Optimum Design and Analysis of a Composite Drive Shaft for an Automobile

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.

Author: Sanjay Gummadi, Akula Jagdeesh Kumar

Source: Blekinge Institute of Technology

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1. Notation
2. Introduction
2.1 Description of the Problem
2.2 Aim and Scope
2.3 Optimum Design using Genetic algorithm
2.4 Analysis
3. Background
3.1 Classification of Composites
3.2 Advantages of Fiber Reinforced
3.3 Limitations of composites
3.4 Applications of Composites
3.5 Purpose of Drive Shaft
3.6 Functions of Drive Shaft
3.7 Different types of Shafts
3.8 Drive Shafts in a car Model
3.9 Parts of Drive Shaft and Universal Joint
3.10 Demerits of Convention Drive Shafts
3.11 Merits of Conventional Drive Shaft
3.12 Drive Shaft Vibration
4. Literature Survey
4.1 Composites
4.2 Torsional Buckling
4.3 Lateral Vibrations
4.4 Optimization
5. Design of Steel Drive Shaft
5.1 Specification of Problem
5.2 Torque Transmission capacity of a Shaft
5.3 Torsional Buckling capacity of a Shaft
5.4 Lateral or Bending Vibration
5.4.1 Bernoulli Euler Beam Theory
5.4.2 Timoshenko Beam Theory
5.4.3 The Relation between Timoshenko and Euler Beam Theory
6. Design of Composite Drive Shaft
6.1 Specification of Problem
6.2 Assumptions
6.3 Selection of Cross Section
6.4 Selection of Reinforcement Fiber
6.5 Selection Resin system
6.6 Selection of Materials
6.7 Factor of Safety
6.8 Torque Transmission Capacity of the Shaft
6.8.1 Stress-Strain relationship for Unidirectional Lamina
6.8.2 Stress-strain relationship for Angle-Ply lamina
6.9 Torsional Buckling capacity
6.10 Lateral or Bending vibrations
6.10.1 Bernoulli-Euler Beam Theory
6.10.2 Timoshenko Beam Theory
6.10.3 Relation between Bernoulli-Euler and Timoshenko Beam Theory
7. Design Optimization
7.1 How GA differs from traditional Optimization Techniques
7.2 Objective Function
7.3 Design Variables
7.4 Design Constraints
7.5 Input GA Parameters
8. Finite Element Analysis
8.1 Introduction
8.2 Modelling Linear layered shells
8.2.1 Input Data
8.3 Static Analysis
8.3.1 Boundary Conditions
8.4 Modal Analysis
8.5 Buckling Analysis
8.5.1 Types of Buckling Analysis Non-Linear Buckling Analysis Eigen value Buckling Analysis
9. Results and Discussions
9.1 GA Result
9.1.1 Summation of Results
9.1.2 GA Results of E-Glass/Epoxy Drive Shafts
9.1.3 GA results of HS Carbon/Epoxy drive shaft
9.1.4 GA results of HM Carbon/Epoxy drive shaft
9.2 Stress Strain distribution along thickness of E-Glass/Epoxy Drive Shaft using CLT
9.3 Stress Strain distribution along thickness of HS Carbon/Epoxy Drive Shaft using CLT
9.4 Stress Strain distribution along thickness of HM Carbon/Epoxy
Drive Shaft using CLT
9.5 Deflection
9.6 Elastic constants of the composite drive shafts
9.7 Static analysis of HS Carbon/Epoxy drive shaft
9.8 Modal analysis of HS Carbon/Epoxy drive shaft
9.9 Buckling analysis of HS Carbon/Epoxy drive shaft
9.10 The effect of centrifugal forces on torque transmission capacity
9.11 The effect of transverse shear and rotary inertia on the fundamental natural frequency
9.12 Torsional buckling capacity
10. Conlusions
11. References

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