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