DESIGN & FATIGUE ANALYSIS OF COMPOSITE DRIVE SHAFT OF AUTOMOBILES

Guided By:

Prof Steve Pagare

Presented By :

Ram Hedley

Department of Mechanical Engineering

B.R.HARNE COLLEGE OF ENGINEERING AND TECHNOLOGY,

KARAV, VANGANI
2016- 2017
Introduction
An automotive drive shaft or propeller shaft , transmits the torque from the
transmission to differential of rear wheel-drive or all wheel drive vehicle.
Critical whirling speed is inversely proportional to square of length ,hence two piece
of steel material drive shaft is used traditionally.
Composite material have low density.
Material for Drive Shaft

Conventional Material:

Steel

Aluminium

Carbon Fibre

Composite Material :

Graphite , Carbon ,Kevlar and Glass with suitable resin .

Objective
The general objective is to fatigue analysis of composite drive shaft in automobile
using the finite element method.

The main objective is to analysis the stresses & deflection of drive shaft subjected to
combined bending & torsion.

Then checking for fatigue life as well as comparing the result with analytical
calculation to verify the accuracy of the result.
Literature review
Sr No Year Name of author Name of paper Conclusion

1 April 2015 Vikrant Jagadale and Prof. A Review on Fatigue Analysis The composite material will
S. Y. Taware of Composite Steering Column give upto 2 to 3 times
maximum torsional strength,
the better stiffness values. it is
possible to increase the
strength and lighten the weight
of steering column
2 Dec 2012 M.R. Khoshravan, A. Design of a Composite Drive The replacement of
Paykani* Shaft and its Coupling for composite materials has
Automotive Application resulted in considerable
amount of weight reduction
about 72% when compared
to conventional steel shaft.

3 Aug 2013 Charnont Moolwana,* ,
Samroeng Netpub
Failure Analysis of a Two High
Gearbox Shaft
The failed shaft of the two
high gearbox under this
investigation failed by
fatigue fracture. The
presence of inclusions in
the structure is the root
cause of the failure.

4 Aug 2005 Y.A. Khalid, S.A. Mutasher,
B.B. Sahari, A.M.S.
Hamouda *
Bending fatigue behavior of
hybrid aluminum/composite drive
shafts
Rotating bending fatigue
was carried out for a hybrid
aluminum/composite drive
shaft; four laminates with
different stacking
sequences and number of
layers were studied.
5 Oct 2013 Shahab Zangeneh Fracture failure analysis of AISI Experimental and
,Mostafa Ketabchi,Ali 304L stainless steel shaft numerical simulation of the
Kalaki agitator AISI 304L
stainless steel shaft was
studied. Results showed
that mechanical properties
(uniaxial tension, impact
and hardness tests) and
chemical composition of
the failed shaft were in
acceptable range

6 Oct 2016 Dhiraj D. Patil1* , Rajaram
M. Shinde2 and Suresh M.
Sawant3
Design of Carbon/Epoxy
Composite Drive Shaft for Low
Passenger Vehicles
The weight of the steel
shaft is 3.6 kg and the
weight of the composite
shaft is 0.7 kg i.e. the
amount of energy required
to propel the vehicle is
reduces and thereby the
fuel consumption is
reduced.
7 Oct 2012 R. P. Kumar Rompicharla1 , Design and Optimization of Drive . The usage of composite
Dr. K. Rambabu Shaft with Composite Materials material has resulted to
inconsiderable amount of
weight saving in the range of
28 % when compared to
conventional steel shaft .The
drive shaft of Toyota Qualis
was chosen

8 Oct 2013 Mr.P.G.Tathe,Prof.D.S.Bajaj Review on Failure Analysis of yoke
assembly of a transmission drive
shaft subjected to Torsion and Shear
A finite element stress
analysis need to be carried out
at the failure region to
determine the stress
distribution and possible
design improvement. An FEA
based software like Nastran or
ANSYS, model of Yoke
assembly

9 Jan 2013 Parshuram D 1 , Sunil Design and Analysis of composite materials has
Mangsetty Composite/Hybrid Drive Shaft for resulted in considerable
Automotives amount of weight saving in
the range of 81% to 72%
when compared to
conventional steel drive shaft.
10 Dec 2013 Harshal Bankar1 , Viraj Material Optimization and Weight The use of composite
Shinde2 , P. Baskar3 Reduction of Drive Shaft Using material reduces the weight
Composite Material of shaft significantly as the
composite having lower
densityl. The reduction in
weight gives further
advantage in the increase in
the fuel economy of vehicle.

11 2016 S. Mohan and M. Vinoth Design and Analysis of Composite The usage of composite
Drive Shaft for Automotive materials has resulted in
Application considerable amount of
weight saving in the range of
70% to 63% when compared
to conventional steel drive
shaft. In finally suggestion,
the cost of composite material
compare boron to HS
Carbon/Epoxy is low and best
one.
Methodology
The results are compared with steel shaft to validate our project. Study of cause of failures in drive
shaft

Selection of composite material

Preparation of CAD model

Analysis the CAD model with existing material with Ansys

Analysis of drive shaft by using different composite materials

THANK YOU