Drive shaft manufacturing process pdf

Drive shaft manufacturing process meritor heavy vehicle. A gear shaft with the gearing profiles at each end are called. The component is also used to allow ujoints to rotate smoothly and properly with the drive shaft. Thus, the following fabrication process is belonging to alex from texas university which is worth to be taken as references in this topic discussion. Design, analysis and optimization in automobile drive shaft ijirst. Design of steel drive shaft steel sm45c u sed for automotive drive shaft applications. Industrial shafts drive shaft manufacturer from ahmedabad.

St1 926470000 axle shaft puller st2 28099pa110 axle shaft puller plate 15 after scribing an alignment mark on camber ad. Special manufacturing capabilities to keep contaminants out and lubricants in. Action machine stocks components to manufacture and repair traditional universal joint driveshafts, pto shafts. Could someone add some picture on connection between a gearbox and drive shaft. The shaft manufacturing industry exists in an intense global competition where optimum performance is the key to survival. Mar 25, 2018 a gear shaft manufacturing process application instance with formalized and semantic definition is given to illustrate the capability and effectiveness of the proposed model for providing unified. Material optimization and weight reduction of drive shaft. The endworking process is generally used in highvolume production of shafts where concentricity and productivity are of particular importance. Pdf automotive drive shaft is a very important components of vehicle. Shaft manufacturer company amtech oem shafts manufacturing.

Drive shaft system 12 remove the front arm ball joint from the housing. The drive shaft and differential are used to transfer this torque. Gear shafts provide the rotation that allows one gear to engage with and turn another and contain gear teeth integrated into the shaft. This paper presents a design method and a vibration analysis of a carbonepoxy composite drive shaft. Figure 11 drive train gear transmissions for heavy trucks. Optimization of a process chain for gear shaft manufacturing fritz klocke, markus brumm, bastian nau and arne stuckenberg printed with permission of the holder, the american gear manufacturers association, 1001 n.

The carbonepoxy composite material is used for the shaft tube and the end joints are made of steel. For a shaft transmitting power po at a rotational speed n, the transmitted torque t can be found from t nm 9550 po kw n rpm or. Another emerging application for frp composites is replacing steel or cast iron as a material for manufacturing the high pressure pipes used in city water systems and in petroleum pipe lines. Graphite shafts are made with multiple layers of material wrapped around a mandrel. Dut series kfez series a drive shaft is a revolving shaft used to transmit the power of a motor to a machine. As the automotive drive shaft is a very important component of vehicle. Development of automotive tubular driveshaft using. Drive shaft is an automotive component, which transmits. The invention proposes a process for manufacturing a transmission shaft made of a composite. After baking, the forming mandrel is pulled out of the inside of the shaft through the grip end of the shaft. This means a cars production plant is an active assembly point, where skilled. We are the eminent manufacturer and supplier of a wide range of drive shaft. Shaft sizing stress analysis in design it is usually possible to locate the critical areas, size these to meet the strength requirements, and then size the rest of the shaft to meet the requirements of the shaftsupported elements.

The main challenges presented by this particular gear shaft are its close proximity between gear sets and the diverse bearings locations. An approach for systematic process planning of gear. Products and manufacturing product creation cycle design material selection process selection manufacture inspection feedback typical product cost breakdown 3. We have the machining and assembly capability to provide you with a solution to any of your coupling applications. The steel drive shaft should satisfy three design specifications such as torque transmission capability, buckling torque capability and bending natural frequency. Industrial driveshafts our work with industrial driveshafts combines both of our company strengths. Design of a composite drive shaft and its coupling for. The manufacturing process applies this with either a. Composite shafts combination of steel and carbon fiber are made according to the design and playability characteristics of. Crankshaft design, materials, loads and manufacturing, by. Drive shaft with roll phase adjustment device for bar and rod mill. A method of fabricating a drive shaft for a motor vehicle comprising the steps of. Manufacturing process each radial shaft seal is made for an application, which uses a particular fluid, runs at a predetermined speed, has certain temperatures and pressures, and is in a specific environment.

Gear manufacturing process dynamics are undergoing a major breakthrough in last two. And no further finishing process is required after ball burnishing process. Drive shaft swing diameter plate mills hotcold strip mills rodwire rod mills, etc. The drive shaft must provide a smooth, uninterrupted flow of power to the axles. Drive shaft to eliminate all of the assembly connecting two piece steel drive shaft. From the beginning of the century, the demand for better productivity of gear manufacturing. Most satisfying manufacturing process never seen before duration. Drive shaft services stock the widest range of universal joints and carrier bearings in ireland catering for a vast array of applications. Whether you have a complete product design in mind or you need help with the process, amtechs engineering team is ready to. Its a forging process and it involves a lot of heat, ginormous ovens, huge presses, cranes and pressure. The material properties of the carbonepoxy composite are obtained by performing coupon tests.

Shaft keys that reduce manufacturing costs and machine. Pdf design analysis of an automotive composite drive shaft. In automobiles the drive shaft is used for the transmission of motion. Witco purchased a custom software package and rotary table for the zeiss prismo that allows us to check gears and up to a 48 shaft. Witco has the technology to verify its adherence to the tightest tolerances with a zeiss prismo super accurate cmm. Each end of the shaft includes a yoke that forms one portion of a ujoint.

Download universal joint list download carrier bearing list we also source rare and unusual items throughout europe and the us. A shaft or gear is a wheel with teeth that meshes with the teeth of another shaft to transmit power on a continuous basis combining shafts of different diameters affects rotation speed and force. The invention proposes a process for manufacturing a transmission shaft made of a composite material comprising at least one step for producing an external layer comprising reinforcing fibers impregnated with a heatcurable resin, characterized in that a peripheral sheath made of a knitted article is installed over the external layer prior to the curing of the resin during the polymerization. Balancing the shaft is then easy with straight tube. The fundamental natural bending frequency of drive shaft of passenger cars, small trucks, and vans should be higher than 6500 rpm to avoid whirling vibrations and the torque transmission capacity of the drive shaft should be larger than 3500 nm. The shafts are then put into special ovens whose heat causes the binder material to slowly melt, fusing all the prepreg layers together into one contiguous tube of graphite.

Process for manufacturing a transmission shaft made of a composite. In this study, a composite drive shaft for heavy commercial vehicles is designed and manufactured. The hollow shaft is to be 10% larger in diameter t han the solid shaft. Design and manufacturing sequential process design manufacturing waste resource, waste time concurrent process all disciplines are involved in the earliest stages of product design progress concurrently so iterations results in less wasted effort and time key to success. A shaft has to be designed to meet the stringent design requirements for automotives.

Soft coated lowe glass is more delicate and easily damaged so it is used in. Gear shaft manufacturing capabilities download guide as gear shaft manufacturers, amtech has the production line capabilities to supply oem customers with precision machined gear shafts with a diameter of 50mm to 205mm and a length of 76mm to 915mm. A slip yoke is an integral component of a drive shaft assembly. With a straighter tube, the driveshaft will spin closer to its exact centerline so it needs less balance weight and minimizes the possibility for drive shaft whip at higher rpms. The modeling of the drive shaft assembly was done using solidworks software. In 1966, hayes manufacturing started out as a fledgling, family business. The drive shaft manufacturing is achieved by following the process planning already. The design of the composite drive shaft is divided into. Home tags manufacturing process hajra choudhary pdf download. As reference, the fabrication process by alex has been taken for me to understand the hand make drive shaft by using carbon fiber in real life. Ganga forgings provides yoke forgings in a vast variety of dimensions as these components. Drive shafts for steel production industrial equipment preface throujhout the panufacturinj industr\ the sursuit of jreater sozer outsut at hijher ef cienc\ is a sriorit\ under such circupstances hijhl\ soshisticated and econopical drive shafts that t in a li pited ssace are in jreat deand for use in various etuispent and pachines. Transmission shafts receive and transmit power to the output system and wheels. The drive shaft of transmission system was designed optimally to the specified design requirements the specifications of the drive shaft of an automotive transmission are same as that of the steel drive.

We manufacture the whole range of drive shafts by using latest technology and best material in order to meet the industry standards. The invention proposes a process for manufacturing a transmission shaft made of a. Because of this the manufacturing process of each type of seal may have some additional steps or modifications. Design, analysis and optimization in automobile drive shaft. This thesis examines process planning and manufacturing of complete gear parts. This can be concluded from the failure modes of the splined shaft as they indicate that the splines were able to adequately transfer the load to the torque tube. The drive shaft outer diameter should not exceed 100 mm due to space limitations. The steel drive shaft should satisfy three design specifications such as torque transmission capability, buckling. The drive shaft of transmission system was designed optimally to the specified design requirements the specifications of the drive shaft of an automotive transmission are same as that of the steel drive shaft for optimal design. Since it is installed in a limited space, the axes are seldom aligned.

Another emerging application for frp composites is replacing steel or cast iron as a material for manufacturing the high pressure pipes used. Automobiles, gear boxes, oil engines, machine tools, industrial machinery, agricultural machinery, geared motors etc. Download pdf info publication number us20030129022a1. A twisted tube comes in and you want to salvage the yokes and stubs, then cut off just the ends with the cold saw, chuck the ends up in a lathe, cut out the weld and remove the yoke or stub and. Fairfax street, fifth floor, alexandria, va 223141587. Transmission shaft an overview sciencedirect topics. Drive shaft lineus is certain to satisf\ \our retuirepents in various asslications includinj iron panufacturinj pachines rollinj pills construction pachines and rollinj stocn. Ganga forgings provides yoke forgings in a vast variety of dimensions as these components cater to the numerous applications that require drive shafts. All riten industries products are designed and manufactured to perform at the highest level. The material and process requirements for driving shaft. The mating shaft keyslot is machined with an endmill cutting tool to the same length as the feather key.

This invention relates to a method of fabricating a drive shaft to accommodate axial movement between a vehicle transmission and a drive axle. As iaf16949 iso9001 certified shaft manufacturers, our production team have more than 20 years of experience as precision shaft manufacturers. The evolution of hayes manufacturing from a small garage to a stateoftheart stub shaft, spline couplings, flywheel couplings and drive couplings manufacturing facility is nothing short of an american success story. Shaft are manufactured by filament winding process, fiber strands are unwound from the creels and passed continuously. Typically, a driveline for a motor vehicle includes a shaft extending along an axis between a transmission and a differential of a drive axle. The company has come a long way and is still growing. Through this tube a second shaftwith a connection to the. The material properties of the steel sm45c are given in table 3.

Optimization of a process chain for gear shaft manufacturing. Yoke forgings manufacturers, forged yoke manufacturers. Endworking enhances shaft manufacturing process because endworking is often considered only as a preliminary step for shaft work typical of the automotive industry, potential productivity gains are being passed by. Todays cars are primarily sourced out to produce various subassemblies in over 4,000 disparate locations as far away as china. Transmission shaft the transmission is a sophisticated mechanism permitting a car to function at different speeds while allowing the engine to give its best performance within the rpm range. Pdf design and manufacturing of a composite drive shaft. Other terms commonly used to describe the endworking process include endfinishing, endfacing, face and center, and endfacing and turning. This method eliminates the joining problem between composite and metal because the yoke of a universal joint can be welded to the alumi num shaft or joined. Drive shaft repairing and strengthening welding duration. In addition, the shaft is of a tube designspecified for lightweight needs and realization of the dualclutch concept. Before any shaft is balanced, the tube is straightened to tolerances that are less than half that of oem specs.

Involute splines, both external and internal, are also widely used on various shafts. The yoke allows the drive shaft assembly to flex or slip within the required application. To understand the car manufacturing process, you have to understand the underlying supply chain that drives domestic vehicle assembly. Fluid pressure is applied to the inner diameter of the inner member to.

Use the cold saw to quickly remove the necessary material from the shaft, keeping in mind that the ends will still need to be chamfered for a good weld. Manufacturing processes used to produce finished gear specifications have certain capability limitations. Design and analysis of drive shaft for heavy duty truck. The manufacturing process applies this with either a hard coat or soft coat process. Manufacturing process a sequence of operations and processes designed to create a specific product the process of turning materials into a product. This can be concluded from the failure modes of the splined shaft as they indicate that the splines were.

A solid shaft and a hollow shaft are to be of equal strength in t or sion. This oval shape precisely holds the key in the shaft and prevents axial movement. Gears are used extensively for transmission of power. As gear shaft manufacturers, amtech has the production line capabilities to supply oem customers with precision machined gear shafts with a diameter of 50mm to 205mm and a length of 76mm to 915mm. Process for manufacturing a transmission shaft made of a. This process also ensures a high degree of concentricity between the inner and the outer surfaces of the roller or the shaft. Furthermore, after manufacturing process this shaft is gone through a series of tests to make certain that we are presenting a flawless. A drive shaft, driveshaft, driving shaft, tailshaft australian english, propeller shaft prop shaft, or cardan shaft after girolamo cardano is a mechanical component for transmitting torque and rotation, usually used to connect other components of a drive train that cannot be connected directly because of distance or the need to allow for relative movement between them. Driveshaft materials high performance aluminum or versatile. To meet the strenuous service conditions the gears should have. The preceding unsigned comment was added by mnajib talk contribs 20. Design and manufacturing of a composite drive shaft.

Stages of manufacturing processes are to be accordingly decided. Machine, work fixture, cutter, arbor, machined blanks, and also the cutting parameters add some amount of errors to different gear elements. The manufacture of golf shafts depends upon the type of material that is being used. Action machine stocks components to manufacture and repair traditional universal joint driveshafts, pto shafts as well as high performance shafts like gwb and elbe br. Drive shafts for steel productionindustrial equipment. Design of a composite drive shaft and its coupling for automotive application, m. The steel end connections are bonded to the shaft tube during the filament winding process. Amtech will manufacture your metallic or plastic shaft to print specifications at our stateoftheart production plant.

The torque that is produced from the engine and transmission must be transferred to the rear wheels to push the vehicle forward and reverse. Mar 11, 2017 ever wonder how a turbine shaft was manufactured. Making the gear or shaft is only the first step in the gear manufacturing process. Dec 12, 1995 the invention proposes a process for manufacturing a transmission shaft made of a composite material comprising at least one step for producing an external layer comprising reinforcing fibers impregnated with a heatcurable resin, characterized in that a peripheral sheath made of a knitted article is installed over the external layer prior to the curing of the resin during the polymerization.