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。主要的挑战是轴端载荷引入的设计。已知的解决方案有很多。纵向压配合既能满足重量的要求，又适合批量生产。在Konstruktiver Leichtbau和Bauweisen研究所进行了理论和实验研究。分析了轴在纵向压配合装配和轴在扭转载荷作用下的应力分布，设计参数可直接供设计工程师使用。然而，对于一个合适的布局至关重要的细节仍然缺失。此外，许多优化传动轴的方法尚未得到研究。最重要的未解决的问题将在这个研究项目中解决。纵向压配合接头的微齿化对其轻量化等级有至关重要的影响。它的优化是最紧迫的目标，主要是最合适的齿的几何形状和周长周围的齿的数量必须计算出来。监测齿在层压板中的渗透深度是为了描绘纤维损伤的程度及其对轴强度的影响。如果轮毂从外部安装到传动轴上，则必须在传动轴半径内安装一个柱环。这种柱环的纤维将受到纵向压缩应力的影响。为了避免稳定性失效，必须开发可靠的解决方案。由于需要更大的压力配件，高扭矩负载会产生高压力。必须采取措施，尽量减少加入纵向压合所需的力。更重要的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转力矩的轻质纵向接头。

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.