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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
automobile.
Contents
1) 2) 3) 4) 5) 6) 7) Introduction Literature Survey Methodology and Description of The Problem Modeling And Simulation Results And Discussions Conclusions And Future Scope 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 lowgear 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.
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.
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
Theoretical Calculations
Deflection=Ymax= Maximum shear stress =
Deformation Comparison
From ansys and theoretical it was observed deformation values are 0.59mm and 0.56mm respectively.
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
Modeling in CATIA
Converting geometric model into Fem model using Hypermesh Predicting required results using ANSYS Comparison of Results
Catia model
Hypermesh model
Material Properties
SL no Property Steel (SM 45C) Kevlar epoxy Boron epoxy E-glass Polyester resin 1 Young's Modulus X direction 2 Young's Modulus Y direction 3 Young's Modulus Z direction 4 Major Poisson's Ratio XY 5 Major Poisson's Ratio YZ 6 Major Poisson's Ratio XZ 7 8 9 Shear Modulus XY Shear Modulus YZ Shear Modulus XZ 25.08e9 25.08e9 25.08e9 67.49 67.49 67.49 2.433e9 1.698e9 2.433e9 Pa Pa Pa 0.34 0.2451 0.217 0.37 o.0095 0.366 0.3 0.34 0.2451 0.217 10.45e9 10.88e9 6.3e9 Pa 10.45e9 10.88e9 6.53e9 Pa 2.07e11 95.71e9 281.86e9 3.4e10 Pa units
10
Density
7600
1402
2249
2100
Kg/m3
It was observed from above analysis results Shear Stress values for Steel and Kevlar Drive shafts are 53 MPa and 49 MPa respectively.
It was observed from above analysis results Shear Stress values for E-Glass and Boron Drive shafts are 50 MPa and 51 Mpa respectively.
It was observed from above analysis results Buckling Stress values for Steel and Kevlar Drive shafts are 27.45 MPa and 27 MPa respectively.
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 Frequency of Steel and Kevlar Drive shaft are observed as 3Hz and 2.04Hz respectively.
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 2
Steel Kevlar
0.5816 8.16
45
3.76 2.04
53.80 49.82
27.45 27.23
35 7
80%
3
4
E-glass
Boron
17.389
7.818
2
2
45
45
1.238
1.66
50.061
50.149
24.83
45.23
10
11
71%
68%
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.
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.
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.
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.
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
Carbon drive
shaft Kevlar drive shaft
8.86
49
56
38
27
1.92
2.04
8.1
Weight in kg 41.37
108.96
146
52
142
Thank you