Design and modal analysis of composite drive shaft for automotive application

Abstract

The automotive sector is always looking for ways to improve the performance, safety, and efficiency of vehicles. The drive shaft, which transmits torque from the engine to the wheels, is essential to accomplishing these goals. Due to their strength and longevity, conventional metallic drive shafts have long been the preferred option. They do, however, have certain disadvantages, including weight, corrosion susceptibility, and restricted design flexibility. Progress in material science has spurred investigation into composite alternatives as a response to these issues. Compared to typical metals, composite materials have a high strength-to-weight ratio, are resistant to corrosion, and may be engineered to have particular mechanical qualities. Through the design and analysis of composite drive shafts intended specifically for automotive applications, our research seeks to leverage these advantages. This research's main goals are to create a solid design methodology for composite drive shafts and carry out in-depth modal analysis to evaluate the dynamic characteristics and performance of the components. A thorough selection of composite materials is required during the design phase, taking into account attributes including weight, strength, stiffness, and durability. Sophisticated production processes, including filament winding or resin transfer moulding, are used to guarantee accurate and reliable fabrication of the composite shafts. Wall thickness, length, and diameter are three geometric factors that are optimised to save weight while still fulfilling structural criteria and fitting into modern vehicle architectures. When assessing the dynamic behaviour of the composite drive shafts, modal analysis is essential. Examining intrinsic frequencies, mode shapes, and vibration modes under varied operating circumstances is part of this investigation rotational speeds and torque loads. The composite drive shafts' dynamic response is simulated using finite element analysis (FEA) software, which offers important insights into the performance parameters of the components. The findings of the modal analysis guide design changes intended to lower the possibility of vibration-related failures and enhance the drive shafts' overall performance. The research's conclusions highlight the geometric requirements, material qualities, and manufacturing processes of the designed composite drive shaft. They also offer a thorough comprehension of the dynamic reaction of the drive shaft to outside excitations. All things considered, this research offers a promising substitute for traditional metallic shafts in car engineering and signifies a major technological development in drive shaft design. To fully realise the potential of composite materials, manufacturing techniques, and durability testing, future research efforts might concentrate on further optimising composite drive shafts for use in automobiles.