Static property analyses based on finite element method and torsion tests on carbon fibre composite motor drive shaft

A carbon fibre-reinforced polymer drive shaft consisting of a carbon fibre/epoxy composite tube connected to two adhesively bonded steel flanges was designed. Next, finite element method was used to analyse the carbon fibre-reinforced polymer shaft's static torsional properties. The finite element method results showed that the carbon fibre-reinforced polymer tube was capable of withstanding the designed maximum torque of 6701.8 Nm according to the Tsai-Wu failure criterion. Static torsion and torsional fatigue tests were conducted on the carbon fibre-reinforced polymer shaft specimen, at the applied maximum torque of 5492 Nm and 184 300 fatigue cycles. As the shaft did not sustain any damage, it was concluded that the design of the carbon fibre-reinforced polymer shaft was feasible.