Static and dynamic characteristics of a hybrid aluminium/composite drive shaft

Abstract

A static torque and power transmission capacities of a hybrid aluminium/composite drive shaft, fabricated by a wetted filament winding method, were investigated. Special mechanisms for static torsion and power transmission test setups were designed and fabricated. The following different fibre types were used: carbon, glass, one epoxy, and hardener. The static and dynamic characteristic of the hybrid aluminium/composite drive shaft with respect to the fibre types stacking sequences winding angle and number of layers were investigated. From the experiments, it was found that the static and dynamic torque capacity for a winding angle of 458 is higher than 908 for both glass and carbon fibres. From the power transmission test, it was also found that the percentage between the static torque and dynamic torque is approximately 7 -15 per cent. In addition, in the static torsion test, the aluminium tube yielded first at the central region of the shaft, followed by crack propagation in the composite shaft along the fibre direction, which eventually caused the delamination of the composite layers from the aluminium tube. On the other hand, in the power transmission test, different locations of failure were observed along the gauge length of the specimen. The shaft's being laminated with a stacking sequence of [90/ þ 45/245/90] and [þ45/245/90/90] resulted in the same behaviour in the torque -angle and the twist relation. The power transmission capacities were close to each other and this in turn satisfied the lamination theory. The finite-element method was used to analyse the hybrid shaft under static torsion and ANSYS finite-element software was used to perform the numerical analysis for the hybrid shaft. A full scale hybrid specimen analysis was done. Elasto-plastic properties were used for the aluminium tube and linear elastic for composite materials. Good agreement was obtained between the finite-element predictions and experimental results.

Research on torsional capacity of composite drive shaft under clockwise and counter-clockwise torque

“…Mutasher et al 6 compared the results of composite shaft torsion test with the results of the finite element analysis and found that the maximum torque coming from experiment was 4%-20% lower than the results from finite element analysis, which showed the reliability of finite element analysis result as well.…”

“…They are calculated from these formulas Table 3 shows the mechanical properties of Tsai-Wu criteria of T300/5208. 6 The stress state of the lamina calculated by the program is described by the components s 1 , s 2 , and t 12 . s 1 is the laminate stress along the fiber direction, s 2 is the laminate stress transverse to the fiber direction, and t 12 is the laminate shear stress.…”

“…And many papers have indicated that the 45°layer has a great influence on shaft torsional performance because the main loading of drive shaft is torque. 6,7 Therefore, in order to increase the shaft torsional performance, the 45°layers were mostly designed to wind around the outermost layer of the shaft. For example, Kim et al 8 selected a stacking sequence of [0°c arbon /( 6 45°) N,glass ] in the design of a composite propeller shaft, and it was shown that glass prepregs of at least 32 plies (N = 16) were required for the static torque transmission capability of 3500 N m. With the increase in the number of 45°layers, the shaft's torsional performance increased, and when N = 31, the static torque transmission capability increased to 7380 N m. Shokrieh et al 9 and Mallick 10 designed carbon fiber drive shaft according to shear buckling strength.…”

Manufacturing of polygon fiber reinforced plastic profiles by rotational molding and intrinsic hybridization

“…For example, Esmaael and Taheri [3] investigated adhesively bonded joints, interference fit joints were examined by Lee and Lee [4] regarding finite-element simulation or by Croccolo et al [5] regarding additional adhesive bonding. Khalid et al [6] and Mutasher et al [7] reinforced metal pipes by wet filament winding. Figure 1 shows an example of a hybrid drive shaft.…”

Design to Replace Steel Drive Shaft in Automobiles with Hybrid Aluminium Metal Matrix Composite

“…Design of composite drive shafts for automotive applications [8,9] explained the comprehensive approach to the design of composite drive shafts and developed the preliminary design tools for quick analysis to meet the drive shaft performance requirements [10,11].…”