University of New Haven

ME 451

Composite Materials and Material Selection

Design Analysis and Performance of Mechanical Drive Shafts Using

Composite Materials

Author: Franco Pezza

Objective• Design optimization of composite material

mechanical Driveshaft

Approach #1: Experimental

Approach #2: Analytical

• Compare results with the traditional steel drive shaft

Main Goal

Weight Reduction

Mechanical Drive Shaft

A Drive Shaft is a

mechanical device

used to transfer

torque

Reference: http://en.wikipedia.org/wiki/File:Cardan_Shaft.jpg

Background

Reference: http://www.fallbrooktech.com/dutch/images/DaVinci_CVP_illustration.jpg

Materials usedin the past:

WoodIron

Leonardo Da Vinci (1492-1519)

Drawbacks

• Low torque

• Low efficiency

• Low R.P.M.

• High maintenance

• Short life

• Unreliable

Reference:http://www.fallbrooktech.com/dutch/images/DaVinci_CVP_illustration.jpg

Actual Materials

• Steel alloys

http://www.flickr.com/photos/cbmd/2359279156/sizes/m/

Detail of a driveshaft in a large vessel

Drawback

Reference: http://chestofbooks.com/crafts/scientific-american/Scientific-American-Reference-Book/images/American-Freight-Locomotives-And-The-Engines-Of-Th-95.jpg

•Weight

Why Composite ?

• Strong• Light• Tailorable• Low Inertia

Reference: http://www.amarillogear.com/AGCWEB.data/Components/composite4.jpg

Manufacturing Process:

Filament Winding

Reference: http://www.azom.com/details.asp?articleid=401

•Fibers are resin wetted•Winded on a mandrel•Tension is controlled•Orientation is controlled•Cured in oven

Theory:

Classic Laminate Theory

It derives from the general form of Hook’s law:

Ex & Ey Lamina Modulus

Reference: Gummadi Sanjay, Akula Jagadeesh Kumar, 2007 “Optimum Design and

Analysis of a Composite Drive shaft for an Automobile”

Gxy Lamina Shear Modulus

Reference: Gummadi Sanjay, Akula Jagadeesh Kumar, 2007 “Optimum Design and Analysis of a Composite Drive shaft for an Automobile”

General Laminate Equation

where N is the force, M is the moment, A is the extensional stiffness, B is the coupling stiffness, D is the bending stiffness and Q’ is the reduced elastic constant

Driveshaft DesignConstrains:• Max Outside Diameter• Max Transmissible Torque• Critical Speed (Flexural resonance)• Buckling Torque (Torsional resonance)

Variables (steel):– Shear modulus of the material– Thickness of tubing

Variables (composite):– Matrix material– Fibers material– Number of layers– Stacking sequence (orientation)– Thickness of layers (tows size)

Experimental Approach #1

Driveshaft constrains:– Shaft length L = 1730 mm– Mean diameter d = 101.6 mm– Max torque Tq = 2030 Nm– Critical speed 90 Hz (5400 RPM)

This research was published on the “International Journal of Engineering and Technology” Vol. 3, No.2, 2006, pp. 227-237

Max Torque vs. OrientationDirectly from Lamina theory shear stress equation Gxy

Natural Frequency vs. Orientation

Critical Speed vs. Orientation(Number in parenthesis is the layer thickness in mm)

Buckling Torque vs. Orientation

Buckling Torque vs. Staking

Experimental Results• Max torque: ± 45o

• Critical speed: 0o

• Buckling torque: 90o

• Best stacking sequence : [45/-45/0/90]

Analytical Approach #2

Driveshaft constrains:

– Shaft length L = 1250 mm

– Mean diameter d = 90 mm

– Max torque Tq = 3500 Nm

– Critical speed 108 Hz (6500 RPM)

This paper was presented at the “International Symposium of Research Students on Materials Science and Engineering”

Reference: T.Rangaswamy, S. Vijayarangan, R.A. Chandrashekar, T.K. Venkatesh and K.Anantharaman, “Optimal Design and Analysis of Automotive Composite Drive Shaft” Dept. of Mech. Engineering, PSG College of Technology, Coimbatore 641004, India.

•Genetic Algorithms are based on probability algorithms

•Uses the concept of “Natural Selection”

•Simulate the concept of “Survival of the Most Fit”

GA Flow Chart

Fitness Evaluation

Roulette Wheel Distribution

Reference: Grant A. E. Soremekun, 1997,”Genetic Algorithms for Composite Laminate Design and Optimization”, paper, Blacksburg, Virginia, USA

Weight Convergence

Layers Convergence

GA Analytical Result

Conclusion

• Composite materials are suitable for the design of drive shafts.

• Both approaches have proved that a consistent weight reduction is achieved.

• Composite materials are used also for gears, couplings, timing belts and many other mechanical transmission devices.

Questions?

Reference: http://www.b2bcarbonfiber.com/rimages/601/tube-1.jpg