Faculty Of Engineering and Built Environment

Department of Mechanical Engineering

Subject: Mechanical Engineering Design 2 (MED260S)

DRIVE SHAFT

Submitted by:

1. A. Mpambo
2. INL. Dolwana
3. G. Mzimasi
4. KK. Thari
5. P. Kokwe
6. SE. Mpofu
7. XL. Mngadi
8. YN. Tshazibane
Ethics Statement and Signatures

The work submitted in this project is solely prepared by a team consisting of the below
list of students, and it is original. Excerpts from others’ work have been clearly
identified, their work acknowledged within the text and listed in the list of references.
All of the engineering drawings, computer programs, formulations, design work,
prototype development and testing reported in this document are also original and
prepared by the same team of students.

List of team members

1. A. Mpambo 219097283
2. INL. Dolwana 218248237
3. G. Mzimasi 219226237
4. KK. Thari 219381291
5. P. Kwokwe 219094721
6. SE. Mpofu 219116601
7. XL. Mngadi 219435162
8. YN. Tshazibane 219229961
Abstract
Engineers are expected to be creative, inquisitive, analytical, and detailed oriented.
They should be able to work as a team. The purpose of the report is to improve the
shaft that is already designed. The report includes details on shaft brittle fracture,
ductile fracture, distortion, and corrosion. Metal part abrasion and adhesive wear are
also examined. This paper will focus more on the shafts of Toyota Hilux.

A shaft is a rotating machine element usually in a circular cross-section which is

used to transmit power from one part to another. It is very important to design shaft
that will withstand and survive weather conditions and accidents. Different materials
were considered and the best materials was taken to improve the best of material.
The paper concludes with a consideration of the effects of surface coatings, as well
as metallurgical variables and fabrication techniques, on the fatigue properties of
materials.
Table of Contents

1. Introduction............................................................................................................................ 1
1.1 Problem Statement.......................................................................................................... 1
1.2 Motivation ......................................................................................................................... 2
1.3 Literature Survey ............................................................................................................. 2
2. Project Formulation .............................................................................................................. 3
2.1 Overview .......................................................................................................................... 3
Causes of failure ..................................................................................................................... 4
Benefits .................................................................................................................................... 6
2.2 Project Objective ............................................................................................................. 6
2.3 Design Specification ........................................................................................................ 7
2.4 Constraints and other Considerations ........................................................................... 7
3. Project Management............................................................................................................. 7
3.1 Breakdown of Work into Specific Task ............................................................................... 7
3.2 Gantt Chart for the organization of and Timeline see Appendix B ................................... 7
3.3 Breakdown of Responsibilities among Team Members see Appendix C ........................ 7
3.4 Commercialization of the Final Production ......................................................................... 7
4. Engineering Design and Analysis ..................................................................................... 8
4.2 Material selection.................................................................................................................. 8
5. Prototype Construction ....................................................................................................... 8
5.1 Overview .......................................................................................................................... 8
5.2 Description of the prototype ................................................................................................. 9
5.3 Part list................................................................................................................................... 9
5.4 Prototype cost analysis ........................................................................................................ 9
6. Conclusion ............................................................................................................................. 9
6.1 Conclusion and Discussion ................................................................................................. 9
6.2 Evaluation of Design Aspects.............................................................................................. 9
6.3 Recommendations ............................................................................................................... 9
Bibliography................................................................................................................................... 10
Appendix A .................................................................................................................................. 11
Calculations ............................................................................................................................... 11
Appendix B .................................................................................................................................. 13
Appendix C .................................................................................................................................. 14
Table of Figures

Figure 1............................................................................................................................................ 2
Figure 2............................................................................................................................................ 3
Figure 3: faulty Drive Shaft ............................................................................................................ 5
Figure 4: overall data of Drive failed by Quarter from 2012 -2014 ............................................. 5
Figure 5: Drive Shaft....................................................................................................................... 8
Figure 6: Drive Shaft Prototype ..................................................................................................... 8
Acknowledgment

We would like to express our special thanks of appreciation to our lecture Dr Ali who
gave us the golden opportunity to carry out this amazing project for Mechanical
Engineering Design 2 which as well assisted us in doing more research and we gained
to know about a lot of new things.

Secondly we would to appreciate our selves as groupmates for putting more effort
,and working prudent with each other which aided a lot in finalizing this project
within the limited time frame
1. Introduction
This report represents a detailed analysis and design of hollow shaft, refer to figure1
below. Hollow shafts are preferable for structural applications because they can
withstand the same loads as solid shafts while weighing less
(MECHANICALFUNDA, 2019). It is always preferable to use a hollow shaft for load-
bearing purposes since it has higher stiffness and rigidity and can withstand
somewhat higher bending moments. When it comes to torque transmission shafts
like crankshafts and driveshafts, a solid shaft is always superior because it has more
torsional rigidity. The aim of this project is to familiarize ourselves with mechanical
design aspects (MECHANICALFUNDA, 2019).

The design of a hollow shaft will be the subject of this study. The problem statement,
motivation, and literature review shall all be listed first. Second, a project formulation
will be created, which will include project objectives and design specifications. In
addition, the project management, design analysis, prototype, and testing will all be
put to the test. Finally, based on the complete experience of the design and analysis,
a conclusion and recommendations will be drawn.

1.1 Problem Statement

Many vehicles are involved in accidents nowadays. Many parts of the vehicle are
damaged because of the accident. The drive shaft (drive axle) is one of them. A
drive shaft is a mechanical device that transfers power from an engine or motor to a
place where it can be used to perform useful work. Many failures have occurred in
the shaft, particularly after an accident, such as fatigue failure, torsional stress,
bending stress, and so on. People frequently inquire about the hardness of the
material used in the drive shaft and how long the shaft will last if the car is not
involved in an accident.
The purpose of this project is to investigate the failure of the drive shaft. Determine
the cause of the failure and the condition of the drive shaft first. Then do a research
based on the material used in the drive shaft. After that, we can conduct an analysis
and attempt to resolve the issue.

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 1.2 Motivation
The goal of this research is to look into the failure of a car's drive shaft to evaluate
the material's hardness, fatigue testing to discover the material's endurance limit,
and stress analysis to estimate the driveshaft's maximum stress tolerance.

1.3 Literature Survey

The term drive shaft firstly appeared for the first time in mid 1800 were is was used
to refer to the belt driven shaft by which machine is driven. But as time went by latter
around 1891 the name was used again as some people referred to the shaft
between transmission and driving trucks on locomotives as drive shaft. The term
shaft refers to a rotating machine element with a circular cross section that supports
and transmits power to elements such as rollers, gears, and pulleys
(InternationalResearchjournalofEngineeringScience, 2014). The shaft is always
stepped, with the largest diameter in the middle and the smallest at the ends, where
the Bearings are installed. The steps give shoulders for gears, pulleys, and bearings
to be positioned. The fillet radius is included to reduce stress concentration caused
by abrupt cross section changes (Hariom&Kumar, 2008).

Figure 1
They're made by hot rolling and then cold drawing or rotating and grinding them to
size. To reach the desired strength and hardness, they are further toughened by oil-
quenching (MECHANICALFUNDA, 2019). For very big sizes, billets are forged into
the bars and then turned and ground to finish. The design of shafts is mostly
determined by:

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1. the strength of the material.
2. Torsional stiffness as a foundation

Axle, Spindle, Countershaft, Jackshaft, Line Shaft, and other names for shafts vary
depending on the application. Ordinary transmission shafts are built of medium
carbon steels with a carbon percentage of 0.15-0.40%, such as 30C8 or 40C8, while
higher carbon steels, such as 45C8 or 50C8, are utilized for increased strength. Alloy
steel shafts are employed in applications where corrosion and severe wear are a
concern. 16Mn5Cr4, 40Cr4Mo6 are common grades. Figure 2 shows an example of
a drive shaft.

Figure 2

Shafts are designed to work in a variety of situations, including corrosive environments

and extreme temperatures (Writer, n.d.). Shafts can be subjected to a variety of
loading conditions. Shafts can be loaded in a variety of ways, including tension,
compression, bending, torsion, or a combination of these. Shafts may also be
subjected to vibrational stresses.

2. Project Formulation
2.1 Overview
The drive shaft is a component of a car that transmits motion from the differential to
the wheels. The shafts act in tandem with the movement of the vehicle. During the
operation of the shaft, torsion, bending, and normal forces occur. Manufacturing and
design defects, maintenance flaws, raw material flaws, and user-caused flaws are
some of the most common causes of failure. Failure can occur because of the rotating
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drive shaft, which includes fatigue and torsion failure. A variety of materials are used
to construct a drive shaft to reduce the likelihood of failure. As a result, the students
selected materials with high hardness and strength to ensure that the drive shaft will
last a long period.

Causes of failure
• Shaft failure is frequently caused by wear. Wear is a process of interaction
between surfaces, which causes the deformation and removal of material on
the surface due to the effect of mechanical action. One of the types of wear
failures is abrasive wear. Abrasive wear, also known as abrasion, is the
displacement of material from a solid surface because of abrasive particles or
protuberances sliding across it. A shaft's size and form can be reduced through
abrasive wear. Foreign particles in the lubricant, such as sand, dirt, metallic
particles, and other debris, are instances of abrasive wear of shafts. Wear from
this debris can harm a shaft.
• Misalignment can lead to failures. Misalignment can be caused by mismatched
mating pieces. Misalignment might occur during the equipment's first
construction. After an overhaul or repair of equipment, misalignment can occur.
Misalignment can also be caused by Deflection or Deformation of Supporting
Components in Service. Misalignment might result in shaft fatigue failure due
to vibration.
• Fatigue is one of the most common reasons of shaft failure. Metal fatigue is
caused by the load being cycled repeatedly. It is a type of progressive localized
damage caused by the material's varying stresses and strains. Metal fatigue
cracks begin and spread in areas where the tension is the greatest.
• Forces that surpass the yield strength or tensile strength of a material produce
overload failures. The appearance of an overload failure depends on whether
the shaft material is brittle or ductile, as shown in Figure.3. There are no
materials that are completely brittle or ductile when it comes to shafts. Almost
all motors, reducers, and fans have shafts made of low- or medium-carbon
steels that are reasonably ductile. As a result, when these materials are
subjected to excessive overload, they twist and distort.

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 Figure 3: faulty Drive Shaft

• According to research since from 2012 to 2014 the numbers of failures of drive
shafts has been tremendously increasing, the following graph shows the statics
of the statement.

Figure 4: overall data of Drive failed by Quarter from 2012 -2014

• Fatigue is induced by cyclical loads, and the forces involved in fatigue failures
are far lower than those involved in plastic deformation. The fact that
corrosion reduces a material's fatigue strength further complicates the matter.
Both the degree of the corrosion and the number of stress cycles influence
the amount of decrease. Cracks always grow perpendicular to the plane of
highest tension once they become visible to the naked eye.

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Benefits
The fundamental benefit of the hollow shaft's unique construction is the significant
weight savings it provides, which is beneficial not just from an engineering standpoint
but also from a functional standpoint. The hollow itself has additional benefit: it saves
space by allowing operating supplies, media, and even mechanical pieces like axles
and shafts to be stored in it or channelled through the workstation. Furthermore, hollow
shafts typically have a high resonance frequency. Harmonic Drive AG's Canis Drive
line of servo drives also features a big central hollow shaft, which is one of the key
features of the product's diverse application spectrum.

The method of making a hollow shaft is far more difficult than making a solid shaft.
Dimensions such as diameter and length, in addition to wall thickness, material,
occurring load, and acting torque, have a significant impact on the hollow shaft's
stability (Engineering, 2020). If, for example, wall thickness and diameter are not
designed in a physical law-compliant relationship, the resulting structure may be
unstable. The transmissible torque of a hollow shaft is just slightly less than that of a
solid shaft of the same diameter.

The hollow shaft is an important part of the hollow shaft motor, which is utilized in
electrically powered vehicles like trains. Hollow shafts can also be used to build jigs
and fittings, as well as automatic machinery.

2.2 Project Objective

The hollow shaft is an important part of the hollow shaft motor, which is utilized in
electrically powered vehicles like trains. Hollow shafts can also be used to build jigs
and fittings, as well as automatic machinery:
1. Identify and investigate the nature and characteristics of stresses occurring on
the component utilizing software tools (for simulation/analysis).
2. Examine how the nature and extent of stresses are affected by the loads,
mass, geometry, and boundary conditions.
3. Examine the current design and identify ways to modify it to avoid the negative
effects of undue stress (Torsion or Shear).
4. Validate the mode through practical experimentation.

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 2.3 Design Specification

The following requirements should be met to ensure a successful design:

• The focus on one element of the machine.

• Improving an existing design.
• A factor of safety of 1.2 must be maintained.
• The production cost must be reduced.

2.4 Constraints and other Considerations

• Length
• Weight
• Diameter
• Factor of safety

3. Project Management
3.1 Breakdown of Work into Specific Task

The following are the topics that should be followed doing this project.
1. Introduction
2. Project formulation
3. Project Management
4. Engineering design and analysis
5. Prototype Construction
6. Conclusion
7. Recommendations
8. Peer evaluation
9. Appendices
10. Bibliography

3.2 Gantt Chart for the organization of and Timeline see Appendix B
3.3 Breakdown of Responsibilities among Team Members see Appendix
C
3.4 Commercialization of the Final Production

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4. Engineering Design and Analysis
4.1 Structural Design

Figure 5: Drive Shaft

4.2 Material selection

High Carbon steel AIS108

5. Prototype Construction
5.1 Overview
The following chapter discusses the prototype that we designed, it also mentions
the material used and construction process. The cost analysis shall also be
touched on briefly.

Figure 6: Drive Shaft Prototype

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 5.2 Description of the prototype
The material will be produced using an AISI 1080 high carbon steel with an inner
diameter of 35mm and an outer diameter of 40mm including a uniform length of
1100mm.

5.3 Part list

• U-joint
• Tube
• Centre bearing
• Midship shaft
• End yoke
• Slip yoke and Tube yoke
• Flanges

5.4 Prototype cost analysis

According to research the Galvanizing coat cost around $1.20 per kg.

6. Conclusion
6.1 Conclusion and Discussion
After considering many variables and conditions a conclusion can be drawn that
coating a shaft with a galvanise coat would be effective reason being it will avoid
corrosion and that would reduce shaft failure. According to research it was proven that
high carbon steel is the correct material to use, to be specific the AISI 1080.

6.2 Evaluation of Design Aspects

6.3 Recommendations
• The shaft should be coated for high quality.
• It should be made from strong raw material to avoid corrosion which normally
causes cracks if the car travels on a road with high friction.

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Bibliography
Engineering, 2020. Advantages and disadvantages of hollow shaft over solid shaft.
Mechanical Engineering. [Online]
Available at: https://www.mechstudy.com/2020/09/advantages-and-disadvantages-
of-hollow.html
[Accessed 23 October 2021].

Hariom&Kumar, 2008. A Review of Fundimentals Shafts failure Analysis.

International Research Journal of Engineering and Technology. [Online]
Available at: http://www.irejet.net/archives/V3/I10/IRJET-V31077.pdf.
[Accessed 22 October 2021].

InternationalResearchjournalofEngineeringScience, 2014. Technology and

Innovation. International Research Journal pf Engineering Science, 03(1).

Kumari, J., 2017. A Literature Review on composite Material For Drive Shaft. Journal
of Science and Technology (JST) www.jst.org.in 1 | Page. [Online]
Available at: http://jst.org.in/wp-content/uploads/2019/03/1.-A-Literature-Review-on-
composite-Material-For-Drive-Shaft.pdf
[Accessed 22 October 2021].

MECHANICALFUNDA, 2019. MECHANICALFUNDA For Mechanical Engineering.

[Online]
Available at: https://www.mechanicalfunda.com/2017/03/hollow-vs-solid-
shaft.html#:~:text=For%20the%20load%2Dbearing%20type,it%20has%20higher%20
torsional%20stiffness.
[Accessed 23 October 2021].

Writer, S., n.d. What Is the Function of a Drive Shaft?. [Online]

Available at: https://www.reference.com/world-view/function-drive-shaft-
20545613c0dd5d71
[Accessed 24 October 2021].

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Appendix A
Calculations

𝑆𝑢𝑡 = 965.2660206 𝑀𝑃𝑎

𝑆𝑒′ = 0.5 × 𝑆𝑢𝑡

𝑆′𝑒 = 0.5 × 965,2660206
𝑆′𝑒 = 482.6330103 𝑀𝑃𝑎

𝑏
𝑘𝑎 = 𝑎𝑆𝑢𝑡

𝑘𝑎 = 57.7(965.2660206)−0.718
𝑘𝑎 = 0.4151444

𝑑 −0.107
𝑘𝑏 = ( )
7.62
𝑘𝑏 = 0.8494814529

𝑘𝑐 = 0.59 (𝑇𝑜𝑟𝑠𝑖𝑜𝑛)
𝑘𝑑 = 1
𝑘𝑓 = 1.486

Reliability = 99.99

𝑘𝑐 = 0.702
𝑆𝑒 = 𝑘𝑎 𝑘𝑏 𝑘𝑐 𝑘𝑑 𝑘𝑒 𝑘𝑒 𝑘𝑓 𝑆′𝑒

𝑆𝑒 = (0.4151444669)(0.8494814529)(0.59)(1)(0.702)(482.6330103)
𝑆𝑒 = 70.49516017𝑀𝑃𝑎
1 𝜎𝑎 + 𝜎𝑚
=
𝑛 𝑆𝑒 + 𝑆𝑢𝑡
1 17.2985924 137.2722151
= +
𝑛 70.49516017 965.2660206
𝑛 = 2.579987697

32(1.486)(49) 2 1 16(1.3344)(500) 2 1
𝜎′𝑚𝑎𝑥 = {[( ) ]2 + [3 ( ) ]}2
𝜋(0.035)3 𝜋(0.035)3

𝜎′𝑚𝑎𝑥 = (17.298596 + 137.2722151) × 106

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 𝜎′𝑚𝑎𝑥 = 154.5708114 × 106 𝑃𝑎

𝑆𝑦
𝑛𝑦 =
𝜎′𝑚𝑎𝑥
584.675418
𝑛𝑦 =
154.5708124
𝑛𝑦 = 3.78257326

Max load
𝜋 𝐷4 − 𝑑4
𝑇𝑚𝑎𝑥 = ( ) 𝜎𝑚𝑎𝑥 ( )
16 𝐷
𝜋 0.044 −0.0354
=( ) (154.5708114𝑋106 ) ( )
16 0.04

= 803.7983406N.m

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Appendix B

October Gannt Chart

D D D D D D
D D D D D D D D D 1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5
Description of Number
Activities of days
Introduction 2
Project
formulation 2
Project
management 1
Engineering design
and analysis 4
Prototype
construction 2
Conclusion 1
Final touch ups 1
Peer Evaluation 1
Submission 1

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Appendix C

Task Responsible Person(s) Name and

Surname
Introduction Kabelo Thari, Palesa Kokwe and
Xoliswa Mngadi
Project formulation Anita Mpambo, Xoliswa Mngadi, Palesa
Kokwe and Gcobisa Mzimasi
Project Management Anita Mpambo, Xoliswa Mngadi, Palesa
Kokwe and Gcobisa Mzimasi
Engineering design and analysis Kabelo Thari, Yongamele Tshazibane,
Inga Dolwana and Siyabonga Mpofu
Prototype Construction Kabelo Thari, Yongamele Tshazibane,
Inga Dolwana and Siyabonga Mpofu
Conclusion Anita Mpambo and Gcobisa Mzimasi
Recommendations Siyabonga Mpofu and Inga Dolwana
Peer evaluation Gcobisa Mzimasi and Yongamele
Tshazibane.
Appendices Xoliswa Mngadi and Palesa Kokwe
Bibliography Anita Mpambo and Palesa Kokwe

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