Drive shaft by using composite material

MECHANICAL BEHAVIOUR OF ALUMINIUM BASED

METAL MATRIX COMPOSITES REINFORCED WITH SiC

AND AFOR SHAFT

PRESENT BY:A.Kalaiyarasan & Ragupathi.PAssistant Professor, Department of mechanical Engineering ,Muthayammal Engineering college Rasipuram.

PRESENTATION TOPICS Objective

Introduction

Literature Survey

Methodology

Identification of problem

Material Selection

Aluminum Series

Properties of reinforcement

Core Materials

Parameter selection

Testing

Type of analysis

Static Analysis

Modal Analysis

Analysis Results

Application

Work in progress

Future work

References

OBJECTIVE

The main objective of project to avoid whirling vibration. The operating parameter of the composite as its control the properties of the composite material.

These is focus on the study of mechanical behavior of Aluminum metal matrix composite with varies composition of reinforcement particles of graphite or nanoparticles, Sic and Al2O3 composite produced by the stir casting technique. Different percentage of reinforcement is used. Tensile test, Hardness test and torsional test.

INTRODUCTION

A composite material is defined as a material system which consist of a

mixture or a combination of two or more different materials which are

insoluble in each other and differ in form or chemical composition.

Composite materials should comprise component materials that are congenital

with each other. In the field of high modulus composites, resin-matrix

composites find considerable interest is easy to fabricate into engineering

structures.

Two Phase of Composite materials.(i)Matrix (ii)Reinforcement.

Classification of composite materials:

1. Based on matrix material.

2. Based on material structure.

INTRODUCTION (Cont.…)

The major composite classes based on structural composition of the matrix are:

Polymer-matrix composites Metal- matrix composites Ceramic- matrix composites Carbon- carbon composites The composite gives indication of the combinations of two or more

materials in order to improve the properties of monolithic material for adjusting to global need for reduced weight, low cost,quality,and high performance in structural materials.

LITERATURE SURVEYSI.No

TITLE AUTHOR YEAR INFERENCE

1. Preparation of Aluminum matrix composite by using stir casting method

Rajesh Kumar Gang Aram Bhandare

2013 Stir casting process, Aluminum Matrix reinforcement, mixing and agitation.

2.A review of friction stir welding of aluminum matrix composite

Umar S.Salih, Hengan

2015 Friction stir welding, Al- Matrix ,microstructural and mechanical properties.

3. Characterization of Silicon Carbide reinforced Aluminum matrix composite

M.D.Habibur Rahman,H.M.

Mamunal Rashed

2013 MMCs,stir casting,Hardness,Micro Structure, wear resistance.

LITERATURE SURVEY(Cont...)SI.No

TITLE AUTHOR YEAR INFERENCE

4. Fabrication of Al-Sic composite through power metallurgy process and testing properties.

C.S.Verma RajeshPurohit,

R. S.Rana

2012 MMCs,mechanical alloying, micro-structural analysis.

5.Effects of process parameter of stir casting on metal matrix composite.

Alok Barnwal Shubham Mathur

2013 Silicon carbide, Stir pouring temperature,UTM,Hardness.

6. A study on microstructure of Al matrix composite.

Pardeep shrma,Dinesh

khanduja

2015 Al –MMC graphite, Microstructure scanning.

7. Experimental investigation on machining characteristics of Al6061 hybrid metal matrix composite processed by EDM

C.Velmuruga Subramanian

2011 Aluminum composite, stir casting, Hybrid composite.

LITERATURE SURVEY(Cont...)SI.No

TITLE AUTHOR YEAR INFERENCE

8. Characterization of SiC particulate reinforced AA6061 Aluminium alloy composite produced via stir casting.

N. Chawla, J.J. Williams, G. Piotrowski, and R. Saha

2014 Tensile strength, microstructure,

stir casting, MMCs.

9.Material optimization and weight reduction of drive shaft using composite material.

G. B. Veeresh Kumar, C. S.

P. Rao, N. Selvaraj, M.

S. Bhagyashekar

2013 Composite, propeller shaft, transmission,

universal joint.

10. Experimental investigation to study tool wear during turning of alumina reinforced Aluminium.

Balasivanandha Prabu,L.

Karunamoorthy, S.

Kathiresan, B. Mohan

2013 MMC graphite, Harness

toughness, Microstructure

scanning.

METHODOLOGY

OBJECTIVE

SELECTION OF MATERIAL

STARTING ALUMINUM ALLOY LM6 WITH REINFORCEMENT SiC AND Al2O3

PROBLEM DEFINITION

DATA COLLECTION

PRODUCTION OF COMPOSITE BY STIR CASTING

TENSILE TEST HARDNESS TEST TORSIONAL TEST

STATIC AND MODAL ANALYSIS OF SHAFT

RESULT AND CONCLUSION

Characterization (SEM,XRD)

FINISH

PHA

SE-I

PHA

SE-I

I

IDENTIFICATION OF PROBLEM

The passenger cars, trucks and vans should have the torque transmission capacity more than 3500Nm and the natural frequency must be higher than 6500 rpm to avoid whirling vibration.

In that the critical speed of shaft is inversely proportional to the square of the length.so that the vibration problem could be solve by increasing the length of shaft but its not permitted due to space limitations.

So that its only for manufacturers and manufacture the shaft in two pieces.

SCHEMATIC ARRANGEMENT OF UNDERBODY OF AN AUTOMOBILE

MATERIAL SELECTION

Aluminum alloy Silicon carbide and alumina (Reinforcement Particles) Graphite particles

ALUMINUM SERIES

ALLOY SERIES FEATURES APPLICATION

Al2024 Good corrosion resistance & High

strength

High strength structural(aircraft),

automotive parts, screws and rivets.

Al6061 Good formability, weld ability, corrosion

resistance and strength.

Automobile parts, Marine, aircraft's

Al7079 High strength alloy Aircraft and structure, recreation equipment's.

PROPERTIES OF REINFORCEMENT MATRIXPROPERTY Al2O3 SiC GRAPHITE

Density(at 20) g/c 3.97 3.22 2.09-2.23

Melting point 2288 2973 3915

Thermal expansion )

7.1 4 2.6

Thermal conductivity

(W/m K)

35.6 126 85

Young's modulus GPa

370 410 10

CORE MATERIALS

PROPERTIES/ MATERIALS

ALUMINUM STEEL

Stiffness(N/m) 22.9 22.65

Density(Kg/) 2700 7800

Weight Low High

Young's modulus(GPa)70 21

Poisson ratio 0.33 0.3

Co.eff of Thermal expansion ()

23.4 12

Correction resistance High Low

VOLUME FRACTIONS

Fiber and Matrix volume fraction is,

Sum of volume fraction is

volume of composite, fiber, and matrix

density of composite, fiber, and matrix

MASS FRACTIONS

Fiber and Matrix mass fraction is

mass of composite, fiber, and matrix

Sum of volume fraction is

DENSITY of the composite

PARAMETER SELECTION

PARAMETERS NEW MATERIAL OLD MATERIAL

Density(Kg/) 2810 2700

Poisson ratio 0.31 0.33

Young modulus(Pa) 1.21e11 7.0e10

TESTING

Tensile test Hardness test Torsional test Characterization (SEM,XRD)

TYPE OF ANALYSIS

Static analysis of composite shaft Torsional analysis Dynamic analysis (modal)

STATIC ANALYSIS

A static analysis is used to determine the displacements, stresses, strains and forces in structures or components caused by loads that do not induce significant inertia and damping effects.

In static analysis loading and response conditions are assumed, that is the loads and the structure responses are assumed to vary slowly with respect to time.

BOUNDARY CONDITION

DEFORMATION,VON MISES STRESS & EQUIVALENT ELASTIC STRAIN

STATIC ANALYSIS RESULTS

  Al-SiC Aluminium Steel

Total Deformation

[m]6.893 1.1927 4.147

Equivalent (von-

miss)stress[Pa]

1.39851.3985

1.4634

Equivalent Elastic

Strain[No Unit]

1.1604 2.0716 7.3721

TOTA

L DEF

ORMATION

EQUIVALEN

T(VON-M

ISS)ST

RESS

EQUIVALEN

T ELA

STIC ST

RAIN

0.00E+00

2.00E+05

4.00E+05

6.00E+05

8.00E+05

1.00E+06

1.20E+06

1.40E+06

1.60E+06

STEELAl

Al -SiC

STEELAlAl -SiC

MODAL ANALYSIS

The natural frequencies and the mode shapes are important parameters in the design of a structure for dynamic loading conditions. Modal analysis is used to determine the vibration characteristics such as natural frequencies and mode shapes of a structure or a machine component while it is being designed.

The natural frequency depends on the diameter of the shaft, thickness of the hollow shaft, specific stiffness and the length.

MODE 1 & 2

MODE 3 & 4

MODE 5 & 6

MODE 7

MODAL ANALYSIS RESULTS

Mode 1 mode 2 mode 3 mode 4 mode 5 mode 6 mode 70

100

200

300

400

500

600

700

800

900

1000

Al-SiC

Al-SiC

APPLICATIONS

Aircrafts structures Automotive parts Aerospace Marine

WORK IN PROGRESS

FIRST REVIEW

• Field Research• Literature Survey

SECOND REVIEW

• Problem Identification • Material selection

THIRD REIVEW

• Design and Analysis of shaft• Static and Dynamic Analysis is done using ANSYS Workbench

15.0

PRESENT CONCLUSION

The behaviour of Aluminium alloy (LM6) and Silicon carbide literature was collected and studied.

The finite element analysis is used in this work to predict the deformation of shaft.

The fabrication of the section will be done in the next phase. Fabrication of section will be based on the design created in the first phase.

The modeling and analysis of shaft is done by using ANSYS Workbench.

FUTURE WORK

The volume fraction (5%,10%,15%,20%) of aluminum alloy(LM6) and SiC with Alumina will be fabricate through stir casting technique.

The specimen will be evaluated by using Hardness test, tensile test, Torsional test and SEM/XRD.

The specimens are going to be prepared by liquid metallurgy method, the Anna University CEG campus, Chennai was identified to prepare casting of composite materials by stir casting method.

The testing is identified at Root India Pvt ltd, Ganapathi Coimbatore.

Material purchase

Specimen preparation

Submission Project PhaseII Report

Mechanical testing and

Result analysis

REFERENCES Manoj,S. Dwivedi,D.D., Lakhvir,S.andVikas,C.(2009):”Development of Aluminum

Based Silicon Carbide Particulate Metal Matrix Composite". Journal of Minerals and Materials Characterization and engineering, Vol.8,No.6,pp455-467.

Dunia Abdul Sahib, Aluminum silicon carbide and aluminum graphite particulate composites,ARPN J.Engg Appl. Sci.6(2011)41-46.

Muhammad Hayat Jokhio,Muhammad Ibrahim Pan war, and Mukhtiar Ali Unar “Manufacturing of aluminum composite material using stir casting process”. Mehran University Research Journal of Engineering and Technology, volume 30,NO.1, January,2011[ Issan 0254-7821].

Hashmi Looney L, Hashmi MSJ(1996).MMCs: Production by stir casting method. Journal of Materials Processing Technology,92-93pp1-7

Lilholt H , Aspects of Deformation of Metal Matrix Composites, Materials. Kurt A, Uygur I, Cete E. Surface modification of aluminum by friction stir

processing. J Mater Process Techno 2011;211:313–7. Mostafapour Asl A, Khandani ST. Role of hybrid ratio in microstructural,

mechanical and sliding wear properties of the Al5083/Graphite /Al2O3p a surface hybrid Nano composite fabricated via friction stir processing method. Mater Sic Eng. A 2013;559:549–57.

REFERENCES(Cont...)

Vijayarangan.S., Rajendran.I,Optimal design of a composite leaf spring using Genetic algorithm computers and Structure 79 2001:pp.1121-1129.

T.Rangaswamy “Optimal design and analysis of Automotive Composite Drive Shaft” International symposium of research students on materials science and engineering December 2002-004 Chennai India.

Kim C.D 1992”Critical speed analysis of laminated shafts". Composite engg.vol.3,pp.633-643.

J.H.Park,J.H.Wang 2001.”Stacking sequences design of Composite laminates for maximum strength using Genetic Algorithm". Journal of Composite Structure,Vol.52.pp.217-231.

Mr.V.I.Narayana, Mr.D.Mojeswararao and Mr. Kumar. ”Optimization of composite drive shaft assembly and comparison with conventional steel drive shaft,vol.I issues 6 august 2012.

https://www.google.co.in/properties of aluminum https://www.google.co.in/properties of steel https://www.google.co.in/properties of stainless steel pdf https://www.google.co.in/properties of silicon carbide

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