Analysis of Composite Shaft

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Analysis of a composite shaft under static torsion

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Overview • • • • • •

Introduction Prerequisites FEA of hybrid aluminium/composite drive shaft FEA results and discussion Comparison between the experimental and nite element results Conclusions

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Introduction !ubstitutin" composite materials for conventional metals has many advanta"es includin" hi"her specic sti#ness and stren"th • Advanced composite materials seem ideal for lon"$ power drive shaft applications • Composites li%e carbon/epoxy or "lass/epoxy or their hybrids successfully used as propeller shafts in aerospace applications • Apart from hi"her specic sti#ness and stren"th$ they also o#er superior vibration dampin"$ fati"ue characteristics and corrosion resistance •

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Introduction •

&ue to hi"h material cost of carbon ber/epoxy composite materials$ rather inexpensive aluminium used partly composite materials as in'

Hybrid aluminium/composite driveshaft o Aluminium: transmits the required torque o Composite: increases bendin" natural

frequency •

In this wor%$ FEA was used to investi"ate maximum torsion capacity of hybrid aluminium/composite drive shaft

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Introduction (ax) torsion capacity of aluminium tube wounded outside by o E*"lass/epoxy$ o carbon ber/epoxy$ and o their +ybrids • Evaluated at di#erent •

winding angles o number of layers, and o stacking sequences o

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Prerequisites • ,hat is a composite • ,hy composite • ,hat is a lamina and laminate • LAMINATION CO! Guidelines

•

•

•

. / /  . / / n ****** for repeated layers . / / s ****** for symmetric laminates

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Prerequisites •  An example

.01/234/*34/01

•

,indin" an"le in case of composite tubes

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Finite element analysis of hybrid aluminium/composite drive shaft Modelin" of the specimen in AN#$#

Con"uration and dimensions of the specimen

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Finite element analysis of hybrid aluminium/composite drive shaft •

Element type ' o o

for composite layers **** !O5I& 36 For aluminium tube **** !O5I& 34

Finite element meshes

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Finite element analysis of hybrid aluminium/composite drive shaft (aximum strain failure critera was used to predict failure load in this wor% •  7he failure index (   I   ) was calculated as •

I

=

ϕ 

where ϕ 

=

allowable an"le of twist$ and

ϕ f  ϕ f 

=

failure an"le of twist

Fracture is said to occur when I = 8 i)e) when the an"le of twist equals the failure an"le of twist •

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Finite element analysis of hybrid aluminium/composite drive shaft %lass &bers

Carbon &bers

Case 8

.934n

.934n

Case :

.01m

.01m

Case ; Case 3

.234/*34/01/01 .01/234/*34/01

.234/*34/01/01 .01/234/*34/01 /=934>  carbon "lass 5aminates and their stac%in" sequences =934>"lass

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Finite element analysis of hybrid aluminium/composite drive shaft Material properties Carbon fiber

Glass fiber  

 Properties 45º

90º

45º

90º

 E r 

(GPa)

9.789

5.71

9.072

5.4

 E θ 

(GPa)

9.789

101.2

9.072

36.6

G rθ 

(GPa)

5.22

4.346

4.368

4.085

0.126

0.0186

0.11

0.074

υrθ 

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Finite element analysis of hybrid aluminium/composite drive shaft Aluminium tube Tensile modulus, E 

(GPa)

69

 Shear modulus, G 

(GPa)

26.5 0.3

 Poisson’s ratio, m

(kg/m3)

2700

Ultimate tensile stress

(MPa)

131

ield stren!th

(MPa)

69

 Shear stren!th

(MPa)

69

 Density, ρ

 

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Finite element analysis of hybrid aluminium/composite drive shaft

Ideali?ed stress@strain curve for nonlinear property of the aluminum tube

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Finite element analysis of hybrid aluminium/composite drive shaft 'oundary conditions •

 7he idea **** subect the hybrid shaft to pure torsion o One end xed$ all &OF arrested o Apply torque on the other end o Arrest &OF in r  direction to restrict movement of nodes in radial direction

&eformed

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Finite element analysis results and discussion •

E#ect of (indin" an"le and number of layers on torsional stren"th

3 layers

6 layers

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Finite element analysis results and discussion •

E#ect of stac)in" se*uence on torsional stren"th

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Finite element analysis results and discussion •

E#ect of hybridi+ation on torsional stren"th

3 layers

6 layers

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Comparison between experimental and nite element results • Tor*ue versus an"le of t(ist

comparison

.234/234; laminate

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Comparison between experimental and nite element results •

Comparion of ma,imum tor*ue capaicity

Aluminum tube wound by E*"lass/epoxy composite

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Comparison between experimental and nite element results •

Comparion of ma,imum tor*ue capaicity

Aluminum tube wound by carbon ber/epoxy composite

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Conclusions As the number of layers are increased$ the static torque capacities of the hybrid shaft for both carbon and "lass ber composite materials also increases) • A hybrid aluminum/composite wound with 34B layers can withstand hi"her static torsion compared to 01B in all cases) • !haft bein" laminated with stac%in" sequence .01/234/*34/01 and .234/*34/01/01 "ave the same behaviour of torque*an"le of twist relation) • A nite element study was carried out usin" A!D! software to predict the static torsion capacity includin" the elasto*plastic properties for aluminum tube and linear elastic for composite materials) 7he comparisons between the experimental and predicted results carried out usin" A!D! software "ave "ood a"reement) •

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eferences !)A) (utasher$ Prediction of the torsional stren"th of the hybrid aluminum/composite drive shaft$ (aterials and &esi"n ;1 =:110> Pa"e' :84@::1 • &)