Contribution to the introduction of torsional moments in highly stressed fiber composite drive shafts

轴是使用纤维聚合物复合材料进行轻量化设计的完美应用。主要的挑战是在轴端引入载荷的设计。已知有许多解决方案。纵向压配合满足这两个要求：重量最佳，适合批量生产。在该研究所Konstruktiver Leichtbau und Bauweisen的理论和实验研究已经进行。通过分析确定了轴在纵向压配合装配过程中和扭转载荷过程中的应力分布，设计参数可供设计工程师直接使用。然而，对于适当的布局至关重要的重要细节仍然缺失。此外，许多方法来优化传动轴还没有工作。最重要的未回答的问题将在本研究项目中解决。纵向压配合接头的微齿对轻量化等级具有关键影响。其优化是最迫切的目标，首先必须计算出最合适的齿几何形状和圆周上的齿数。监测齿进入层压板的穿透深度是为了描绘纤维损坏的程度及其对轴强度的影响。如果轮毂从外侧安装到驱动轴上，则必须将柱环连接到内驱动轴半径上。该支柱环的纤维将受到纵向压缩应力的应力。为了避免稳定性故障，必须开发可靠的解决方案。由于需要更大的压配合，高扭矩负载引起高压力。重要的是，采取措施以最小化连接纵向压配合所需的力的量。其上级目标是为复合材料设计工程师制定设计指南，为他们提供必要的数据，以开发能够传递最大扭矩的轻质纵向接头。

Shafts are a perfect application for lightweight design using fiber-polymer-composites. The primary challenge is the design of the load introduction at the shaft ends. A number of solutions are known. The lengthwise press fit fulfills both requirements: it is best in weight and suitable for series production. At the institute Konstruktiver Leichtbau und Bauweisen theoretical and experimental investigations have been carried out. The stress distribution during the lengthwise press fit assembly and during torsional load of the shaft were analytically specified, the design parameters can directly be used by the design engineers. However, important details which are crucial for an appropriate layout are still missing. In addition, many approaches to optimize driveshafts have not been worked on.The most important unanswered questions will be addressed in this research project. The micro-toothing of the longitudinal press fit joint has a critical effect on the lightweight grade. Its optimization is the most urgent aim, primarily the most suitable tooth geometry and the number of teeth around the circumference have to be worked out. Monitoring the depth of penetration of the teeth into the laminate is to picture the extent of fiber damage and its influence on the strength of the shaft. If the hub is fitted from the outside onto the driveshaft, a pillar ring must be attached to the inner driveshaft radius. The fibers of this pillar ring will be stressed by longitudinal compression stresses. To avoid stability failure, reliable solutions have to be developed. High torque loads induce high press forces, due to the larger press fitting needed. It is essential that measures are taken to minimize the amount of force needed to join the lengthwise press fit. The superior goal is to develop design guidelines for composite design engineers, providing them with the necessary data to develop lightweight longitudinal joints able to transfer maximum torsional moments.