Finite element modeling of conventional and hybrid composite driveshaft performance

Abstract EN

Composite materials have been used in the automotive industry for the last several decades due to their superior mechanical characteristics.

They open a new door of opportunities for the design of driveshafts because they allow production of single-part components instead of two-part components made of steel and aluminum.

Apart from having adequate performance characteristics, composites significantly reduce the weight of driveshafts thus enhancing fuel economy.

This paper comparatively analyzes the differences in weight, twist angle, flexural deflection, and natural frequencies of driveshaft models produced from conventional materials including En S275JR stainless steel and 7075 aluminum alloy, and composites including knitted E-glass fabric, carbon E-glass polyester, and Kevlar-50.

Numerical calculations of models were completed using ANSYS and Autodesk Helius Composites software solutions.

This paper also assessed differences in mechanical characteristics of hybrid composite driveshafts made using the combination of En S275JR stainless steel, 7075 aluminum alloy, and S-glass with variations in the number of layers as well as different fiber direction layers.

The findings suggest that hybrid driveshafts have advantages over conventional driveshafts, which is therefore an essential factor to be considered by the automotive and space industries in deciding on an alternative to using steel and/or aluminum in manufacturing driveshafts.