Design, Analysis and weight optimization of LMV shaft by using AL + GF composite

Abstract

Aluminum composites are mainly used due to their lower weight and high strength among the Metal Matrix Composites. Aluminum is selected as matrix and E-glass fiber is selected as reinforcement. Fabrication of composite is done by the winding of composite method. Each shaft fabrication content of E-glass fiber and aluminum with different ratios depends on ANSYS results. The present article attempts to evaluate the mechanical properties of E-glass fiber-reinforced composite and study the effect of reinforcement on the matrix alloy through mechanical properties. The results are analyzed for different types of winding angles with an aluminum layer. The mechanical properties of composites have improved with the increase in the weight percentage of glass fiber in the aluminum matrix.

Introduction

I. INTRODUCTION

Rapid  technological  advances  in  engineering  design  field  result  in  finding  the alternate solution for the conventional materials. The design engineers brought to a point to finding the materials which are more reliable than conventional materials.  Researchers and designers are constantly looking for the solutions to provide stronger and durable materials which will answer the needs of fellow engineers.

A  drive  shaft,  or  propeller  shaft  (prop  shaft),  or  Carbon  shaft  is  a  mechanical component for transmitting torque and rotation, usually used to connect other components of a drive train  that cannot be  connected  directly because  of distance or  the  need to allow for relative movement  between  them. 

Drive shafts are carriers of torque.  They are subject to torsion and shear stress, equivalent to the diff erence between the input torque and the load. They must therefore be strong enough to bear the stress, while avoiding too much additional weight as that would in turn increase their inertia.

An automotive drive shaft is a rotating shaft that transmits power from the engine to the differential gear of rear wheel drive (RWD) vehicles. The torque  that is produced from the  engine  and  transmission  must  be  transferred  to  the  rear  wheels  to  push  the  vehicle forward and reverse.

The drive shaft must provide a smooth, uninterrupted flow of power to the axles. [ 3]  The drive shaft and  differential  are used  to  transfer  this  torque.

Moreover, a composite driveshaft can be perfectly designed to effectively meet the strength and stiffness requirements. Since  composite  materials  generally have  a  lower  elasticity  modulus,  during torque  peaks  in  the driveline,  the  drive  shaft  can  act  as  a  shock  absorber.  Moreover,  the breakage of composite a drive  shaft (particularly in  SUV’s)  is less -risky, since it results in splitting  up of the fine fibers as  compared to  the  scattering of  broken steel parts in  various directions.

Composite materials have been widely used to  improve the  performance of  various types of structures. Compared to conventional materials, the main advantages of composites are their superior stiffness to mass ratio as well as high strength to weight ratio. Because of these advantages,  composites have  been  increasingly  incorporated  in structural components in  various  industrial  fields.  Some  examples  are  helicopter  rotor  blades,  aircraft  wings  in aerospace  engineering,  and  bridge  structures  in  civil  engineering  applications. Some of  the And Weight Optimization Of Composite Drive Shaft Using ANSYS Design, Analysis  basic  concepts  of  composite  materials  are  discussed  in  the  following  section  to  better acquaint ourselves with the behavior of composites.

II. METHODOLOGY

After  referring  to  multiple  references  it  was  understood  that  how  composite  drive shaft having optimum weight can be selected using the exact methodology.

For this process we use CATIA V5 R20 and ANSYS workbench 14.5 software

1. CAD model of conventional drive shaft is prepared in CATIA V5 R20 as per actual dimension.  Then this model is imported to ANSYS workbench 14.5 software.  For pre-processing  and  to  derive  a  final  solution  results  are  derived  from ANSYS software.
2. CAD  model  of  composite  drive  shaft  is  prepared  in  CATIA  V5  R20  as  per  actual dimension.  Then this model is imported in ANSYS workbench 14.5.  For pre- processing and to derive a final solution results are derived from ANSYS software.
3. Compare conventional drive shaft and composite drive shaft results.
4. For  validation,  we  require  the  results  derived  from  theoretical  and  experimental calculations.
5. To  perform  the  experiment,  we  manufacture  the  sample  composite  material  and conventional  drive  shaft.  Testing  of  these  two  shafts  is  been  done  in  torsion  test machine and the results are been derived.
6. Later CAD model for these two shafts having same dimensions was been generated and was imported in ANSYS.  Results were derived after this process and were compared with the experimental results.
7. Theoretical calculations for sample conventional and composite drive shaft were calculated.
8. Lastly  ANSYS,  theoretical  and  experimental  results  were  compared  and  preferable shaft was selected in automobile.

Conclusion

Reducing weight and increasing strength of products have high demands in the automobile world. Composite materials can satisfy these demands considerably. The present work involves the static analysis of conventional steel shaft and composite shaft. Model is prepared in CATIA V5R20 and then analysis is performed through ANSYS R14.5. A comparative study has been made between steel and composite shaft to find out material having high strength to weight ratio. From the results obtained it is concluded that, 1) Stress occurred in the composite drive shaft is less as compared to conventional drive shaft. 2) Results obtained through ANSYS are validated from experimental testing. 3) Comparison of the results also shows that the results derived using all the calculation methods are similar to each other. Hence, FEA results can be considered as valid method for design purpose. 4) Composite Glass fiber shaft has less weight than conventional steel drive shaft for analyzed stress. So composites can be suggested for driving shaft of light passenger vehicle.

References

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Copyright

Copyright © 2022 Mr. Deepak Rohidas Bhise, Prof. D. H. Nimbalkar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.