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Journal of Advances in Mechanical Engineering and Science, Vol. 2(3) 2016, pp. 1-13
*Corresponding author. Tel.: +919962455889
Email address: dr.sarravanan@gmail.com (R.Saravanan)
Double blind peer review under responsibility of DJ Publications
http://dx.doi.org/10.18831/james.in/2016031001
2455-0957 © 2016 DJ Publications by Dedicated Juncture Researcher’s Association. This is an open access
article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-ncnd/4.0/) 1
RESEARCH ARTICLE
Is Kevlar29/Epoxy Composite an Alternate for Drive Shaft?
*R Saravanan
1, P Vivek
1, T Vinod Kumar
1
1Department of Mechanical Engineering, Vels Institute of Science, Technology and Advanced Studies
(VISTAS), Vels University, Pallavaram, Chennai-600117, India.
Received-11 May 2016, Revised-8 June 2016, Accepted-17 June 2016, Published-17 June 2016
ABSTRACT
Advances in engineering and technology replace old materials with new materials having
superior advantages in specialized, personalized as well as general applications. The new materials are
more reliable than conventional ones and are designed to be stronger and durable. The recent
researches in design engineering are focused on to provide composite materials as a substitute for
conventional materials in many applications due to their unique properties. This research is focused on
investigating the suitability of an alternate composite material for SM45 steel shaft for automobile
applications. SM45 steel, carbon epoxy, E glass epoxy and Kevlar29 epoxy composites were
considered for investigation of sample shaft fabrication and extraction properties. The actual shaft was
modelled by using Pro-E wildfire 5 software. Then it was imported in ANSYS workbench 14.5 giving
the actual boundary conditions for the drive shaft for SM45C material. Under the same boundary
conditions carbon epoxy, E glass epoxy and Kevlar29 epoxy composites were analyzed. Total
deformation, equivalent stress, equivalent elastic strain and buckling deformation analysis were
concentrated. The Kevlar29 epoxy composite outperforms others in terms of weight saving, buckling
capability, induced shear stress and torque transmission capability.
Keywords: Composite material, Conventional material, SM45 steel, Torque, Kevlar29 epoxy
composite.
1. INTRODUCTION
[1] highlighted that in recent days,
there is a huge demand for lightweight
materials. Fibre reinforced polymer composites
seems to be a promising solution to this rising
demand. These materials have gained attention
due to their applications in the field of
automotive, aerospace, sports goods, medicinal
and household appliances. [2] investigated the
mechanical properties of E-glass fibre
reinforced epoxy composites filled with fly
ash, aluminum oxide, magnesium hydroxide
and hematite. They reported that composites
filled to 10% of volume exhibited maximum
ultimate tensile strength and hardness. In
addition to it the fly ash filled composites
exhibited maximum impact strength, but
weight of the shaft was not reduced
significantly. [3] The materials, boron/epoxy
composite, Kevlar/epoxy composite, aluminum
– glass/epoxy hybrid and carbon – glass/epoxy
hybrid can be chosen for replacing steel drive
shaft and recommended the use of hybrid
composites. However the shaft is not a single
piece. [4] proposed a single-piece e-
glass/epoxy, high strength carbon/epoxy and
high modulus carbon/epoxy composite drive
shaft for an automotive application by
considering the advantages of higher specific
stiffness and strength of composite materials.
The optimized design parameters showed
significant potential improvement in the
performance of the composite drive shaft. [5]
attempted a new manufacturing method, in
which a carbon fibre 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. 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
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
2
capacity protrusion shape is provided on the
inner surface of steel yoke which will fit on
universal joints.
It is proposed that the mix of graphite
Nano platelets in the carbon fibre/epoxy
composites matrix improve its mechanical
properties. It was experimentally found that
such reinforcement enhanced in-plane shear
properties and compressive strength. The
authors used analytical model to predict the
longitudinal compressive strength and the
same was validated by the experimental
results. [6]. [7] investigated the suitability of
e-glass/ epoxy, high strength carbon/epoxy and
high modulus carbon epoxy composite drive
shaft for an automotive application with the
objective of minimizing the weight of drive
shaft. [8] and [1] also designed e–glass /
epoxy, high strength carbon/ epoxy and high
modulus carbon/epoxy composite drive shafts
as an alternative for steel shaft by using genetic
algorithm with the same objective of
minimization of weight. [9] included
deflection, stresses, natural frequencies under
subjected loads using FEA and estimation of
stress intensity factor for both steel and
composite materials to optimize the weight and
reported that the single piece composite shaft
saved weight up to 28% than a two piece steel
shaft. [10] designed a high modulus
carbon/epoxy multilayered composite drive
shaft and obtained a weight reduction of about
72% compared to conventional steel with the
influence of fiber orientation and dynamic
characteristics. [11] dealt the review of
optimization of drive shaft using genetic
algorithm and ANSYS. The finite element
analysis is used in this work to predict the
deformation of shaft. The deflection of steel,
HS carbon / epoxy and HM carbon / epoxy
shafts was 0.00016618, 0.00032761 and
0.0003261 mm respectively. [12] used
numerical investigation methods by
considering variation in fibre volume and
validated it through experimentation. The
authors reported that tensile strength of
composite increases with increase in fibre
volume. This research also made an attempt to
experimentally investigate the compatibility of
composite to replace SM45C steel made drive
shaft. [13] investigated and recommended
hybrid aluminum metal matrix composites as
an alternate material for SM45C steel in terms
of weight reduction. This research also aims to
perform the same with Kevlar29 epoxy fibre
composite materials and validate the same with
carbon epoxy and E glass epoxy fiber
composites.
2. NEED FOR THE RESEARCH
A drive shaft is the one which
transmits torque and rotation. The drive shaft is
usually subjected to torsional as well as shear
stress, which is used to find the difference
between the input torque and the load.
Therefore the alternate material for it must be
strong enough to bear the stress. At the same
time it should be light weight. In automobiles
used for city driving the reduction of weight is
almost directly proportional to vehicle’s fuel
consumption.
3. MATERIAL SELECTION
This research focused on replacement
of SM 45 steel propeller shaft by suitable
composite materials. Even though many
studies were reported in the specific topic, this
research is unique by finding the suitability for
specific type of branded vehicle’s propeller
shaft. The most widely tested carbon/epoxy
and glass/epoxy is primarily selected for
investigating its appropriateness for this
specific case. Then Kevlar29 epoxy is selected
based on its unique properties of high tensile
strength-to-weight ratio. By this measure it is 5
times stronger than steel. It can withstand high
impact; possess good resistance to organic
solvents, good fabric integrity at elevated
temperatures, starting of degradation at 500°C,
no melting point etc.
4. COMPOSITE PROPELLER SHAFT
A sample shaft of e-glass/epoxy
composite shaft is fabricated by hand lay-up
technique. The materials used and the
fabricated specimen shaft is shown in figure
B1. The wax, which acts as a releasing agent,
is applied to the mould. Then the glass fibre
layer is placed on the mould surface and is
impregnated with the resin - hardener mixture
in the ratio 10:1 by weight. The liquid resin is
applied to the mould and then fibre glass is
placed on the top. Another resin and
reinforcement layer of e-glass is kept as an
alternate layer. This alternate layer continued
up to the building up of suitable thickness.
Then the sheet was rolled and the shaft was
allowed to cure at room temperature for a
week. After curing, the model of the propeller
shaft is removed from the mould and it was
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
3
sized and finished by using a file. The
dimensions of specimen propeller shaft (inner
and outer diameter of Ø40mm and Ø46mm
respectively and length of 900mm) were
obtained from the conventional propeller shaft
of ambassador car.
5. MODELLING AND ANALYSIS OF
PROPELLER SHAFT
The basic view of propeller shaft is
shown in figure B2.The mechanical properties
of composites were furnished in table A1. The
actual shaft was modelled by using Pro-E
wildfire 5 software. Then it was imported in
ANSYS workbench 14.5 and the actual
boundary conditions for the drive shaft for
SM45C material were analyzed.
5.1. Total deformation analysis on propeller
shafts
The total deformation analysis on
propeller shafts of SM45 steel, carbon/epoxy,
E glass/epoxy and Kevlar29/epoxy composites
were carried out and results were furnished in
figure 1, figure 2, figure 3 and figure 4
respectively.
5.2. Equivalent elastic strain analysis on
propeller shafts
The equivalent elastic strain analysis
on propeller shafts of SM45 steel,
carbon/epoxy, E glass/epoxy and Kevlar29/
epoxy composites were carried out and results
are furnished in figure 5, figure 6, figure 7 and
figure 8 respectively.
5.3. Equivalent stress analysis on propeller
shafts
The equivalent elastic stress analysis
on propeller shafts of SM45 steel,
carbon/epoxy, E glass/epoxy and
Kevlar29/epoxy composites were carried out
and results are furnished in figure 9, figure 10,
figure 11 and figure 12 respectively.
5.4. Torsional stress on propeller shafts
The torsional stress on propeller shafts
of SM45 steel, carbon/epoxy, E glass/epoxy
and Kevlar29/epoxy composites were carried
out and results are furnished in figure B3,
figure B4, figure B5 and figure B6
respectively.
5.5. Buckling deformation on propeller
shafts
The buckling deformation on propeller
shafts of SM45 steel, carbon/epoxy, E
glass/epoxy and Kevlar29/epoxy composites
were carried out and results are furnished in
figure B7, figure B8, figure B9 and figure B10
respectively.
Figure 1.SM45C propeller shaft
Figure 2.Carbon-epoxy propeller shaft
Figure 3.E glass-epoxy propeller shaft
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
4
Figure 4.Kevlar-epoxy propeller shaft
Figure 5.SM45C propeller shaft
Figure 6.Carbon-epoxy propeller shaft
Figure 7.E glass-epoxy propeller shaft
Figure 8.Kevlar-epoxy propeller shaft
Figure 9.SM45C propeller shaft
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
5
Figure 10.Carbon-epoxy propeller shaft
Figure 11.E glass-epoxy propeller shaft
Figure 12.Kevlar-epoxy propeller shaft
Figure 13.Composite shafts performance in total
deformation
Figure 14.Composite shafts performance in
equivalent elastic strain
Figure 15.Composite shafts performance in
equivalent stress
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
Carbon/Epoxy E-Glass/Epoxy Kevlar 29/Epoxy
Per
cen
tage
of
Red
uct
ion
Composite Shafts
Maximum Total deformation Decreased by use of Composite shafts
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
Carbon Epoxy E-Glass Epoxy Kevlar 29 Epoxy
Per
cen
tage
of
Red
uct
ion
Composite Shafts
Maximum Equivalent Elastic Strain Decreased by use of Composite shafts
72.00%
73.00%
74.00%
75.00%
76.00%
77.00%
78.00%
79.00%
80.00%
81.00%
82.00%
Carbon Epoxy E-Glass Epoxy Kevlar 29 Epoxy
Per
cen
tage
of
Red
uct
ion
Composite Shafts
Maximum Equivalent stress Decreased by use of…
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
6
Figure 16.Composite shafts performance in
torsional stress
The results for five types of analysis
such as total deformation, equivalent elastic
strain, equivalent stress, torsional stress on
propeller shaft and buckling deformation
analysis were consolidated. The minimum and
maximum responses were consolidated and
furnished in table A2 and table A3
respectively. The weight details of drive shaft
are given in table A4. The details are given in
figures 13, 14, 15, 16, 17 and 18.
Figure 17.Composite shafts performance in weight
reduction
Figure 18.Composite shafts performance in
buckling deformation
6. CONCLUSION
This research made an attempt to
make a right choice of composite material for
ambassador car propeller shaft (made up of
SM 45 Steel). The suitability was examined in
terms of mechanical behaviours such as total
deformation, equivalent strain, torsional
behaviour and buckling deformation. The
developed model is verified in terms of
mechanical behaviours for conventional SM45
steel propeller shaft and is validated. Then the
E-glass/epoxy, carbon/epoxy and Kevlar29/
epoxy were considered for the analysis. The
following conclusions can be drawn from the
results of the investigation. It is obvious that
Kevlar epoxy composite drive shaft has
81.05% reduced weight than SM45C
conventional steel shaft. It has 0.22%
reduction in torsion stress and also has 57.1%
increase in buckling capability than SM45C
steel. Due to weight reduction fuel
consumption will be reduced. Apart from light
weight, the use of composites also ensures less
noise and vibration. Taking into account the
weight saving, buckling capability, shear stress
induced and torque transmission capability it is
evident that Kevlar/epoxy composite has the
most encouraging properties to act as an
alternate material for steel shaft.
REFERENCES
[1] Bhirud Pankaj Prakash and Bimlesh
Kumar Sinha, Analysis of Drive
Shaft International Journal of Mechanical
and Production Engineering, Vol. 2, No.
2, 2014, pp.24–29.
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
0.35%
Carbon Epoxy E-Glass Epoxy Kevlar 29 Epoxy
Per
cen
tage
of
Red
uct
ion
Composite Shafts
Maximum Torsion stress Decreased by use of Composite shafts
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
Carbon Epoxy E-Glass Epoxy Kevlar 29 Epoxy
Per
cen
tage
Imp
roved
By
Composite Shafts
Maximum Buckling deformation increased by use of Composite shafts
71.00%
72.00%
73.00%
74.00%
75.00%
76.00%
77.00%
78.00%
79.00%
80.00%
81.00%
82.00%
Carbon Epoxy E-Glass Epoxy Kevlar 29 Epoxy
Per
cen
tage
of
Red
uct
ion
Composite Shafts
Weight Reduction by Composite shafts
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
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[2] K.Devendra and T.Rangaswamy, Strength
Characterization of E-glass Fiber
Reinforced Epoxy Composites with Filler
Materials, Journal of Minerals and
Materials Characterization and
Engineering, Vol. 1 No. 6, 2013, pp. 353-
357.
[3] Harshal Bankar, Viraj Shinde and
P.Baskar, Material Optimization and
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Composite Material, IOSR Journal of
Mechanical and Civil Engineering, Vol.
10, No. 1, 2013, pp. 39-46.
[4] F. Anand Raju and D. Dinesh, Optimum
Design and Analysis of a Composite
Drive Shaft for an Automobile by using
Ansys, International Journal of
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Vol. 2, No. 4, 2012, pp. 1874-1880.
[5] Bhushan K. Suryawanshi and Prajitsen G.
Damle, Review of Design of Hybrid
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Automobile International Journal of
Innovative Technology and Exploring
Engineering, Vol. 2, No. 4, 2013, pp-259-
266.
[6] J.Cho, J.Y.Chen and I.M.Daniel,
Mechanical Enhancement of Carbon
Fiber/Epoxy Composites by Graphite
Nanoplatelets Reinforcement, Scripta
Materialia, Vol. 56, No. 8, 2007, pp.685–
688.
[7] Gummandi Sanjay and Akul Jagadeesh
Kumar, Optimum Design and Analysis of
a Composite Drive Shaft for an
Automobile, Master’s Degree Thesis,
Blenkinge Institute of Technology,
Swedan, 2007, pp. 1-72.
[8] D.Dinesh and F.Anand Raju, Optimum
Design and Analysis of a Composite
Drive Shaft for an Automobile by Using
Genetic Algorithm and ANSYS,
International Journal of Engineering
Research and Applications, Vol. 2, No. 4,
2012, pp.1874-1880.
[9] R.P.Kumar Rompicharla and K.Rambabu,
Design and Optimization of Drive Shaft
with Composite Material, International
Journal of Modern Engineering Research,
Vol. 2, No. 5, 2012, pp. 3422-3428.
[10] M.R.Khosharavan and A.Paykani, Design
of a Composite Drive Shaft and it’s
Coupling for Automotive Application,
Journal of Applied Research and
Technology, Vol. 10, 2012, pp. 826-834.
[11] Sagar R. Dharmadhikari, Sachin G.
Mahakalkar, Jayant P. Giri and Nilesh D.
Khutafale, Design and Analysis of
Composite Drive Shaft using ANSYS and
Genetic Algorithm, International Journal
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(IJMER), Vol. 3, No. 1, 2013, pp. 490-
496.
[12] S.B.Khandagale, A.P.Shrotri,
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3941-3948.
[13] S.Johny James, M.Ganesan and
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http://dx.doi.org/10.18831/james.in/20150
31005 .
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
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APPENDIX A
Table A1.Mechanical properties of composite shafts
Description of property E-glass epoxy Kevlar29 epoxy Carbon epoxy
Young’s modulus 1.20e+5 MPa 1.35e+5 MPa 2.1e+5 MPa
Poisson’s ratio 0.29 0.36 0.36
Density 1900 kg/m3 1440 kg/m
3 1600 kg/m
3
Bulk modulus 95.24 GPa 150 GPa 1.4706e+5 MPa
Shear modulus 46.51 GPa 50 GPa 4.7619e+5 MPa
Table A2.Minimum responses
Minimum responses SM45C Steel Carbon epoxy E-glass epoxy Kevlar29 epoxy
Total deformation (mm) 0 0 0 0
Equivalent Elastic Strain 1.875e-5 3.89e-6 8.004e-6 5.81e-6
Equivalent stress (MPa) 3.649 0.768 0.901 0.744
Torsion stress (N/m2) 0.055993 0.056081 0.056073 0.056126
Buckling deformation (mm) 0 0 0 0
Table A3.Maximum responses
Maximum responses SM45C steel Carbon epoxy E-glass epoxy Kevlar29 epoxy
Total deformation (mm) 0.723 0.150 0.312 0.209
Equivalent elastic strain 0.00462 9.594e-4 1.98e-3 1.366e-3
Equivalent stress (MPa) 955.83 201.23 238.48 183.19
Torsion stress (N/m2) 0.061028 0.060902 0.060843 0.060894
Buckling deformation (mm) 0.532739 0.978677 1.161 1.242
Table A4.Weight details of drive shafts
Drive shaft materials Weight (Kg)
SM45 steel 2.77170
Carbon epoxy 0.58352
E glass epoxy 0.69293
Kevlar29 0.52517
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
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APPENDIX B
Figure B1. E-glass, epoxy, hardener, wax and fabricated composite propeller shaft
Figure B2. Views of propeller shaft with dimensions
Figure B3. SM45C propeller shaft
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
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Figure B4. Carbon-epoxy propeller shaft
Figure B5. E glass-epoxy propeller shaft
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
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Figure B6. Kevlar-epoxy propeller shaft
Figure B7. SM45C propeller shaft
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
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Figure B8. Carbon-epoxy propeller shaft
Figure B9. E glass-epoxy propeller shaft
R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13
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Figure B10. Kevlar-epoxy propeller shaft
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