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<p>Composite materials combine high mechanical strength, corrosion resistance, vibration damping, lightweight design, and durability, enhancing the performance of vehicle components. This study presents a comprehensive methodology for the optimal design and experimental validation of composite driveshafts. The process involves material characterization according to ASTM D3039/D3039M-17, macroscopic stress–strain modeling, strength evaluation using the Tsai-Wu failure criterion, and design optimization using a genetic algorithm (GA). Numerical simulations in ANSYS, based on the optimized design and including static and modal analyses, predicted a torsional strength of 684 N<InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="170_2025_15863_Article_IEq1.gif" Format="GIF" Height="9" Rendition="HTML" Resolution="72" Type="Linedraw" Width="8" /> </InlineMediaObject> <EquationSource Format="TEX">\( \cdot \)</EquationSource> <EquationSource Format="MATHML"><math> <mo>·</mo> </math></EquationSource> </InlineEquation>m, a safety factor of 3, and a first bending mode natural frequency of 269.7 Hz. Subsequently, a carbon/epoxy composite prototype with the optimized laminate stacking sequence [0/—45/45]<sub>s</sub> was manufactured via filament winding process, achieving a mass of 0.202 kg. Experimental modal analysis (EMA) validated the predicted natural frequency with an error below 6.5%, demonstrating excellent correlation between experimental results and the numerical model. This integrated approach bridges the gap between theoretical optimization and practical validation, contributing to the advancement of manufacturing technologies for lightweight, high-performance rotating components.</p>

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Optimal design and experimental validation of composite driveshafts: a comprehensive methodology

  • 期刊论文

  • 发表日期：

    2025年6月24日

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  • Brian Farid Morales-Hernández,
  • Heller Guillermo Sánchez-Acevedo,
  • Reynel Germán Barrera-Santos

摘要

Composite materials combine high mechanical strength, corrosion resistance, vibration damping, lightweight design, and durability, enhancing the performance of vehicle components. This study presents a comprehensive methodology for the optimal design and experimental validation of composite driveshafts. The process involves material characterization according to ASTM D3039/D3039M-17, macroscopic stress–strain modeling, strength evaluation using the Tsai-Wu failure criterion, and design optimization using a genetic algorithm (GA). Numerical simulations in ANSYS, based on the optimized design and including static and modal analyses, predicted a torsional strength of 684 N \( \cdot \) · m, a safety factor of 3, and a first bending mode natural frequency of 269.7 Hz. Subsequently, a carbon/epoxy composite prototype with the optimized laminate stacking sequence [0/—45/45]s was manufactured via filament winding process, achieving a mass of 0.202 kg. Experimental modal analysis (EMA) validated the predicted natural frequency with an error below 6.5%, demonstrating excellent correlation between experimental results and the numerical model. This integrated approach bridges the gap between theoretical optimization and practical validation, contributing to the advancement of manufacturing technologies for lightweight, high-performance rotating components.