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• W80701826 abstract "The purpose of drive shaft is to transmit static and dynamic torques with vibrationstability. Extensive researches have been carried out on the fiber-reinforcedcomposite drive shaft for the last two decades. Hybrid shafts made of unidirectionalglass fiber or carbon fiber epoxy and steel or aluminum have high fundamentalbending natural frequency as well as high torque transmission capability. The fiberincreases the fundamental bending natural frequency due to its high specific stiffnessand aluminum or steel transmits the required torque.In the present work experimental tests were carried out to study the bending fatiguelife, static torsion capacity and power transmission capacity of a hybrid aluminum/composite drive shaft. The composite used are glass and carbon fiber/epoxy. Atensile test was carried out to find the mechanical properties of composite materialsused throughout this work.A hybrid shaft was fabricated using a wet filament winding method by winding glassand carbon fibers onto aluminum tube with different winding angles, numbers ofivlayers and stacking sequence. A filament winding machine was developed tofabricate the hybrid aluminum/ composite drive shaft. A special mechanism wasdesigned and fabricated for carrying out the static torsion test of the hybrid shaft. Inaddition, an apparatus was designed and fabricated to investigate the powertransmission capacity of the hybrid shaft. Minor modifications were made for therotating bending fatigue machine to perform the bending fatigue test.Flexural moment fatigue life relationships were obtained and the failure modes of thehybrid shaft were studied under fully reversed bending load, R = -1. The results showthat the fatigue life for a winding angle of 45o is larger than that for 90o, for bothglass and carbon fibers. The [±45]3 carbon fiber/epoxy laminates enhanced thefatigue life of aluminum tube up to 54% and the hybrid specimen did not fail till 107cycles at 14.7 N.m applied bending moment. In the hybridized specimens two carbonpercentage contained 34% and 51% were examined. The results show that thepercentage contained of carbon and glass fibers were significantly affected thefatigue life of the hybrid shaft at high and low levels of bending load.The use of matrix inside the aluminum tube increased the fatigue life by 6.5% andincreases the weight of the hybrid specimen by 16%. The results of fatigue test on amacroscopic level indicate that the cracks initiated in the fiber free zones or in theouter skin of resin and increased with increasing number of cycles until failure ofspecimen. On other hand the micro damage shows that the delamination completelytook place between the composite layer and surface of aluminum tube before thecatastrophic failure of a hybrid specimen. In addition, the aluminum tube failure wasperpendicular to the applied bending load and this phenomenon is the same as thatfor the aluminum shaft under bending fatigue test. There is no fiber breakage beingobserved from the rotating bending fatigue test.vThe torque-angle-of-twist response under static torsion load was obtained and thefailure modes of the hybrid shaft were studied. The results show that the static torquecapacity for a winding angle of 45o is larger than that for 90o, for both glass andcarbon fibers. The maximum static torsion for aluminum tube wound by [+45/-45]3laminates are 273.2 N.m and 173.5 N.m for carbon and glass fiber respectively. Thepercentage difference is approximately 36%.The aluminum tube yielded first at the central region of the shaft, followed by crackpropagation in the composite part along the fiber direction, which eventually causeddelamination of the composite layers from the aluminum tube. This due to the matrixcrack and finally the fibers broke and the catastrophic failure took place.For a hybrid shaft wound with fiber configurations of [90/+45/-45/90] and [+45/-45/90/90], the torque-angle-of-twist response results were similar and this satisfiedthe Classical Lamination Theory. In addition, the torque capacity increased byapproximately 12 times for the case of an aluminum tube wound with six layers ofthe carbon fiber at winding angle of 45o compared to the aluminum tube alone. Fromthe power transmission test, it was found out that the difference between the statictorque and dynamic torque is approximately 7%-15%.The finite element analysis has been used to analyzed the hybrid shaft under statictorsion. ANSYS finite element software was used to perform the numerical analysisfor the hybrid shaft. Full scale hybrid specimen was analyzed. Elasto-plasticproperties were used for aluminum tube and linear elastic for composite materials.The predicted results gave good agreement with the experimental results, thepercentage differences between the experimental and theoretical results isapproximately 3.5%-25%." @default.
• W80701826 created "2016-06-24" @default.
• W80701826 creator A5025612596 @default.
• W80701826 date "2006-04-01" @default.
• W80701826 modified "2023-09-26" @default.
• W80701826 title "Evaluation of Mechanical Properties of Hybrid Aluminium/Fiber-Reinforced Composites" @default.
• W80701826 hasPublicationYear "2006" @default.
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