Design and Optimization of Drive Shaft with Different Composite Materials

Author(s)	Mr. Junaid Pathan, Prof. , Ganesh Kondhalkar, Prof. Ashish Pawar
Country	India
Abstract	This study investigates the torsional performance of a fully composite drive shaft manufactured using CFRP laminates with different, stacking sequences, and laminate thickesses. The objective is to evaluate how fiber orientation and layup design influence the shaft’s maximum static torsion capacity. A comprehensive finite element analysis (FEA) was conducted in ANSYS Workbench, modeling the CFRP structure as an orthotropic laminate to accurately capture directional stiffness and shear behavior. The result shows that torsional performance is highly sensitive to laminate configuration, with ±45° fiber orientations delivering the highest shear strength and torque-carrying capability. Increasing the number of CFRP layers further enhances stiffness while maintaining a low structural mass. Comparative analysis confirms that CFRP shafts outperform traditional metal-based and hybrid aluminum/composite shafts in both strength-to-weight ratio and static torsional capacity. These findings demonstrate that optimized hybrid construction significantly enhances torsional performance compared to conventional shafts, making it a viable candidate for lightweight, high-strength power transmission systems.
Keywords	Drive shaft, Ansys, Composite materials
Field	Engineering
Published In	Volume 8, Issue 3, May-June 2026
Published On	2026-05-15

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