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Differential Shaft-Report
Differential Shaft-Report
INTRODUCTION
A driveshaft or driving shaft is a device that transfers power from the engine
to the point where work is applied. In the case of automobiles, the drive shaft
transfers engine torque to the drive axle, which connects the two wheels together
on opposite sides and with which they turn. The driveshaft is also sometimes called
propeller shaft. Drive shafts are essentially carriers of torque. Before they became a
vogue, older automobiles used chain drive and even generators to transmit power
to the wheels. Drive shaft today, however, has U-joints, devices which help them
to move up and down during suspension. Some drive shafts also have another kind
of joint, called slip joints, which allow them to adjust their lengths to the
lengths depending on their use. Long shafts are used in front-engine, rear-drive
vehicles while shorter ones are used when power must be sent from a central
must be strong enough to bear the stress that is required in the transmission of
power.
1
TYPES OF DRIVE SHAFTS:
1. One-piece driveshaft
2. Two-piece driveshaft
UNIVERSAL JOINT: A universal joint sometimes called carden joint, allows the
one-piece drive shaft. For front wheel drive systems, the short distance between
wheel hubs and final drive housing. Combined with a large movement of wheel
due to suspension deflection and steering angle i.e., maximum drive angle of
universal joints are great. A CV joint at each end of drive shaft meets the angle
requirement.
Fig.1.1: One-piece drive shaft
analyzing a part design. The failure mode will be influenced by the nature of load,
the expected response of the material and the geometry and constraints. In an
failure considered here are related to mechanical loads and structural analysis. A
is to predict what combination of principal stresses will result in failure. There are
number of theories to describe failure criteria, of them these are the widely
accepted theories.
Ultimate strength:
shafts are carriers of torque. They are subject to torsion and shear stress, equivalent
to the difference between the input torque and the load. They must therefore be
strong enough to bear the stress, whilst avoiding too much additional weight as that
stiffness and strength of composite materials. This work deals with the replacement
high strength carbon/epoxy and high modulus carbon/epoxy composite drive shaft
eliminate all of the assembly connecting two piece steel drive shaft. Also,
torque peaks occur in the driveline, the driveshaft can act as a shock absorber and
have been widely used to improve the performance of various types of structures.
Analysis of Composite Drive Shaft using ANSYS and Genetic Algorithm”. This
automobile. Use of conventional steel for manufacturing of drive shaft has many
disadvantages such as low specific stiffness and strength. Conventional drive shaft
is made up into two
parts to increase its fundamental natural bending frequency. Two piece drive shaft
increases the weight of drive shaft which is not desirable in today‟s market. Many
methods are available at present for the design optimization of structural systems
gradient search and direct search. These methods assume that the design variables
are continuous. But in practical structural engineering optimization, almost all the
“Design and Analysis of Drive Shaft for heavy duty truck”. In automobiles the
drive shaft is used for the transmission of motion from the engine from the
differential. An automotive propeller shaft, or drive shaft, transmits power from the
engine to differential gears of rear wheel driving vehicle. The power from
transmission shaft should be transmitted to the rear axle of the vehicle. The axis of
the transmission and the connecting member of rear axle are at an angle, which
changes with the variation on load or the road condition. To facilitate the power
geometrical construction the propeller shafts are categorized into single-piece, two-
piece and three-piece propeller shaft. In case of two or multi stage propeller shaft
length of the rear propeller shaft is subjected to variation while the remaining
propeller shafts are rigid members i.e. do not change in length. The variation in the
length of rear propeller shaft is allowed using a splined shaft. Generally length of
3.1. Objective:
The power train of vehicle have several parts in which propeller shaft is
damage is due to several faults, the main reason is material and its manufacturing
and maintenance. Early automobiles often used chain drive or belt drive
mechanisms rather than a drive shaft. Some used electrical generators and motors
to transmit power to the wheels. Hence now it is challenging to design the drive
one of the important issues for transmitting variable torque to wheels with different
road conditions. In this comparative has been made in analysis of shafts with
material differ which leads to weight deduction by analyzing in static structural and
In Front wheel drive (FWD) car, maximum power is transmitted through drive
shaft. This power transmission mainly depends on size of drive shaft. The drive
reliability, less cost and high quality, the drive shaft should be with less weight
and more strength
and stiffness. Because of this reason weight optimization of front wheel drive shaft
plays a major role in achieving these major goals like less cost, high quality and
shaft.
3.3 Methodology:
1. Design of one-piece drive shaft was done through CREO 2.0 software.
3. Finite element analysis of one-piece drive shaft was done in Ansys software.
4. Performance analysis of drive shaft pass through Ansys software with structural
steel material.
5. A transient, model analysis of drive shaft is done with the help of Ansys
software for structural steel material.
6. Results obtained from the analysis are tabulated and the best material is
proposed based on the weight to strength ratio.
3.4 SELECTION OF MATERIAL
variety of shapes. Many structural steel shapes take the form of an elongated beam
having a profile of a specific cross section. Structural steel shapes, sizes, chemical
Most structural steel shapes, such as I-beams, have high second moments of area,
which means they are very stiff in respect to their cross-sectional area and thus can
Structural steel
structural steel is one of the most commonly used materials in commercial and
which are either bolted or welded together in construction. Structural steel can
be erected as soon as the materials are delivered on site, whereas concrete must
be
cured at least 1–2 weeks after pouring before construction can continue, making
heated to temperatures seen in a fire scenario, the strength and stiffness of the
providing water resistance. Also, the fire resistance material used to envelope
Mold - Steel provides a less suitable surface environment for mold to grow than
wood.
constructed using structural steel due to its constructability, as well as its high
strength-to-weight ratio. In comparison, concrete, while being less dense than steel,
has a much lower strength-to-weight ratio. This is due to the much larger volume
required for a structural concrete member to support the same load; steel, though
denser, does not require as much material to carry a load. However, this advantage
becomes insignificant for low-rise buildings, or those with several stories or less.
Low-rise buildings distribute much smaller loads than high-rise structures, making
concrete the economical choice. This is especially true for simple structures, such
Computer aided design or CAD has very broad meaning and can be
form concept to final product. Instead of bringing in quality control during the
final inspection it helps to develop a process in which quality is there through the
life cycle of the product. CAD/CAE can eliminate the need for prototypes. But it
required prototypes can be used to confirm rather predict performance and other
all mechanical designers still uses 2D CAD applications. This may be mainly
due to the high cost of high-end systems and a lack of expertise. Mid-end
systems are actually similar high-end systems with all their design capabilities
with the difference that they are offered at much lower prices. 3D sold
and powerful hardware, strong sound software that offers windows case of use
downstream application. More and more designers and engineers are shifting
4.2 MODELING:
other than that of the entity itself. Modeling is the process of producing a
represents. One purpose of a model is to enable the analyst to predict the effect
approximation to the real system and incorporate most of its salient features.
include simulating the model under known input conditions and comparing
model output with system output. Generally, a model intended for a simulation
Creo
CATIA
Unigraphics, etc
4.2.1 SOLIDWORKS:
SolidWorks is a 3D mechanical CAD (computer-aided design)
Solid Works High-end CAD/CAE software‟s are for the complete modelling,
4.2.2 ANSYS:
ANSYS is the usually preferred analysis software package because of its
functionality. In this interface, you can apply forces, pressures, torques, etc on
technology is built. An innovative project schematic view ties together the entire
simulation process, guiding the user through even complex multi physics analyses
and use it to analyses structures it not at all a big deal always remember to study
the FEA theory very well before you start to use ansys. the reason is that in many
real case scenarios, the ansys always gives some result or the other never 100%
accurate and its generally impossible to find out how correct/incorrect the results
but FEA engineers know how to mesh their models and how to configure the
solver in order
to get accurate results most of the time hence always understand the FEM before
CREO 2.0:
Creo is a family or suite of Computer-aided design (CAD) apps
supporting product design for discrete manufacturers and is developed by PTC. The
suite consists of apps, each delivering a distinct set of capabilities for a user role
Creo runs on Microsoft Windows and provides apps for 3D CAD parametric
Analysis and simulation, schematic design, technical illustrations, and viewing and
visualization.
with CATIA, Siemens NX/Solid edge, and SolidWorks. The Creo suite of apps
Create, and Product View Creo has many different software package solutions and
PTC began developing Creo in 2009, and announced it using the code name
Project Lightning at Planet PTC Live, in Las Vegas, in June 2010. In October
2010, PTC unveiled the product name for Project Lightning to be Creo. PTC
released Creo
1.0 in June 2011.
4.3 FINITE ELEMENT METHOD:
simple problems. It divides the model into many small pieces of simple shapes
called elements.
Elements share common points called nodes. The behavior of these elements
is well-known under all possible support and load scenarios. The motion of each
called degrees of freedom (DOFs). Analysis using FEM is called Finite Element
Analysis (FEA).
taking into consideration its connectivity to other elements. These equations relate
Next, the program organizes the equations into a large set of simultaneous
directions at each node. Using the displacements, the program calculates the strains
calculate stresses. Finite element proceeds at present very widely used in the
engineering analysis.
actual continuum or body of the matter like solid, liquid or gas is represented as an
assemblage of sub division called finite element. These finite elements of field
variable inside the finite element can approximately by the single function.
The approximately functions are defined in terms of the values of the field
variable of the nodes by solving the solid variables the total values of the field
variable of the nodes by solving the solid variables the total values of the nodes by
soling the solid variables the total values of the field variable can be found out.
Coordinate transformation.
Assembly of element equations.
Approximately it is easily improved by grading the mesh so that more
elements appear where field gradients are high and more resolution is
required.
Compounds that have different behavior and different mathematical
description can be solved.
FEA structure closely resembles closely the actual body or region to be
analyzed.
4.3.4 USES OF FEA:
Structural analysis
Mass transport
CHAPTER V
axis. The shaft has a uniform, circular cross section. The shaft is perfectly
balanced. Hexa Mesh is made for better result and 20000 elements made with
fine mesh size. The regular FEA procedure is followed and obtained results were
isotropic solid these consist of the Young's modulus and the Poisson's ratio of the
material.
Then, the structure is broken (or meshed) into small elements. This involves
defining the types of elements into which the structure will be broken, as well as
specifying how the structure will be subdivided into elements (how it will be
meshed). This subdivision into elements can either be input by the user or, with
some
finite element programs (or add-ons) can be chosen automatically by the computer
Next, the boundary conditions (e.g. location of supports) and the external
solution is processed. This data can be viewed in a variety of graphs and displays.
accuracy of the approximation increases with the number of elements used. The
number of elements needed for an accurate model depends on the problem and the
Thus, in order to judge the accuracy of results from a single finite element
run, you need to increase the number of elements in the object and see if or how
This step is perhaps the most critical step in the entire analysis because it
requires that the modeller use his or her fundamental knowledge of mechanics to
interpret and understand the output of the model. This is critical for applying
In preparing the model for analysis, Ansys subdivides the model into many
small tetrahedral pieces called elements that share common points called nodes.
FIGURE 5.2 mesh model of differential shaft
Red dots represent the element's nodes.
The process of subdividing the part into small pieces (elements) is called
meshing. In general, smaller elements give more accurate results but
require more computer resources and time.
Ansys suggests a global element size and tolerance for meshing. The size
is only an average value, actual element sizes may vary from one
location to another depending on geometry.
It is recommended to use the default settings of meshing for the initial
run. For a more accurate solution, use a smaller element size.
RESULT SUMMARY:
Total Deformation 0.0061519mm
Equivalent stress 5.8138MPa
Strain energy 0.14634
CHAPTER VI
CONCLUSION
structural and model analysis are very important significance for the of the life of
the specific parts. This concept of Transient structural and model analysis is
followed by number of researches for their application. This project provides the
background of alloy propeller shaft Transient structural and model analysis to carry
out further research work in same era. In existing design of Propeller shaft of
vehicle was very weighted so fuel consumption rate is higher. And it’s minimizing
the weight of Propeller shaft through new material selection. And we have applied
all loads on the model of differential shaft with structural steel materials and find