Analysis Results

Figure 3 Deformation of SM45C

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 Parametric Optimization of Composite Drive Shaft Using Ansys Workbench 14.0)

Figure 4 Deformation of HM Carbon Epoxy

Figure 5 Deformation of E Glass Polyester

Figure 6 Von Mises Stress of SM45C

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 I.V.S. Yeswanth and A. Abraham Eben Andrews

Figure 7 Von Mises Stress of HM Carbon Epoxy

Figure 8 Von Mises Stress of E Glass Polyester

Results of Modal Analysis

Figure 9 First mode frequency of SM45C

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Figure 10 First Mode Frequency of HM Carbon Epoxy

Figure 11 First Mode Frequency of E Glass Polyester

Figure 12 Sixth Mode Frequency of SM45C

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 I.V.S. Yeswanth and A. Abraham Eben Andrews

Figure 13 Sixth mode frequency of HM Carbon Epoxy

Figure 14 Sixth Mode Frequency of E Glass Polyester

Results of Parametric Optimization

Figure 16 Parametric optimization for steel

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 Parametric Optimization of Composite Drive Shaft Using Ansys Workbench 14.0)

Figure 17 Parametric optimization for HM Carbon Epoxy

Figure 18 Parametric Optimization for E Glass polyester

7. CONCLUSIONS
The present work is aimed at weight minimization of drive shaft. Composite materials are
analyzed taking into consideration of weight reduction, deformation, Von moisses stresses
and frequency. It is evident that HM carbon Epoxy has encourage properties over SM45C and
E Glass polyester and weight reduction is 79.02% less than SM45C and 24.09% less than E
Glass polyester.
Parametric Optimization helps us to see how the output quantities in postprocessor are
varying with the change in input parameters helps in saving the time required to perform
another analysis.

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