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INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING
 International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME
                          AND TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)
ISSN 0976 – 6359 (Online)
                                                                                    IJMET
Volume 3, Issue 3, September - December (2012), pp. 438-449
© IAEME: www.iaeme.com/ijmet.asp
Journal Impact Factor (2012): 3.8071 (Calculated by GISI)
                                                                               ©IAEME
www.jifactor.com




     OPTIMUM DESIGN OF AUTOMOTIVE COMPOSITE DRIVE SHAFT
        WITH GENETIC ALGORITHM AS OPTIMIZATION TOOL
                                   Ghatage K.D1, Hargude N.V2
     1
       Department of Mechanical Engineering, RIT Sakhrale 415414, Sangli, Maharashtra, India;
   2
     Department of Mechanical Engineering,PVPIT Budhgon 416416, Sangli, Maharashtra, India
                    E-mail- ghatagekishor89@gmail.com; nvhargude@gmail.com

  1. ABSTRACT

  Substituting composite materials for conventional metallic structures has many advantages because of
  higher specific stiffness and strength of composite materials. Advanced composite materials seem ideally
  suited for long, power drive shaft applications. Their elastic properties can be tailored to increase the
  torque and the rotational speed at which they operate. This study has been carried out to investigate
  maximum torque; buckling torque transmission and critical speed of composite drive shaft. Main aim of
  this work is to investigate either replacing steel structure of drive shaft; for rear wheel drive passenger
  cars; by composite structures such as carbon/Epoxy and Glass/Epoxy materials will be convenient or not.
  For finding out the suitability of composite structures for automotive drive shaft application the
  parameters such as; ply thickness, number of plies and stacking sequence are optimized for carbon/Epoxy
  and Glass/Epoxy shafts using Genetic Algorithm as an optimization tool with the objective of weight
  minimization of the composite shaft which is subjected to constraints such as torque transmission,
  torsional buckling load and fundamental natural frequency.

  2. INTRODUCTION

  A driveshaft is the connection between the transmission and the rear axle of the car. The advanced
  composite materials such as Boron, Graphite, Carbon, Kevlar and Glass with suitable resins are widely
  used because of their high specific strength (strength/density) and high specific modulus
  (modulus/density). Polymer matrix composites were proposed for light weight shafts in drivelines for
  automotive, industries.




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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME




           Fig 1: The conventional two-piece steel drive shaft for a rear wheel driving vehicle.

The entire driveline of the car is composed of several components, each with rotating mass. The rule of
thumb is that 17-22% of the power generated by the engine is lost in rotating mass of the drive train. The
power is lost because it takes more energy to spin heavier parts. This energy loss can be reduced by
decreasing the amount of rotating mass. Light weight flywheels and transmission gears, aluminum and
carbon-fiber drive shafts, riffle-drilled axels, and aluminum hubs are all examples of replacement or
modified parts used to reduce the amount of rotating mass.

The torque capability of the drive shaft for passenger cars should be larger than 3500 Nm and the
fundamental bending natural frequency should be higher than 9200 rpm to avoid whirling vibration [2].
Since the fundamental bending natural frequency of a one-piece drive shafts made of steel or aluminum is
normally lower than 5700 rpm when the length of the drive shaft is around 1.5 m [2], the steel drive shaft
is usually manufactured in two pieces to increase the fundamental bending natural frequency because the
bending natural frequency of a shaft is inversely proportional to the square of beam length and
proportional to the square root of specific modulus. The two-piece steel drive shaft consists of three
universal joints, a center supporting bearing and a bracket, which increases the total weight of an
automotive vehicle and decreases fuel efficiency.
In the previous study by the authors [12], Genetic algorithm (GA) is applied for the design optimization
of steel leaf springs. Although design optimization of steel springs and composite leaf springs has been
the subject for quite few investigators; but few of the attempts were involving Genetic Algorithm as an
optimization tool.
In the present work an attempt has been made to evaluate the suitability of composite material such as E-
glass / epoxy and Carbon / epoxy for the purpose of automotive transmission applications. A one-piece
composite drive shaft for rear wheel drive automobile is designed optimally by using GA with the
objective of minimization of weight of the shaft which is subjected to the constraints such as torque
transmission, torsional buckling strength capabilities and natural bending frequency.

3. PROBLEMS ASSOCIATED WITH THE CONVENTIONAL STEEL DRIVE SHAFT

The torque transmission capability of the drive shaft for passenger cars, small trucks, and vans should be
larger than 3500 Nm (Tmax) and fundamental natural bending frequency of the drive shaft should be higher
than 6500 rpm (Nmax) to avoid whirling vibration. The drive shaft outer diameter do should not exceed
100 mm due to space limitations. Here outer diameter of the shaft is taken as 90 mm. For the purpose of
experimentation the composite drive shaft of 200 mm length and do= 32 mm amd di= 22 mm was
manufactured. Conventional steel drive shafts ; having less specific modulus and strength; are usually
manufactured in two pieces to increase the fundamental bending natural frequency because the bending
natural frequency of a shaft is inversely proportional to the square of beam length and proportional to the


                                                   439
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME

square root of specific modulus. Therefore the steel drive shaft is made in two sections connected by a
support structure, bearings and U-joints and hence over all weight of assembly will be more.

While on the other hand the fundamental natural frequency of the carbon fiber composite drive shaft can
be twice as high as that of steel or aluminium because the carbon fiber composite material has more than 4
times the specific stiffness of steel or aluminium, which makes it possible to manufacture the drive shaft of
passenger cars in one piece. A one-piece composite shaft can be manufactured so as to satisfy the vibration
requirements. Lower rotating weight transmits more of available power. This eliminates all the assembly,
connecting the two piece steel shafts and thus minimizes the overall weight, vibrations and the total cost.
Due to the weight reduction, fuel consumption will be reduced. Composite materials have high damping
capacity and hence they produce less vibration and noise with the ability of good corrosion resistance.
Composite structures have longer fatigue life than steel or aluminium shaft.


4. DESIGN OF COMPOSITE DRIVE SHAFT

While designing the composite drive shaft some assumptions are made such as the shaft rotates at a
constant speed about its longitudinal axis and has uniform circular cross section. All damping and
nonlinear effects are excluded and since lamina is thin and no out-of-plane loads are applied, it is
considered as under the plane stress. The stress-strain relationship for composite material is linear &
elastic; hence, Hook’s law is applicable for composite materials.
The drive shaft can be solid circular or hollow circular. Here hollow circular cross-section was chosen
because the hollow circular shafts are stronger in per kg weight than solid circular and the stress
distribution in case of solid shaft is zero at the centre and maximum at the outer surface while in hollow
shaft stress variation is smaller. In solid shafts the material close to the centre are not fully utilized.

                Table 1: Mechanical properties of E-glass / epoxy and HM carbon / epoxy

                             Property          Glass / epoxy      Carbon / epoxy
                             E11 (GPa)         50.0               190.0
                             E22 (GPa)         12.0               7.7
                             G12 (GPa)         5.6                4.2
                             ν12               0.3                0.3
                              T     C
                             σ 1= σ 1
                                               800.0              870.0
                             (MPa)
                              T    C
                             σ 2= σ 2
                                               40.0               54.0
                             (MPa)
                             τ12 (MPa)         72.0               30.0
                                        3
                             ρ (kg/m )         2000.0             1600.0
                             Vf                0.6                0.6

Table shows the properties of the E-glass / epoxy and high modulus carbon / epoxy materials used for
composite drive shafts. E11 , E22 , G12 , σT1 , σC1 , σT2 and σC2 represent lamina properties in longitudinal and
transverse directions (Fig. 2) respectively. ν12 , τ12 , ρ and Vf are the Poisons ratio, shear stress and fiber
volume fractions. Since, composites are highly orthotropic and their fractures were not fully studied the
factor of safety is taken as 2



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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME

4.1. Torque transmission of the composite drive shaft

Since the lamina is thin and no out-of-plane loads are applied, it is considered as the plane stress problem
and 3-D problem can be reduced into 2-D problem. For unidirectional 2-D lamina, the stress-strain
relationship in terms of physical material direction for unidirectional is given by [11],

  σଵ      Qଵଵ         Qଵଶ     0     εଵ
൝ σଶ ൡ = ൥Qଵଶ         Q ଶଶ    0 ൩ ൝ εଶ ൡ,
 τଵଶ       0           0     Q ଺଺ γଵଶ

where σ, τ, γ and ε represent stresses and strains in material directions. The matrix Q is referred as the
reduced stiffness matrix for the layer and its terms are given by [11]:
          ாభభ                              ௩భమ ாమమ
ܳଵଵ =                             ܳଵଶ =             	;
        ଵି௩భమ ௩మభ                         ଵି௩భమ ௩మభ
                  ,

           ா
ܳଶଶ = ଵି௩ మమ௩ ,                   ܳ଺଺ = ‫ܩ‬ଵଶ .        ܳଶଵ = ‫ܩ‬ଵଶ .
              భమ మభ


4.2. STRESS-STRAIN RELATIONSHIP FOR ANGLE-PLY LAMINA

The relation between material co-ordinate system and X-Y-Z co-ordinate system is shown in figure 2
below. Co-ordinate 1-2-3 are principle material directions co-ordinate X-Y-Z are transferred or laminate
axis




                    Fig 2: Relation between material coordinate system and X-Y coordinate system

For an angle-ply lamina, where fibbers are oriented at an angle with the positive X-axis (Longitudinal
axis of shaft), the effective elastic properties are given by [11],
   ଵ      ଵ            ଵ     ଶ௩                ଵ
1. ா = ா ‫ ܥ‬ସ +ቂீ − ா ቃ ܵ ଶ ‫ ܥ‬ଶ + ா ܵ ସ
   ೣ      భభ           భమ     భభ                మమ

   ଵ      ଵ            ଵ     ଶ௩                ଵ
2. ா = ா ܵ ସ +ቂீ − ா ቃ ܵ ଶ ‫ ܥ‬ଶ + ா ‫ ܥ‬ସ
   ೤      భభ           భమ     భభ               మమ

  ଵ            ଶ      ଶ      ଶ௩      ଵ                   ଵ
3. ீ = 2 ቂா + ா + ா − ீ ቃ ܵ ଶ ‫ ܥ‬ଶ + ீ [‫ ܥ‬ଶ + ܵ ଶ ]
               భభ     మమ     భభ      భమ                  భమ


The Stress strain relationship for an angle-ply lamina is given by;




                                                              441
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME

  σ୶      തതതതത
          Qଵଵ       തതതതത
                    Qଵଶ       തതതതത εଵ
                              Qଵ଺
൝ σ୷ ൡ = ቎തതതതത
          Qଵଶ       തതതതത
                    Q ଶଶ      തതതതത቏ ൝ εଶ ൡ;
                              Q ଶ଺
 τ୶୷      തതതതത
          Qଵ଺       തതതതത
                    Q ଶ଺      തതതതത γଵଶ
                              Q ଺଺


ܳ௜௝ matrix denotes transformed reduced stiffness. Its terms are individually given by [11]:
where σ and ε represent normal stresses and strains in X, Y and XY directions respectively and bar over


തതതതത
Qଵଵ = Qଵଵ c ସ + Q ଶଶ sସ + 2(Qଵଶ + 2Q ଺଺ )sଶ c ଶ;
തതതതത = (Qଵଵ + Q ଶଶ − 4Q ଺଺ )s ଶ c ଶ + Qଵଶ (c ସ + s ସ );
Qଵଶ
തതതതത = (Qଵଵ − Qଵଶ − 2Q ଺଺ )c ଷ s − (Q ଶଶ − Qଵଶ − 2Q ଺଺ )csଷ ;
Qଵ଺
തതതതത = Qଵଵ sସ + Q ଶଶ s ସ + 2(Qଵଵ + 2Q ଺଺ )s ଶ c ଶ ;
Q ଶଶ
തതതതത = (Qଵଵ − Qଵଶ − 2Q ଺଺ )csଷ − (Q ଶଶ − Qଵଶ − 2Q ଺଺ )c ଷ s;
Q ଶ଺
തതതതത = (Qଵଵ + Q ଶଶ − 2Qଵଶ − 2Q ଺଺ )sଶ c ଶ + Q ଺଺ (s ସ + c ସ ); with C = cosθ and S = sinθ.
Q ଺଺


4.3. TORSIONAL BUCKLING CAPACITY:

Since long thin hollow shafts are vulnerable to torsional buckling, the possibility of the torsional buckling
of the composite shaft was checked by the expression for the torsional buckling load Tcr of a thin walled

                                                                 ଴.ଶହ ‫ݐ‬
                                                                         ଵ.ହ
orthotropic tube, which is expressed below [3]:
                                ܶ௖௥ = (2ߨ‫ ݎ‬ଶ ‫)272.0()ݐ‬൫‫ܧ‬௫ ‫ܧ‬௬ ଷ ൯     ൬ ൰
                                                                      ‫ݎ‬
where Ex and Ey are the Young’s modulus of the composite shaft in axial and hoop direction, r and t are
the mean radius and thickness of the composite shaft.
This equation has been generated from the equation of isotropic cylindrical shell and has been used for
the design of drive shafts. From the equation, the torsional buckling capability of composite shaft is
strongly dependent on the thickness of composite shaft and the average modulus in the hoop direction.

4.4. Timoshenko beam theory (Nୡ୰୲ ):

Timoshenko beam theory considers both transerverse shear deformation as well as rotary inertia. Natural
frequency fnt based on the Timoshenko beam theory is given by:

           ଷ଴గ௣మ ாೣ ௥ మ
݂௡௧ = ‫ܭ‬௦        ට ଶఘ ;
             ௅మ
 ଵ           ௣మ గమ ௥ మ        ௙ா
       =1+             ൤1   + ீ ೞ ൨,
                               ೞ
௄ೞ మ           ଶ௅మ             ೣ೤


where fnt and p are the natural and first natural frequency. Ks is the shear coefficient of the natural
frequency (< 1), fs is a shape factor (equals to 2) for hollow circular cross-sections [7].


ܰ௖௥௧ = 60݂௡௧ .
Critical speed:

5. DESIGN OPTIMIZATION OF COMPOSITE DRIVE SHAFT

First, fibers are selected to provide the best stiffness and strength beside cost consideration. It is the best
selection, indeed, to use carbon fibers in all layers but due to their high prices a hybrid of layers of
carbon-epoxy and E-glass-epoxy could be utilized. Since the fiber orientation angle that offers the
maximum bending stiffness which leads to the maximum bending natural frequency is to place the fibers
longitudinally at zero angles from the shaft axis, on the other hand, the angle of ±45º orientation realizes

                                                     442
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME

the maximum shear strength and 90º is the best for buckling strength [4]. The main design goal is to
achieve the minimum weight while adjusting the variables to meet a sufficient margin of safety, which is
translated in a critical speed (natural frequency) higher than the operating speed, a critical torque higher
than the ultimate transmitted torque and a nominal stress (the maximum at fiber direction) less than the
allowable stress after applying any of the failure criteria like the maximum stress criteria [4].
Due to the physical geometry (larger radius) of the drive shafts used in the mentioned applications
including automotive applications, the shear strength which specify the load carrying capacity, is of minor
design importance since the failure mode is dominated by buckling, therefore the main design factors are
the bending natural frequency and the torsional buckling strength, which are functions of the longitudinal
and hoop bending stiffness, respectively [4]. The variable of the laminate thickness has a big effect on the
buckling strength and slight effect on bending natural frequency.

5.1. Objective Function:
         The objective for the optimum design of the composite drive shaft is the minimization of weight,

݉ = ߩ‫,ܮܣ‬
so the objective function of the problem is given as weight of the shaft:


        గ
݉ = ߩ (݀௢ ଶ − ݀௜ ଶ )‫,ܮ‬
Or
        ସ

5.2. Design Variables:
The design variables of the problem are
     • Number of plies [n];
     • Stacking Sequence [θk];
    • Thickness of the ply [tk].
The limiting values of the design variables are;

    2] -90≤ ߠ௞ ≤90
    1] n ≥ 0

    3] 0.1≤ ‫ݐ‬௞ ≤0.5
where k = 1, 2,…, n and n = 1, 2, 3,…, 32.
The number of plies required depends on the design constraints, allowable material properties, thickness
of plies and stacking sequence. Based on the investigations it was found that up to 32 numbers of plies are
sufficient.

5.3. Design Constraints:

1. Torque transmission capacity of the shaft: ܶ ≥ ܶ௠௔௫
2. Bucking torque capacity of the shaft: ܶ௖௥ ≥ ܶ௠௔௫
3. Lateral fundamental natural frequency: ܰ௖௥௧ ≥ ܰ௠௔௫

The constraint equations may be written as:
            ்
‫ܥ‬ଵ = ቀ1 − ் ቁ, If ܶ < ܶ௠௔௫
            ೘ೌೣ
                       = 0 Otherwise;
             ்೎ೝ
‫ܥ‬ଶ = ቀ1 −   ்೘ೌೣ
                 ቁ,   If ܶ௖௥ < ܶ௠௔௫
                      = 0 Otherwise;
            ே೎ೝ೟
‫ܥ‬ଷ = ቀ1 −        ቁ,   If ܰ௖௥௧ < ܰ௠௔௫
            ே೘ೌೣ


‫ܥ=ܥ‬ଵ +	‫ܥ‬ଶ + ‫ܥ‬ଷ.
                      = 0 Otherwise



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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME

A new algorithm has been developed using MATLAB R2007b for optimum design of automobile
composite drive shaft for following design specification which should be sustained by both steel and
composite drive shafts.

                    Table 2: constraints of design optimization of composite drive shaft

                         Material                    Steel (SM45C)           Glass/Epoxy and
                                                                              Carbon Epoxy
                          Length                          200mm                  200 mm
                    Inner Diameter                          22                    24 mm
                   Outer Diameter                           32                    34 mm

                                                                             (in terms of ߠ)
              Possible angle combination                     -                 -45/0/45/90
                 (Stacking sequence)
               Maximum number of plies                       1                     10
             Maximum torque transmission                  1350 Nm               1350 Nm
                   capacity (ܶ௠௔௫ )
               Maximum buckling torque                    1350 Nm               1350 Nm
            transmission capacity (ܶ௖௥	௠௔௫ )
                 Critical Speed (ܰ௖௥௧ )                   4500 Nm               4500 rpm


6. RESULTS AND DISCUSSION

Following table 3 & 4 shows the optimized results for Carbon/Epoxy and Glass/Epoxy composite drive
shaft;

                            Table 3: Optimization of carbon/epoxy drive shaft

   NO. OF          STACKING            MAXIMUM              BUCKLING          Critical Speed   MASS

                  (In ࣂ and from
  LAYERS           SEQUENCE             TORQUE               TORQUE                (Ncrt)       (m)
                                      TRANSMISS-          TRANSMISSI-ON           (rpm)        (KG)
                   Inner layer to    ION CAPACITY           CAPACITY
                    outer layer)         (Tmsx)                (Tcrt)
                                          (Nm)                 (Nm)


      1       0                           340.32                 507.55            19187       0.101
      2       0/0                         528.65                 1029.01           27285       0.131
      3       0/0/0                       730.23                 1564.02           27936       0.271
      4       90/0/0/0                    947.78                 2112.25           28534       0.418
      5       45/90/0/0/0                1179.58                 2317.90           29087       0.573
      6       -45/45/90/0/0/0           1429.5472            2526.4331             29595       0.612
      7       0/-45/45/90/0/0/0          1698.96                 3093.27           30067       0.894
      8       90/0/-                     1985.24                 3672.69           30495       1.082
              45/45/90/0/0/0




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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
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                      Table 4: Optimization of glass-carbon/epoxy drive shaft

 NO. OF        STACKING                                MAXIMUM          BUCKLING           Critical   MASS

              (In ࣂ and from
 LAYERS        SEQUENCE                                 TORQUE           TORQUE             Speed      (m)
                                                      TRANSMISS-       TRANSMISSI-           (Ncrt)   (KG)
            Inner layer to outer                          ION          ON CAPACITY          (rpm)
                   layer)                              CAPACITY            (Tcrt)
                                                         (Tmsx)            (Nm)
                                                          (Nm)
     1      0                                            309.52            463.8619         8747      0.105
     2      0/90                                        480.49             1244.0453        8486      0.131
     3      0/90/90                                     663.29             2044.4965        8887      0.271
     4      0/90/90/90                                  860.13             2864.7149        9013      0.418
     5      -45/0/90/90/90                              1072.09            3085.8766       10376      0.573
     6      45/-45/0/90/90/90                           1299.57            3309.3942        8281      0.635
     7      90/-                                       1543.5649           4145.5415        9325      0.829
            45/45/0/90/90/90
     8      0/90/-                                      1804.76            4705.2754        9410      1.082
            45/45/0/90/90/90

           Graph: Maximum torque transmission capacity of Carbon/Epoxy Shaft

                                            CARBON/EPOXY: MAXIMUM TORQUE
                                              TRANSMISSION CAPACITY (Nm)
                   Transmission Capacity




                                           2000
                     Maximum Toeque




                                           1500                                             1
                                           1000                                             2
                           (Nm)




                                            500
                                                                                            3
                                              0
                                                  0     2        4     6      8       10    4
                                                                                            5
                                                  Stacking Sequence in Degrees




                                                                 445
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME

         Graph: Maximum torque transmission capacity of Glass-Carbon/Epoxy Shaft

                                       GLASS-CARBON/EPOXY:- MAXIMUM TORQUE
                                             TRANSMISSION CAPACITY (Nm)
                                             2000


                    transmission Capacity
                                             1500                                                      1
                      Maximum Torque         1000                                                      2
                                              500
                            ()Nm
                                                0                                                      3

                                                     0            2       4       6       8       10   4

                                                            Stacking Sequence in Degrees               5




            Graph: Buckling torque transmission capacity of Carbon/Epoxy Shaft

                                                   CARBON/EPOXY: BUCKLING TORQUE
                                                     TRANSMISSION CAPACITY (Nm)
               Capacity in (Nm)
                Transmission
                  Buckling




                                            4000                                                           1
                                            2000                                                           2
                                              0                                                            3
                                                        1     2       3       4   5   6       7   8        4
                                                            Stacking Sequence in Degrees                   5




        Graph: Buckling torque transmission capacity of Glass-Carbon/Epoxy Shaft

                                       GLASS-CARBON/EPOXY:-BUCKLING TORQUE
                                              TRANSMISSION CAPACITY
                 Buckling Torque

                  capacty (Nm)
                  Transmission




                                            6000                                                       1
                                            4000
                                            2000                                                       2
                                               0                                                       3
                                                    0         2           4       6       8       10   4
                                                            Stacking Sequence in Degrees
                                                                                                       5




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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep Dec (2012) © IAEME
                                                         Sep-

                                   Graph: Carbon/Epoxy: Number of layers Vs Critical speed

                                               CARBON/EPOXY: NOMBER OF LAYERS Vs CRITICAL
                                             40000             SPEED (rpm)



                     Critical Speed (rpm)
                                                                                                               1
                                             20000
                                                                                                               2
                                                                                                               3
                                                 0
                                                                                                               4
                                                      0      2         4
                                                                  Number Of layers
                                                                                  6        8        10

                  Graph: Glass-Carbon/Epoxy: Number of layers Vs Critical speed
                               Carbon/Epoxy:

                                              GLASS-CARBON/EPOXY: NUMBER OF LAYERS Vs CRITICAL SPEEED (rpm)
                                                    CARBON/EPOXY:-


                                             15000
                                                                                                               1
                    Critical Speed (rpm)




                                             10000
                                                                                                               2
                                              5000
                                                 0                                                             3
                                                      0       2        4          6        8        10         4
                                                                   Number Of Layers                            5


                                               Graph: Critical speed analy in composite drive shafts
                                                                     analysis



                                                           Shaft Length and Critical Speed
                                             20000
                      Critical Speed (rpm)




                                             15000

                                             10000                                              Composite Drive
                                                                                                Shaft
                                              5000
                                                                                                Steel Drive Shaft
                                                  0
                                                      0    1000    2000    3000   4000
                                                          Shaft Length (mm)



Graph shows that for the steel drive shaft having about 6000 revolutions per minute can be manufactured
of length about 1m to 1.5m while on the other hand for composite drive shaft it is possible to manufacture
a shaft of length 1.5m to 2 m for same revolutions.
         f




                                                                           447
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME

6.1. Mass Comparison between Steel and Composite drive Shafts

Following table gives the comparison of masses of conventional steel drive shaft, Carbon/Epoxy and
Glass-Carbon/Epoxy composite drive shaft.


                                          Material            Weight          Weight
                                                               (Kg)          Reduction
                                                                               (%)
                                            Steel              0.489             -

                                       Glass-                  0.412           15.75
                                   Carbon/Epoxy

                                    Carbon Epoxy               0.352           28.01


                                           Graph: Mass Comparison of three shafts

                                        Mass comparison between Steel and Composite Drive
                                                             Shaft
                                  0.6
                                  0.5
                                                                                STEEL
                     Mass in Kg




                                  0.4
                                  0.3
                                  0.2                                           Glass-
                                  0.1                                           Carbon/Epoxy
                                    0
                                                                                Carbon Epoxy




7. CONCLUSION
From preliminary experiments and studies of physical properties like weight, material combination,
torque transmitting capacities, etc. it is concluded that:
    • A one-piece composite drive shaft made of Carbon/Epoxy and Glass-Carbon/Epoxy is designed
         optimally with Genetic Algorithm as optimization tool with the objective of minimization of
         weight of drive shaft which is subjected to constraints such as Maximum torque transmission
         capacity, Buckling torque transmission capacity and critical speed.
    • About 28.01 % of weight saving is achieved with Carbon/Epoxy shaft with increase in critical
         speed enabling manufacturing of shaft of length 1.8m to 2 m; as compared to steel shaft; by
         experimentation.
    • About 15.75% weight saving is achieved with Glass-Carbon/Epoxy composite shaft with increase
         in critical speed enabling manufacturing of shaft of length 1.7 m to 2m; as compared to steel
         shaft; by experimentation.
    • The results reveal that the orientation of fibers has great influence on the dynamic characteristics
         of the composite material shafts in a positive direction.
    • Genetic Algorithm is suggested as an effective optimization tool.


                                                             448
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME

8. REFERENCES

1. Thimmegowda Rangaswamy, and Sabapathy Vijayarangan “Optimal Sizing and Stacking Sequence of
Composite Drive Shafts” journal of Material science, Vol.11, No.2, 2005.

2. R.R Ajith, T. Rangaswamy, S. Vijayarangan and G. Chandramohan “Genetic Algorithm Based
Optimal Design Of Composite Shaft” International journal of Material Science and Engineering,
December2004.

3. Dai Gil Lee and Hak Sung Kim “Design and manufacture of an automotive hybrid
aluminum/composite drive shaft” journal of composite structure, Vol 63, 2004 pp.87-99.

4. M. A. Badie, A. Mahdi, and A. R. Abutalib “Automotive composite drive shafts: Investigation of the
design variable effects” International Journal of Engineering and Technology, Vol. 3, No.2, 2006, pp.
227-237.

5. Durk Hyun Cho, Dai Gil Li, Jin Ho Choi “Manufacture of one-piece automotive drive shafts with
aluminum and composite materials” journals of Composite structure, Vol. 38, No. l-4, 1997 pp. 309-319.

6. M.A.K. Chowdhuri , R.A. Hossain, Design Analysis of an Automotive Composite DriveShaft,
International Journal of Engineering and Technology Vol.2(2), 2010, 45-48.

7. Rajeev., S., Krishnamoorthy, C. S. Discrete Optimization of Structure Using Genetic Algorithms J.
Structural Engg. ASCE 118 1992: pp. 1233 – 1250.

8. Goldberg, D. E. Genetic Algorithms in Search, Optimization and Machine Learning, Reading MA,
Addison-Wesley, 1989.

9.Rastogi, N. (2004), Design of composite driveshafts for automotive applications, SAE, Technical Paper
Series, 2004-01-0485.

10. Darlow, M. S. and Creonte, J. (1995), Optimal design of composite helicopter power transmission
shafts with axially varying fibre lay-up, Journal of the American Helicopter Society 40 (2): 50-56.

11. Rao, S. S. Mechanical Vibrations. Addision-Wesely Publishing Company, NY: pp. 537 – 541.

12. Vijayarangan, S., et. al. Design Optimization of Leaf Springs Using Genetic Algorithms Inst. Engrs.
India Mech. Engng. Div. 79 1999: pp. 135 – 139.

13. A.R. Abu Talib et al “Developing a hybrid, carbon/glass fiber-reinforced, epoxy composite
 automotive drive shaft” journal of Materials and Design 31 (2010) 514–521




                                                  449

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OPTIMIZING COMPOSITE DRIVE SHAFT DESIGN WITH GENETIC ALGORITHM

  • 1. INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME AND TECHNOLOGY (IJMET) ISSN 0976 – 6340 (Print) ISSN 0976 – 6359 (Online) IJMET Volume 3, Issue 3, September - December (2012), pp. 438-449 © IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2012): 3.8071 (Calculated by GISI) ©IAEME www.jifactor.com OPTIMUM DESIGN OF AUTOMOTIVE COMPOSITE DRIVE SHAFT WITH GENETIC ALGORITHM AS OPTIMIZATION TOOL Ghatage K.D1, Hargude N.V2 1 Department of Mechanical Engineering, RIT Sakhrale 415414, Sangli, Maharashtra, India; 2 Department of Mechanical Engineering,PVPIT Budhgon 416416, Sangli, Maharashtra, India E-mail- ghatagekishor89@gmail.com; nvhargude@gmail.com 1. ABSTRACT Substituting composite materials for conventional metallic structures has many advantages because of higher specific stiffness and strength of composite materials. Advanced composite materials seem ideally suited for long, power drive shaft applications. Their elastic properties can be tailored to increase the torque and the rotational speed at which they operate. This study has been carried out to investigate maximum torque; buckling torque transmission and critical speed of composite drive shaft. Main aim of this work is to investigate either replacing steel structure of drive shaft; for rear wheel drive passenger cars; by composite structures such as carbon/Epoxy and Glass/Epoxy materials will be convenient or not. For finding out the suitability of composite structures for automotive drive shaft application the parameters such as; ply thickness, number of plies and stacking sequence are optimized for carbon/Epoxy and Glass/Epoxy shafts using Genetic Algorithm as an optimization tool with the objective of weight minimization of the composite shaft which is subjected to constraints such as torque transmission, torsional buckling load and fundamental natural frequency. 2. INTRODUCTION A driveshaft is the connection between the transmission and the rear axle of the car. The advanced composite materials such as Boron, Graphite, Carbon, Kevlar and Glass with suitable resins are widely used because of their high specific strength (strength/density) and high specific modulus (modulus/density). Polymer matrix composites were proposed for light weight shafts in drivelines for automotive, industries. 438
  • 2. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME Fig 1: The conventional two-piece steel drive shaft for a rear wheel driving vehicle. The entire driveline of the car is composed of several components, each with rotating mass. The rule of thumb is that 17-22% of the power generated by the engine is lost in rotating mass of the drive train. The power is lost because it takes more energy to spin heavier parts. This energy loss can be reduced by decreasing the amount of rotating mass. Light weight flywheels and transmission gears, aluminum and carbon-fiber drive shafts, riffle-drilled axels, and aluminum hubs are all examples of replacement or modified parts used to reduce the amount of rotating mass. The torque capability of the drive shaft for passenger cars should be larger than 3500 Nm and the fundamental bending natural frequency should be higher than 9200 rpm to avoid whirling vibration [2]. Since the fundamental bending natural frequency of a one-piece drive shafts made of steel or aluminum is normally lower than 5700 rpm when the length of the drive shaft is around 1.5 m [2], the steel drive shaft is usually manufactured in two pieces to increase the fundamental bending natural frequency because the bending natural frequency of a shaft is inversely proportional to the square of beam length and proportional to the square root of specific modulus. The two-piece steel drive shaft consists of three universal joints, a center supporting bearing and a bracket, which increases the total weight of an automotive vehicle and decreases fuel efficiency. In the previous study by the authors [12], Genetic algorithm (GA) is applied for the design optimization of steel leaf springs. Although design optimization of steel springs and composite leaf springs has been the subject for quite few investigators; but few of the attempts were involving Genetic Algorithm as an optimization tool. In the present work an attempt has been made to evaluate the suitability of composite material such as E- glass / epoxy and Carbon / epoxy for the purpose of automotive transmission applications. A one-piece composite drive shaft for rear wheel drive automobile is designed optimally by using GA with the objective of minimization of weight of the shaft which is subjected to the constraints such as torque transmission, torsional buckling strength capabilities and natural bending frequency. 3. PROBLEMS ASSOCIATED WITH THE CONVENTIONAL STEEL DRIVE SHAFT The torque transmission capability of the drive shaft for passenger cars, small trucks, and vans should be larger than 3500 Nm (Tmax) and fundamental natural bending frequency of the drive shaft should be higher than 6500 rpm (Nmax) to avoid whirling vibration. The drive shaft outer diameter do should not exceed 100 mm due to space limitations. Here outer diameter of the shaft is taken as 90 mm. For the purpose of experimentation the composite drive shaft of 200 mm length and do= 32 mm amd di= 22 mm was manufactured. Conventional steel drive shafts ; having less specific modulus and strength; are usually manufactured in two pieces to increase the fundamental bending natural frequency because the bending natural frequency of a shaft is inversely proportional to the square of beam length and proportional to the 439
  • 3. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME square root of specific modulus. Therefore the steel drive shaft is made in two sections connected by a support structure, bearings and U-joints and hence over all weight of assembly will be more. While on the other hand the fundamental natural frequency of the carbon fiber composite drive shaft can be twice as high as that of steel or aluminium because the carbon fiber composite material has more than 4 times the specific stiffness of steel or aluminium, which makes it possible to manufacture the drive shaft of passenger cars in one piece. A one-piece composite shaft can be manufactured so as to satisfy the vibration requirements. Lower rotating weight transmits more of available power. This eliminates all the assembly, connecting the two piece steel shafts and thus minimizes the overall weight, vibrations and the total cost. Due to the weight reduction, fuel consumption will be reduced. Composite materials have high damping capacity and hence they produce less vibration and noise with the ability of good corrosion resistance. Composite structures have longer fatigue life than steel or aluminium shaft. 4. DESIGN OF COMPOSITE DRIVE SHAFT While designing the composite drive shaft some assumptions are made such as the shaft rotates at a constant speed about its longitudinal axis and has uniform circular cross section. All damping and nonlinear effects are excluded and since lamina is thin and no out-of-plane loads are applied, it is considered as under the plane stress. The stress-strain relationship for composite material is linear & elastic; hence, Hook’s law is applicable for composite materials. The drive shaft can be solid circular or hollow circular. Here hollow circular cross-section was chosen because the hollow circular shafts are stronger in per kg weight than solid circular and the stress distribution in case of solid shaft is zero at the centre and maximum at the outer surface while in hollow shaft stress variation is smaller. In solid shafts the material close to the centre are not fully utilized. Table 1: Mechanical properties of E-glass / epoxy and HM carbon / epoxy Property Glass / epoxy Carbon / epoxy E11 (GPa) 50.0 190.0 E22 (GPa) 12.0 7.7 G12 (GPa) 5.6 4.2 ν12 0.3 0.3 T C σ 1= σ 1 800.0 870.0 (MPa) T C σ 2= σ 2 40.0 54.0 (MPa) τ12 (MPa) 72.0 30.0 3 ρ (kg/m ) 2000.0 1600.0 Vf 0.6 0.6 Table shows the properties of the E-glass / epoxy and high modulus carbon / epoxy materials used for composite drive shafts. E11 , E22 , G12 , σT1 , σC1 , σT2 and σC2 represent lamina properties in longitudinal and transverse directions (Fig. 2) respectively. ν12 , τ12 , ρ and Vf are the Poisons ratio, shear stress and fiber volume fractions. Since, composites are highly orthotropic and their fractures were not fully studied the factor of safety is taken as 2 440
  • 4. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME 4.1. Torque transmission of the composite drive shaft Since the lamina is thin and no out-of-plane loads are applied, it is considered as the plane stress problem and 3-D problem can be reduced into 2-D problem. For unidirectional 2-D lamina, the stress-strain relationship in terms of physical material direction for unidirectional is given by [11], σଵ Qଵଵ Qଵଶ 0 εଵ ൝ σଶ ൡ = ൥Qଵଶ Q ଶଶ 0 ൩ ൝ εଶ ൡ, τଵଶ 0 0 Q ଺଺ γଵଶ where σ, τ, γ and ε represent stresses and strains in material directions. The matrix Q is referred as the reduced stiffness matrix for the layer and its terms are given by [11]: ாభభ ௩భమ ாమమ ܳଵଵ = ܳଵଶ = ; ଵି௩భమ ௩మభ ଵି௩భమ ௩మభ , ா ܳଶଶ = ଵି௩ మమ௩ , ܳ଺଺ = ‫ܩ‬ଵଶ . ܳଶଵ = ‫ܩ‬ଵଶ . భమ మభ 4.2. STRESS-STRAIN RELATIONSHIP FOR ANGLE-PLY LAMINA The relation between material co-ordinate system and X-Y-Z co-ordinate system is shown in figure 2 below. Co-ordinate 1-2-3 are principle material directions co-ordinate X-Y-Z are transferred or laminate axis Fig 2: Relation between material coordinate system and X-Y coordinate system For an angle-ply lamina, where fibbers are oriented at an angle with the positive X-axis (Longitudinal axis of shaft), the effective elastic properties are given by [11], ଵ ଵ ଵ ଶ௩ ଵ 1. ா = ா ‫ ܥ‬ସ +ቂீ − ா ቃ ܵ ଶ ‫ ܥ‬ଶ + ா ܵ ସ ೣ భభ భమ భభ మమ ଵ ଵ ଵ ଶ௩ ଵ 2. ா = ா ܵ ସ +ቂீ − ா ቃ ܵ ଶ ‫ ܥ‬ଶ + ா ‫ ܥ‬ସ ೤ భభ భమ భభ మమ ଵ ଶ ଶ ଶ௩ ଵ ଵ 3. ீ = 2 ቂா + ா + ா − ீ ቃ ܵ ଶ ‫ ܥ‬ଶ + ீ [‫ ܥ‬ଶ + ܵ ଶ ] భభ మమ భభ భమ భమ The Stress strain relationship for an angle-ply lamina is given by; 441
  • 5. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME σ୶ തതതതത Qଵଵ തതതതത Qଵଶ തതതതത εଵ Qଵ଺ ൝ σ୷ ൡ = ቎തതതതത Qଵଶ തതതതത Q ଶଶ തതതതത቏ ൝ εଶ ൡ; Q ଶ଺ τ୶୷ തതതതത Qଵ଺ തതതതത Q ଶ଺ തതതതത γଵଶ Q ଺଺ ܳ௜௝ matrix denotes transformed reduced stiffness. Its terms are individually given by [11]: where σ and ε represent normal stresses and strains in X, Y and XY directions respectively and bar over തതതതത Qଵଵ = Qଵଵ c ସ + Q ଶଶ sସ + 2(Qଵଶ + 2Q ଺଺ )sଶ c ଶ; തതതതത = (Qଵଵ + Q ଶଶ − 4Q ଺଺ )s ଶ c ଶ + Qଵଶ (c ସ + s ସ ); Qଵଶ തതതതത = (Qଵଵ − Qଵଶ − 2Q ଺଺ )c ଷ s − (Q ଶଶ − Qଵଶ − 2Q ଺଺ )csଷ ; Qଵ଺ തതതതത = Qଵଵ sସ + Q ଶଶ s ସ + 2(Qଵଵ + 2Q ଺଺ )s ଶ c ଶ ; Q ଶଶ തതതതത = (Qଵଵ − Qଵଶ − 2Q ଺଺ )csଷ − (Q ଶଶ − Qଵଶ − 2Q ଺଺ )c ଷ s; Q ଶ଺ തതതതത = (Qଵଵ + Q ଶଶ − 2Qଵଶ − 2Q ଺଺ )sଶ c ଶ + Q ଺଺ (s ସ + c ସ ); with C = cosθ and S = sinθ. Q ଺଺ 4.3. TORSIONAL BUCKLING CAPACITY: Since long thin hollow shafts are vulnerable to torsional buckling, the possibility of the torsional buckling of the composite shaft was checked by the expression for the torsional buckling load Tcr of a thin walled ଴.ଶହ ‫ݐ‬ ଵ.ହ orthotropic tube, which is expressed below [3]: ܶ௖௥ = (2ߨ‫ ݎ‬ଶ ‫)272.0()ݐ‬൫‫ܧ‬௫ ‫ܧ‬௬ ଷ ൯ ൬ ൰ ‫ݎ‬ where Ex and Ey are the Young’s modulus of the composite shaft in axial and hoop direction, r and t are the mean radius and thickness of the composite shaft. This equation has been generated from the equation of isotropic cylindrical shell and has been used for the design of drive shafts. From the equation, the torsional buckling capability of composite shaft is strongly dependent on the thickness of composite shaft and the average modulus in the hoop direction. 4.4. Timoshenko beam theory (Nୡ୰୲ ): Timoshenko beam theory considers both transerverse shear deformation as well as rotary inertia. Natural frequency fnt based on the Timoshenko beam theory is given by: ଷ଴గ௣మ ாೣ ௥ మ ݂௡௧ = ‫ܭ‬௦ ට ଶఘ ; ௅మ ଵ ௣మ గమ ௥ మ ௙ா =1+ ൤1 + ீ ೞ ൨, ೞ ௄ೞ మ ଶ௅మ ೣ೤ where fnt and p are the natural and first natural frequency. Ks is the shear coefficient of the natural frequency (< 1), fs is a shape factor (equals to 2) for hollow circular cross-sections [7]. ܰ௖௥௧ = 60݂௡௧ . Critical speed: 5. DESIGN OPTIMIZATION OF COMPOSITE DRIVE SHAFT First, fibers are selected to provide the best stiffness and strength beside cost consideration. It is the best selection, indeed, to use carbon fibers in all layers but due to their high prices a hybrid of layers of carbon-epoxy and E-glass-epoxy could be utilized. Since the fiber orientation angle that offers the maximum bending stiffness which leads to the maximum bending natural frequency is to place the fibers longitudinally at zero angles from the shaft axis, on the other hand, the angle of ±45º orientation realizes 442
  • 6. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME the maximum shear strength and 90º is the best for buckling strength [4]. The main design goal is to achieve the minimum weight while adjusting the variables to meet a sufficient margin of safety, which is translated in a critical speed (natural frequency) higher than the operating speed, a critical torque higher than the ultimate transmitted torque and a nominal stress (the maximum at fiber direction) less than the allowable stress after applying any of the failure criteria like the maximum stress criteria [4]. Due to the physical geometry (larger radius) of the drive shafts used in the mentioned applications including automotive applications, the shear strength which specify the load carrying capacity, is of minor design importance since the failure mode is dominated by buckling, therefore the main design factors are the bending natural frequency and the torsional buckling strength, which are functions of the longitudinal and hoop bending stiffness, respectively [4]. The variable of the laminate thickness has a big effect on the buckling strength and slight effect on bending natural frequency. 5.1. Objective Function: The objective for the optimum design of the composite drive shaft is the minimization of weight, ݉ = ߩ‫,ܮܣ‬ so the objective function of the problem is given as weight of the shaft: గ ݉ = ߩ (݀௢ ଶ − ݀௜ ଶ )‫,ܮ‬ Or ସ 5.2. Design Variables: The design variables of the problem are • Number of plies [n]; • Stacking Sequence [θk]; • Thickness of the ply [tk]. The limiting values of the design variables are; 2] -90≤ ߠ௞ ≤90 1] n ≥ 0 3] 0.1≤ ‫ݐ‬௞ ≤0.5 where k = 1, 2,…, n and n = 1, 2, 3,…, 32. The number of plies required depends on the design constraints, allowable material properties, thickness of plies and stacking sequence. Based on the investigations it was found that up to 32 numbers of plies are sufficient. 5.3. Design Constraints: 1. Torque transmission capacity of the shaft: ܶ ≥ ܶ௠௔௫ 2. Bucking torque capacity of the shaft: ܶ௖௥ ≥ ܶ௠௔௫ 3. Lateral fundamental natural frequency: ܰ௖௥௧ ≥ ܰ௠௔௫ The constraint equations may be written as: ் ‫ܥ‬ଵ = ቀ1 − ் ቁ, If ܶ < ܶ௠௔௫ ೘ೌೣ = 0 Otherwise; ்೎ೝ ‫ܥ‬ଶ = ቀ1 − ்೘ೌೣ ቁ, If ܶ௖௥ < ܶ௠௔௫ = 0 Otherwise; ே೎ೝ೟ ‫ܥ‬ଷ = ቀ1 − ቁ, If ܰ௖௥௧ < ܰ௠௔௫ ே೘ೌೣ ‫ܥ=ܥ‬ଵ + ‫ܥ‬ଶ + ‫ܥ‬ଷ. = 0 Otherwise 443
  • 7. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME A new algorithm has been developed using MATLAB R2007b for optimum design of automobile composite drive shaft for following design specification which should be sustained by both steel and composite drive shafts. Table 2: constraints of design optimization of composite drive shaft Material Steel (SM45C) Glass/Epoxy and Carbon Epoxy Length 200mm 200 mm Inner Diameter 22 24 mm Outer Diameter 32 34 mm (in terms of ߠ) Possible angle combination - -45/0/45/90 (Stacking sequence) Maximum number of plies 1 10 Maximum torque transmission 1350 Nm 1350 Nm capacity (ܶ௠௔௫ ) Maximum buckling torque 1350 Nm 1350 Nm transmission capacity (ܶ௖௥ ௠௔௫ ) Critical Speed (ܰ௖௥௧ ) 4500 Nm 4500 rpm 6. RESULTS AND DISCUSSION Following table 3 & 4 shows the optimized results for Carbon/Epoxy and Glass/Epoxy composite drive shaft; Table 3: Optimization of carbon/epoxy drive shaft NO. OF STACKING MAXIMUM BUCKLING Critical Speed MASS (In ࣂ and from LAYERS SEQUENCE TORQUE TORQUE (Ncrt) (m) TRANSMISS- TRANSMISSI-ON (rpm) (KG) Inner layer to ION CAPACITY CAPACITY outer layer) (Tmsx) (Tcrt) (Nm) (Nm) 1 0 340.32 507.55 19187 0.101 2 0/0 528.65 1029.01 27285 0.131 3 0/0/0 730.23 1564.02 27936 0.271 4 90/0/0/0 947.78 2112.25 28534 0.418 5 45/90/0/0/0 1179.58 2317.90 29087 0.573 6 -45/45/90/0/0/0 1429.5472 2526.4331 29595 0.612 7 0/-45/45/90/0/0/0 1698.96 3093.27 30067 0.894 8 90/0/- 1985.24 3672.69 30495 1.082 45/45/90/0/0/0 444
  • 8. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME Table 4: Optimization of glass-carbon/epoxy drive shaft NO. OF STACKING MAXIMUM BUCKLING Critical MASS (In ࣂ and from LAYERS SEQUENCE TORQUE TORQUE Speed (m) TRANSMISS- TRANSMISSI- (Ncrt) (KG) Inner layer to outer ION ON CAPACITY (rpm) layer) CAPACITY (Tcrt) (Tmsx) (Nm) (Nm) 1 0 309.52 463.8619 8747 0.105 2 0/90 480.49 1244.0453 8486 0.131 3 0/90/90 663.29 2044.4965 8887 0.271 4 0/90/90/90 860.13 2864.7149 9013 0.418 5 -45/0/90/90/90 1072.09 3085.8766 10376 0.573 6 45/-45/0/90/90/90 1299.57 3309.3942 8281 0.635 7 90/- 1543.5649 4145.5415 9325 0.829 45/45/0/90/90/90 8 0/90/- 1804.76 4705.2754 9410 1.082 45/45/0/90/90/90 Graph: Maximum torque transmission capacity of Carbon/Epoxy Shaft CARBON/EPOXY: MAXIMUM TORQUE TRANSMISSION CAPACITY (Nm) Transmission Capacity 2000 Maximum Toeque 1500 1 1000 2 (Nm) 500 3 0 0 2 4 6 8 10 4 5 Stacking Sequence in Degrees 445
  • 9. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME Graph: Maximum torque transmission capacity of Glass-Carbon/Epoxy Shaft GLASS-CARBON/EPOXY:- MAXIMUM TORQUE TRANSMISSION CAPACITY (Nm) 2000 transmission Capacity 1500 1 Maximum Torque 1000 2 500 ()Nm 0 3 0 2 4 6 8 10 4 Stacking Sequence in Degrees 5 Graph: Buckling torque transmission capacity of Carbon/Epoxy Shaft CARBON/EPOXY: BUCKLING TORQUE TRANSMISSION CAPACITY (Nm) Capacity in (Nm) Transmission Buckling 4000 1 2000 2 0 3 1 2 3 4 5 6 7 8 4 Stacking Sequence in Degrees 5 Graph: Buckling torque transmission capacity of Glass-Carbon/Epoxy Shaft GLASS-CARBON/EPOXY:-BUCKLING TORQUE TRANSMISSION CAPACITY Buckling Torque capacty (Nm) Transmission 6000 1 4000 2000 2 0 3 0 2 4 6 8 10 4 Stacking Sequence in Degrees 5 446
  • 10. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep Dec (2012) © IAEME Sep- Graph: Carbon/Epoxy: Number of layers Vs Critical speed CARBON/EPOXY: NOMBER OF LAYERS Vs CRITICAL 40000 SPEED (rpm) Critical Speed (rpm) 1 20000 2 3 0 4 0 2 4 Number Of layers 6 8 10 Graph: Glass-Carbon/Epoxy: Number of layers Vs Critical speed Carbon/Epoxy: GLASS-CARBON/EPOXY: NUMBER OF LAYERS Vs CRITICAL SPEEED (rpm) CARBON/EPOXY:- 15000 1 Critical Speed (rpm) 10000 2 5000 0 3 0 2 4 6 8 10 4 Number Of Layers 5 Graph: Critical speed analy in composite drive shafts analysis Shaft Length and Critical Speed 20000 Critical Speed (rpm) 15000 10000 Composite Drive Shaft 5000 Steel Drive Shaft 0 0 1000 2000 3000 4000 Shaft Length (mm) Graph shows that for the steel drive shaft having about 6000 revolutions per minute can be manufactured of length about 1m to 1.5m while on the other hand for composite drive shaft it is possible to manufacture a shaft of length 1.5m to 2 m for same revolutions. f 447
  • 11. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME 6.1. Mass Comparison between Steel and Composite drive Shafts Following table gives the comparison of masses of conventional steel drive shaft, Carbon/Epoxy and Glass-Carbon/Epoxy composite drive shaft. Material Weight Weight (Kg) Reduction (%) Steel 0.489 - Glass- 0.412 15.75 Carbon/Epoxy Carbon Epoxy 0.352 28.01 Graph: Mass Comparison of three shafts Mass comparison between Steel and Composite Drive Shaft 0.6 0.5 STEEL Mass in Kg 0.4 0.3 0.2 Glass- 0.1 Carbon/Epoxy 0 Carbon Epoxy 7. CONCLUSION From preliminary experiments and studies of physical properties like weight, material combination, torque transmitting capacities, etc. it is concluded that: • A one-piece composite drive shaft made of Carbon/Epoxy and Glass-Carbon/Epoxy is designed optimally with Genetic Algorithm as optimization tool with the objective of minimization of weight of drive shaft which is subjected to constraints such as Maximum torque transmission capacity, Buckling torque transmission capacity and critical speed. • About 28.01 % of weight saving is achieved with Carbon/Epoxy shaft with increase in critical speed enabling manufacturing of shaft of length 1.8m to 2 m; as compared to steel shaft; by experimentation. • About 15.75% weight saving is achieved with Glass-Carbon/Epoxy composite shaft with increase in critical speed enabling manufacturing of shaft of length 1.7 m to 2m; as compared to steel shaft; by experimentation. • The results reveal that the orientation of fibers has great influence on the dynamic characteristics of the composite material shafts in a positive direction. • Genetic Algorithm is suggested as an effective optimization tool. 448
  • 12. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) © IAEME 8. REFERENCES 1. Thimmegowda Rangaswamy, and Sabapathy Vijayarangan “Optimal Sizing and Stacking Sequence of Composite Drive Shafts” journal of Material science, Vol.11, No.2, 2005. 2. R.R Ajith, T. Rangaswamy, S. Vijayarangan and G. Chandramohan “Genetic Algorithm Based Optimal Design Of Composite Shaft” International journal of Material Science and Engineering, December2004. 3. Dai Gil Lee and Hak Sung Kim “Design and manufacture of an automotive hybrid aluminum/composite drive shaft” journal of composite structure, Vol 63, 2004 pp.87-99. 4. M. A. Badie, A. Mahdi, and A. R. Abutalib “Automotive composite drive shafts: Investigation of the design variable effects” International Journal of Engineering and Technology, Vol. 3, No.2, 2006, pp. 227-237. 5. Durk Hyun Cho, Dai Gil Li, Jin Ho Choi “Manufacture of one-piece automotive drive shafts with aluminum and composite materials” journals of Composite structure, Vol. 38, No. l-4, 1997 pp. 309-319. 6. M.A.K. Chowdhuri , R.A. Hossain, Design Analysis of an Automotive Composite DriveShaft, International Journal of Engineering and Technology Vol.2(2), 2010, 45-48. 7. Rajeev., S., Krishnamoorthy, C. S. Discrete Optimization of Structure Using Genetic Algorithms J. Structural Engg. ASCE 118 1992: pp. 1233 – 1250. 8. Goldberg, D. E. Genetic Algorithms in Search, Optimization and Machine Learning, Reading MA, Addison-Wesley, 1989. 9.Rastogi, N. (2004), Design of composite driveshafts for automotive applications, SAE, Technical Paper Series, 2004-01-0485. 10. Darlow, M. S. and Creonte, J. (1995), Optimal design of composite helicopter power transmission shafts with axially varying fibre lay-up, Journal of the American Helicopter Society 40 (2): 50-56. 11. Rao, S. S. Mechanical Vibrations. Addision-Wesely Publishing Company, NY: pp. 537 – 541. 12. Vijayarangan, S., et. al. Design Optimization of Leaf Springs Using Genetic Algorithms Inst. Engrs. India Mech. Engng. Div. 79 1999: pp. 135 – 139. 13. A.R. Abu Talib et al “Developing a hybrid, carbon/glass fiber-reinforced, epoxy composite automotive drive shaft” journal of Materials and Design 31 (2010) 514–521 449