PARAMETRIC OPTIMIZAT ION OF COMPOSITE …€¦ · COMPOSITE DRIVE SHAF T USING ANSYS WORKBENCH 14.0...

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 5, May 2017, pp. 10–23, Article ID: IJMET_08_05_002 Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=5 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed

PARAMETRIC OPTIMIZATION OF COMPOSITE DRIVE SHAFT USING ANSYS

WORKBENCH 14.0 I.V.S. Yeswanth

P.G Student, Mechanical Engineering, Hindustan Institute of Technology and Science, Chennai, India

A. Abraham Eben Andrews Assistant Professor, Mechanical Engineering,

Hindustan Institute of Technology and Science, Chennai, India

ABSTRACT This study mainly aims at replacing the conventional steel drive shaft used in

automobiles with composite material such as High Modulus carbon/ Epoxy or E glass polyester. Conventional drive shaft has the disadvantages such as more weight, low specific stiffness and low strength. Composite materials offer the advantage of high specific strength, light weight and longer life compared to conventional drive shaft. For finding the suitability of composite structures for automobile applications the parameters such as ply thickness, number of plies for HM carbon/ Epoxy and E- glass polyester shafts are analyzed using ANSYS tool with the object of weight reduction. When the shaft is subjected to torque transmission and fundamental bending natural frequency. The drive shaft, which is used in heavy automobiles like truck, was taken to model the drive shaft assembly using CATIAV5R20 to create a shaft model and ANSYS 16 is used for predicting the results. The comparison is carried out for conventional steel shat and composite materials. Parametric optimization is done to compare the results of steel and composite drive shaft by varying the design variables such as inner diameter, outer diameter and Torque of the drive shaft and the results of change in design variables are compared. Key words: Driveshaft, composite materials, HM carbon, Epoxy, E-glass polyester, CATIA, ANSYS, Parametric Optimization Cite this Article: I.V.S. Yeswanth and A. Abraham Eben Andrews, Parametric Optimization of Composite Drive Shaft Using Ansys Workbench 14.0. International Journal of Mechanical Engineering and Technology, 8(5), 2017, pp. 10–23. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=5

1. INTRODUCTION A shaft is an important rotating machine element which is responsible for transmitting the power generated from source to the required part. The power is transmitted to the shaft by

I.V.S. Yeswanth and A. Abraham Eben Andrews


tangential force and the resultant torque helps the shaft to transmit power to various parts which are connected to it. In automobile applications the drive shafts receives power from the engine through clutch assembly and transmission system transfers the power to rare wheels, which is responsible for the actual movement of the vehicle. One of the desirable goals for the design engineers is to increase the fuel efficiency of the automobile. The conventional material used in drive shaft for automobile applications is carbon steel of grades 40C8, 45c8, 50c4 etc. The conventional materials are more weight because of high density. The thumb rule is that around 22% of the power generated by the engine is lost because more energy is required to rotate heavier parts. The conventional materials of drive shaft can be replaced by composite materials as it offers the advantage of high specific strength and high modulus without affecting the reliability of the component. The composite materials also offer the advantage of long fatigue life when compared to conventional materials. The various types of composite materials that can be used for automobile application are HM carbon epoxy, HS carbon, Kevlar, E-glass polyester etc. Various other applications where drive shafts are used is aerospace, marine application and automobile applications.

Sagar R. Dharmadhikari [1] discusses the application of optimization of drive shaft using Genetic algorithm and substitution of conventional drive shaft with composite material. This paper discusses about optimization of structural systems based on mathematical programming involving gradient search and direct search. S.Mohan [2] designs a composite drive shaft for application of drive shaft in automobile applications and carries out investigation to estimate the stresses, deflection and natural frequency using ANSYS software and compares the result with steel shaft to validate the results. R.P.Kumar [3] discusses about design and analysis of composite drive shaft which is used in power transmission applications. It also discusses about optimization of design parameters with the objective of weight reduction. It also discusses about uses of composite drive shaft at higher critical speed with longer life. V.S.Bhajantri [4] discusses about replacement of conventional drive shaft with composite materials like HS carbon, HM carbon and E-glass fiber. It also discusses about the importance of fiber angle orientation in the design of composite drive shaft which offers the advantages of lower weight, higher strength and power consumption. Ghatage [5] discusses about replacing metallic shafts with composite materials as the offer the advantage high specific stiffness and high strength. This paper uses Genetic Algorithm as optimizing tool with the objective of weight reduction which is constrained to torque transmission; fundamental natural frequency and torsional buckling with a view of optimizing number of plies and stacking sequence are optimized for composite materials. A.Sridhar [6] predicts the deformation of the shaft and compares with conventional steel and composite materials like HS carbon, HM carbon and Glass epoxy using ANSYS software and discuss the suitability of replacement of steel with composite materials. Pankaj k.Hatwar[ 7] discuss about polymeric materials reinforced with synthetic fibers such as glass carbon and aramid fibers which offers the advantage of high weight strength to weight ratio when compared to conventional materials.

This paper aims at reducing the fuel consumption of automobiles by reducing the weight of drive shaft. Replacement of steel drive shaft with composite materials reduces about 72-82% of the drive shaft. M.R.Khoshravan [8] discuss about design method and vibration analysis of composite drive shaft. The parameters such as torque, critical speed, fiber orientation and adhesive joints are studied. The results reveal that the fiber orientation has great influence on dynamic characteristics of the composite shaft. Amit Soni [9] designs a drive shaft with a different taper angle and ANSYS software is used for doing buckling analysis and modal analysis to study the behavior of shaft whether it can be replaced with composite drive shaft. Belawagi Gireesh [10] this papers compares the design of conventional steel drive shaft with composite drive shaft by using different composite material and

Parametric Optimization of Composite Drive Shaft Using Ansys Workbench 14.0)


concludes around 72% reduction of weight and also concludes that there is a great influence of fiber orientations on the static and dynamic characteristics of the composite shafts.

2. PROBLEM DESCRIPTION Conventional drive shafts used in automobile applications are made of stainless steel which offers the advantage of high strength, but there are disadvantages like stainless steel has low specific modulus, low specific strength. More over because of high density the weight of the shaft is increased which also increases the fuel consumption.

The objective of the work is to replace the conventional steel drive shafts with composite material which offers the advantages of high strength and reduces the weight of the shaft as the density of the composite materials is low without affecting the reliability of the composite material.

3. DESIGN METHODOLOGY Study the cause of failures in the conventional drive shaft

Selection of composite materials

Preparation of a 3-D model of drive shaft using CATIA software

Analysis of composite drive shaft using ANSYS

Comparing the results with conventional drive shaft to validate the project.

4. MATERIAL SELECTION The present material used in industry for manufacturing conventional drive shafts is SM45C

SM45C: It also known as S45C which is an unalloyed carbon mechanical structural steel belonging to ISD3752-1986 steel grade standard. It is widely used in ladder shaft, hollow shaft, crank shaft, mould base structural applications.

Table 1 Properties of SM45C

Property Symbol value Units Poisson’s ratio µ 0.3 Young’s modulus of elasticity

E 207 GPa

Shear modulus G 80 GPa Density Ρ 7600 Kg/ Yield strength 370 MPa

4.1. Selection of Composite Materials The composite material chosen for Analysis are HM carbon/ Epoxy and E-Glass fiber.

HM carbon Epoxy: High Modulus Carbon epoxy is a composite material which is used where high strength and rigidity are required. HM carbon epoxy is widely used in the areas of automotive, aeronautical, marine and civil engineering applications as it reduces the weight of mechanical structure without affecting the reliability of the component.

The material and their properties were used in this analysis [6]



Table 2 Properties of HM carbon epoxy

Property Symbol Value units Young’s Modulus of Elasticity

E =190, =7.7, =7.7

GPa

Poisson’s ratio µ μ =0.3, μ =0.3, μ =0.3

Shear modulus G 4.2 GPa Density Ρ 1600 Kg/

E Glass polyester: The E Glass fiber is a high glass fiber which is used in almost all automobile applications which offers the advantage of low cost, high chemical resistance and good electrical properties.

Table 3 Properties of E Glass polyester

Property Symbol Value units Young’s Modulus of Elasticity

E =34, =6.5, =6.5

GPa

Poisson’s ratio µ μ =0.217, μ =0.366, μ =0.217

Shear modulus G =2.4, =1.6, =24

GPa

Density Ρ 2100 Kg/

5. DESIGN CALCULATIONS OFDRIVESHAFT Specification of Engine: H series Ashok Leyland Engine Truck Model: 6DT120

Maximum Power [P] =132KW Speed [N] =1200rpm Length [L] =1800mm DESIGN OF STEEL SHAFT

P= ∗ ∗ ∗

132*10^3= ∗ ∗ ∗

T= 1050.42 N-m

= 1.25 (from PSG data book)

Ʈ = 50N/ Based on stiffness equation equation

= ( )

G= shear modulus



=

∗ ∗ . = .( . )

= 56mm =70mm

For long shafts torsional buckling ( ) = ∗ (2 ∗ ∗ ∗ )

Where = critical stress

= √ ( )

*( / )

= √ ( . )

*(7/31.5)

= 5485.7281 N/ =239.405 KN-m

Mass of steel drive shaft m=ρAL m=ρ* ( − ) ∗

m= 7600* (0.07 − 0.056 )*1.8

m= 18.93kg Fundamental bending frequency

= 2 ∗∗∗

= Fundamental natural frequency (Hertz)

= 2 ∗207 ∗ 10 ∗ 6.95 ∗ 10^ − 7

1.8^4 ∗ 10.52

= 56.66 HZ

5.1. Design of Composite Drive Shaft

HM carbon epoxy = ∗ (2 ∗ ∗ ∗ )

= √ ( )

*( / )

= ∗ ^

√ ( . ) *(7/31.5)

= 5035.20 N/ = 5035.20∗ (2 ∗ ∗ 7 ∗ 31.5 ) = 219.74 KN-m

Mass of HM carbon epoxy drive shaft



m=ρAL m=ρ* ( − ) ∗

m= 1600* (0.07 − 0.056 )*1.8

m= 3.99 Kg Fundamental bending frequency

= 2 ∗∗∗

= 2 ∗190 ∗ 10 ∗ 6.95 ∗ 10^ − 7

1.8^4 ∗ 2.21

= 118.50 Hz

Design of E-Glass polyester = ∗ (2 ∗ ∗ ∗ )

= √ ( )

*( / )

= √ ( . )

*(7/31.5)

= 870.43 N/ = 870.43∗ (2 ∗ ∗ 7 ∗ 31.5 ) = 37.98 KN-m

Mass of steel drive shaft m=ρ* ( − ) ∗

m= 2100* (0.07 − 0.056 )*1.8

m= 5.23Kg Fundamental bending frequency

= 2 ∗∗∗

= 2 ∗34 ∗ 10 ∗ 6.95 ∗ 10^ − 7

1.8^4 ∗ 2.90

= 43.76 Hz



6. DESIGN AND ANALYSIS OF DRIVESHAFT

Table 4 Design Specification of the drive shaft

Parameter Symbol Value Unit Outer diameter of shaft

70 mm

Inner diameter of shaft

56 mm

Length of shaft L 1800 mm Thickness of shaft T 7 mm

The design of drive shaft is done using CATIAV5 as per the design specification mentioned in the above table.

The composite drive shaft is designed by considering number of layers as 3 and the stacking sequence 0/45/45 because at this stacking sequence more shear load will be applied on the shaft.

Figure 1 Drive shaft modeled using CATIA V5

ANALYSIS OF DRIVE SHAFT: The modeled drive shaft in CATIAV5 is imported into ANSYS. MESHING ELEMENT: The mesh element chosen is SHELL181. SHELL 181has the advantage of adding up to 250 layers and has six degrees of freedom. It also helps us to give different mechanical properties in X, Y and Z directions. BOUNDARY CONDITION: One end of the shaft is fixed and 3000M-m load us applied on other end.



Figure 2 Meshing

Types of Analysis STATIC ANALYSIS: A static analysis is used to calculate the effects of steady loading conditions ignoring the effects of inertia and damping. In static analysis loading and response conditions doesn’t vary with time. The input loading conditions that can be given in a static analysis are moment, applied force and pressure and the output can by displacement, forces in a structure, stress and strain. If the values obtained in static analysis crosses the allowable values it will result in the failure of structure. MODAL ANALYSIS: Modal analysis is a type of dynamic analysis which is used to determine natural frequency and mode shape of a component. Mode shape and natural frequency is an important parameter in the design of the component for dynamic loading. PARAMETRIC OPTIMIZATION: A parametric tool is an useful element is a useful tool for evaluating design sensitivity from a variety of levels. Input quantities consists of geometric dimension, material coefficients and boundary conditions, whereas the output quantities include post processing entities such as reaction forces, displacement forces and stresses etc.

Analysis Results

Static Analysis Results

Figure 3 Deformation of SM45C



Figure 4 Deformation of HM Carbon Epoxy

Figure 5 Deformation of E Glass Polyester

Figure 6 Von Mises Stress of SM45C



Figure 7 Von Mises Stress of HM Carbon Epoxy

Figure 8 Von Mises Stress of E Glass Polyester

Results of Modal Analysis

Figure 9 First mode frequency of SM45C



Figure 10 First Mode Frequency of HM Carbon Epoxy

Figure 11 First Mode Frequency of E Glass Polyester

Figure 12 Sixth Mode Frequency of SM45C



Figure 13 Sixth mode frequency of HM Carbon Epoxy

Figure 14 Sixth Mode Frequency of E Glass Polyester

Results of Parametric Optimization

Figure 16 Parametric optimization for steel



Figure 17 Parametric optimization for HM Carbon Epoxy

Figure 18 Parametric Optimization for E Glass polyester

7. CONCLUSIONS The present work is aimed at weight minimization of drive shaft. Composite materials are analyzed taking into consideration of weight reduction, deformation, Von moisses stresses and frequency. It is evident that HM carbon Epoxy has encourage properties over SM45C and E Glass polyester and weight reduction is 79.02% less than SM45C and 24.09% less than E Glass polyester.

Parametric Optimization helps us to see how the output quantities in postprocessor are varying with the change in input parameters helps in saving the time required to perform another analysis.

REFERENCES [1] Sagar R Dharmadhikari, Sachin G Mahakalkar Jayant P Giri, “Design and analysis of

composite drive shaft using ANSYS Genetic Algorithm”, International Journal of Modern Engineering Research(IJMER), vol 3, Issue 1, Jan-Feb. 2013 pp-490-496 , ISSN: 2249-6645

[2] K. Rajesh, Mr. A.Ramesh, “Design and analysis of composite drive shaft”, International Journal of Professional Engineering Studies, Vol 4/ Issue 4/ July 2016.

[3] R.P.Kumar Rompicharla, Dr.K.Rambabu, “Design and analysis of Drive shaft with composite Materials”, Research Expo International Multidisciplinary Research Journal, Vol 2, issue 2, June 2012, ISSN: 2250-1630.



[4] V.S. Bhajantri, S.C.Bjanatri, A.M.Shindolakar, S.S. Amarapure,” Design and Analysis of composite drive shaft”, International Journal of Research in Engineering and Technology, ISSN: 2319-1163.

[5] Ghatage K.D, Hargude N.V,”Optimum design of automotive composite drive shaft with Genetic Algorithm as optimizing tool”, International Journal Of Mechanical Engineering and Technology, vol 3, issue3, September- December-2012, ISSN 0976-6340.

[6] A.Sridhar, Dr.R.Mohan, R.Vinoth Kumar, “Design and Analysis of composite drive shaft”, International Journal of Scientific and Engineering Research, volume 7, Issue 5, May-2016, ISSN 2229-5518.

[7] Pankaj K. Hatwar, Dr.R.S.Dalu, “Design and analysis of composite drive shaft”, International Journal of science and research (IJSR)- ISSN-2319-7604,2013

[8] M.R.Khoshravan, A.paykani, “Design of a composite Drive shaft and its coupling for Automotive application”, vol 10, December 2012.

[9] Amit Soni, Mr. Hari Ram Chandrakar,” Design and Analysis of Drive shaft of composite material using ANSYS”, International Journal for Research in Applied Science and Technology, IC value: 13.98, vol 3, issue 7, July 2015.

[10] Belawagi Gireesh, Sollapur Shirishali B, V.N.Satwik, “Finite Element and experimental investigation of composite Torsion shaft “, International Journal of engineering research and appplications, volume 3, March-april 2013, ISSN: 2248-9662.

[11] Manjunath K, S. Mohan Kumar, Channakeshava K.R, Optimization and Simulation of Composite Driveshaft for Automobile Applications. International Journal of Mechanical Engineering and Technology, 1(1), 2010, pp. 76–94

PARAMETRIC OPTIMIZAT ION OF COMPOSITE …€¦ · COMPOSITE DRIVE SHAF T USING ANSYS WORKBENCH 14.0...

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