Shaft Analysis
Shaft Analysis
Shaft Analysis
COMPOSITE MATERIALS
ABSTRACT:
Automotive drive Shaft is a very important components of vehicle. The overall
objective of this paper is to design and analyze a composite drive shaft for power
transmission. 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
Composite materials. In this work Kevlar /Epoxy is used as composite material 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. In this present work an attempt has been to estimate the
deflection, stresses, natural frequencies under subjected loads using FEA. Further
comparison carried out for both steel and composite materials and weight of the shaft is
optimized and stress intensity factor found for both Steel and composite drive shafts.
INTRODUCTION
A driveshaft is a rotating shaft that transmits power from the engine to the
differential gear of a rear wheel drive vehicles Driveshaft must operate through constantly
changing angles between the transmission and axle. High quality steel (Steel SM45) is a
common material for construction. Steel drive shafts are usually manufactured in two pieces
to increase the fundamental bending natural frequency because the bending natural
frequency of a shaft is inversely proportional to the square of beam length and proportional
to the square root of specific modulus. The two piece steel drive shaft consists of three
universal joints, a center supporting bearing and a bracket, which increase the total weight of
a vehicle. Power transmission can be improved through the reduction of inertial mass and
light weight. Substituting composite structures for conventional metallic structures has many
advantages because of higher specific stiffness and higher specific strength of composite
materials. Composite materials can be tailored to efficiently meet the design requirements of
strength, stiffness and composite drive shafts weight less than steel or aluminum of similar
strength. It is possible to manufacture one piece of composite. Drive shaft to eliminate all of
the assembly connecting two piece steel drive shaft. Also, composite materials typically
have a lower modulus of elasticity. As a result, when torque peaks occur in the driveline, the
driveshaft can act as a shock absorber and decrease stress on part of the drive train extending
life. Many researchers have been investigated about hybrid drive shafts and joining methods
of the hybrid shafts to the yokes of universal joints. But this study provides the analysis of
the design in many aspects.
ASSUMPTIONS
The shaft rotates at a constant speed about its longitudinal axis. The shaft has a
uniform, circular cross section. The shaft is perfectly balanced, all damping and nonlinear
effects are excluded. The stress-strain relationship for composite material is linear and
elastic; hence, Hooks law is applicable for composite materials. Since lamina is thin and no
out-of-plane loads are applied, it is considered as under the plane stress.
MERITS OF COMPOSITE DRIVE SHAFT
1. They have high specific modulus and strength.
2. Reduced weight.
3. Due to the weight reduction, fuel consumption will be reduced.
4. They have high damping capacity hence they produce less vibration and
noice.
5. They have good corrosion resistance.
6. Greater torque capacity than steel or aluminum shaft.
7. Longer fatigue life than steel or aluminum shaft.
SHAFT MODELING:
Shaft Modeling
Dimensions of a shaft:
For the the hollow shaft,
let
Ro = 0.036m
Ri = 0.011m
L= 1.5 m
VON-MISES STRESS
von-mises results
It observed from above analysis results von-Misses value for steel shaft is 96Mpa
Deformation comparison
Catia Model
Step2:
3D FE Model Creation The 3D FE model for drive shaft was created by using FE
modeling software HYPERMESH v10.0. The mesh has been generated using 2nd order
Hexa elements (SOLID 95 and Solid 186) in Hypermesh.
Step-3:
using above hypermesh model with boundary conditions in ansys12.0 required results
are predicted
Step-4;
By applying boundary conditions and loading conditions obtained results will
compared and suitable material suggested which gives less torsional value and frequency
nearer to steel.
Finding stress intensity value
Being able to determine the rate of crack growth, an engineer can schedule
inspection accordingly and repair or replace the part before failure happens. Being able to
predict the path of a crack helps a designer to incorporate adequate geometric tolerance in
structural design to increase the part life. The methodology used to investigate the mechanics
of crack propagation consists of the following steps:
Step 1:
Introducing crack with 1mm width and 3mm depth in Catia geometric model
Step 2:
Creating 3D FE model by using Hpermesh and creating fine mesh at crack
located area. Using contact elements at universal joint locations
Step3:
Applying Boundary conditions and to solve to get shear stress value at different
locations nearer to cracktip
Step 4:
Using above predicted values to plot graphs for finding stress intensity values
for both Steel and Composite shafts
Step 5:
Interpretation of results for both Steel and composite Intensity values
Generic element
type name
Ansys Name
Description
20 Node Quadratic
Hexahedron
Solid 95
20 Node structural
solid
20 Node Quadratic
Hexahedron
Solid 186
20 Node structural
solid
Quadratic
Quadrilateral Contact
Conta 174
3D 8 Node surface to
surface contact
Property
Kevlar/ Epoxy
Units
2.07e11
95.71e9
Pa
10.45e9
Pa
10.45e9
Pa
0.3
0.34
0.37
0.34
Young's Modulus X
direction (E11)
Young's Modulus Y
direction (E23)
Young's Modulus Z
direction (E31)
Major Poisson's Ratio
XY ()
Major Poisson's Ratio
YZ ()
Major Poisson's Ratio
XZ ()
Shear Modulus XY (12)
25.08e9
Pa
25.08e9
Pa
25.08e9
Pa
10
Density
7600
1402
Kg/m3
2
3
4
5
6
ANALYSIS RESULTS
Steel and Kevlar/Epoxy shaft deformation comparison.
Steel drive shaft defromation result
S.NO
Distance (r)
KI value ((r))
29.51
0.08770
0.472
28.93
0.00904
0.09
30.59
-0.000055
-0.0003
By considering graph plotted between Distance (r) and stress r from crack tip
the stress intensity factor value for steel shaft is observed as 0.13Mpamm.
KI value ((r))
29.51
0.000741
0.003993
28.93
0.0001126
0.0007
-0.000056
3
30.59
-0.0003
By considering graph plotted between Distance (r) and stress r from crack tip the
stress intensity factor value for composite shaft is observed as 0.012 Mpamm
RESULTS
S.No
Steel
Kevlar/Epoxy
0.5816
8.16
Number of layers
Angle of ply
45
Natural Frequency in HZ
3.76
2.04
53.80
49.82
27.45
27.23
23
Material
Deformation in mm
Weight reduction in %
S.No
Material
Steel
0.13
Kevlar/Epoxy
0.012
CONCLUSION
The usage of composite material has resulted to inconsiderable amount of weight
saving in the range of 28 % when compared to conventional steel shaft
Taking into considerations the weight saving, deformation, shear stress induced
and resonant frequencies it is evident that Kevalar/Epoxy composite has the most
encouraging properties to act as replacement for steel out of the considered two
materials .
The presented work was aimed to reduce the fuel consumption of the automobile in
the particular or any machine, which employs drive shafts ,in general it is achieved by
using light weight composites like Kevelar/Epoxy
The presented work also deals with design optimization i.e converting two piece drive
shaft (conventional steel shaft) in to single piece light weighted composite drive shaft.
The drive shaft of Toyota Qualis was chosen for determining the dimensions, which
were used then used for the material properties of composites were used the stability
of drive shaft is ensured by limiting the include values with in the permissible range in
Ansy 12.0
The stress intensity value (KIII) at crack tip is observed for composite driveshaft is
low.
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