Journal of Advances in Mechanical Engineering and … · mechanical properties of E-glass fibre ... E glass/epoxy and Kevlar29/epoxy composites were carried out and results were furnished

Journal of Advances in Mechanical Engineering and Science, Vol. 2(3) 2016, pp. 1-13

*Corresponding author. Tel.: +919962455889

Email address: [email protected] (R.Saravanan)

Double blind peer review under responsibility of DJ Publications

http://dx.doi.org/10.18831/james.in/2016031001

2455-0957 © 2016 DJ Publications by Dedicated Juncture Researcher’s Association. This is an open access

article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-ncnd/4.0/) 1

RESEARCH ARTICLE

Is Kevlar29/Epoxy Composite an Alternate for Drive Shaft?

*R Saravanan

1, P Vivek

1, T Vinod Kumar

1

1Department of Mechanical Engineering, Vels Institute of Science, Technology and Advanced Studies

(VISTAS), Vels University, Pallavaram, Chennai-600117, India.

Received-11 May 2016, Revised-8 June 2016, Accepted-17 June 2016, Published-17 June 2016

ABSTRACT

Advances in engineering and technology replace old materials with new materials having

superior advantages in specialized, personalized as well as general applications. The new materials are

more reliable than conventional ones and are designed to be stronger and durable. The recent

researches in design engineering are focused on to provide composite materials as a substitute for

conventional materials in many applications due to their unique properties. This research is focused on

investigating the suitability of an alternate composite material for SM45 steel shaft for automobile

applications. SM45 steel, carbon epoxy, E glass epoxy and Kevlar29 epoxy composites were

considered for investigation of sample shaft fabrication and extraction properties. The actual shaft was

modelled by using Pro-E wildfire 5 software. Then it was imported in ANSYS workbench 14.5 giving

the actual boundary conditions for the drive shaft for SM45C material. Under the same boundary

conditions carbon epoxy, E glass epoxy and Kevlar29 epoxy composites were analyzed. Total

deformation, equivalent stress, equivalent elastic strain and buckling deformation analysis were

concentrated. The Kevlar29 epoxy composite outperforms others in terms of weight saving, buckling

capability, induced shear stress and torque transmission capability.

Keywords: Composite material, Conventional material, SM45 steel, Torque, Kevlar29 epoxy

composite.

1. INTRODUCTION

[1] highlighted that in recent days,

there is a huge demand for lightweight

materials. Fibre reinforced polymer composites

seems to be a promising solution to this rising

demand. These materials have gained attention

due to their applications in the field of

automotive, aerospace, sports goods, medicinal

and household appliances. [2] investigated the

mechanical properties of E-glass fibre

reinforced epoxy composites filled with fly

ash, aluminum oxide, magnesium hydroxide

and hematite. They reported that composites

filled to 10% of volume exhibited maximum

ultimate tensile strength and hardness. In

addition to it the fly ash filled composites

exhibited maximum impact strength, but

weight of the shaft was not reduced

significantly. [3] The materials, boron/epoxy

composite, Kevlar/epoxy composite, aluminum

– glass/epoxy hybrid and carbon – glass/epoxy

hybrid can be chosen for replacing steel drive

shaft and recommended the use of hybrid

composites. However the shaft is not a single

piece. [4] proposed a single-piece e-

glass/epoxy, high strength carbon/epoxy and

high modulus carbon/epoxy composite drive

shaft for an automotive application by

considering the advantages of higher specific

stiffness and strength of composite materials.

The optimized design parameters showed

significant potential improvement in the

performance of the composite drive shaft. [5]

attempted a new manufacturing method, in

which a carbon fibre epoxy composite layer

was co-cured on the inner surface of an

aluminum tube rather than wrapping on the

outer surface to prevent the composite layer

from being damaged by external impact and

absorption of moisture. The joining of the

aluminum - composite tube and steel yoke with

improved reliability and optimum

manufacturing cost is done by press fitting. In

order to increase the torque transmission

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R.Saravanan et al./Journal of Advances in Mechanical Engineering and Science, Vol. 2(3), 2016 pp. 1-13

2

capacity protrusion shape is provided on the

inner surface of steel yoke which will fit on

universal joints.

It is proposed that the mix of graphite

Nano platelets in the carbon fibre/epoxy

composites matrix improve its mechanical

properties. It was experimentally found that

such reinforcement enhanced in-plane shear

properties and compressive strength. The

authors used analytical model to predict the

longitudinal compressive strength and the

same was validated by the experimental

results. [6]. [7] investigated the suitability of

e-glass/ epoxy, high strength carbon/epoxy and

high modulus carbon epoxy composite drive

shaft for an automotive application with the

objective of minimizing the weight of drive

shaft. [8] and [1] also designed e–glass /

epoxy, high strength carbon/ epoxy and high

modulus carbon/epoxy composite drive shafts

as an alternative for steel shaft by using genetic

algorithm with the same objective of

minimization of weight. [9] included

deflection, stresses, natural frequencies under

subjected loads using FEA and estimation of

stress intensity factor for both steel and

composite materials to optimize the weight and

reported that the single piece composite shaft

saved weight up to 28% than a two piece steel

shaft. [10] designed a high modulus

carbon/epoxy multilayered composite drive

shaft and obtained a weight reduction of about

72% compared to conventional steel with the

influence of fiber orientation and dynamic

characteristics. [11] dealt the review of

optimization of drive shaft using genetic

algorithm and ANSYS. The finite element

analysis is used in this work to predict the

deformation of shaft. The deflection of steel,

HS carbon / epoxy and HM carbon / epoxy

shafts was 0.00016618, 0.00032761 and

0.0003261 mm respectively. [12] used

numerical investigation methods by

considering variation in fibre volume and

validated it through experimentation. The

authors reported that tensile strength of

composite increases with increase in fibre

volume. This research also made an attempt to

experimentally investigate the compatibility of

composite to replace SM45C steel made drive

shaft. [13] investigated and recommended

hybrid aluminum metal matrix composites as

an alternate material for SM45C steel in terms

of weight reduction. This research also aims to

perform the same with Kevlar29 epoxy fibre

composite materials and validate the same with

carbon epoxy and E glass epoxy fiber

composites.

2. NEED FOR THE RESEARCH

A drive shaft is the one which

transmits torque and rotation. The drive shaft is

usually subjected to torsional as well as shear

stress, which is used to find the difference

between the input torque and the load.

Therefore the alternate material for it must be

strong enough to bear the stress. At the same

time it should be light weight. In automobiles

used for city driving the reduction of weight is

almost directly proportional to vehicle’s fuel

consumption.

3. MATERIAL SELECTION

This research focused on replacement

of SM 45 steel propeller shaft by suitable

composite materials. Even though many

studies were reported in the specific topic, this

research is unique by finding the suitability for

specific type of branded vehicle’s propeller

shaft. The most widely tested carbon/epoxy

and glass/epoxy is primarily selected for

investigating its appropriateness for this

specific case. Then Kevlar29 epoxy is selected

based on its unique properties of high tensile

strength-to-weight ratio. By this measure it is 5

times stronger than steel. It can withstand high

impact; possess good resistance to organic

solvents, good fabric integrity at elevated

temperatures, starting of degradation at 500°C,

no melting point etc.

4. COMPOSITE PROPELLER SHAFT

A sample shaft of e-glass/epoxy

composite shaft is fabricated by hand lay-up

technique. The materials used and the

fabricated specimen shaft is shown in figure

B1. The wax, which acts as a releasing agent,

is applied to the mould. Then the glass fibre

layer is placed on the mould surface and is

impregnated with the resin - hardener mixture

in the ratio 10:1 by weight. The liquid resin is

applied to the mould and then fibre glass is

placed on the top. Another resin and

reinforcement layer of e-glass is kept as an

alternate layer. This alternate layer continued

up to the building up of suitable thickness.

Then the sheet was rolled and the shaft was

allowed to cure at room temperature for a

week. After curing, the model of the propeller

shaft is removed from the mould and it was

http://en.wikipedia.org/w/index.php?title=Torque

http://en.wikipedia.org/w/index.php?title=Shear_stress

http://en.wikipedia.org/w/index.php?title=Shear_stress


3

sized and finished by using a file. The

dimensions of specimen propeller shaft (inner

and outer diameter of Ø40mm and Ø46mm

respectively and length of 900mm) were

obtained from the conventional propeller shaft

of ambassador car.

5. MODELLING AND ANALYSIS OF

PROPELLER SHAFT

The basic view of propeller shaft is

shown in figure B2.The mechanical properties

of composites were furnished in table A1. The

actual shaft was modelled by using Pro-E

wildfire 5 software. Then it was imported in

ANSYS workbench 14.5 and the actual

boundary conditions for the drive shaft for

SM45C material were analyzed.

5.1. Total deformation analysis on propeller

shafts

The total deformation analysis on

propeller shafts of SM45 steel, carbon/epoxy,

E glass/epoxy and Kevlar29/epoxy composites

were carried out and results were furnished in

figure 1, figure 2, figure 3 and figure 4

respectively.

5.2. Equivalent elastic strain analysis on

propeller shafts

The equivalent elastic strain analysis

on propeller shafts of SM45 steel,

carbon/epoxy, E glass/epoxy and Kevlar29/

epoxy composites were carried out and results

are furnished in figure 5, figure 6, figure 7 and

figure 8 respectively.

5.3. Equivalent stress analysis on propeller

shafts

The equivalent elastic stress analysis

on propeller shafts of SM45 steel,

carbon/epoxy, E glass/epoxy and

Kevlar29/epoxy composites were carried out

and results are furnished in figure 9, figure 10,

figure 11 and figure 12 respectively.

5.4. Torsional stress on propeller shafts

The torsional stress on propeller shafts

of SM45 steel, carbon/epoxy, E glass/epoxy

and Kevlar29/epoxy composites were carried

out and results are furnished in figure B3,

figure B4, figure B5 and figure B6

respectively.

5.5. Buckling deformation on propeller

shafts

The buckling deformation on propeller

shafts of SM45 steel, carbon/epoxy, E

glass/epoxy and Kevlar29/epoxy composites

were carried out and results are furnished in

figure B7, figure B8, figure B9 and figure B10

respectively.

Figure 1.SM45C propeller shaft

Figure 2.Carbon-epoxy propeller shaft

Figure 3.E glass-epoxy propeller shaft


4

Figure 4.Kevlar-epoxy propeller shaft







5




Figure 13.Composite shafts performance in total

deformation

Figure 14.Composite shafts performance in

equivalent elastic strain


equivalent stress

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

Carbon/Epoxy E-Glass/Epoxy Kevlar 29/Epoxy

Per

cen

tage

of

Red

uct

ion

Composite Shafts

Maximum Total deformation Decreased by use of Composite shafts

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

Carbon Epoxy E-Glass Epoxy Kevlar 29 Epoxy

Per

cen

tage

of

Red

uct

ion

Composite Shafts

Maximum Equivalent Elastic Strain Decreased by use of Composite shafts

72.00%

73.00%

74.00%

75.00%

76.00%

77.00%

78.00%

79.00%

80.00%

81.00%

82.00%


Per

cen

tage

of

Red

uct

ion

Composite Shafts

Maximum Equivalent stress Decreased by use of…


6


torsional stress

The results for five types of analysis

such as total deformation, equivalent elastic

strain, equivalent stress, torsional stress on

propeller shaft and buckling deformation

analysis were consolidated. The minimum and

maximum responses were consolidated and

furnished in table A2 and table A3

respectively. The weight details of drive shaft

are given in table A4. The details are given in

figures 13, 14, 15, 16, 17 and 18.

Figure 17.Composite shafts performance in weight

reduction


buckling deformation

6. CONCLUSION

This research made an attempt to

make a right choice of composite material for

ambassador car propeller shaft (made up of

SM 45 Steel). The suitability was examined in

terms of mechanical behaviours such as total

deformation, equivalent strain, torsional

behaviour and buckling deformation. The

developed model is verified in terms of

mechanical behaviours for conventional SM45

steel propeller shaft and is validated. Then the

E-glass/epoxy, carbon/epoxy and Kevlar29/

epoxy were considered for the analysis. The

following conclusions can be drawn from the

results of the investigation. It is obvious that

Kevlar epoxy composite drive shaft has

81.05% reduced weight than SM45C

conventional steel shaft. It has 0.22%

reduction in torsion stress and also has 57.1%

increase in buckling capability than SM45C

steel. Due to weight reduction fuel

consumption will be reduced. Apart from light

weight, the use of composites also ensures less

noise and vibration. Taking into account the

weight saving, buckling capability, shear stress

induced and torque transmission capability it is

evident that Kevlar/epoxy composite has the

most encouraging properties to act as an

alternate material for steel shaft.

REFERENCES

[1] Bhirud Pankaj Prakash and Bimlesh

Kumar Sinha, Analysis of Drive

Shaft International Journal of Mechanical

and Production Engineering, Vol. 2, No.

2, 2014, pp.24–29.

0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

0.30%

0.35%


Per

cen

tage

of

Red

uct

ion

Composite Shafts

Maximum Torsion stress Decreased by use of Composite shafts

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%


Per

cen

tage

Imp

roved

By

Composite Shafts

Maximum Buckling deformation increased by use of Composite shafts

71.00%

72.00%

73.00%

74.00%

75.00%

76.00%

77.00%

78.00%

79.00%

80.00%

81.00%

82.00%


Per

cen

tage

of

Red

uct

ion

Composite Shafts

Weight Reduction by Composite shafts


7

[2] K.Devendra and T.Rangaswamy, Strength

Characterization of E-glass Fiber

Reinforced Epoxy Composites with Filler

Materials, Journal of Minerals and

Materials Characterization and

Engineering, Vol. 1 No. 6, 2013, pp. 353-

357.

[3] Harshal Bankar, Viraj Shinde and

P.Baskar, Material Optimization and

Weight Reduction of Drive Shaft Using

Composite Material, IOSR Journal of

Mechanical and Civil Engineering, Vol.

10, No. 1, 2013, pp. 39-46.

[4] F. Anand Raju and D. Dinesh, Optimum

Design and Analysis of a Composite

Drive Shaft for an Automobile by using

Ansys, International Journal of

Engineering Research and Applications,

Vol. 2, No. 4, 2012, pp. 1874-1880.

[5] Bhushan K. Suryawanshi and Prajitsen G.

Damle, Review of Design of Hybrid

Aluminum/ Composite Drive Shaft for

Automobile International Journal of

Innovative Technology and Exploring

Engineering, Vol. 2, No. 4, 2013, pp-259-

266.

[6] J.Cho, J.Y.Chen and I.M.Daniel,

Mechanical Enhancement of Carbon

Fiber/Epoxy Composites by Graphite

Nanoplatelets Reinforcement, Scripta

Materialia, Vol. 56, No. 8, 2007, pp.685–

688.

[7] Gummandi Sanjay and Akul Jagadeesh

Kumar, Optimum Design and Analysis of

a Composite Drive Shaft for an

Automobile, Master’s Degree Thesis,

Blenkinge Institute of Technology,

Swedan, 2007, pp. 1-72.

[8] D.Dinesh and F.Anand Raju, Optimum

Design and Analysis of a Composite

Drive Shaft for an Automobile by Using

Genetic Algorithm and ANSYS,

International Journal of Engineering

Research and Applications, Vol. 2, No. 4,

2012, pp.1874-1880.

[9] R.P.Kumar Rompicharla and K.Rambabu,

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[10] M.R.Khosharavan and A.Paykani, Design

of a Composite Drive Shaft and it’s

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[11] Sagar R. Dharmadhikari, Sachin G.

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31005 .




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APPENDIX A

Table A1.Mechanical properties of composite shafts

Description of property E-glass epoxy Kevlar29 epoxy Carbon epoxy

Young’s modulus 1.20e+5 MPa 1.35e+5 MPa 2.1e+5 MPa

Poisson’s ratio 0.29 0.36 0.36

Density 1900 kg/m3 1440 kg/m

3 1600 kg/m

3

Bulk modulus 95.24 GPa 150 GPa 1.4706e+5 MPa

Shear modulus 46.51 GPa 50 GPa 4.7619e+5 MPa

Table A2.Minimum responses

Minimum responses SM45C Steel Carbon epoxy E-glass epoxy Kevlar29 epoxy

Total deformation (mm) 0 0 0 0

Equivalent Elastic Strain 1.875e-5 3.89e-6 8.004e-6 5.81e-6

Equivalent stress (MPa) 3.649 0.768 0.901 0.744

Torsion stress (N/m2) 0.055993 0.056081 0.056073 0.056126

Buckling deformation (mm) 0 0 0 0

Table A3.Maximum responses

Maximum responses SM45C steel Carbon epoxy E-glass epoxy Kevlar29 epoxy

Total deformation (mm) 0.723 0.150 0.312 0.209

Equivalent elastic strain 0.00462 9.594e-4 1.98e-3 1.366e-3

Equivalent stress (MPa) 955.83 201.23 238.48 183.19

Torsion stress (N/m2) 0.061028 0.060902 0.060843 0.060894

Buckling deformation (mm) 0.532739 0.978677 1.161 1.242

Table A4.Weight details of drive shafts

Drive shaft materials Weight (Kg)

SM45 steel 2.77170

Carbon epoxy 0.58352

E glass epoxy 0.69293

Kevlar29 0.52517


9

APPENDIX B

Figure B1. E-glass, epoxy, hardener, wax and fabricated composite propeller shaft

Figure B2. Views of propeller shaft with dimensions

Figure B3. SM45C propeller shaft


10

Figure B4. Carbon-epoxy propeller shaft

Figure B5. E glass-epoxy propeller shaft


11

Figure B6. Kevlar-epoxy propeller shaft

Figure B7. SM45C propeller shaft


12

Figure B8. Carbon-epoxy propeller shaft

Figure B9. E glass-epoxy propeller shaft


13

Figure B10. Kevlar-epoxy propeller shaft

Documents

Journal of Advances in Mechanical Engineering and … · mechanical properties of E-glass fibre ... E glass/epoxy and Kevlar29/epoxy composites were carried out and results were furnished