Final 2003

Design And Analysis of Drive Shaft With Composite Materials

Under the guidance of Dr.K.Rambabu

By R.P.Kumar Rompicharla (310277133007)

Abstract

• The overall objective of this project is to design and analyze a

composite drive shaft for power transmission. All vehicles use a

drive shaft for the transmission of motion from the engine to the

differential. In this work attempt was made for design

optimization of drive shaft with composite materials. The single

piece drive shaft using composite materials was designed to

replace two-piece conventional steel drive shaft of an

automobile.

The design parameters were optimized with the objective of

minimizing the weight of composite drive shaft. In this present

work an attempt was made to estimate the deflection, stresses,

natural frequencies and stress intensity factor under the subjected

loads using FEA.

A further comparison carried out for both steel and composite

materials. More efforts considered on Kevlar composite because it

has the most encouraging properties.

Contents

1) Introduction

2) Literature Survey

3) Methodology and Description of The Problem

4) Modeling And Simulation

5) Results And Discussions

6) Conclusions And Future Scope

7) References

Introduction

Purpose of Driveshaft:-

• First, it must transmit torque from the transmission to the differential gear box.

• During the operation, it is necessary to transmit maximum low-gear torque developed by the engine.

• The drive shafts must also be capable of rotate at the very fast speeds required by the vehicle.

• The drive shaft must also operate through constantly changing angles between the transmission, the differential and the axles

• The length of the drive shaft must also be capable of changing while transmitting torque.

Merits of composite Drive Shaft

• They have high specific modulus and strength.• Reduced weight.• Due to the weight reduction, fuel consumption will be

reduced.• They have high damping capacity hence they produce

less vibration and noice.• They have good corrosion resistance.• Greater torque capacity than steel or aluminum shaft.• Longer fatigue life than steel or aluminum shaft.• Lower rotating weight transmits more of available

power

Components in Drive Shaft

Comparison of Drive Shafts

Literature Review

• Many research papers have studied, The Spicer U-Joint

Division of Dana Corporation for the Ford Econoline van

models developed the first composite propeller shaft in 1985

• Agarwal B.D.and Broutman reviewed the theoretical details of

composite materials and composite structures in" Analysis and

performance of fiber composites 1990".

• [1] 73332270 Design and Analysis of a Propeller Shaft of a

Toyota Qualis by “Syed Hasan”.

• [4] Optimal Sizing and Stacking Sequence of Composite Drive

shafts- Thimmigowda rangaswami,Sabapathy Vijayarangan.

• [7] Automotive Composite Drive shaft: Investigation of

Design variables Effects- M.A.Badie, A.Mahdi, A.R.Abutalib,

E.J.Aabdullah and R.Yonus.

Methodology and Description Of The Problem

The methodology followed in this thesis is as follows:-

1.The detailed study of the driveshaft for its loading and operating

conditions.

2.Obtained 2D drawings and loading conditions from design

specifications.

3. Created of 3D CATIA model using CATIA V5

4. 3D FE model Created by using HYPERMESH

5. Obtained boundary conditions required for analysis

6. The above HYPERMESH model get analyzed in ANSYS 12

Description of Problem• When conventional materials such as Steel or Aluminum are

used, the weight of the drive shaft assembly is considerably

high, which has certain role in increasing the overall weight of

vehicle. Also, due to the increased weight of the shaft there are

more chances of whirling of the shaft. To avoid this in

conventional drive shafts, which have a length exceeding 1.2m,

the shafts are made in two pieces. However, the two piece steel

propeller shaft has complex and heavy configuration because

three universal joints and a center support bearing in addition to

a spine are required, which produces noise and vibrations that

are transmitted to the center support bearing.

Theoretical Calculations

Deflection=Ymax=

Maximum shear stress =

Maximum von mises stress =

Deformation Comparison

From ansys and theoretical it was observed deformation values are 0.59mm and 0.56mm respectively.

Shear Stress Comparison

From ansys and theoretical it was observed Shear Stress values are 28MPa and 26.78 MPa respectively

Von-Mises stress

From ansys and theoretical it was observed von-mises Stress values are 96 MPa and 91.28 MPa respectively

Theoretical and analysis results comparison

• By comparing the theoretical values and hollow shaft analysis values it is observed that the calculated deformation value is 0.56 mm and the simulated value for deformation is 0.59 mm, Shear stress value calculated is 26.78MPa for simulated it was 28MPa, And for von-misses those values are 91.28MPa and 96MPa these results shows variation between theoretical and simulated up to 5.2 % only .

Modeling And Simulation

Process steps for analysis

• Modeling in CATIA

• Converting geometric model into Fem model using

Hypermesh

• Predicting required results using ANSYS

• Comparison of Results

Catia model

Hypermesh model

Ansys model with boundary conditions

Material PropertiesSL no Property Steel

(SM 45C)

Kevlar

epoxy

Boron epoxy E-glass

Polyester

resin

units

1 Young's Modulus X

direction

2.07e11 95.71e9 281.86e9 3.4e10 Pa

2 Young's Modulus Y

direction

- 10.45e9 10.88e9 6.53e9 Pa

3 Young's Modulus Z

direction

- 10.45e9 10.88e9 6.3e9 Pa

4 Major Poisson's Ratio

XY

0.3 0.34 0.2451 0.217

5 Major Poisson's Ratio

YZ

- 0.37 o.0095 0.366

6 Major Poisson's Ratio

XZ

- 0.34 0.2451 0.217

7 Shear Modulus XY - 25.08e9 67.49 2.433e9 Pa

8 Shear Modulus YZ - 25.08e9 67.49 1.698e9 Pa

9 Shear Modulus XZ - 25.08e9 67.49 2.433e9 Pa

10 Density 7600 1402 2249 2100 Kg/m3

Analysis Results And Discussionsshear stress results for Steel and Kevlar

It was observed from above analysis results Shear Stress values for Steel and Kevlar Drive shafts are 53 MPa and 49 MPa respectively.

Shear stress results for E-glass and Boron:-

It was observed from above analysis results Shear Stress values for E-Glass and Boron Drive shafts are 50 MPa and 51 Mpa respectively.

Buckling analysis resultsfor both Steel and Kevlar

It was observed from above analysis results Buckling Stress values for Steel and Kevlar Drive shafts are 27.45 MPa and 27 MPa respectively.

Buckling analysis resultsfor both E-Glass and Boron

It was observed from above analysis results Buckling Stress values for E-Glass and Boron Drive shafts are 24 MPa and 45 Mpa respectively.

Natural frequencies of steel and Kevlar Drive Shafts

Natural Frequency of Steel and Kevlar Drive shaft are observed as 3Hz and 2.04Hz respectively.

Natural frequencies of E-glass and Boron Drive Shafts

Natural Frequency of E-glass and Boron Drive shaft are observed as 1.238Hz and 1.66 Hz respectively.

Results summary

Sl

no

Material Deform

-ation

in mm

No of

layers

Angle

of ply

( 0 )

Natural

Frequency

in(Hz)

Trosional

(Shear)

Stress

value in

(N/mm2)

Buckling

Stress

Value in

(N/mm2)

Weight

in Kg

% of

Weight

reductio

n

1 Steel 0.5816 - - 3.76 53.80 27.45 35 -

2 Kevlar 8.16 2 ±45 2.04 49.82 27.23 7 80%

3 E-glass 17.389 2 ±45 1.238 50.061 24.83 10 71%

4 Boron 7.818 2 ±45 1.66 50.149 45.23 11 68%

Finding stress intensity values for cracked shaft

Energy Release Rate

Stress intensity values

S.NoS.No MaterialMaterial Stress Intensity value in Mpa√mm.Stress Intensity value in Mpa√mm.

11 SteelSteel 0.130.13

22 Kevlar/EpoxyKevlar/Epoxy 0.0120.012

Graphs for finding stress intensity factor

Discussion and Comparison of results

From the above Figure it was observed that the Kevlar possess low stress values compared

to E-Glass, Boron and Steel respectively. Hence Kevlar has been chosen to be the best

suitable composite material for torque applications due its low stress and high strength.

Buckling stress Comparison

From the above Figure it was observed that the buckling stress of E-glass is low when compared to Kevlar, steel and Boron respectively. At the same time it is inferred from the above graph, that buckling stress is almost same for both E-glass and Kevlar composites when compared to Boron and steel.

Stress Intensity Factor Comparison

From the above Figure, it was observed that Stress intensity value is very low for

Kevlar when compared to steel, E-glass and Boron. Therefore, Kevlar has less

crack propagation chances.

Weight comparison

From the above Figure it was observed that weight is low for Kevlar composite than E-glass, Boron and steel respectively. At the same time, it was also observed that weight reduction is found to be 80%, 71% and 68% for Kevlar, E-glass and Boron respectively. Therefore, fuel consumption of that particular automobile is reduced

Deformation Comparison

From the above Figure, it was observed that the deformation produced in Steel is less

when compared to Boron, Kevlar and E-Glass respectively. But, Kevlar and Boron

provides still less deformation when compared to E-Glass.

Natural Frequency Comparison

From the above Figure, it was observed that the Steel possess high Natural

Frequency compared to Kevlar, Boron and E-Glass respectively. But, the

natural Frequency of Kevlar is higher when compared to E-Glass and Boron.

Thus it can be applied for high critical speed operations.

Conclusions And Future Scope

• A single piece drive shaft was designed from a two piece steel drive shaft by eliminating one universal joint and slip yoke for the rear wheel of an automobile using ANSYS with the objective of reducing weight. Later in the design of shaft, Steel was replaced with three different composites (I.e. Kevlar, Boron and E-glass), due to their low weight to high strength ratio.

• All the three composites were analyzed (I.e. Kevlar, Boron and E-glass) in terms of shear stress, buckling stress, stress intensity factor, deformation and natural frequency. Kevlar-epoxy composite exhibited better results like low shear stress, low torsional buckling stress and low stress intensity factor and become a better option in shear stress, torsional buckling stress and stress intensity factor aspects.

• It was found that Kevlar composite has exhibited 80% of weight reduction when compared to Steel.

• It was observed that the natural frequency of Kevlar and steel are higher than the other two composites (Boron and E-glass). Hence Kevlar can be chosen for shaft material to operate at high critical speeds as a replacement for steel.

• Hence it was concluded that Kevlar is the best suitable material as a replacement to steel (CK 45) material due to its encouraging properties, among three composite materials considered.

Scope for Future Work

• The present work can be extended for transient and shock loads

References

[1] 73332270 Design and Analysis of a Propeller Shaft of a Toyota Qualis by “Syed Hasan”

[2] Mechanics of laminated composite plates and shells: theory and analysis – by Junuthula Narasimha Reddy.

[3] Design Data”- Data book of engineering.

[4] Optimal Sizing and Stacking Sequence of Composite Drive shafts- Thimmigowda rangaswami,Sabapathy Vijayarangan.

[5] Polymer Matrix composites In Drive line Applications-Drf Andrew Pollard, GKN Technology,Wolverhampton , UK.

[6] Static Torsion Capacity of Hybrid Aluminum Glass Fiber Composite Hallow Shaft-S.A.Mutasher , B.B.Sahari and A.M.S Hamouda, S.M.Sapuan

Harmonic Comparison between steel and Kevlar composite shafts

Comparison between carbon and Kevlar shaft

Material Deformation

in mm

Shear stress

in Mpa

Buckling

stress in Mpa

Natural

frequency in

Hzs

Carbon drive

shaft

8.86 49 38 1.92

Kevlar drive

shaft8.1

56 27 2.04

Critical speed comparison

Material Steel Kevlar Boran E-glass Carbon

Weight in kg 41.37 7.66 12.44 11.63 8.88

Critical speed

in Hz.

68.96 108.96 146 52 142

Thank you