A STUDY ON THE PROPELLER SHAFT OF CAR USING CARBON COMPOSITE FIBER FOR LIGHT WEIGHT

International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 5, May 2018, pp. 603 611, Article ID: IJMET_09_05_066 Available online at http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=9&itype=5 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 IAEME Publication Scopus Indexed A STUDY ON THE PROPELLER SHAFT OF CAR USING CARBON COMPOSITE FIBER FOR LIGHT WEIGHT KIBONG HAN Aeromechanical Engineering Dept., Jungwon University YONGTAG LEE and DONGCHAN SHIN Convergence Engineering Dept, Jungwon University ABSTRACT In this study, a propeller shaft made of carbon composite fiber (T700) was proposed for lightening the propeller shaft. The carbon composite fiber propeller shaft consists of a carbon fiber composite tube and metal flanges. The carbon fiber composite tube was fabricated by mixing the inside of the tube and the outside of the tube with the helical winding method and the hoop winding method, respectively. In this case, the winding angle was set to 54.5 degrees in consideration of the fracture index and the buckling coefficient. The flange, which is the joint, was fabricated by machining the metal into a concave-convex structure and then joining the carbon fiber-composite fiber tube to the concavo-convex portion of the flange and joining it with the bonding material. The finished carbon composite fiber propeller shafts were subjected to balancing work to solve rotational imbalance and passed the existing evaluation criteria as a result of maximum torque, joint strength, eccentricity degree and fatigue endurance test. It was also found that the mass of the proposed propeller shaft was half the mass of the same performance propeller shaft made of metal. Keyword: Propeller Shaft, Carbon Composite Fiber, Light Weight, Kinetic Energy, Automobile. Cite this Article: Kibong Han, Yongtag Lee and Dongchan Shin, A Study on the Propeller Shaft of Car Using Carbon Composite Fiber for Light Weight, International Journal of Mechanical Engineering and Technology, 9(5), 2018, pp. 603 611 http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=9&itype=5 1. INTRODUCTION Recently, regulation of automobile exhaust gas has been strengthened to preserve atmospheric environment. As a result, there is an urgent need to reduce fuel consumption and fuel consumption in automobiles. In order to improve fuel efficiency, there have been studies to improve engine performance, drive system efficiency, and driving resistance reduction. Recently, however, interest in development of various materials and weight reduction has http://www.iaeme.com/ijmet/index.asp 603 editor@iaeme.com

A Study on the Propeller Shaft of Car Using Carbon Composite Fiber for Light Weight been increasing.[1],[2] That is, weight reduction of automobile parts as well as automobile body for lightening of automobiles is being carried out. Particularly, among the automobile parts, the power transmission device is a main component of the automobile. The power train consists of an engine, a clutch, a transmission, a propeller shaft, an axle shaft, differential gears, and wheels. Here, the propeller shaft is not only one of the heaviest parts as a single part among the parts constituting the power transmission device but also consumes energy by adding linear kinetic energy by mass and rotational kinetic energy by rotational inertia when the car accelerates. Therefore, there is a greater focus on this part than on the other parts. The propeller shaft is a remote power transmission component that transmits the rotational force generated by the engine directly to the distant wheel. Since this part is a long shaft, it was made of two-stage separation type using steel in the past. This is because the specific stiffness of the material, which is a mechanical property, is low, which limits the production of an integral propeller shaft. Also, the integrated propeller shaft made of steel has a problem that resonance occurs and whirling occurs because the first natural frequency is located within the operating range of the propeller shaft.[3]in order to solve these drawbacks, various composite materials have recently been developed, and research on integral propeller shafts is actively under way. In this study, an integrated propeller shaft was proposed using carbon composite fiber material (T700). The carbon composite fiber propeller shaft consists of a carbon fiber composite tube and a metal flange. The carbon fiber composite tube has a winding angle of 54.5 degrees considering the fracture index and the buckling coefficient. The inside of the tube and the outside of the tube are made by mixing the helical winding method and the hoop winding method.[4]the flange, which is the joint part, was fabricated by metal in the form of concavo - convex structure, and the carbon composite fiber tube was inserted into the uneven part of the flange and joined with the bonding material to complete the carbon fiber propeller shaft.[5] The finished carbon composite fiber propeller shafts were subjected to balancing work to resolve the unbalance of the propeller shaft and passed the maximum torque, bond strength, eccentricity and fatigue endurance test standard of the existing propeller shaft. The propeller shafts made of carbon fiber composite material were found to be 1/2 of mass and rotational inertia moment, respectively, as compared with the propeller shafts proposed in this study and those made of metal and metal. And it can be seen that the energy requirement is saved by more than half in the linear motion and the rotational motion respectively. Therefore, the propeller shaft manufactured using carbon fiber composite material will contribute not only to weight reduction but also to energy saving 2. MANUFACTURE OF PROPELLER SHAFT USING CARBON COMPOSITE FIBER Propeller shaft using carbon composite fiber consists of tube and flange. Here, the tube is fabricated by a carbon fiber composite fiber winding method, and the metal flange is manufactured by cutting process and then bonded using an adhesive. Fig. 1 shows a design drawing for a tube of an integral carbon fiber propeller shaft considering the assembly space of the vehicle. The design dimensions of the inner diameter, outer diameter, and length are Ø66mm, Ø74mm, and 1,664mm, respectively. Figure 1 Tube design drawing of propeller shaft made of carbon composite fiber http://www.iaeme.com/ijmet/index.asp 604 editor@iaeme.com

Kibong Han, Yongtag Lee and Dongchan Shin Fig. 2 shows the flange design of the carbon fiber propeller shaft. Carbon composite fiber propeller shafts have metal flanges joined to both ends of the carbon tube, so that the carbon composite tube on the joint often breaks. To prevent this, the flange is machined into a concavo-convex shape as shown in the Fig. 2, and the tube is fitted to the concavo-convex part and joined with the bonding material. Figure 2 Flange design drawing of the carbon fiber propeller shaft Fig. 3 shows the flange of a carbon fiber propeller shaft fabricated from metal. Here, the flange was processed into a concavo-convex shape in a portion contacting with the tube made of carbon composite fiber. Figure 3 Flange of a carbon fiber propeller shaft fabricated from metal Fig. 4 shows the working process of carbon composite propeller shaft manufactured in this study. Fig. 4(a) shows the winding process. Here, the inside and the outside of the carbon fiber composite tube were produced by mixing the helical winding method and the hoop winding method, respectively. In this case, the winding angle was 54.5 degrees considering the fracture index and the buckling coefficient. Fig. 4(b) shows the curing operation. This is an operation to uniformly process the surface of the tube made of carbon fiber composite after winding is finished. Fig. 4(c) shows the process of extracting a tube made of carbon fiber composite from a metal mandrel. Fig. 4(d) shows the dipping operation of a tube made of carbon fiber. Fig.4 (e) shows the bonding between the carbon fiber composite tube and the flange using an adhesive. Fig.4 (f) shows the inspection process of the finished carbon fiber propeller shaft. http://www.iaeme.com/ijmet/index.asp 605 editor@iaeme.com

A Study on the Propeller Shaft of Car Using Carbon Composite Fiber for Light Weight Figure 4 Work process of carbon composite propeller shaft Fig. 5 shows the finished carbon fiber propeller shaft. Here, the mass of the carbon fiber propeller shaft is 8kg, and the length is 1,700mm. Figure 5 Finished carbon fiber propeller shaft 3. KINETIC ENERGY OF THE PROPELLER SHAFT MADE OF CARBON COMPOSITE FIBER Fig. 6 shows the power transmission of a rear-wheeled vehicle equipped with the propeller shaft made of carbon-fiber composite. Figure 6 Power transmission of a rear-wheeled vehicle The power train is transmitted from the engine to the wheels via the clutch, transmission, propeller shaft, and differential gear. Here, the propeller shaft is more interested in lighter weight because it consumes energy by the addition of linear kinetic energy due to mass and rotational kinetic energy due to rotational inertia when the vehicle accelerates. The amount of energy consumed by the propeller shaft when the vehicle is traveling at a speed of can be obtained as follows. Here, the velocityof the vehicle is obtained as follows. = + 1 In Eq. (1), and are the initial velocity of the vhicle and the changing velocity of the vehicle, respectively. Here, A and B are obtained as follows. =2π 2.1 =2π 2.2. http://www.iaeme.com/ijmet/index.asp 606 editor@iaeme.com

Kibong Han, Yongtag Lee and Dongchan Shin In Eq. (2),,, represent the initial rotational speed of the axle, the varying rotational speed of the axle, and the radius of the automobile tire, respectively. Equation (2) is substituted into Equation (1) and summarized as follows. =2π + 3 As shown in Fig. 6, if the ratio of the rotational speed between the drive shaft and the driven shaft of the differential gear is, the rotational speed of the propeller shaft is as follows. = += 4 Next, the total kinetic energy consumed by the propeller shaft when the vehicle travels at the speed is as follows. = + 5 In Eq.(5), and represent the linear kinetic energy and rotational kinetic energy of the propeller shaft, respectively. Here, and can be obtained as follows = + 6.1 = + 6.2 In Eq. (6), and represent the mass and moment of inertia of the propeller shaft, respectively. 4. RESULTS AND DISCUSSION In this study, we propose the propeller shaft fabrication using carbon composite fiber in order to investigate the kinetic energy savings of a propeller shaft made of composite carbon fiber and following tests were carried out to verify the feasibility of the proposed propeller shaft. Fig. 7 shows a device for measuring the rotational unbalance of a carbon fiber propeller shaft and performing balancing using the measured unbalance value. The mass, length, and outer diameter of the propeller shaft were 80kg, 1700mm, and 76mm, respectively, and the balancing test speed was set at 1500RPM considering the vehicle speed. Figure 6 Balancing device Table 1 shows the rotational unbalance value before balancing. Where mass, diameter, and rotation speed are 80kg, 76mm, and 1500RPM, respectively, the reference unbalance amount should generally be less than 0.41 grams. The initial rotation unbalance amount of the carbon fiber propeller shaft manufactured in this study was larger than the reference value, so balancing was required. http://www.iaeme.com/ijmet/index.asp 607 editor@iaeme.com

A Study on the Propeller Shaft of Car Using Carbon Composite Fiber for Light Weight Table 1 Rotational unbalance value before balancing Inspection Left Flange Right Flange Unbalance 6.57grams 3.76grams Angle 91 degrees 40 degrees Result Fail Fail Table 2 shows the results of balancing propeller shafts made of carbon composite fibers in this study. Where the unbalanced values on both sides are 0.33 and 0.40, respectively. This is less than the balancing reference value. Table 2 Rotational unbalance value after balancing Inspection Left Flange Right Flange Unbalance 0.33 grams 0.40 grams Angle 257 degrees 249 degrees Result Pass Pass Fig. 8 shows the measurement of the eccentricity of a tube made of carbon-fiber composite. Here, both ends of the tube are fixed to a spin chuck, and the eccentricity is measured using LVDT at the trisection of the tube while rotating the propeller shaft 360 degrees. Figure 7 Eccentricity measurement of the tube Fig. 9 shows the eccentricity measurement results of the propeller shaft tube. It can be seen that the eccentric displacement (maximum, minimum) in LVDT1, LVDT2, and LVDT3 sensors are (310µm, -300µm), (140µm, -350µm), and (330µm, -230µm), respectively. It meets the standard of propeller shaft. Figure 8 Eccentricity measurement results Fig. 10 shows strength test of the propeller shaft made of carbon composite fiber. Here, one end of the propeller shaft is fixed to a spin chuck, and torque is applied to the other until the propeller shaft cracks Figure 9 Strength test of the propeller shaft http://www.iaeme.com/ijmet/index.asp 608 editor@iaeme.com

Kibong Han, Yongtag Lee and Dongchan Shin Fig. 11 shows the result of strength test of propeller shaft made of carbon fiber composite. Here, the maximum strength immediately before the cracking of the propeller shaft is 438kg f, and the deformed angle is 23.55 degrees. This satisfies the strength of the existing propeller shaft. Figure 10 Strength test results of the propeller shaft Figure 12 shows the fatigue endurance test of a carbon fiber propeller shaft. In this study, one end of a propeller shaft is fixed, and then a repetitive torque is applied 2,000,000 times on the other side. At this time, the torque is as follows. =! sin +% Here,!,, % are 30kg f -m, 120rad/min, 15kg f -m, respectively. Fig. 11. Fatigue endurance test of the propeller shaft Figure 13 shows the results when repeated torque is applied to the propeller shaft made of composite carbon fiber. Figure 12 Fatigue endurance test results of the propeller shaft Fig. 14 shows photographs of the propeller shaft after fatigue endurance test. As a result of applying the cyclic load of 2 million cycles, it can be seen that there is no crack or deformation in the propeller shaft. http://www.iaeme.com/ijmet/index.asp 609 editor@iaeme.com

A Study on the Propeller Shaft of Car Using Carbon Composite Fiber for Light Weight Figure 13 Propeller shaft after fatigue endurance test As described above, the carbon fiber propeller shaft manufactured in this study satisfies the physical standards of the conventional propeller shaft. In this study, we compared the kinetic energy consumed when the car runs at 80km/h, 100km/h, and 120km/h to compare the energy savings due to the weight reduction of the proposed carbon fiber propeller shafts. Also, kinetic energy was calculated assuming that the propeller shaft was attached to the Equus automobile produced by Hyundai Motor as a standard car. Here, the tire standard of the Equus automobile is 275/40R/18, and the rotation ratio between the input shaft and the output shaft of the differential gear is 1/4. In order to compare the kinetic energy of the propeller shaft with the vehicle speed, we compared the propeller shaft manufactured by using the metal of the same size as the propeller shaft proposed in this study. The mass and moment of inertia of the carbon fiber propeller shaft proposed in this study are 8kg and 0.017kg m 2, and the mass and moment of inertia of the compared metal propeller shaft are 17.5kg and 0.030 kg m 2, respectively. Table 3 shows the kinetic energy of propeller shaft made of carbon composite fiber and propeller shaft made of metal, ignoring all friction loss. The total kinetic energy of the propeller shaft is the sum of kinetic energy due to running and kinetic energy due to rotation. The results of Table 3 show that the total kinetic energy required to operate a conventional metal propeller shaft is about two times greater than the total kinetic energy required to operate propeller shafts made of carbon composite fibers. Table 3 Kinetic energy of the propeller shaft Carbon fiber propeller shaft Metal propeller shaft Speed 80km/h 100km/h 120km/h Kinetic energy of linear 1,975 3,086 4,444 motion Kinetic energy of rotational 581.2 907.8 1,308 motion Total kinetic energy 2,556 3,994 5,752 Kinetic energy of linear 4,321 6,752 9,722 motion Kinetic energy of 1,026 1,602 2,307 http://www.iaeme.com/ijmet/index.asp 610 editor@iaeme.com

Kibong Han, Yongtag Lee and Dongchan Shin rotational motion Total kinetic energy 5,347 8,354 12,029 As described above, in this study, propeller shaft made of carbon composite fiber was fabricated. Experiments on eccentricity measurement, torsional strength test and fatigue durability of the manufactured propeller shaft were found to satisfy the standard of propeller shaft. As a result of comparing the total energy required for the propeller shafts when driving, it was found that the propeller shaft made of carbon composite fiber proposed in this study saves about 50% energy compared to the energy required for existing propeller shaft made of metal. 5. CONCLUSION In this study, a propeller shaft was fabricated using integral carbon composite fiber for light weight. It consists of a carbon fiber composite tube and a metal flange on both ends of the tube. In this study, the maximum and minimum values of the eccentric displacement are 140µm and -350µm, respectively, and the torsional strength value is 438kg f at the midpoint of the propeller shaft made of carbon fiber composite. It meets the standard of propeller shaft. In addition, carbon fiber propeller shafts passed the fatigue durability test of propeller shaft. The mass and rotational moment of inertia of the proposed propeller shaft are 8kg and 0.017kg m 2, respectively, which shows that the energy requirement of the propeller shaft is 50% less than that of existing propeller shaft made of metal. Therefore, in this study, propeller shaft made of integral carbon composite fiber proposed for light weight has sufficient strength and fatigue durability, which will contribute to energy saving in automobile adopting this component. REFERENCES [1] Kim K., Park S., "Technique status of carbon fibers reinforced composites for air crafts", Elastomers. Composites, vol. 46(2), pp. 118-124, 2011 [2] Savage, G., Bomphary, I., and Oxley, M., "Exploiting the fracture properties of the carbon fiber composites to design lightweight energy absorbing structures", Engineering Failure Analysis, vol. 11(5), pp.677-694, 2004. [3] Kim K., Bae K., "Trend of Carbon Fiber-reinforced Composites for Lightweight Vehicles", Elastomers and Composites, vol. 47(1), pp. 65-74, 2012 [4] Han K., "A Study on the Tube of Integral Propeller Shaft for the Rear-wheel Drive Automobile Using Carbon Composite Fiber", international Journal of Applied Engineering Research, vol. 12(18), pp. 7530-7535, 2017 [5] Ha J., Sin D., Lee Y. and Han K.," A Study on Tube and Flange Joint of Car Propeller Shaft Made of Carbon Composite Fiber", international Journal of Applied Engineering Research, vol. 12(19), pp. 8227-8231, 2017 [6] V. Murali Mohan, Dr. T.V. Karthikeyan and Dr. Sriram Venkatesh, Performance of 3-D Polar Weave Carbon-Carbon Composites In High Thermal Erosive Environment, International Journal of Mechanical Engineering and Technology, 8(3), 2017, pp. 219 228. [7] B. Saritha and Dr. M.P. Chockalingam, Photodradation of Malachite Green Dye Using TiO2 / Activated Carbon Composite, International Journal of Civil Engineering and Technology, 8(8), 2017, pp: 156 163 http://www.iaeme.com/ijmet/index.asp 611 editor@iaeme.com