Structural analysis and optimization of a composite drive shaft for automotive applications

In this study; Science, which was conducted with the support of Industry and Technology Ministry, 529.STZ.2013-2 number SAN-TEZ project, which will be made from composite materials, composite drive shaft design whic includes computer-aided analysis details and optimization study were presented on composite shaft of the layer stacking sequence. This eighteen-month project is evaluated under the work packages that need to be spread over a period. From the theoretical solution portion to computer based analysis of the model and to the study of optimization portion, the whole results are discussed by making comparings with each results. As a priority in our study; geometric specific safety factor according to the structural and production details have been revealed on the basis of a conceptual design when examining existing structure concept design consists of a tube and two hook connection elements. When considering that the joint Hooke designed and manufactured according to various standards in the market, which will focus on issues in the study, the design of the composite will be the reduced tube. However, this case raises a new study in the subtitle. This title is the method which will be held in connection with the composite tube and metal joint elements. The required connection method between composite and metallic materials must have been diversified through the patent literature should work to ensure that appropriate and necessary structural features examined reproducibility of the method were obtained through various experiences. In this sense, an interference fit as the connection method, one is folded over the bonding results were analyzed in detail. Building composite tube began initially a primitive design (one layer), starting tube static state under the condition where the torque application from the one end other one is from the another end and Tsai-Wu strength ratio based on a safety factor was obtained the required number of layers selected as 2. The resulting structure is needed to achieve the required minimum bending buckling natural frequency, without changing the number of layers it has been introduced by adding a total of fifteen different models suitable low angled winding layers production. Fifteen models analyzed and modeled through finite element analysis program based Abaqus results with theoretical solutions were compared with values achieved after. In the second part of the study, modal analysis, which will be effective in the case of dynamic structural behavior of the vehicle it is made. Modal analysis calculations have been completed under free-free boundary conditions. The theoretical results for modal analysis is based on the formula that the minimum value for existing buildings. In this thesis an optimization study is also made with respect to the orientation of the layer composite tubes. To optimize the overall objective; To reduce the cost of expensive application it can be arranged as to obtain a mechanically ergonomics. The objective of our study to ensure the structure will serve optizational working simultaneously on three different purpose and is thus expected to show the structural behavior of the structure. Structural optimization is possible to perform many different optimization theory. However, many of these methods can not achieve the desired global value or will increase the time resolution. Literature in this type of work allows us to reduce to two the number of titles that can be dealt with if theoretically. These are the genetic algorithm and particle swarm optimization method. Genetic algorithm is a method of bio-based and mutations in terms of showing the necessary approaches to the convergence point for the global optimum value of interest objective function, crossing over like is preferred since it is packed with features that provide some feedback. However, since the problem has to be dealt with multiple and complex objective function increases the resolution time. For this reason, our work easier and particle swarm optimization algorithm that will produce quick solutions are preferred. Particle swarm optimization method, examining the fish and bird feeding behavior is a method of optimization is revealed upon quantified and considered a bird with the aim of removal of each particle nutritional needs of the application carried out any problems. When considered here as bird advancing food so with the aim of improving the value of the corresponding particle objective function by updating its position and velocity by particles in the best position on the results of each iteration the value of function regarding particle's direction and velocity, for example, in a maximization problem is the worst position and the particles have speeds in order to improve the objective function it is to ensure contribute. Three objective function is interested in the thesis; Tsai-Wu strength ratio value, minimum value of flexural and torsional natural frequency is in the form of critical buckling-induced torque. That this calculation of bending and torsional natural frequency purpose induced torsional torque of the three critical functions of the objective function can be expressed directly as simple formulas. Elasticity values representing the mechanical properties associated with the structure In these formulas the variables are assumed to be constant values. The independent variables fiber winding angle and layer sequence is selected. Calculation of the Tsai-Wu strength value is based on the performed repeatedly a number of solutions. There are many arguments as the quantity that can be selected. The content of this thesis required quantities needed in the formula given under headings theoretical approaches can be seen in the flow diagram given under the title optimization. However, as in the other two objective functions Tsai-Wu strength ratio of the fiber winding angle in the calculation flow and layer sequence as an argument in the literature by considering three different layering structure; symmetrical, three models for different composite tube-balanced and symmetrical random situations created and the results are given. Finally the thesis is focused on the method of connection between the metal and composite tube joint. Mentioned two connection methods; After bonding concept models and theoretical calculations before building the model for retaining two separate connection and finally compliance with Abaqus applications were evaluated by performing the static analysis. All in all, the thesis includes the topics from the concept design to optimization of the concept and the concept has been developed both theoretical and analysis by using commercial prograrams that's for obtaining model in better condition. The final condition of the composite tube is ready to get used in fabrication step of design processes.