MATERIAL OPTIMIZATION AND WEIGHT REDUCTION OF DRIVE SHAFT USING COMPOSITE MATERIAL

Mechanical Engineering

This Paper deals with the study of replacement of conventional two-piece steel drive shafts with one-piece automotive hybrid aluminum/composite drive shaft & was developed with a new manufacturing method, in which a carbon fiber epoxy composite layer was co-cured on the inner surface of an aluminum tube rather than wrapping on the outer surface to prevent the composite layer from being damaged by external impact and absorption of moisture. Replacing composite structures with conventional metallic structures has many advantages because of higher specific stiffness and higher specific strength of composite materials. By considering the thermal residual stresses of the interface between the aluminum tube and the composite layer, the optimum stacking sequence is calculated with the help of Finite element analysis. Press fitting method for the joining of the aluminum/composite tube and steel yokes was devised to improve reliability and to reduce manufacturing cost, compared to other joining methods such as adhesively bonded, bolted or riveted and welded joints. The joining of the aluminum - composite tube and steel yoke with improved reliability and optimum manufacturing cost is done by press fitting. In order to increase the torque transmission capacity protrusion shape is provided on the inner surface of steel yoke which will fit on Universal joints.

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