1. University of New Haven
ME 451
Composite Materials and Material Selection
Design Analysis and Performance
of Mechanical Drive Shafts Using
Composite Materials
Author: Franco Pezza

2. Objective
• Design optimization of composite material
mechanical Driveshaft
Approach #1: Experimental
Approach #2: Analytical
• Compare results with the traditional steel
drive shaft

3. Main Goal
Weight Reduction

4. Mechanical Drive Shaft
A Drive Shaft is a
mechanical device
used to transfer
torque
Reference: http://en.wikipedia.org/wiki/File:Cardan_Shaft.jpg

5. Background
Reference: http://www.fallbrooktech.com/dutch/images/DaVinci_CVP_illustration.jpg
Materials used
in the past:
Wood
Iron
Leonardo Da Vinci (1492-1519)

6. Drawbacks
• Low torque
• Low efficiency
• Low R.P.M.
• High maintenance
• Short life
• Unreliable
Reference:http://www.fallbrooktech.com/dutch/images/DaVinci_CVP_illustration.jpg

7. Actual Materials
• Steel alloys
http://www.flickr.com/photos/cbmd/2359279156/sizes/m/
Detail of a driveshaft in a large vessel

8. Drawback
Reference: http://chestofbooks.com/crafts/scientific-american/Scientific-American-Reference-
Book/images/American-Freight-Locomotives-And-The-Engines-Of-Th-95.jpg
•Weight

9. Why Composite ?
• Strong
• Light
• Tailorable
• Low Inertia
Reference: http://www.amarillogear.com/AGCWEB.data/Components/composite4.jpg

10. Manufacturing Process:
Filament Winding
Reference: http://www.azom.com/details.asp?articleid=401
•Fibers are resin wetted
•Winded on a mandrel
•Tension is controlled
•Orientation is controlled
•Cured in oven

11. Theory:
Classic Laminate Theory
It derives from the general form of Hook’s law:

12. Ex & Ey Lamina Modulus
Reference: Gummadi Sanjay, Akula Jagadeesh Kumar, 2007 “Optimum Design and
Analysis of a Composite Drive shaft for an Automobile”

13. Gxy Lamina Shear Modulus
Reference: Gummadi Sanjay, Akula Jagadeesh Kumar, 2007 “Optimum Design and Analysis of a
Composite Drive shaft for an Automobile”

14. General Laminate Equation
where N is the force, M is the moment, A is the extensional stiffness, B is the
coupling stiffness, D is the bending stiffness and Q’ is the reduced elastic
constant

15. Driveshaft Design
Constrains:
• Max Outside Diameter
• Max Transmissible Torque
• Critical Speed (Flexural resonance)
• Buckling Torque (Torsional resonance)
Variables (steel):
– Shear modulus of the material
– Thickness of tubing
Variables (composite):
– Matrix material
– Fibers material
– Number of layers
– Stacking sequence (orientation)
– Thickness of layers (tows size)

16. Experimental Approach #1
Driveshaft constrains:
– Shaft length L = 1730 mm
– Mean diameter d = 101.6 mm
– Max torque Tq = 2030 Nm
– Critical speed 90 Hz (5400 RPM)
This research was published on the “International Journal of Engineering and Technology” Vol. 3,
No.2, 2006, pp. 227-237

17. Max Torque vs. Orientation
Directly from Lamina theory shear stress equation Gxy

18. Natural Frequency vs. Orientation

19. Critical Speed vs. Orientation
(Number in
parenthesis is the
layer thickness in
mm)

20. Buckling Torque vs. Orientation

21. Buckling Torque vs. Staking

22. Experimental Results
• Max torque: ± 45o
• Critical speed: 0o
• Buckling torque: 90o
• Best stacking sequence : [45/-45/0/90]

23. Analytical Approach #2
Driveshaft constrains:
– Shaft length L = 1250 mm
– Mean diameter d = 90 mm
– Max torque Tq = 3500 Nm
– Critical speed 108 Hz (6500 RPM)
This paper was presented at the “International Symposium of Research Students on Materials Science
and Engineering”
Reference: T.Rangaswamy, S. Vijayarangan, R.A. Chandrashekar, T.K. Venkatesh and K.Anantharaman,
“Optimal Design and Analysis of Automotive Composite Drive Shaft” Dept. of Mech. Engineering, PSG
College of Technology, Coimbatore 641004, India.
•Genetic Algorithms are based on probability algorithms
•Uses the concept of “Natural Selection”
•Simulate the concept of “Survival of the Most Fit”

24. GA Flow Chart

25. Fitness Evaluation
Roulette Wheel Distribution
Reference: Grant A. E. Soremekun, 1997,”Genetic Algorithms for Composite Laminate Design
and Optimization”, paper, Blacksburg, Virginia, USA

26. Weight Convergence

27. Layers Convergence

28. GA Analytical Result

29. Conclusion
• Composite materials are suitable for the
design of drive shafts.
• Both approaches have proved that a
consistent weight reduction is achieved.
• Composite materials are used also for
gears, couplings, timing belts and many
other mechanical transmission devices.

30. Questions?
Reference: http://www.b2bcarbonfiber.com/rimages/601/tube-1.jpg