International Journal of Scientific Research and Review ISSN NO: 2279-543X

PROPELLER SHAFT DESIGN AND ANALYSIS

BY USING COMPOSITE MATERIAL

Srinivasa Rao A1, Ch.Lakshmi Poornima2,

K.Sunil Ratna Kumar3, B.V Subrahmanyam4
1,2,3,4
Department of Mechanical Engineering,
1,2,3,4
SIR C.R.Reddy College of Engineering, Eluru, Andhra Pradesh, India.

Abstract: Propeller shaft is an essential part in control transmission of a car. Customary steel drive shafts have restrictions of
weight and low basic speed. To get the greatest proficiency for control transmission, weight lessening of the drive shaft is
generally imperative. This work manages the substitution of ordinary two-piece steel drive shafts with a solitary piece e-
glass/epoxy, high quality Kevlar epoxy and high modulus aluminum T6-6063 composite drive shaft for a car application.
The fundamental idea of our task is to diminish the heaviness of car drive shaft with the use of composite material. In our
undertaking shaft coupling gathering need to transmit torque 15000 Nm at 30 rpm. As the car drive shaft is an essential part of
vehicle. The displaying of the drive shaft gathering was finished utilizing CATIAV5 programming. A pole must be intended to
meet the stringent outline necessities for auto thought processes. In vehicles the drive shaft is utilized for the transmission of
movement from the motor to the differential. In exhibit work an endeavor has been to appraise shear stresses, stresses and
strains under subjected loads and regular frequencies utilizing Ansys programming.
Keywords: Propeller shaft, composite material, weight lessening, CATIA V5, ANSYS

INTRODUCTION

A propeller shaft is a mechanical segment for transmitting torque and movement, typically used to associate
different parts of a drive prepare that can't be associated specifically on account of separation or the need to consider
relative development between them. In the get together the yield torque required is in the range 5000Nm-25000Nm
and speed prerequisite is in the range 24-40rpm in light of the fact that, rotational pumps requires to pump very thick
liquid, so it must be worked at lessened speed on the grounds that, at higher speed the fluid can't stream into the
packaging sufficiently quick to fill it. To defeat this issue we will outline propeller shaft. A transmission shaft
supporting a rigging in a speed reducer, the pole is constantly ventured with greatest distance across in the center
segment. A drive shaft, driving shaft, propeller shaft (prop shaft), or Cardan shaft is a mechanical segment for
transmitting torque and turn, typically used to interface different parts of a drive prepare that can't be associated
specifically in view of separation or the need to take into account relative development between them.
As torque bearers, drive shafts are liable to torsion and shear pressure, identical to the contrast between the
information torque and the heap. They should along these lines be sufficiently solid to hold up under the pressure,
while maintaining a strategic distance from an excessive amount of extra weight as that would thus build their
latency.
To take into account varieties in the arrangement and separation between the driving and driven parts, drive shafts as
often as possible fuse at least one general joints, jaw couplings, or cloth joints, and at times a splined joint or
kaleidoscopic joint
PROCEDURE:
Displaying and investigation of 3-Dimensional models of the drive shaft were done utilizing Catia and Solid words
and examination is done utilizing Ansys programming auxiliary examination of composite drive shaft and steel drive
shaft are completed. Study of cause of failures in drive shaft

Selection of composite material

Preparation of CAD model

Analysis the CAD model with existing material with Ansys

Analysis of drive shaft by using different composite materials

The results are compared

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International Journal of Scientific Research and Review ISSN NO: 2279-543X

PROBLEM DESCRIPTION

Stainless steel was essentially utilized in light of its high quality. Be that as it may, this stainless steel shaft has less
particular quality and less particular modulus. Stainless steel has less damping limit. Due to its higher thickness of
particles of stainless steel, its weight is high. As a result of increment in weight fuel utilization will in increment, the
impact of inactivity will be more. As a result of increment in weight of the propeller shaft we are supplanting the
stainless steel with the composite materials, which are less weight when contrasted with that of stainless steel. The
cost of composite materials is less when contrasted with that of stainless steel.

It the gathering the yield torque required is in the range 5000Nm-25000Nm and speed prerequisite is in the range
24-40rpm in light of the fact that, rotational pumps requires to pump exceptionally viscous fluid, so it must be
worked at diminished speed on the grounds that, at higher speed the fluid can't stream into the packaging sufficiently
quick to fill it. At this condition we utilized customary couplings then it comes up short. To conquer this issue we
will outline propeller shaft. Torque is the inclination of a power to cause or change rotational movement of a body.
It is the result of power and opposite separation. On account of high torque and low speed shaft and coupling get
together is falls flat. To transmit torque from engine to pump PSP Pumps Pvt. Ltd. Utilize diverse extras.

Analytical design calculation:

Physical properties:
Density= 7600 kg/m3, Coefficient of thermal expansion= 11.6 × 10-6 per o c, Modulus of elasticity= 207000
N/mm2, Hardness= 180 BHN, Yield stress= 590 N/mm2, Poisson’s ratio= 0.295

Design of Solid Shaft:

Speed(N)=30 rpm
Torque(Mt)=15000000 Nmm
Yield Stress(Syt)=490 N/mm2
Max Shear Stress(߬ max )=158 Mpa
Mt=ߨ/16×߬ d3
15000×103 = ߨ /16×158 d3
d =137.44 mm

Figure: 2D and 3D model of hollow shaft

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International Journal of Scientific Research and Review ISSN NO: 2279-543X

Pm=permissible pressure on spline=6.5 N/mm2

Mt=15000000 Nmm
do =119.1461 mm
Design of Universal Coupling:
Torque(Mt)=15000000 N-mm
Yield Stress(Syt)=490 N/mm2
Factor of safety(fs)=1.5
Ssy=0.577×Syt

Figure: 2D and 3D model of cross of universal coupling

Ssy =282.73 N/mm2
τ = Ssy/fs=188.41 N/mm2
D=diameter of shaft=100mm
dp =diameter of pin
Mt=2×(3.14/4)×dp²×τ×D
dp = 22.76009 mm

Inner cage of needle bearing:

Figure: 2D and 3D model of Inner cage of needle bearing

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International Journal of Scientific Research and Review ISSN NO: 2279-543X

Design of Flanges:
Dia. Of solid shaft=D=100mm
Outer dia. Of hub=dh=2D=200 mm,
Length of hub=lh=1.5D=150 mm
PCD of bolt=D=3D=300 mm
Thickness of flange=t=0.5D=50 mm
Thickness of protecting rim=t1=0.25D=25 mm
Dia. Of spigot and recess=dr=1.5D=150 mm
Outer dia. Of flange=Do=(4d+2t1)=450 mm

Figure: 2D and 3D model of flange

FOR FLANGE:
Mt=15000000 Nmm
Syt=490 N/mm2
fs=1.5
Ssy=0.577 × Syt=282.73 N/mm2
τ=Ssy/fs=188.49 N/mm2

Diameter of Bolt:
N=no. of bolts
N=6 for 100<=d<180
take N=6
d12=8×Mt/3.14×300×6×51.93
d1=15.44325 mm

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International Journal of Scientific Research and Review ISSN NO: 2279-543X

Design of Key;

σc (permissible compressive stress)

=Syt/3=163 N/mm2
length of key=l=lh=150 mm Ssy=0.5Syt=245 N/mm τ(key)= Ssy/fs=163.34N/mm2
Key dimensions b=h=D/4=25 mm

Figure: 2D and 3D model of

key l=2×Mt/(τ×D×b)=73.47 mm

Figure: 2D model of shaft coupling assembly

Material properties:

Material Density Young’s Shear Poisson’s Ratio

(kg/m3) Modulus Modulus
(pa) (pa)

Steel SM45
7600 2.07×10^11 7.9615×10^10 0.3
Epoxy-Glass 2580 3.9×10^11 3.8×10^10 0.3
Kevlar epoxy 1402 9.571×10^11 2.3×10^10 0.34
Aluminum T6-6063 2700 6.89×10^11 2.58×10^10 0.33

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DESIGN PROCEDURE IN CATIA

Create the half piston profile in sketcher workbench next go to exist work bench now go to the sketched based
features and go to shaft option apply angle 360 after create the planes offset to xy Planes create the circles and apply
pocket around the up to surface now go to mirror option apply mirror Finally as shown the figure below.

Figure: Explode model in CATIA

Figure: Final shape of propeller shaft in CATIA

Analysis procedure on ANSYS.

Meshing of propeller shaft

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International Journal of Scientific Research and Review ISSN NO: 2279-543X

RESULTS AND DISCUSSIONS

Shear stress result of structural steel Strain result of structural steel

SHEAR STRESSES, STRESS AND STRAINS OF KEVLAR EPOXY

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International Journal of Scientific Research and Review ISSN NO: 2279-543X

SHEAR STRESSES, STRESS AND STRAINS OF EPOXY- GLASS

SHEAR STRESSES, STRESS AND STRAINS OF ALUMINIUM T6-6063

MODAL ANALYSIS OF STRUCTURAL STEEL

Mode-1 Mode-2

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International Journal of Scientific Research and Review ISSN NO: 2279-543X

Mode-3 Mode-4

Mode-5

MODAL ANALYSIS OF KEVLAR EPOXY

Mode-1 Mode-2

Equivalent Shear stresses Equivalent stresses Equivalent Strains

(Mpa) (Mpa)
MATERIAL
Minimum Maximum Minimum Maximum Minimum Maximum

Structural steel 0.00095169 154.12 0.001815 293.64 2.4627e-8 0.0016699

Kevlar Epoxy 0.00089392 144.77 0.0017049 275.82 2.3133e-8 0.0015685

Epoxy - Glass 0.00090027 145.79 0.001717 277.77 2.3297e-8 0.0015797

Aluminum 0.00090725 146.92 0.0017303 279.3 2.3477e-8 0.0015919

T6-6063

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RESULTS OF MODAL ANALYSIS

MODES MATERIAL
STRUCTURAL KEVLAR EPOXY
STEEL
Mode-1 0 0
Mode-2 7.2032e-004 7.1961e-004
Mode-3 1.5034e-003 1.48e-003
Mode-4 4.1371 4.1404
Mode-5 6.6597 6.6651
Mode-6 23.071 23.09

CONCLUSION

• The use of composite material has come about to irrelevant measure of weight sparing in the scope of 24-29% when
contrasted with customary steel shaft.
• The displayed work was intended to decrease the fuel utilization of the vehicle in the specific or any machine, which
utilizes drive shafts; when all is said in done it is accomplished by utilizing light weight composites like
Kevlar/Epoxy.
• By taking into contemplations the weight sparing, distortion, shear pressure instigated and full Frequencies it is clear
that Kevlar/Epoxy composite has the most reassuring properties to go about as substitution for steel out of the
considered two materials.
• The gave work also deals with design optimization i.e. changing over two piece drive shaft (ordinary steel shaft) in
to single piece light weighted composite drive shaft
According to the plan and examination comes about we presume that our shaft coupling assembly design is most
appropriate to transmit torque at required speed. The shaft coupling assembly transmits the torque 15000 Nm at 30
rpm without failure and the greatest pressure created at the cross of the universal coupling which is surpass the
reasonable pressure so it needs to overhaul.

REFERENCES

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2. A.S.chavan, S.S.chavan European journal of operation research. 179(2007) 788-805
3. Soderberg C.R.,Working stresses, j.Appl.Mechanics
4. Loewenthal,S.H.,. proposed Design procedure for Transmission shafting under Fatigue loading,Technical Note
TM-7802,NASA,1978
5. Dr Andrew Pollard,,GKN Technology, Wolverhampton,UK Polymer matrix composites in driveline
applications
6. Kliger S, Yates D, Davis G, Economic and manufacturing considerations for composite drive shafts SAE paper
80005,1980
7. Sagar Dharmadhikari, Sachin Mahakalkar, Jayant Giri, Nilesh Khutafale Design and analysis of composite drive
shaft using Ansys and genetic algorithm,IJMER,vol.3,issue 1,jan-feb.2013 Pp-490-496
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