3D numerical analysis of the structural behaviour of a carbon fibre reinforced polymer drive shaft

Due to their high strength and favourable mechanical behaviour, metals are used in a variety of applications within the automotive industry, including drive shafts. However, the use of metallic drive shafts in the automotive sector presents some disadvantages such as high inertial masses. This work investigates the mechanical benefits of using Carbon Fibre Reinforced Polymers (CFRP) for manufacturing drive shafts. A Formula Student car was used as a model for the present work design for the drive shaft. Drive shafts made of Steel AISI 4340, Aluminium, and CFRP are investigated when subjected to mechanical excitations. Simulation includes the use of Comsol Multiphysics software. The CFRP drive shaft was modelled using the layered material feature. Various stacking sequences are tested. Results show that [90°/0°/-45°/+45°] sequence presents the best mechanical behaviour. Analytical and numerical calculations for the natural frequencies are performed and compared. CFRP drive shaft is observed to give the highest fundamental natural frequency when compared to the metallic counterparts. Fatigue analysis are also studied and revealed that the drive shafts can sustain the applied load for its expected fatigue life, with the CFRP drive shaft having the highest fatigue usage factor. Critical buckling analysis showed that the drive shaft made of steel has the highest critical buckling torque. However, drive shafts made of carbon fibre reinforced polymer was found to be 40.7% lighter than the aluminium tube and 79.6% lighter than the steel tube.