| In this paper an attempt has been made for design and manufacture composite drive shaft for power transmission applications by classical laminated theory (CLT) and finite element (FEM). The composite drive shaft is designed to replace conventional steel drive shaft of an automobile.Epoxy resin formulation and curing temperature is determined. Using E-56 epoxy resin, methyl hexahydrophthalic anhydride (MHHPA) as curing agent, polyethylene glycol ether(PEG) as toughening agent, DMP-30 as accelerator, the middle temperature curing epoxy resin system which used in carbon fiber wet winding process is studied. The effect of toughening agent with different contents on viscosity of epoxy resin is studied, when the contents of toughening agent increases from 0% to 30% at 30℃, the viscosity of E-56 epoxy resin decreases from 4795mPa·s to 589mPa·s. The curing kinetics of the epoxy resin is studied by non-isothermal DSC test, the curing reaction apparent activation energy is 62.60kJ/mol calculated by Kissinger equation while is 68.36kJ/mol calculated by Ozawa equation. The two methods give similar results that validate the two methods. Curing reaction order is 0.9106 indicating that the curing reaction is a complex reaction. The system gel time is 106.77℃, curing temperature is 134.25℃, post-curing temperature is 155.91℃, the reaction rate is 0.003 in 80℃, the reaction rate is 0.03 in 120℃. Finally,80℃/2 hours +120℃/4hours +80℃/1 hour as epoxy resin system curing temperature is selected, casting mold and six different formulations are designed, mechanical properties of the epoxy resin system have be investigated,85% curing agent,15% toughening agent,1% accelerator as the formulation using in winding to manufacture carbon fiber drive shaft is determined, the bending strength is 94.67MPa and impact strength is 2.34KJ/m2.Classical laminated theory (CLT) and finite element (FEM) are used to design the composite drive shaft, the influence of different ply angles, thickness and sequence is investigated. Classical laminated theory show that increase the 0 degree ply, can increase the axial modulus there for increasing the fundamental flexural resonance frequency of composite drive shaft; increase 45 degrees ply, can provides structural strength for torque loading; increase 90 degrees ply, serves as a base layer for friction and for compaction, can increase torsional yield strength. The stacking sequence has effect on the performance of composite drive shaft under asymmetric plies while has no effect on the performance of composite drive shaft under symmetric plies. The finite element simulation show that the stacking sequence has no effect on the frequency, while has effect on the torsional yield strength. Buckling analysis show that Mises stress in both ends of composite drive shaft is larger than other areas, the distribution area is small and very easy to damage; Mises stresses near the ends of the middle part is small; Mises stress in the middle part is at a minimum.Carbon fiber drive shaft that inner diameter is 30mm, thickness is 2mm, length is 710mm, is made of epoxy resin and T700 carbon fiber which have six different stacking sequences by filament winding process, chuck is designed and assembled. Torsion tests show that the torque of No.5 plies [90/15/-15/15/-15/-45/45/-45/45/90] carbon fiber drive shaft reaches a maximum of 551Nm. When the plies have the same ply angle, the stacking sequences influence the torque. As carbon fiber drive shaft is broken, the shaft simply turns into a bunch of loose carbon fibers; the carbon fiber drive shaft is safe. |
PDF Full Text Request