• Proceedings of the Korean Society For Composite Materials Conference
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• 2000.04a
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• pp.149-153
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• 2000

Substituting composite structures for conventional metallic structures has many advantages because of higher specific stiffness and specific strength of composite materials. In this work, one-piece propeller shafts composed of carbonfepoxy and glass/epoxy composites were designed and manufactured for a rear wheel drive automobile satisfying three design specifications, such as static torque transmission capability, torsional buckling and the fundamental natural bending frequency. Single lap adhesively bonded joint was employed to join the composite shaft and the aluminum yoke. For the optimal adhesive joining of the composite propeller shaft to the aluminum yoke, the torque transmission capability of the adhesively bonded composite shaft was calculated with respect to bonding length and yoke thickness by finite element method and compared with the experimental result. Then an optimal design method was proposed based on the failure model which incorporated the nonlinear mechanical behavior of aluminum yoke and epoxy adhesive. From the experiments and FEM analyses, it was found that the static torque transmission capability of composite propeller shaft was maximum at the critical yoke thickness, and it saturated beyond the critical length. Also, it was found that the one-piece composite propeller shaft had 40% weight saving effect compared with a two-piece steel propeller shaft.

• Transactions of the Korean Society of Automotive Engineers
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• v.11 no.1
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• pp.151-159
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• 2003

The front 2 pieces of the 3-piece steel propeller shaft installed on a 8.5-ton truck were redesigned with a 1 -piece composite propeller shaft with steel yokes and spline parts to get the reduction of weight and the improvement of NVH characteristics. Based on the analysis of bending vibration, strength and cure-induced residual stresses of the composite propeller shaft, proper composite materials and stacking sequences were selected. The composite propeller shaft requires a reliable joining method between the shaft and steel end parts through a steel connector. From 3-D contact stress analyses of the laminated composite shaft with bolted Joints, the 3-row mechanical joint which satisfies the torque transmission capability has been designed. Several full-scale composite shafts were fabricated and tested to verify the design analyses. The design requirements are shown to be satisfied. With the newly designed composite shaft, the weight reduction more than 50% and improvements in NVH characteristics have been achieved.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2002.05a
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• pp.22-26
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• 2002

The goal of this study is to replace the current forward 2-piece propeller shaft of 8 ton large truck made of steel with 1-piece composite propeller shaft. A low cost Glass/Epoxy composite propeller shafts were successfully developed, which satisfy requirements such as the capacity of static torque transfer, fatigue strength and bending natural frequency. Devising secure joining method of a composite tube and metal yoke was the most critical issue in successful development of a high torque composite propeller shaft. In this study, joining method using thermal interference fit was adopted for composite to metal joint. Optimum conditions of heating temperature and interference level of thermal interference fit were determined from thermal stress analysis using 3D finite element method. Static torsion test, fatigue test, RPM and balance test were performed to verify the design.

• Proceedings of the Korean Society For Composite Materials Conference
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• 1999.11a
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• pp.49-52
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• 1999

Substituting composite structures for conventional metallic structures has many advantages because of higher specific stiffness and specific strength of composite materials. In this work, one-piece propeller shafts composed of carbon/epoxy composite and glass/epoxy one were designed and manufactured for a rear wheel drive automobile, which uses generally a steel two-piece propeller shaft. From the tests of the composite propeller shafts, it was found that the propeller shafts satisfied requirements of static torque transmission capability, torsional buckling capability and the first natural bending frequency and had 40% weight saving effect compared with steel propeller shaft.

• Journal of the Korean Society of Propulsion Engineers
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• v.3 no.1
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• pp.104-117
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• 1999

The Composite materials has been used in the field of high technology industry because of high specific stiffness and high specific strength. Specially, the composite materials has been widely applied to the field of the aircraft and the transportation by the effectiveness of light weight due to low specific weight and reduction of the parts due to bonding, molding and so on. These advantages about the composite have led to study and apply in the transmission shaft for the aircraft and the drive shaft for the automobile. The composite material propeller shaft with the high vibrational stability was designed and analyzed. In order to verify the analysis, two types of experimental test which are the FFT analyzer with impact hammer and the rotational equipment were applied.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.4
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• pp.32-38
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• 2018

In this study, the one-piece propeller shaft composed of carbon/epoxy was designed and manufactured for 4 wheel drive automobiles that can bear the target torsional torque performance of 3.5kN.m. For the CFRP tube, braiding machine was used to weaving carbon fiber and it was formed the braided yarns with the braid angle ${\pm}45^{\circ}$ and axial yarns to improve strength of the lengthwise direction. The final CFRP tube of propeller shaft was evaluated through the torsional torque test. The CFRP propeller shaft satisfied requirement of the target torsional maximum torque of 3.5kN.m. Also, it was found that the one-piece composite propeller shaft with CFRP tube had 30% weight saving effect compared with a two-piece steel propeller shaft.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2008.11a
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• pp.99-104
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• 2008

The Carbon fiber epoxy composite material and aluminum have many advantages about higher specific stiffness and good fatigue characteristics. basically, the propeller shaft of automobile must satisfy high natural frequency more than 9,200 rpm to satisfy high number of rotation and high torsion torque more than 2,700Nm. In these reason, studied natural frequency and torsion torque characteristics of shaft according to parameter variations with the outdiameter and thickness. From the torsion tester and natural frequency experiments FE analyses was compared vibration and torque characteristics of hybrid shaft Designed hybrid shaft was experimented through FFT analyzer and torsion tester each and satisfied that hybrid shaft reverence 60mm and thickness 5mm by a these experiment is most suitable. Therefore, that can manufacture existent steel two piece type propeller shaft to one piece type hybrid shaft.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.19 no.3
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• pp.274-281
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• 2009

The carbon fiber epoxy composite material and aluminum have many advantages over other materials because of their high specific stiffness and good fatigue characteristics. Basically, the propeller shaft of automobile requires bending frequency of higher than 2,700 Nm and high natural frequency of higher than 9,200 rpm occurred by fast revolution. For this reason, natural frequency and torsion torque characteristics of hybrid shaft was studied in variation of its outer-diameter and thickness. Vibration and torque characteristics of hybrid shaft were compared by torsion tester, natural frequency experiments and FE analysis. Designed hybrid shaft satisfied its vibration and torque characteristics when its outer-diameter was 60 mm and thickness was 5 mm. Therefore, hybrid material enables to manufacture one piece structure hybrid propeller shaft rather than current two piece structure.

• Proceedings of the KSME Conference
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• 2004.11a
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• pp.226-231
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• 2004

Press fitting method for joining of a hybrid tube and steel ring with small teeth for automotive aluminum/composite hybrid propeller shaft was devised to improve reliability and to reduce manufacturing cost, compared to other joining methods such as an adhesively bonded joint, bolted joint or welded joint. To obtain high strength of the press fit joint, an optimal design method for the teeth was devised with respect to number and shape of the steel teeth. Torsional static, fatigue tests and finite element analysis of the press fit joint were performed with respect to experimental variables. The developed optimal design method predicted well the static torque capability and failure mode of the press fit joint. Also, it provided design guide line of press fit joint for improving torsional static and fatigue characteristics.

• Journal of the Korean Society of Propulsion Engineers
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• v.5 no.4
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• pp.31-39
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• 2001

Composite propeller shafts for a vehicle have major advantages such as reduction of vibration, noise, and weight. A propeller shaft was designed with a carbon/epoxy composite material using the finite element method(FEM), and prototype shafts for tests were manufactured by the filament winding manufacturing process. In order to verify the design procedure by FEM, Two kinds of experimental tests were carried out using a FFT analyzer with impact hammers and a critical speed measuring apparatus for measurement of natural frequencies and critical speeds. The difference between the FEM analysis result and the test result was less than 3.4%, showing FEM analysis results to be acceptable. The parametric study was focused on determining the factor affecting the vibration and strength characteristics of the propeller shaft based on FEM. In investigation of the change in natural frequency without an increase in propeller shaft weight, it was found that the winding angle is the most significant factor affecting the vibration and strength characteristics.