Simulation-Based Failure Analysis of Torsionally Stressed Lightweight Structures in Fiber Composite-Elastomer Hybrid Design

Due to their high strength-to-density ratio, fiberreinforced lightweight components such as drive and cardan shafts have become established in the aerospace, automotive and shipbuilding industries. To increase the performance of such components, new hybrid material combinations of load-transmitting fiber-reinforced plastics (FRPs) and elastomeric decoupling layers offer a promising concept. The aim of this study is to evaluate the influence of the integrated use of elastomers on the structural stability of hybrid drive shafts. For this purpose, conventional composite drive shafts and hybrid designs of different lengths are systematically investigated and compared by means of finite element simulations. The focus is on the analysis of damage behavior, which is manifested by strength or stability failure and has a significant impact on the performance. The study results present the torsional stiffness of the corresponding drive shafts, illustrating the precise time point at which a strength or stability failure arises. For visualization, the damage patterns at the failure occurrence time from the finite element simulations have been shown. In summary, this study provides valuable insights for the material selection and design of drive shafts, which should be considered in the development of future drive systems.

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