Finite Element Analysis of Two-Piece Cardan Shafts Using Conventional and Composite Materials

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Abstract This study investigates the structural and modal behavior of two-piece cardan shafts constructed from conventional and composite materials. Material selection included Steel SM45C, Hardox 400, Stainless Steel, and two composite coatings Carbon Epoxy and E-Glass Polyester applied on a steel core. Finite element analyses in ANSYS Workbench 2021 R2 were conducted to assess the cardan shaft's total deformation, shear stress, maximum principal stress, strain energy, and natural frequency. Under torsional loading of 1250 N·mm at 2000 rpm, Hardox 400 showed the highest total deformation of 0.778 mm, while Steel SM45C had the lowest at 0.398 mm. Maximum principal stresses ranged between 2.4041 MPa (Stainless Steel) and 3.1634 MPa (E-Glass Polyester). Modal analysis revealed that Hardox 400 displayed the lowest fundamental natural frequency at 1191.1 Hz, while Carbon Epoxy exhibited the highest at 952.96 Hz. Across higher-order modes up to Mode 16, Carbon Epoxy and Stainless Steel consistently yielded the highest natural frequencies (~ 8802.3 Hz), while Hardox 400 showed the most compliant behavior (~ 5314.5 Hz). These findings highlight that material selection greatly influences dynamic performance, making composite and stainless-steel coatings promising for lightweight, high-speed automotive driveshafts.
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Finite Element Analysis of Two-Piece Cardan Shafts Using Conventional and Composite Materials | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Finite Element Analysis of Two-Piece Cardan Shafts Using Conventional and Composite Materials Noha Muhammad Abd Elsalam, Ahmed Abdullah Hussien, Noha M. Abdeltawab, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7777720/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This study investigates the structural and modal behavior of two-piece cardan shafts constructed from conventional and composite materials. Material selection included Steel SM45C, Hardox 400, Stainless Steel, and two composite coatings Carbon Epoxy and E-Glass Polyester applied on a steel core. Finite element analyses in ANSYS Workbench 2021 R2 were conducted to assess the cardan shaft's total deformation, shear stress, maximum principal stress, strain energy, and natural frequency. Under torsional loading of 1250 N·mm at 2000 rpm, Hardox 400 showed the highest total deformation of 0.778 mm, while Steel SM45C had the lowest at 0.398 mm. Maximum principal stresses ranged between 2.4041 MPa (Stainless Steel) and 3.1634 MPa (E-Glass Polyester). Modal analysis revealed that Hardox 400 displayed the lowest fundamental natural frequency at 1191.1 Hz, while Carbon Epoxy exhibited the highest at 952.96 Hz. Across higher-order modes up to Mode 16, Carbon Epoxy and Stainless Steel consistently yielded the highest natural frequencies (~ 8802.3 Hz), while Hardox 400 showed the most compliant behavior (~ 5314.5 Hz). These findings highlight that material selection greatly influences dynamic performance, making composite and stainless-steel coatings promising for lightweight, high-speed automotive driveshafts. Cardan shaft SOLIDWORKS finite elements analysis Ansys composite material hardox400 Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. 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Materials","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Cardan shaft, SOLIDWORKS, finite elements analysis, Ansys, composite material, hardox400","lastPublishedDoi":"10.21203/rs.3.rs-7777720/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7777720/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study investigates the structural and modal behavior of two-piece cardan shafts constructed from conventional and composite materials. Material selection included Steel SM45C, Hardox 400, Stainless Steel, and two composite coatings Carbon Epoxy and E-Glass Polyester applied on a steel core. Finite element analyses in ANSYS Workbench 2021 R2 were conducted to assess the cardan shaft's total deformation, shear stress, maximum principal stress, strain energy, and natural frequency. Under torsional loading of 1250 N\u0026middot;mm at 2000 rpm, Hardox 400 showed the highest total deformation of 0.778 mm, while Steel SM45C had the lowest at 0.398 mm. Maximum principal stresses ranged between 2.4041 MPa (Stainless Steel) and 3.1634 MPa (E-Glass Polyester). Modal analysis revealed that Hardox 400 displayed the lowest fundamental natural frequency at 1191.1 Hz, while Carbon Epoxy exhibited the highest at 952.96 Hz. Across higher-order modes up to Mode 16, Carbon Epoxy and Stainless Steel consistently yielded the highest natural frequencies (~\u0026thinsp;8802.3 Hz), while Hardox 400 showed the most compliant behavior (~\u0026thinsp;5314.5 Hz). These findings highlight that material selection greatly influences dynamic performance, making composite and stainless-steel coatings promising for lightweight, high-speed automotive driveshafts.\u003c/p\u003e","manuscriptTitle":"Finite Element Analysis of Two-Piece Cardan Shafts Using Conventional and Composite Materials","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-27 11:32:17","doi":"10.21203/rs.3.rs-7777720/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"ee697998-baac-4e68-81a7-dcaabb9853e8","owner":[],"postedDate":"October 27th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-12-23T02:09:12+00:00","versionOfRecord":[],"versionCreatedAt":"2025-10-27 11:32:17","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7777720","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7777720","identity":"rs-7777720","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}

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