This project report summarizes a group project analyzing the use of composites for an automobile propeller shaft. The group members are listed. The project aims to reduce the weight and improve fuel efficiency by replacing the steel propeller shaft with a composite material like carbon epoxy or glass epoxy. Various materials were modeled and analyzed for deformation, stresses, and weight. Carbon epoxy and aluminum alloy AA 6063 showed the most reduction in weight (around 65-80%) and were recommended to replace conventional steel propeller shafts.

1. PROJECT REPORT
GROUP MEMBERS
ASHISH SINGH ASWAL
DEEP PRAKASH PANT
GAURAV PRAKASH JOSHI
AYUSH THAPLI

2. PROJECT TITLE
Analysis of Propeller (Drive) Shaft using
Composites
Project Guide – Mr. Rohit Pandey

3. Propeller shaft
 It is a connection between the transmission and
rear axle.
 It is a long cylindrical structure of two piece
steel drive shafts, consists of three universal
joints, center supporting bearing and a bracket.

4. Literature review
 V. S. Bhajantri , Arun Ravi Analysis of a Composite Drive
Shaft for Automotive by using Carbon/Epoxy.
 D.dinesh done Optimum Analysis of a Composite Drive
Shaft for an Automobile by Using Ansys using
Carbon/Epoxy.
 Harshal Bankar done Material Optimization and Weight
Reduction of Drive Shaft Using Composite Material
Boron/Epoxy.

5. Problem definition
In the steel drive shaft, the weight of the steel is
more due to which power is lost, because it takes
more energy to spin the heavier steel parts. This
power can be reduced by replacing the steel with
the composite drive shaft to enhance fuel
efficiency.

6. Overcoming Problem Definition
In this, stainless steel will be replaced by the
composites on the basis of various procedures.
composites like glass epoxy, carbon epoxy and
aluminium metal matrix composites undergo through
the deformation and theories of failure and then a
comparison will take and a most suitable material will
be chosen for the propeller shaft against stainless steel.
Thus by using composites the weight of the propeller
shaft will decrease and hence, fuel consumption will
also decrease.

7. Model
Drawing
CATIA Model

8. Engineering data
materials are either selected or created manually

9. Boundary condition :
- Meshing
- Fixed
support
MESHING :

10. - Torque
= 500Nm
In this, the finite element model of shaft - One end is fixed and a torque
of 500 Nm is applied at other end.

11. Deformation
Stainless steel
Carbon Epoxy AA 6061
Glass Epoxy

12. Deformation
AA 6063 AA 7075

13. Equivalent (von misses) stress
Stainless steel AA 6061
AA 6063 AA 7075

14. Maximum Principal stress
Carbon EpoxyGlass Epoxy
Stainless Steel

15. Maximum Shear stress
Stainless steel
AA 6063 AA 7075
AA 6061

16. Calculation
Formula :- m = Density* area * Length
= Density *(π/4) * ((90^2) – (84^2)) * 1000
Parameter Stainless
steel
Carbon
Epoxy
Glass Epoxy AA 6061 AA 6063 AA 7075
Density(kg/
m^3)
7750 1600 2500 2700 2700 2800
Length(mm) 1000 1000 1000 1000 1000 1000
External
Diameter(m
m)
90 90 90 90 90 90
Thickness(
mm)
3 3 3 3 3 3
Mass(Kg) 6.35 1.32 2.03 2.22 2.22 2.29
% saved ---- 79.2 68.03 65.3 65.3 63.93

17. RESULT AND CONCLUSION
Result
Material Deformation(m) Von-misses
stress
Maximum
Shear stress
Maximum
Principle stress
Stainless Steel Maximum 0.00019634 2.5184e7 1.454e7 1.4857e7
Minimum 0000 2.2429e7 1.2949e7 1.288e7
Carbon epoxy Maximum 0.00017907 ---- ---- 1.4855e7
Minimum 0000 ---- ---- 1.288e7
Glass epoxy Maximum 0.00043273 ---- ---- 1.4855e7
Minimum 0000 ---- ---- 1.288e7
AA 6061 Maximum 0.00041296 2.5182e7 1.4539e7 ----
Minimum 0000 2.2429e7 1.2949e7 ----
AA 6063 Maximum 0.00035124 2.5182e7 1.4539e7 ----
Minimum 0000 2.2429e7 1.2949e7 ----
AA 7075 Maximum 0.00035124 2.5182e7 1.4539e7 ----
Minimum 0000 2.2429e7 1.2949e7 ----

18. Conclusion
From the calculations & result it is seen that the
replacement of conventional drive shaft with the
composites results in reduction in weight of
automobile propeller shaft. Thus, Carbon Epoxy
and AA 6063 can be used instead of the
conventional drive shaft.

19. Thank You