• Transactions of the Korean Society of Automotive Engineers
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• v.11 no.1
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• pp.151-159
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• 2003

The front 2 pieces of the 3-piece steel propeller shaft installed on a 8.5-ton truck were redesigned with a 1 -piece composite propeller shaft with steel yokes and spline parts to get the reduction of weight and the improvement of NVH characteristics. Based on the analysis of bending vibration, strength and cure-induced residual stresses of the composite propeller shaft, proper composite materials and stacking sequences were selected. The composite propeller shaft requires a reliable joining method between the shaft and steel end parts through a steel connector. From 3-D contact stress analyses of the laminated composite shaft with bolted Joints, the 3-row mechanical joint which satisfies the torque transmission capability has been designed. Several full-scale composite shafts were fabricated and tested to verify the design analyses. The design requirements are shown to be satisfied. With the newly designed composite shaft, the weight reduction more than 50% and improvements in NVH characteristics have been achieved.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2000.04a
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• pp.149-153
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• 2000

Substituting composite structures for conventional metallic structures has many advantages because of higher specific stiffness and specific strength of composite materials. In this work, one-piece propeller shafts composed of carbonfepoxy and glass/epoxy composites were designed and manufactured for a rear wheel drive automobile satisfying three design specifications, such as static torque transmission capability, torsional buckling and the fundamental natural bending frequency. Single lap adhesively bonded joint was employed to join the composite shaft and the aluminum yoke. For the optimal adhesive joining of the composite propeller shaft to the aluminum yoke, the torque transmission capability of the adhesively bonded composite shaft was calculated with respect to bonding length and yoke thickness by finite element method and compared with the experimental result. Then an optimal design method was proposed based on the failure model which incorporated the nonlinear mechanical behavior of aluminum yoke and epoxy adhesive. From the experiments and FEM analyses, it was found that the static torque transmission capability of composite propeller shaft was maximum at the critical yoke thickness, and it saturated beyond the critical length. Also, it was found that the one-piece composite propeller shaft had 40% weight saving effect compared with a two-piece steel propeller shaft.

• Transactions of the Korean Society of Automotive Engineers
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• v.1 no.3
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• pp.109-117
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• 1993

A carbon/epoxy composite drive shaft used for the power transmission of the automobiles with steel joints. Compared with the metallic drive shaft, the composite one has the weight saving of 50% with equivalent torsional strength and fatigue characteristics. In this study, the filament winding technique for the composite tube and composite/metal joining technique are estabilished. The performance test of the drive shaft is carried out. The optimal condition of the surface roughness of the steel adherend was $1.5{{\mu}m}$ to $2.5{{\mu}m}$, and the optimal condition of the bonding thickness was 0.15mm. Maximum torque and torsional stiffness of the composite drive shaft manufactured by filament winding process were found to be $210kg{\cdot}m$ and $18.5kg{\cdot}m/deg$, respectively.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2002.05a
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• pp.22-26
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• 2002

The goal of this study is to replace the current forward 2-piece propeller shaft of 8 ton large truck made of steel with 1-piece composite propeller shaft. A low cost Glass/Epoxy composite propeller shafts were successfully developed, which satisfy requirements such as the capacity of static torque transfer, fatigue strength and bending natural frequency. Devising secure joining method of a composite tube and metal yoke was the most critical issue in successful development of a high torque composite propeller shaft. In this study, joining method using thermal interference fit was adopted for composite to metal joint. Optimum conditions of heating temperature and interference level of thermal interference fit were determined from thermal stress analysis using 3D finite element method. Static torsion test, fatigue test, RPM and balance test were performed to verify the design.

• Steel and Composite Structures
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• v.48 no.4
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• pp.429-441
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• 2023

This research presents an advanced finite element formulation for analyzing the vibratory behaviour of tapered composite shaft rotors, taking into account the impact of the draft angle on the stiffness of the composite shaft laminate. The vibration response of the shaft rotating around its axis is studied using both the finite element hierarchical method and the classical finite element formulation, based on the theory of transverse shear deformation, rotary inertia, gyroscopic effect, and coupling effect due to the stratification of the composite layers of the shaft. The study also includes the development of a program to calculate the Eigen frequencies and critical speeds of the system, and the obtained results are compared with those available in the literature. This research provides valuable insights into the vibratory behaviour of tapered composite shaft rotors and can be useful for designing and optimizing such structures in various industrial applications.

• Proceedings of the Korean Society For Composite Materials Conference
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• 1999.11a
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• pp.49-52
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• 1999

Substituting composite structures for conventional metallic structures has many advantages because of higher specific stiffness and specific strength of composite materials. In this work, one-piece propeller shafts composed of carbon/epoxy composite and glass/epoxy one were designed and manufactured for a rear wheel drive automobile, which uses generally a steel two-piece propeller shaft. From the tests of the composite propeller shafts, it was found that the propeller shafts satisfied requirements of static torque transmission capability, torsional buckling capability and the first natural bending frequency and had 40% weight saving effect compared with steel propeller shaft.

• Proceedings of the KSME Conference
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• 2001.06b
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• pp.361-365
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• 2001

Laboratory tests are conducted to validate the mechanical model of a filament-wound composite shaft. Also, design charts are produced by validated analytical calculations based on the Timoshenko beam model of a layered steel/composite structure. The major results found are that steel/composite hybrid shafts can lead to better dynamic and static performances over steel or pure composite shafts of the same volume, and the most effective composite structures contain some steel in the form of a tubular core. These results can be used in the design process of composite boring bars and automotive drive shafts.

• Steel and Composite Structures
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• v.52 no.6
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• pp.663-672
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• 2024

This paper researched on the bending vibration characteristics of composite drive shaft with internal damping. To analyze the unbalanced excitation response in full speed range, a transfer matrix model was built based on the improved Layer-wise theory and the numerical damping, and compared with the metal drive shaft. The results show that the effect of internal damping of the composite shaft tube on bending vibration response was different in the subcritical, critical and supercritical speed ranges. Then, the finite element analysis and vibration tests were carried out to verify the analysis results of transfer matrix model.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2001.05a
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• pp.193-196
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• 2001

The purpose of this study is the design of composite shaft which is wound by Filament Winding method. Classical laminated plate theory was used for analyzing the stress, and for structure design. The diameter and thickness of composite shaft were calculated by this theory. The result that if tensile stress was zero, torsion stress was a certain value below 0.4(diameter rate) and torsion strength was the highest value on $45^{\circ}C$(winding angle). In case of $90^{\circ}C$(winding angle), we have to consider the torsional monent when the composites shaft was load.

• Advances in aircraft and spacecraft science
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• v.5 no.1
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• pp.51-71
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• 2018

This work proposes a theoretical and numerical study on the behavior of a tapered shaft rotor made of composite materials by the classical version h and the version p of the finite element method. Hierarchical form functions are used to define the model. The purpose of this paper is to determine the expressions of the kinetic and potential energies of the tree necessary for the results of the equations of motion. A comparison between the version h and the p version of the finite element method of the functions of polynomial and trigonometric hierarchical forms with six degrees of freedom per node, of a composite tapered and cylindrical shaft which rotates at a constant speed about its axis. It is found that when the number of functions of form (the version p) is increased, the solution converges. It is also observed that the conicity of the shaft increases the rigidity with respect to a uniform shaft having the same mechanical properties. The numerical simulation allowed us to determine the natural frequencies and the critical speeds of the composite shaft systems are compared with those available in the literature and the effectiveness of the methods used are discussed.