Design, Analysis and Optimization of Composite Propeller Shaft

Most of the automobiles have Rear wheel drive and front engine installation consists of a transmission shaft. Substitution of conventional metallic (SM45C) Propeller Drive Shaft with the composite (CFRP) structure has many advantages. Composite materials have acquired prominence in the engineering industry due to their remarkable strength-to-weight ratio, corrosion resistance, and adaptability. This paper explores the multifaceted process of designing, analysing, and optimizing composite propeller shafts, with a primary focus on their application in marine and automotive industries, aiming to maximize performance while reducing weight. The design phase initiates by establishing precise requirements, encompassing torque loads, rotational speeds, environmental conditions, and safety factors. Material selection is a pivotal decision point, considering factors like fiber type, resin matrix, and layup orientation. Advanced Finite Element Analysis (FEA) technologies are used to simulate the mechanical behaviour of composite propeller shafts under a variety of operational scenarios, assisting in the identification of stress concentrations. Deformations, as well as key failure modes. The design process is iterative. The feedback from these simulations is used to improve the basic design. The analysis phase stress distribution, torsional vibrations, and dynamic behaviour of the composite propeller shaft. A comprehensive study of various layup configurations and boundary conditions is conducted to assess their impact on structural performance and reliability. Additionally, manufacturing considerations, encompassing fabrication techniques, quality control, and cost-effectiveness, are addressed to ensure practical feasibility. The goal of the optimization phase is to lower the weight of the composite propeller shaft while retaining structural integrity and operational reliability. The optimisation outcomes provide information on the best material mix, layup sequence, and geometric factors that achieve the best balance of weight reduction, greater performance and productivity. The findings from this study contribute substantially to the advancement of composite propeller shaft technology, offering engineers valuable insights into the intricacies of design, analysis, and optimization processes. By harnessing the ability of composite materials effectively, industries can realize significant benefits, including reduced fuel consumption, improved efficiency, and enhanced overall system performance, resulting in more sustainable and competitive products for the maritime and automotive sectors.


Introduction
In rear-wheel-drive vehicles, the driveshaft serves as the pivotal link transferring power from the engine to the differential gear, necessitating adaptability to various angles with the gearbox and axle.Steel SM45C, a premium construction steel, is frequently employed for its durability.Steel driveshafts, often bifurcated, enhance the bending natural frequency, proportional to the square root of the specific modulus and inversely related to the square of the beam length [3].However, the two-piece steel variant increases overall vehicle weight due to its inclusion of three universal joints, a central bearing, and a bracket.Recognizing the importance of lightweight and reducing inertial mass, the automotive industry has turned to composite materials with higher specific stiffness and strength.Composite driveshafts, being lighter than steel or aluminium counterparts, offer comparable strength and stiffness while allowing for a single-component design [6].The appeal of composite materials, particularly for rotating systems, lies in their superior strength-to-weight ratio.Applications extend beyond vehicles to helicopters, centrifugal separators, and cylindrical tubes in the automotive and marine industries [7].Designers leverage the versatility of composites by varying ply orientation and quantity to achieve specific behaviours, including control over critical speeds.In pursuit of enhanced performance and efficiency, the industry introduced the graphite/carbon/fiberglass/aluminium composite driveshaft tube for light trucks, vans, and highperformance cars [9].This innovation not only reduces weight but also provides superior vibration damping, improved cabin comfort, minimized wear on drivetrain components, and increased tire traction.The integration of composite materials exemplifies the automotive sector's commitment to advancing technology and achieving optimal balance between strength, weight, and functionality in drive shaft design [12].

Problem identified
To reduce whirling vibration, the resonant frequency of the propeller shaft for Cars, small trucks, and vans should be greater than 6,500 rpm and the propeller shaft's ability to transmit torque should be greater than 3,500 Nm.Due to limited space, The propeller shaft's outside diameter should not be larger than 100 mm.

Torque Transmission Capacity of Shaft
The Torque transmission capacity of the hollow propeller shaft is determined by using below Equation: T= Where K= బ

Bending Natural Frequency
The Bending natural frequency "݂݊" uses a corresponding expression: ) Where E, I, m, L, are the Youngs modulus, moment of inertia, mass of shaft, length of shaft

Crucial speeds of the shaft
The shaft's critical speed is determined by:

Modelling and Mesh generation 4.1 CAD Modelling
Creating a CAD model utilizing SolidWorks software involves meticulous design and dimensioning, particularly for a shaft with specified parameters.In this instance, the shaft features an outer diameter of 90 mm, and an interior diameter of 80 mm, and a length extending to 1200 mm.

Mesh generation
Mesh generation holds paramount importance in numerical simulations, involving the discretization of a geometric domain into elemental shapes like triangles, quadrilaterals, tetrahedra, or hexahedra.The resulting mesh approximates the actual shape of the studied issue, forming the foundation for accurate simulations.The creation of this mesh is a pivotal phase, as the precision and efficiency of simulation results hinge on its quality.Recognizing the critical role of mesh quality, ongoing improvements in mesh creation techniques are imperative.

Study of the research and identification of the problem
Study Technology to improve failures and Reduce mass Taking all dimensions of the existing driveshaft of the automobile.
Create the CAD model.

Investigating Composite Materials
Analysis of a propeller shaft Utilizing Ansys Workbench.
Evaluating and suggesting the optimal material for the Drive shaft.
These enhancements are essential for refining simulation capabilities in diverse scientific and engineering domains, ensuring a more accurate representation of complex real-world scenarios.The continuous pursuit of advancement in mesh creation underscores its significance in pushing the boundaries of simulation accuracy and effectiveness across a broad spectrum of applications.
Mesh Quality Parameters:

Finite Element Analysis
Utilizing Finite Element Analysis (FEA), a computer-based numerical method proves instrumental in assessing the behaviour and strength of engineering structures, allowing for the calculation of various phenomena such as deflection, stress, vibration, and buckling behaviour.The ANSYS FEA program was specifically employed in this project to conduct Static and Modal analyses, leveraging specified measurements and material characteristics for both the steel and composite driveshaft.In the context of composite materials, the Ansys ACP pre-post tool was employed to create plies and stacking sequences for the composite propeller shaft.This tool facilitates a comprehensive analysis of composite structures, ensuring a thorough understanding of their performance characteristics.The application of FEA, particularly within the ANSYS framework, underscores its versatility in providing valuable insights for optimizing the design and performance of engineering components like driveshafts.

Static analysis
Static structural analysis is a crucial engineering technique focused on assessing the mechanical behaviour of structures subjected to static loading conditions.The primary objective is to understand how structures respond to continuous loads or external forces.By analyzing stress, strains, and displacement distributions within the structure, this method empowers engineers to make informed decisions about design optimization and ensures the overall structural integrity of the system.Static structural analysis is a key tool in the engineering arsenal, providing valuable insights that guide the decision-making process for creating robust and efficient structures.

Structural analysis of steel (SM45C) shaft 1] Boundary conditions
One end of the propeller shaft is fully Constrained, preventing movement in all directions, while the opposite end is subjected to a 3500 N-m moment, simulating real-world conditions for static structural analysis.

Modal Analysis
Modal analysis, a powerful technique in dynamic and structural engineering, focuses on studying the vibration characteristics of a structure.This analytical approach provides crucial insights into the dynamic behaviour of systems, showing information about natural frequencies, mode shapes, and damping ratios.Central to the modal analysis is the identification of vibrational modes, representing inherent oscillation patterns exhibited by a structure under dynamic loads.The primary outcome of modal analysis is the identification of natural frequencies, which signify the inherent vibration rates of a structure, each associated with a specific mode shape.Mode shapes articulate the spatial distribution of motion within the structure for each natural frequency, allowing engineers to visualize how different structural components move relative to each other during vibration.This information is essential for anticipating, identifying, and addressing potential resonance and undesired vibration issues in structural systems.

Modal analysis of steel (SM45C) propeller shaft
The propeller shaft is subjected to fixed support at both ends, so boundary conditions are used to perform a modal analysis of the shaft.

× 100
When comparing the carbon-fibre and Glass-fiber composite shafts with a conventional steel shaft the carbon-fibre composite shaft provides 80% mass savings and the glass-fiber composite shaft provides 73.02% mass savings than the steel shaft.Compared to conventional steel shaft the weight of composite propeller shafts is low, which will increase vehicle performance and fuel efficiency.

Conclusion
This paper examines the replacement of a two-piece steel drive shaft with a one-piece composite drive shaft.In addition to finite element analysis, the design process is examined, and several significant parameters are found.In order to improve efficiency as well as to lower the price and weight.
¾ All of the structural outcomes fall within acceptable bounds when it comes to the application of the composite materials under study.¾ Comparing of Composite shaft with the Conventional metallic shaft the Carbon-fiber composite shaft provides 80% mass saving and the Glass-fiber composite shaft provides 73.02% mass saving than the steel propeller shaft.¾ Composite shafts have lower mass and inertia compared to conventional shafts, which results in reduced rotational forces and improved efficiency of power transmission.¾ Corrosion never occurs with composite materials.¾ Composite shafts have higher natural frequencies, which implies that they are less prone to resonance and vibration problems.This can lead to smoother operation and longer equipment lifespan.

Table 2 :
Material properties of SM45C, Carbon-Epoxy and Glass-Epoxy Composite