Review of Design of Hybrid Aluminum/ Composite Drive Shaft for Automobile
Bhushan K. Suryawanshi1, Prajitsen G.Damle2

1Bhushan K. Suryawanshi, Pursuing M.E Student, Department of Mechanical Engineering, SSBT’s College of Engineering & Technology, Bambhori, Jalgaon (Maharashtra), India.
2Prof. Prajitsen G. Damle, Professor M.E. Department of Mechanical Engineering, SSBT’s College of Engineering &Technology, Bambhori, Jalgaon (Maharashtra), India.
Manuscript received on 12 March 2013 | Revised Manuscript received on 21 March 2013 | Manuscript Published on 30 March 2013 | PP: 259-266 | Volume-2 Issue-4, March 2013 | Retrieval Number: D0580032413/13©BEIESP
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Abstract: This topic deals with the study of replacement of conventional two-piece steel drive shafts with one-piece automotive hybrid aluminum/composite drive shaft & was developed with a new manufacturing method, in which a carbon fiber 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. Replacing composite structures with conventional metallic structures has many advantages because of higher specific stiffness and higher specific strength of composite materials. By considering the thermal residual stresses of the interface between the aluminum tube and the composite layer, the optimum stacking sequence is calculated with the help of Finite element analysis. Press fitting method for the joining of the aluminum/composite tube and steel yokes was devised to improve reliability and to reduce manufacturing cost, compared to other joining methods such as adhesively bonded, bolted or riveted and welded joints. 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 capacity protrusion shape is provided on the inner surface of steel yoke which will fit on Universal joints.
Keywords: Drive Shaft, Composite Material, Aluminum / Composite Drive Shaft Design. Press Fitted Joints, Static Torque.

Scope of the Article: Composite Materials