COMPOSITE DRIVE SHAFT FEA ANALYSIS

A PROJECT REPORT

Submitted by
SHAHUL HAMEED.M
MERLIN ANTO.M
MIDHUN SEBASTIAN
RAHUL CHANDRAN.R
in partial fulfillment for the award of the degree
of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

UDAYA SCHOOL OF ENGINEERING, VELLAMODI

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2018
 ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “COMPOSITE DRIVE SHAFT FEA

ANALYSIS” Is the bonafide work of “M.SHAHUL HAMEED
(962614114315), M.MERLIN ANTO(962614114036),MIDHUN
SEBASTIAN(962614114037),R.RAHUL CHANDRAN (962614114041)”
who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Mr.C. SARAVANAN, M.E., Mr.N. SIVA RAJ, M.E.,

HEAD OF THE DEPARTMENT SUPERVISOR
DEPARTMENT OF MECHANICAL DEPARTMENT OF MECHANICAL
ENGINEERING, ENGINEERING,
UDAYA SCHOOL OF ENGINEERING, UDAYA SCHOOL OF ENGINEERING,
VELLAMODI, VELLAMODI.

Submitted for the Anna University, Chennai project examination held on

Udaya School of Engineering, vellamodi on.........................

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT

First of all I would like to thank the Almighty for showering his
blessings upon us. I wish to thank Mr. C. THAYAPARAN, ME., Our
respected and honorable chairman for his encouragement. We express our
heartfelt gratitude to our Principal Prof. S. JOTHI BASU, M.E,(Ph.D)., of
our institution for his constant support.
We are also highly obliged to Asst.Prof.,Mr. S. SARAVANAN,
M.E, H.O.D in Mechanical Engineering Department for rendering his full
support both mentally and technically by encouraging us at all times as
needed.

We wish to express of our sense of gratitude of our

guide Asst.Prof., Mr. C. SIVA RAJ , M.E., Assistant Professor of the
Department of Mechanical engineering, for his valuable & timely
suggestions and also motivated as to take this project.

We thank all the teaching and non-teaching staff members of

Mechanical Engineering Department and our friends for their sole help and
cooperation in successful completion of this project.

We thank our parents for their prayers and support for completing this
project and above all with God’s grace we completed this project
successfully.

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 ABSTRACT

Substituting composite structures for conventional metallicstructures

has many advantagesbecause ofhigher specific stiffness and strength of
composite materials. In the recent days, there is a huge demand for a light
weight material such as fibre reinforced polymer composites seems to be a
promising solution to this arising demand. These materials have gained
attention due to their applications in the field of automotive, aerospace,
sports goods, medicines and household appliances. The overall objective of
this work is to analyze a composite drive shaft for power transmission.
Substituting composite structures forconventional metallic structures has
many advantages because of higher specific stiffness and strength of
composite materials. This work deals with the replacement of conventional
steel drive shafts with a Kevlar/ epoxy or E glass polythene resin composite
drive shaftfor an automotive application. The intention of work is to
minimize the weight of drive shaft. In this present work, an attempt has
been to estimate the deflection, stresses, and natural frequencies under
subjected loads using FEA (Ansys). Further comparison carried out for both
loads using FEA. Further comparison carried out for both optimized and
stress intensity factor found for both Steel and composite drive shafts.

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 TABLE OF CONTENTS

CHAPTER PARTICULAR PAGE

NO.
ACKNOWLEDGEMENT iii
ABSTRACT iv
LIST OF TABLES vii
LIST OF TABLE vii
LIST OF FIGURES viii
1. INTRODUCTION 1

1.1 COMMON CATEGORIES OF COMPOSITE MATERIALS 4

1.2 BENEFITS OF COMPOSITES 4

1.3 ABOUT FIBRE RENIFORCED POLYMER 4

1.4 APPLICATION OF FRP COMPOSITES 5

1.5 ROTO-SHAFT SYSTEM 6

2. LITERATURE REVIEW 10

2.1 ANALYSIS OF DRIVE SHAFT 10

2.2 INFINITE ELEMENT MODELING OF

COMPOSITE ROTOR –SHAFT- SYSTEM 11

3. MATERIALS AND METHODS 16

 3.1 BORON-EPOXY 16

4. SOFTWARE USED 21
4.1 CREO PARAMETRIC 23
4.2 The Leading Product Design 3D CAD Software 23
4.3 Creo Capabilities 23
4.4 ANSYS 23
4.5 Geometry 28
4.6 Meshing 31
4.7 Physics Solution 32
4.8 Results 37
5. DESIGN 38
5.1 DRIVE SHAFT DESIGN IN CREO 38
5.2 SELECTING MATERIAL 39
5.3 STATIC STUCTURAL 39
5.3.1 FIXED SUPPORT 39
5.3.2 ROTATIONAL VELOCITY 40
5.3.3 MOMENT 41
5.4 APPLY SOLUTION 42
5.5 WORKING FOR RESULT 42
6. RESULT 43
7. CONCLUSION 51
8. REFERENCES 53

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 LIST OF TABLE

SL.NO DESCRIPTION PAGE

NO
1. STRENGTH PROPERTIES OF BORON 17
2. CONTENT ANALYSIS OF TEST 22
3. BASIC PROPERTIES OF KEVLAR 24

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 LIST OF FIGURES

SL.NO FIGURES PAGE NO

1.1 DRIVING SHAFT PARTS 8
5.1 DRIVING SHAFT DESIGN IN CREO 38
5.2 STATIC STRUCTURAL 40
5.3 WORKING FOR RESULT 42
6.1 TOTAL DEFORMATION OF STEEL 43
6.2 EQUIVALENT ELASTIC STRAIN OF STEEL 44
6.3 EQUIVALENT STRESS 44
6.4 TOTAL DEFORMATION OF KEVLAR 45
6.5 EQUIVALENT ELASTIC STRAIN OF KEVLAR 45
6.7 EQUIVALENT STRESS 46
6.8 TOTAL DEFORMATION OF E-GLASS 47
6.9 EQUIVALENT ELASTIC STRAIN OF E-GLASS 48
6.10 EQUIVALENT STRESS 49

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