Material Optimization and Weight Reduction of Drive Shaft Using Composite Material
TL;DR: In this article, a two-piece metallic drive shaft was replaced by a composite drive shaft by three different ply orientations of composites in order to suggest the most suitable ply orientation of the material that would give the maximum weight reduction while conforming to the stringent design parameters of passenger cars and light commercial vehicle.
Abstract: The objective of the drive shaft is to connect with the transmission shaft with the help of universal joint whose axis intersects and the rotation of one shaft about its own axis results in rotation of other shaft about its axis. Shafts must be exceptionally tough and light to improve the overall performance of the vehicle. Automobile industries are exploring composite materials in order to obtain reduction of weight without significant decrease in vehicle quality and reliability. This is due to the fact that the reduction of weight of a vehicle directly impacts its fuel consumption. Particularly in city driving, the reduction of weight is almost directly proportional to fuel consumption of the vehicle. Also at the start of vehicle the most of the power get consumed in driving transmission system, if we able to reduce the weight of the propeller shaft that surplus available power can be used to propel the vehicle. Thus, in this paper, the aim is to replace a two-piece metallic drive shaft by a composite drive shaft. The following materials can be chosen Steel, Boron/Epoxy Composite, Kevlar/Epoxy Composite, Aluminum - Glass/Epoxy Hybrid, Carbon - Glass/Epoxy Hybrid. The analysis was carried out for three different ply orientations of the composites in order to suggest the most suitable ply orientation of the material that would give the maximum weight reduction while conforming to the stringent design parameters of passenger cars and light commercial vehicle.
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TL;DR: In this paper, the authors review the work carried out on composite drive shafts which are used in the automotive applications; fabrication techniques and materials used in composite shafts (c) finite element analysis on composite shaft and steel shaft.
22 citations
Journal Article•
TL;DR: In this article, a composite drive shaft is optimally analyzed using ANSYS for hybrid of high strength carbon fiber, high modulus carbon fiber and Kevlar fiber with Epoxy resin composites with the objective of minimization of the shaft which is subjected to the constraints such as torque transmission, tensional and buckling strength capabilities.
Abstract: This paper examines the result of fiber orientation angles and stacking sequence on the torsional stiffness, natural frequency and buckling strength of composite drive shaft. The weight reduction of the drive shaft can have a certain role in the general weight reduction of the vehicle and is a highly desirable goal. Substituting composite structures for conventional metallic structures has many advantages because of higher specific stiffness and strength of composite materials. The advanced composite materials such as graphite, carbon, Kevlar and Glass fibers with suitable resins are widely used because of their high specific strength and high specific modulus. The automotive industry is exploiting composite material technology for structural components construction in order to obtain the reduction of the weight without decrease in vehicle functional quality and reliability. It is known that energy conservation is one of the most important objectives in vehicle design and reduction of weight is one of the most effective measures to obtain this result. Actually, there is almost a direct proportionality between the weight of a vehicle and its fuel consumption, particularly in city driving. In the present work an attempt is made to evaluate the suitability of composite material for the purpose of automotive transmission applications. A composite drive shaft is optimally analyzed using ANSYS for hybrid of high strength carbon fiber, high modulus carbon fiber and Kevlar fiber with Epoxy resin composites with the objective of minimization of weight of the shaft which is subjected to the constraints such as torque transmission, tensional and buckling strength capabilities. The present work includes analysis on drive shaft of Indian car with composite material and concludes that the use of composite materials for drive shaft would induce less amount of stress which additionally reduces the weight of the shaft.
16 citations
01 May 2017
TL;DR: In this article, a composite drive shaft using composite materials such as Graphite, Carbon and Glass with proper resins ware resulted in remarkable achievements in automobile industry because of its greater specific strength and specific modulus, improved fatigue and corrosion resistances and reduction in energy requirements due to reduction in weight as compared to steel shaft.
Abstract: In automobile industry drive shaft is one of the most important components to transmit power form the engine to rear wheel through the differential gear Generally steel drive shaft is used in automobile industry, nowadays they are more interested to replace steel drive shaft with that of composite drive shaft The overall objective of this paper is to analyze the composite drive shaft using to find out the best replacement for conventional steel drive shaft The uses of advanced composite materials such as Kevlar, Graphite, Carbon and Glass with proper resins ware resulted in remarkable achievements in automobile industry because of its greater specific strength and specific modulus, improved fatigue and corrosion resistances and reduction in energy requirements due to reduction in weight as compared to steel shaft This paper is to presents, the modeling and analysis of drive shaft using Kevlar/Epoxy and Glass/Epoxy as a composite material and to find best replacement for conventional steel drive shafts with an Kevlar/epoxy or Glass/Epoxy resin composite drive shaft Modeling is done using CATIA software and Analysis is carried out by using ANSYS 100 software for easy understanding The composite drive shaft reduces the weight by 8167 % for Kevlar/Epoxy and 7266% for Glass/Epoxy when compared with conventional steel drive shaft
4 citations
26 Feb 2018
TL;DR: In this article, a carbon/Epoxy composite drive shafts were fabricated using filament winding process with a fiber orientation of [85 2 /±45 2 /25 2 ] s.
Abstract: Filament winding is a composite material fabrication technique that is used to manufacture concentric hollow components. In this study Carbon/Epoxy composite drive shafts were fabricated using filament winding process with a fiber orientation of [85 2 /±45 2 /25 2 ] s . Carbon in the form of multifilament fibers of Tairyfil TC-33 having 3000 filaments/strand was used as reinforcement with low viscosity epoxy resin as the matrix material. The driveshaft is designed to be used in SAE Baja All Terrain Vehicle (ATV) that makes use of a fully floating axle in its rear wheel drive system. The torsional strength of the shaft was tested and compared to that of an OEM steel shaft that was previously used in the ATV. Results show that the composite shaft had 8.5% higher torsional strength in comparison to the OEM steel shaft and was also lighter by 60%. Scanning electron microscopy (SEM) micrographs were studied to investigate the probable failure mechanism. Delamination, matrix agglomeration, fiber pull-out and matrix cracking were the prominent failure mechanisms identified.
4 citations
01 Feb 2020
2 citations
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01 Jan 2013
TL;DR: In this article, a carbon fiber epoxy composite layer was co-cured on the inner surface of an aluminum tube rather than wrapping on the outer surface to prevent the composite layer from being damaged by external impact and absorption of moisture.
Abstract: This topic deals with the study of replacement of conventional two-piece steel drive shafts with one-piece automotive hybrid aluminum/composite drive shaft & was developed with a new manufacturing method, in which a carbon fiber epoxy composite layer was co-cured on the inner surface of an aluminum tube rather than wrapping on the outer surface to prevent the composite layer from being damaged by external impact and absorption of moisture. Replacing composite structures with conventional metallic structures has many advantages because of higher specific stiffness and higher specific strength of composite materials. By considering the thermal residual stresses of the interface between the aluminum tube and the composite layer, the optimum stacking sequence is calculated with the help of Finite element analysis. Press fitting method for the joining of the aluminum/composite tube and steel yokes was devised to improve reliability and to reduce manufacturing cost, compared to other joining methods such as adhesively bonded, bolted or riveted and welded joints. The joining of the aluminum - composite tube and steel yoke with improved reliability and optimum manufacturing cost is done by press fitting. In order to increase the torque transmission capacity protrusion shape is provided on the inner surface of steel yoke which will fit on Universal joints. Index Terms—Drive shaft, composite material, Aluminum / composite drive shaft design. Press fitted Joints, Static Torque.
14 citations
06 Oct 2011
12 citations
01 Jan 2007
TL;DR: In this paper, a single-piece e-glass/ epoxy, high strength carbon/epoxy and high modulus carbon/poxy composite drive shaft for an automotive application is proposed.
Abstract: Substituting composite structures for conventional metallic structures has many advantages because of higher specific stiffness and strength of composite materials. This work deals with the replacement of conventional two-piece steel drive shafts with a single-piece e-glass/ epoxy, high strength carbon/epoxy and high modulus carbon/epoxy composite drive shaft for an automotive application. The design parameters were optimized with the objective of minimizing the weight of composite drive shaft. The design optimization also showed significant potential improvement in the performance of drive shaft.
10 citations
"Material Optimization and Weight Re..." refers background in this paper
...2 Torque transmission capacity of drive shaft: [2]...
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