Design, Analysis and Optimization of Composite Propeller Shaft

Abstract Most of the automobiles have Rear wheel drive and front engine installation consists of a transmission shaft. Substitution of conventional metallic (SM45C) Propeller Drive Shaft with the composite (CFRP) structure has many advantages. Composite materials have acquired prominence in the engineering industry due to their remarkable strength-to-weight ratio, corrosion resistance, and adaptability. This paper explores the multifaceted process of designing, analysing, and optimizing composite propeller shafts, with a primary focus on their application in marine and automotive industries, aiming to maximize performance while reducing weight. The design phase initiates by establishing precise requirements, encompassing torque loads, rotational speeds, environmental conditions, and safety factors. Material selection is a pivotal decision point, considering factors like fiber type, resin matrix, and layup orientation. Advanced Finite Element Analysis (FEA) technologies are used to simulate the mechanical behaviour of composite propeller shafts under a variety of operational scenarios, assisting in the identification of stress concentrations. Deformations, as well as key failure modes. The design process is iterative. The feedback from these simulations is used to improve the basic design. The analysis phase stress distribution, torsional vibrations, and dynamic behaviour of the composite propeller shaft. A comprehensive study of various layup configurations and boundary conditions is conducted to assess their impact on structural performance and reliability. Additionally, manufacturing considerations, encompassing fabrication techniques, quality control, and cost-effectiveness, are addressed to ensure practical feasibility. The goal of the optimization phase is to lower the weight of the composite propeller shaft while retaining structural integrity and operational reliability. The optimisation outcomes provide information on the best material mix, layup sequence, and geometric factors that achieve the best balance of weight reduction, greater performance and productivity. The findings from this study contribute substantially to the advancement of composite propeller shaft technology, offering engineers valuable insights into the intricacies of design, analysis, and optimization processes. By harnessing the ability of composite materials effectively, industries can realize significant benefits, including reduced fuel consumption, improved efficiency, and enhanced overall system performance, resulting in more sustainable and competitive products for the maritime and automotive sectors.