DEPARTMENT OF AGRICULTURAL ENGINEERING

BAHAUDIN ZAKARIYA UNIVERSITY MULTAN, PAKISTAN

Fakhar Abbas (AG-19-17)

Semester : 6th (2019-23)
Email; [email protected]

Jamshaid Amjad (AG-19-23)

Semester : 6th (2019-23)
Email; [email protected]
 Complex Engineering Problem
Design and Analysis of Drive Shaft using Kevlar/Epoxy and
Glass/Epoxy as a Composite Material

Abstract.
In auto industry drive shaft is quite possibly the main part to communicate power structure the
motor to back tire through the differential stuff. For the most part steel drive shaft is utilized in
car industry, these days they are more intrigued to supplant steel drive shaft with that of
composite drive shaft.
The general goal of this paper is to break down the composite drive shaft involving to figure out
the best swap for regular steel drive shaft. The purposes of cutting edge composite materials,
for example, Kevlar, Graphite, Carbon and Glass with legitimate saps product brought about
noteworthy accomplishments in auto industry due to its more prominent explicit strength and
explicit modulus, further developed exhaustion and erosion protections and decrease in energy
prerequisites because of decrease in weight when contrasted with steel shaft.
This paper is to prepsents, the demonstrating and examination of drive shaft utilizing
Kevlar/Epoxy and Glass/Epoxy as a composite material and to find best substitution for regular
steel drive shafts with a Kevlar/epoxy or Glass/Epoxy pitch composite drive shaft. Displaying is
finished utilizing CATIA programming and Analysis is completed by involving ANSYS 10.0
programming for simple comprehension. The composite drive shaft lessens the load by 81.67 %
for Kevlar/Epoxy and 72.66% for Glass/Epoxy when contrasted and ordinary steel drive shaft.

1. Introduction
A driveshaft in auto is utilized to send power from motor to wheels. Driveshaft should be
worked by continually changing points between the transmission and hub. A great steel is a
typical material utilized for building drive shaft. The bowing regular recurrence of the bar is
straightforwardly relative to the square of the length and corresponding to the square base of
explicit modulus. Due to that the steel drive shafts are produced by two parts of increment the
twisting normal recurrence. The two bits of drive shaft with three all inclusive joints, a section
and a middle supporting bearing, which builds the all out weight of a vehicle and diminishes the
power transmission because of its inertial mass.Replacing customary metallic designs with
composite designs enjoys many benefits because of its higher explicit strength and solidness of
composite materials . Additionally its weight is lesser than steel and aluminum with
comparative strength.
Composite drive shaft is made by single piece it will dispense with the congregations of three
widespread joints, a section and a middle supporting heading of two piece steel drive shaft.
Additionally, composite drive shaft will have lower modulus of flexibility which brings about
decline in pressure and best safeguard when force is more.The progressed composite materials,
for example, Kevlar, graphite, carbon and glass with legitimate pitches product brought about
remarkable accomplishments in vehicle industry. As a result of their versatile propertiesit will
expand the force they can convey as well as endure the rotational speed.
This venture gives the plan and examination of Kevlar/Epoxy and Glass/Epoxy as a composite
material for the drive shaft and by contrasting their outcome and regular steel drive shaft to
track down the best trade for it.

2. Material Selection

2.1 Materials for Steel drive shaft

Steel (SM45C) is a material for the most part utilized for customary drive shaft. The steel
material which are utilized for ordinary drive shaft should fulfill the particulars, for example,
limit of force transmission, bowing normal recurrence and capacity of clasping force. The
properties of the material steel (SM45C) are displayed in Table 1.
2.2 Composite Materials for drive shaft
A composite material is a material made by consolidating at least two constituent materials
with various physical or substance properties and to deliver a material with uniqueness not
quite the same as the singular parts. The singular parts stay discrete and divergent inside the
finished design. By and by elite execution composites are figured out utilizing a mass material
the lattice and fiber or texture support to build the strength and solidness of the
matrix.Reinforcements might be as strands, particles or pieces which gives the length, direction,
shape and material.The network factors gives thecompressive strength, cross over modulus,
shear modulus and strength, co-proficient of warm development and warm opposition.

Glass Fiber
These are made by mixing quarry items like sand, kaolin, limestone, colemanite at 1,600°C to
get fluid glass then it is gone through miniature fine bushings and at the equivalent timeit is
cooled to deliver glass fiber fibers from 5-24μm in measurement. By fluctuating the quarry
items, various sorts of glass can be created. E-glass is the most widely recognized building up
fiber utilized in polymer framework composites. On account of its great malleable and
compressive strength, firmness and unfortunate obstruction. It is accessible as strand, yarns
and Rovings. Strand is a minimalistically related heap of fibers, yarns are firmly related heap of
turned fibers and rovings are inexactly related heap of untwisted fibers. Table1 Mechanical
properties of Steel (SM45C) Properties Symbols Units Steel Young's modulus E GPa 207 Shear
modulus G GPa 80 Poisson's Ratio V - - - 0.3 Density ρ Kg/m3 7600 Yield strength Sy MPa 370
Shear strength Ss MPa.

Kevlar Fiber
Kevlar fiber is created by Stephanie Kwolek at DuPont in 1965, it was first utilized as a swap for
steel in dashing tires due to its high strength. Later it is utilized as a fiber or as an element of
composite materials in ropes or texture sheets. Kevlar fiber has a rigidity of around 3.620×106
KPa, and relative thickness of 1.44. Kevlar's design comprises of generally inflexible particles
which will play out a sheet like designs genuinely like silk protein. By estimating high rigidity to
weight proportion of Kevlar with steel, Kevlar is multiple times more grounded than steel due
to that it has numerous applications on bike tires, dashing body shield and to make present day
drumheads because of its high effect strength.
 3. Material Fabrication and Testing

The examples were ready with the Kevlar/Epoxy and Glass/Epoxy overlays as per the ASTM
standard. The examples were going through for tractable testing, flexure testing and effect
testing by Universal testing machine and Impact testing machine.

3.1 Laminate Materials

In this overlay, Kevlar fiber and Glass fiber were utilized as a support and lattice Epoxy. Pitch,
glue LY556 and Hardener HY951 were utilized at the proportion of 10:1.Epoxy polymer
materials genuinely comprise of two vital parts, a gum and a hardener. At first it will be as fluid
and by substance response it will be changed over into the strong. These sort of polymers are
areas of strength for precisely more glue during the transformation of fluid to solid.The pitch
and hardener are ready with the right amount comparative with each other to draw out the
synthetic response and these are kept in a different holder in fluid structure.

3.2 Laminate Methodology

The material manufacture normally includes blending or immersing the support and afterward
permitting the network to tie together into an inflexible design with the assistance of synthetic
response. The activity is generally finished in an open form by Hand Lay-up technique. Tars are
packed by hand into filaments which are as woven, fasten or fortified textures. This is typically
finished by rollers or brushes, for constraining tar into the textures through alternating rollers
and a tub of pitch. Then the overlays are passed on to fix under ordinary air conditions.
 Step 1 - The surface of the mold is cleaned and a release agent is applied. The release agent
will be in the form of liquid or solid and the improper cleaning of mold will affect the function of
release agent.
Step 2 - The primary layer of fiber glass structure is made with same resin is laid up on the mold
surface. This layer protects the laminate from surface irregularities and surface abrasion. A peel
ply is placed on the top of the primary layer, it will be removed finally.
Step 3 - Prepare the epoxy resin by mixing the adhesive (LY556) and hardener (HY951) in the
ratio 10:1 and mixing it continuously for lamination.
Step 4 - The first peel ply is placed upon the mold and subsequent plies are placed one upon
another. Press each layer after applying resin to get better lamination. Pressure will be given by
a roller or other small hand tool, it will also remove vacuum between the layers. It is important
that the reinforcement material have sufficient tack so that it sticks slightly to the layers of peel
plies.
Step 5 - Make more number of layers to get the lamination of 3mm thickness. Finally place the
primary fabric glass fiber, it will cover both the lamination surface. Apply uniform load along the
surface of the lamination of 4 to 5 kg about 48 hours.
Step 6 - The reinforcement plies are cut according to design specifications (150mmX25mm).
They can be cut by hand using hand shears or a steel knife.
Step 7 - Sealant tape is placed around the entire periphery of the lay-up. The vacuum bag is cut
to size and placed over the lay-up.

3.3 Mechanical Testing

Tensile Testing
Elastic test is one of the principal mechanical test, usually used to choose material under
quality control and response of material under various sorts of power. An example is ready in a
square segment contingent upon the standard check length of the machine. Both finish of the
example was holded by the cross heads and they are immovably held during testing. Power will
be applied on the example by driven cross head until it cracks, during this interaction applied
force and prolonged length is estimated to track down the elasticity.

Flexure Testing
Flexure testing is utilized to track down the bowing strength of the material and modulus of the crack.
Flexure test is finished on a similar malleable testing machine, here the example is put on the seat wise
and power will be applied on the focal point of the example until it gets broken. The figure 1 shows
example testing.
Impact Testing
The effect test is utilized find the sturdiness of the material it is otherwise called the V-score
test, decides how much energy consumed by a material during crack. The effect testing
machine has a pendulum of known length and mass, then, at that point, the pendulum of mass
is had to effect an indented example. This ingested energy is a proportion of a sturdiness of the
given materials and goes about as a device to concentrate on temperature subordinate
bendable weak transformation.

Figure 1. (i) Tensile Testing Machine (ii) Flexure Testing Machine (iii) Impact Testing Machine
 3. Modeling and Analysis of Drive Shaft
4.1 Modeling of Drive Shaft
The 3-D modeling of composite drive shaft is done by using CATIA and analyzed using ANSYS. A
comparisons has been made between composite and steel drive shaft with respect to weight,
cost and strength. The figure 2 shows the 3-D modeling of drive shaft.

Figure 2. 3D Modeling of Drive Shaft in CATIA

4.2 Analysis of Drive Shaft

Analysis is completed by utilizing ANSYS 10.0 programming, the accompanying figures shows all
out misshapening and Equivalent Stresses on Tensile test, Flexure test and Impact trial of steel,
Kevlar/Epoxy and Glass/Epoxy drive shafts under the use of 750N burden. In that red zone
demonstrates the greatest diversion region and blue zone demonstrates the base avoidance
region, which is shown by test.

Total Deformation on Tensile Testing

The figure 3 shows the analysis of total deformation on tensile testing for Steel, Kevlar/Epoxy
and Glass/Epoxy Drive Shafts Respectively.

Figure 3. Total Deformation of Tensile Testing of (i) Steel, (ii) Kevlar/Epoxy,

(iii) Glass/Epoxy Drive Shafts Respectively.
Equivalent Stress on Tensile Testing
The figure 4 shows the analysis of equivalent stress on tensile testing for Steel, Kevlar/Epoxy
and Glass/Epoxy Drive Shafts Respectively.

Figure 4. Von-Misses Stress on Tensile Testing of (i) Steel, (ii) Kevlar/Epoxy,

(iii) Glass/Epoxy Drive Shafts Respectively.

Total Deformation on Flexure Testing

The figure 5 shows the analysis of total deformation on flexure testing for Steel, Kevlar/Epoxy
and Glass/Epoxy Drive Shafts Respectively.

Figure 5. Total Deformation on Flexure Testing of (i) Steel, (ii) Kevlar/Epoxy

(iii) Glass/Epoxy Drive Shafts Respectively.
Total Deformation on Impact Test
The figure 6 shows the analysis of total deformation on impact test for Steel, Kevlar/Epoxy and
Glass/Epoxy Drive Shafts Respectively.

Figure 6. Total Deformation on Impact Testing of (i) Steel, (ii) Kevlar/Epoxy (iii) Glass/Epoxy Drive
Shafts Respectively.

Equivalent Stress on Impact Testing

The figure 7 shows the analysis of equivalent stress on impact test for Steel, Kevlar/Epoxy and
Glass/Epoxy Drive Shafts Respectively.

Figure 7.Von-misses stress on Impact Testing of (i) Steel, (ii) Kevlar/Epoxy

(iii) Glass/Epoxy Drive Shafts Respectively
 5. Resultsant Discussions
The figure8 shows the twisting of Steel, Kevlar/Epoxy and Glass/Epoxy as for load. For elastic
testing and Flexure testing, the twisting of steel is less when contrast with Glass/Epoxy and
Kevlar/Epoxy. Glass/Epoxyis having higher deformity then the Kevlar/Epoxy. Yet, the twisting of
Steel is higher than Glass/Epoxy and Kevlar/Epoxy under influence load. Kevlar/Epoxy and
Glass/Epoxy are having more disfigurement under malleable and flexure load thus it replaces
the two bits of steel drive shaft into single shaft with better transmission of force. In view of
their versatility, they decline the pressure and go about as a best safeguard when the force is
more. Likewise Kevlar/Epoxy and Glass/Epoxy having less misshapening under influence load
with the goal that it can assimilate more energy due to its sturdiness.

Figure 8. Graphs Load vs Deformation

 From table 3, It is seen that the composite drive shaft is lighter and more prudent than the
regular steel drive shaft with comparable plan particulars. It is seen that the weight decrease of
drive shaft is accomplished up to 81.67% in the event of Kevlar/Epoxy and 72.6 if there should
arise an occurrence of Glass/Epoxy than steel.

6. Conclusion
This task made an endeavor to make a superior substitution for a regular steel drive shaft by a
composite material of Kevlar/Epoxy and Glass/Epoxy. It tends to be seen that the Kevlar/Epoxy
and Glass/Epoxy are having more disfigurement under elastic and flexure load consequently it
replaces the two bits of steel drive shaft into single shaft with better transmission of force.
In view of their versatility, they decline the pressure and go about as a best safeguard when
the force is more. Likewise Kevlar/Epoxy and Glass/Epoxy having less twisting under influence
load so it can ingest more energy in light of its sturdiness. The composite drive shaft decreases
the load by 81.67 % for Kevlar/Epoxy and 72.66% when contrasted and traditional steel drive
shaft. The presentation of Kevlar/Epoxy and Glass/Epoxy composite materials will diminish the
heaviness of the drive shaft with practically no drop in force bandwidth and firmness.
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