Static and Model Analysis of an Automotive Composite Propeller Shaft for Performance Optimization

Static and Model Analysis of an AutomotiveComposite Propeller Shaft for PerformanceOptimization

Department of Mechanical EngineeringTRUBA INSTITUTE OF ENGINEERING & INFORMATION TECHNOLOGY, BHOPAL M.P.JUNE-2016

Submitted By:MANOJ KUMAR SHARMA[Enrollment No.0114ME11ME10]

Guide:Dr. NILESH DIWAKAR

Co- guide:Prof. Sharvan Vishwakarma

CONTENTSAbstractChapter 1 Chapter 2Chapter 3Chapter 4Chapter 5Chapter 6Chapter 7

-IntroductionLiterature ReviewObjectiveMethodologyResults And DiscussionConclusionFuture Scope

Abstract

Usually all automotives are corresponding to design with rear wheel drive and front engine installation, having transmission shafts. The reduction of weight of the drive shaft can have a certain role in the general weight reduction of the vehicle is an appreciable desired goal.

The composite structure as compared to conventional metallic structures has many advantages due to higher specific stiffness and strength of composite materials.

The advanced composite materials such as Carbon, Graphite, Kevlar and Glass with suitable resins are widely used because of their high specific strength and high specific modulus.

The Composite materials in advanced form seem ideally suited for long power drive shaft applications.

The main aim of this project is to conduct FEM analysis and to optimize the design with composite materials. effects.

Usually all automotives are corresponding to design with rear wheel drive and frontengine installation, having transmission shafts. The reduction of weight of the drive shaft canhave a certain role in the general weight reduction of the vehicle is an appreciable desiredgoal. The composite structure as compared to conventional metallic structures has manyadvantages due to higher specific stiffness and strength of composite materials. The advancedcomposite materials such as Carbon, Graphite, Kevlar and Glass with suitable resins arewidely used because of their high specific strength and high specific modulus. TheComposite materials in advanced form seem ideally suited for long power drive shaftapplications. The main aim of this project is to conduct FEM analysis and to optimize thedesign with composite materials. The purpose of analyze is to determine the displacement,stress, strain and forces in structure caused by load which do not promote significant inertiaand damping effects. Now-a-days research on material with vast material combination givesoption for replacing the conventional material with that of composite which helps in reducingthe material cost, high strength and higher specific stiffness.4

CHAPTER-1INTRODUCTION:

A propeller shaft also called as prop shaft, driving shaft, is associated with a mechanical component which is used for rotational purpose transmitting torque and rotation.

Since it is used to connect more components of a propeller train which did not connected directly due to distance. At the same time it allow for relative movement between them.

Propeller shafts are carriers of torque so propeller shafts are subject to torsion and shear stress, which is equivalent to the difference between the input torque and the load.

propeller shafts must be strong enough to tolerate the stress, by avoiding more weight.

The common material for construction is high quality steel of grade SM(45C) due to high specific strength (strength/density) and high specific modulus.

The advanced composite materials like Graphite, Carbon, Kevlar and Glass with suitable resins are widely used for long, power propeller shaft.

Introduction to a Propeller Shaft

The term Propeller shaft is used to refer to a shaft, which is used to transfer of motion from one point to another point.

The shaft, which propel is referred to as the propeller shaft. Ships and planes are usually associated with propellers as they are propelled in water or air using a propeller shaft.

They are apart from transmission of the rotary motion from the front end to the rear end of the vehicle forward.

A propeller shaft is an assembly of one or more tubular shaft connected by universal flexible joints at constant velocity.

Purpose of the Propeller Shaft

1. To transmit torque to the differential gear box from the transmission.

2. The propeller shaft must be capable of rotating at the very high speed required by the vehicle.

3. The propeller shaft operates at constantly changing speed by the angles between the transmission, the differential and the axle's.

4. While transmitting torque the length of the propeller shaft must also be capable of changing.

5. Smooth, uninterrupted flow of power to the axles should be provided by the propeller shaft.

Functions of the Propeller Shaft

The main function of propeller shall is that it must transmit torque to the differential gear box from the transmission.

Static and Model Analysis of an Automotive Composite Propeller Shaft for Performance Optimization.

It is necessary for the propeller shaft to transmit maximum low-gear torque developed by the engine during operation.

To operate at constant speed by changing angles between the transmission, the differential and the axles is one important function of propeller shaft.

The differential and the axle move up and down when the rear wheels roll over bumps in the road.

The angle between the differential and the transmission usually changed by its movement.

Parts of Propeller Shaft Assembly

Part of Propeller Shaft and Universal Joint

Types of Propeller ShaftSingle Piece Propeller Shaft

Two Piece Propeller Shaft

Three Piece Propeller Shaft

Demerits of a Conventional Propeller ShaftHave less specific modulus and strengthMore weightCompared to composite materials its corrosion resistance is less.Propeller shaft made of steel have less damping capacity.

Merits of Composite Drive ShaftHave high specific modulus and strength,Less weight,Fuel consumption will be reduced due to weight reduction,They produce less vibration and noise because of high damping capacity.Good corrosion resistance,Torque capacity greater than steel and aluminum shaft,Fatigue life is longer than steel and aluminum shaft.

Composite Materials A structural material called Composite which consists of two or more constituents that are combined at macroscopic level.

These constituents are not soluble in each other. One constituent is called reinforcing phase and the other where it is embedded is called the matrix.

The reinforcing phase may be in the form of fibres, particles or flasks. Due to the high specific modulus (modulus/density) and high specific strength.

The advanced composite materials such as carbon, graphite, Kevlar and glass with appropriate resins are widely used. For long, power propeller shaft applications advanced composite materials seems ideally suited. The elastic properties of advanced composites can be modified for increasing the torque and carry over all the rotational speed.

Classification of Composite MaterialsReinforcement composites.Fibre reinforcement composites.Flake compositesLaminated composites.

Composite Materials Based on MatrixPolymer matrix composites.Metal matrix composites.Ceramic matrix composites.Carbon matrix composites

Advantages of Composites over the Conventional MaterialsStrength to weight ratio is high,Stiffness to weight ratio is high,Impact resistance is high,Better fatigue resistance,Good corrosion resistance,Good thermal conductivity,Coefficient of thermal expansion is lowHigh damping capacity

Limitations of CompositesComplex mechanical characterization compared to metallic structure,

High cost of fabrication of composites,

Repair and rework of composites are not simple,

Composites do not have high combination of strength

The design of fibre reinforced structure is very typical as compared to a metal structure, mainly due to dissimilar in properties,

Cracks and flaws (critical) cannot be detected.

Composites do not necessarily give higher performance,

Applications of CompositesAutomotiveSpaceChemical IndustriesAircraftMarineElectrical

Stresses Acting on Propeller ShaftTorsional stressVibratory loadBending stressFatigue stress

CHAPTER 2LITERATURE REVIEW[1] Mujahid Khan, M. A. Mateen, a V. Ravi Shankar investigated the Design and Development of composite/ Hybrid Propeller Shaft.

In this paper the main aim is to design and develop a propeller shaft which is made from fibre reinforced plastic material (FRP). The whole effort is divided in to four steps, first step is determination of the material in which suitable material properties of a specific fabrication technique is determined, second step is determining the better orientation among [0,90]s ,[45]s and [60]s of the fibre by simulation results obtained from ANSYS. Third step is fabrication of couple of propeller shafts. First one is made of only Glass/Epoxy and the other one Hybrid shaft (Glass/Epoxy and Aluminum) and the last step is performing the static test on the fabricated shafts. Estimation of material properties for the glass/epoxy composite are done based on classical laminate theory.

[2] V. S. Bhajantri, S. C. Bajantri, A. M. Shindolkar, S. S. Amarapure, investigated Material Optimization and Weight Reduction of Propeller Shaft Using Composite Material.

Due to high specific modulus (modulus/density) and high specific strength(strength/density) the advanced composite materials like Kevlar, Graphite, Carbon and Glass with appropriate resins are widely used. For long, power propeller shaft (propeller shaft) applications advanced composite materials seems ideally suited. The elastic properties of advanced composites can be modified for increasing the torque they can carry as well as the rotational speed at which they operate. The propeller shafts are usually used in automotive and aircraft industries. The automotive and aircraft industries are exploiting composite material technology for the construction of structural components for obtaining the reduction of the weight without decrease in reliability and quality of vehicle.

[3] Arun Ravi investigated Designs, Comparison and Analysis of a Composite Propeller Shaft for an automobile.The design of composite propeller shaft with less weight to increase the first natural frequency of the propeller shaft and to reduce the bending stresses is possible using various stacking sequences. By using various stacking sequences the torque transmission and torsion buckling capacities can also be maximized. The main aim of this work is to replace a conventional steel propeller shaft with a propeller shaft manufactured from High Strength Carbon for an automobile application. Due to high specific strength (strength/density) and high specific modulus (modulus/density) the advanced composite materials like Graphite,Carbon, Kevlar and Glass with suitable resins are widely used. The most important objectives in vehicle design are the conservation of energy and the most effective measures to obtain this result are reduction of weight.

[4] Madhu K.S., Darslian B.H., Manjunath K. investigated Buckling analysis of composite propeller shaft for automotive applications.

To increase the fundamental bending natural frequency of an automotive propeller shaft it is usually manufactured in two pieces because frequency is inversely proportional of square of length of beam and directly proportional to the square root of specific modulus. An attempt has been made in this paper to check the suitability of single piece composite propeller shaft along with many composite material combinations to fulfill the functional requirements. First step involves development of a finite element model of composite propeller shaft made of Steel SMC45, Kevlar49/Epoxy and HM Carbon Composite to analyze for static, modal & buckling analysis., it is observed from the results obtained by steel and Kevlar/Epoxy composites with more shear strength and bending natural frequency competed to better buckling strength capability when compared with other composites. The results obtained from FEA are verified with analytical values and found that the single piece composite propeller shaft is better compared to others and suitable for propeller line applications.

[5] S V Gopal Krishna, B V Subrahmanyam, and R Srinivasulu investigated Finite Element Analysis and optimization of Automotive Composite Drive Shaft.

From preliminary experiments and studies of physical properties like weight, material combination, torque transmitting capacities, etc. it is concluded that: The analysis results are tabulated as shown above. By the obtained results it can be conclude that the stresses induced in all the materials are within their allowable limits. And it can also be observed that the materials which develop less von-mises stress exhibit a little more deformation. E-glass polyester has 2.5% reduction in Von-Mises stress and 74% reduction in weight than Structural Steel. But it has 20.6% increases in deformation than Structural Steel. By the obtained results it can be conclude that the stresses induced in all the materials are within their allowable limits. And it can also be observed that the materials which develop less von-mises stress exhibit a little more Though E-Glass Polyester Resin induces 18.75% less stresses compared to structural steel, considering the changes in both deformation and stress and density (which is least - 1600 kg/m3 among all the above materials), it can be concluded that E-Carbon can be used instead of conventional material like structural steel. So that the weight and stresses induced in the drive shaft can be considerably decreased.

[6] Pankaj K. Hatwar, Dr. R.S. Dalu investigated- Design and Analysis of Composite Drive Shaft.

A two-piece steel drive shaft was considered to be replaced by a one-piececomposite drive shaft. The usage of composite materials has resulted in considerable amount of weight saving in the range of 81% to72% when compared to conventional steel drive shaft. Apart from being lightweight, the use of composites also ensures less noise and vibration. Shaft with increase in critical speed enabling manufacturing of shaft of length 1.7 m to 2m; as compared to steel shaft; by experimentation. The results reveal that the orientation of fibers has great influence on the dynamic characteristics of the composite material shafts in a positive direction. Genetic Algorithm is suggested as an effective optimization tool. The torque transmission capacity of the composite drive shafts has been calculated by neglecting and considering the effect of centrifugal forces and it has been observed that centrifugal forces will be reducing the torque transmission capacity of the shaft. Natural frequency using Bernoulli Euler and Timoshenko beam theories was compared. The frequency calculated by using the Bernoulli Euler beam theory is high, because it neglects the effect of rotary inertia& transverse shear.

Summary of Literature Review Now a days massive research works are being carried out to improve the design and development of a propeller shaft, which is made from fibre reinforced plastic material (FRP).Estimation of material properties for the glass/epoxy composite are done based on classical laminate theory. The geometric model is fabricated by using ANSYS platform. The model is then fabricated. The composite material has lower modulus of elasticity. At present the automobile industries are making the better use of composite materials to obtain reduction of weight without significant decrease in reliability and quality of vehicle. Fuel consumption is affected directly due the reduction of weight of a vehicle. While driving in city, the reduction of weight is directly proportional to vehicle fuel consumption. Due to high specific modulus(modulus/density) and high specific strength (strength/density) the advanced composite materials like Kevlar, Graphite, Carbon and Glass with appropriate resins are widely used. The optimization of design parameters were done with the objective of minimizing the weight of composite propeller shaft. The main advantages of composites compared to conventional materials are their superior stiffness to mass ratio as well as high strength to weight ratio. The design of composite propeller shaft with less weight to increase the first natural frequency of the propeller shaft and to reduce the bending stresses is possible using various stacking sequences. The composite materials are also considered to analyze the case to increase its robustness along with alloys of various materials.

CHAPTER-3OBJECTIVES To study the existing design of automotive propeller shaft. To design a propeller shaft with a composite structural member. The experimental test of E- Glass/Epoxy for axial loading, bending and torsion has to be conducted in the respective machines. To conduct structural analysis to understand its behavior. Finally compare the obtained experimental results with Analytical results and valid journals.

CHAPTER-4METHODOLOGY Experimental Analysis: The fiber reinforced polymers laminated hollow shaft was a cylinder of inner diameter28.25 mm, 3.75mm thickness and 145 mm length on which glass fiber reinforced with epoxy resin was wound at different orientation and thickness. Using filament winding machine a total 12 (three specimens of each orientation). The shaft were prepared with fibers wound at 0/90,60/30,45 and 55 orientation and thickness maintained at1,2 ,2.5 and 3.75 mm respectively. The shafts were subjected to torsion loading by using torsion testing machine. The torsion machine can apply torque up to 58.84 Nm. The torque applied on shaft was increased in steps of 2.5 Nm with static loading rate of 1 Nm per second till failure occurred due to shear torsional buckling.

The following Epoxy Shafts were fabricated for Material Testing in PRP Enterprises, Bhopal:

Tensile and Bending Test Conducted at C I P E T , Bhopal on NC Machine of 10 Tones Capacity:

Fibre Glass Epoxy Torsion Test was done on Universal Torsion Testing Machine (TTM) at ICSC, MANIT, Bhopal.

Fibre Glass Epoxy Torsion Test was done on Universal Torsion Testing Machine (TTM) at ICSC, MANIT, Bhopal.

Material Properties of SM(45C) SteelYoung's Modulus (E) 190-210 GpaTensile Strength569 (Standard), 686 (Quenched), MPaRigidity Modulus (G)75 GpaYield Strength (Sy) 343 (Standard), 490 (Quenched), MpaBrinell Hardness160-220 (Annealed) HBMelting Point1520 CPoisson's 0.27-0.30Density7700-8030 Kg/m3DIN EquivalentsC45, CK45, CF45, CQ45ASTM EquivalentsASTM A29 , ASTM A510

Material Properties of E-glass Epoxy(Data Source: ANSYS Material Library)

Density2000 Kg/m2Young Modulus (X- direction) 4 5000 MPaYoung Modulus (Y- direction) 10000 MPaYoung Modulus (Z- direction)10000 MPa

Material Properties of E-glass Epoxy

CHAPTER -5RESULTS AND DISCUSSIONSSample Length(mm)Thickness(mm)Width (mm) MaximumLoad (N)Tensile stress atMaximum Load (MPa)

1353.7521.265604.9370.21353.7521.258750.95109.8

The Tensile strength test results are being given below:

CHAPTER- 6CONCLUSION The weight savings of the sample of high strength carbon/epoxy is equal to 25.39% approximate SM45C steel shaft.

The stresses and displacement induced in the composite shaft that is approx. equivalent to the conventional material used (SM45C).

From the FE results it is clear that the conventional material can be replaced with composite material for the propeller shaft.

CHAPTER- 7FUTURE SCOPE The effect of stress and displacement can be studied.

Dynamic analysis can be carried out to determine the vibration levels on the propeller shaft.

Fabrication of prototype of composite propeller shaft.

Analysis can be done on reinforced composite material prototype as alternative material in order to reduce in the weight.

Thank you SirHave a Nice Day