GB2146097A - Fibre-reinforced shaft assembly and method of manufacture - Google Patents
Fibre-reinforced shaft assembly and method of manufacture Download PDFInfo
- Publication number
- GB2146097A GB2146097A GB8421594A GB8421594A GB2146097A GB 2146097 A GB2146097 A GB 2146097A GB 8421594 A GB8421594 A GB 8421594A GB 8421594 A GB8421594 A GB 8421594A GB 2146097 A GB2146097 A GB 2146097A
- Authority
- GB
- United Kingdom
- Prior art keywords
- external surface
- fibre
- mandrel
- end fitting
- shaft portion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 9
- 238000000034 method Methods 0.000 title claims abstract description 8
- 239000000835 fiber Substances 0.000 claims abstract description 13
- 239000002184 metal Substances 0.000 claims abstract description 7
- 238000004804 winding Methods 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 8
- 239000011159 matrix material Substances 0.000 claims description 7
- 229920001169 thermoplastic Polymers 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 3
- 229920005989 resin Polymers 0.000 claims description 3
- 239000004416 thermosoftening plastic Substances 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 2
- 229920003023 plastic Polymers 0.000 claims description 2
- 239000002861 polymer material Substances 0.000 claims description 2
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 3
- 239000011151 fibre-reinforced plastic Substances 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C3/00—Shafts; Axles; Cranks; Eccentrics
- F16C3/02—Shafts; Axles
- F16C3/026—Shafts made of fibre reinforced resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2023/00—Tubular articles
- B29L2023/22—Tubes or pipes, i.e. rigid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/748—Machines or parts thereof not otherwise provided for
- B29L2031/75—Shafts
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Ocean & Marine Engineering (AREA)
- Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
A fibre-reinforced shaft assembly includes a tubular fibre- reinforced shaft portion 12 and a metal end fitting 14 having at least one external surface part 16a located generally perpendicular to a longitudinal axis of the shaft portion. Fibre filaments are wound helically along the shaft portion and are continued around said external surface part 16a of the end fitting and back along the shaft portion. A method of manufacture using a collapsible mandrel is also disclosed. <IMAGE>
Description
SPECIFICATION
Fibre-reinforced shaft assembly and method of manufacture
THIS INVENTION relates to a fibre-reinforced shaft assembly and to a method of manufacturing same.
By a fibre-reinforced shaft assembly we mean a shaft constructed at least partially from fibre-reinforced plastics material and including at least one end fitting adapted for connecting the shaft in an operational environment. The high specific strength of fibrereinforced materials e.g. carbon fibre-reinforced materials, and the consequent potential weight savings has resulted in such shafts being proposed for use as drive shafts in motor vehicles.
One such prior proposal is disclosed in USA-A-4,325, 174 wherein a two- part metal end fitting is attached to a fibre-reinforced shaft portion by drilling the ends of the fibrereinforced shaft portion after curing, a procedure which may reduce the overall integrity of the assembly by severing and removal of some of the fibres. European-A-0,044,380 also discloses the use of complex two- part end fittings, one of which is provided with a plurality of radially extending anchorage pins, while GB-A-2,051,303 proposes the use of a two-part end fitting having complementary grooves into which the fibres of the shaft portion are sandwiched prior to curing the latter. In all of these prior proposals, the fibres apper to terminate at the ends of the fibrereinforced shaft portion which may represent a potential weakening of the overall assembly.
In considering the use of fibre-reinforced shafts in generally more critical environments, such as for transmitting torque in a helicopter transmission system, the previously proposed devices were not considered to be suitable because of the complex nature of their end fittings, the tendency for the methods of attachment of the end fittings to limit the integrity of the overall assembly, and the excessive weight of the end fittings which tends to erode the weight reduction potentially achieveable by the use of fibre-reinforced plastics materials in place of tranditional materials.
This latter aspect assumes particular importance when considering such shafts for use in an aircraft.
In one aspect the present invention provides a fibre-reinforced shaft assembly including a tubular fibre-reinforced shaft portion having a longitudinal axis and comprising a plurality of helically wound fibre filaments and a synthetic platics matrix material, and at least one metal end fitting, characterised in that the metal end fitting has at least one external surface part locted generally perpendicular to the longitudinal axis of the shaft portion, and the helically wound fibre filaments extend from the shaft portion around said external surface part of the end fitting and back along the shaft portion.
The or each said external surface part of the end fitting may comprise the external surface of an attachment arm extending radially from one end of said end fitting. Conveniently the arm extends from one end of a hollow shank portion located internally of the shaft portion.
The or each said external surface part may comprise a convex surface.
The matrix material may comprise a thermoplastic polymer material.
In another aspect the invention provides a method of manufacturing a tubular fibre-reinforced shaft assembly, characterised by the steps of locating an end fitting at each end of a longitudinally segmented mandrel, the end fittings each having at least one external surface part extending generally perpendicularly to a longitudinal axis of the mandrel; winding pre-impregnated fibre filaments helically around the mandrel towards one end fitting, continuing the winding of the filaments over and around the said external surface part of the end fitting and helically back along the mandrel, over and around the said external surface part of the other end fitting, and back along the mandrel; repeating the above winding process until the desired thickness of preimpregnated fibre reinforced material has been applied to the mandrel; curing the resin to form an integral assembly; and removing the mandrel.
Conveniently the mandrel includes a central core member adapted to protrude through an aperture in one of the end fittings, one of the segments of the mandrel having side surfaces tapered outwardly towards the core member whereby following curing of the assembly and withdrawal of the core member the said segment is movable into the space vacated by the core member for removal through the aperture in the said one of the end fittings followed in turn by removal of the remaining segments.
The invention will now be described by way of example only and with reference to the accompanying drawings, in which:
Figure 1 is a sectioned view of one end of a fibre-reinforced shaft assembly constructed in accordance with one embodiment of the invention;
Figure 2 is a perspective illustration taken generally in the direction of arrow A of Fig. 1, showing the assembly in a partially completed condition;
Figure 3 is a perspective illustration of an assembled mandrel used in the manufacture of the shaft assembly of Figs. 1 and 2; and
Figure 4 is a sectioned view taken along line B-B of Fig. 4.
Fig. 1 illustrates an end of a fibre-reinforced shaft assembly generally indicated at 11 that includes a tubular fibre-reinforced shaft portion 1 2 having a longitudinal axis 13, and a metal end fitting 14 having a hollow shank portion 1 5 located internally of the end of the shaft portion 1 2 and three radially extending attachment arms 126.
Each of the arms 1 6 of the end fitting 14 has an external surface part 1 6a extending generally perpendicularly to the axis 13, and in the illustrated embodiment the external surface parts are generally convex.
The shaft portion 12 comprises a plurality of helically wound individual rovings each consisting of a plurality of parallel fibre filaments e.g. carbon or glass filaments, embedded in an uncured synthetic plastics matrix material such as a thermo-setting resin or a thermo-plastic polymer. Each individual roving is wound towards the end fitting 14 and is continued as illustrated at 1 2a around the convex external surface parts 1 6a of the end fitting (Fig. 2) and helically back along the tubular portion.
The convex external parts 1 6a of the end fitting provide a stable path for the filaments of each roving around the end fitting (Figs. 1 and 2) and together with the natural tackiness of the pre-impregnated filaments of each roving ensures that each roving maintains a desired path around the end fitting 14 during winding to provide an even distribution of fibre filaments laterally along the length of the external surface parts 1 6a
It will be understood that a desired thickness of fibre-reinforced plastics material can be made up by further layers of helical windings of individual rovings as hereinbefore described.
Figs. 3 and 4 illustrate a collapsible mandrel 17 for use in manufacturing the shaft assembly hereinbefore described. The mandrel 1 7 consists of a plurality of segments 1 7a to 1 7g which locate together around a central circular core member 18 to form a circular outer surface corresponding to the desired internal diameter of the shaft portion 12.
It will be noted that the side surfaces of one of the segments 1 7a taper slightly outwardly towards the core 1 8 and that the cross sectional extremities of all of the segments 1 7a to 1 7g are smaller than the diameter of the core member 18.
As shown in Fig. 3 the segments of the mandrel 1 7 are retained together by an end fitting 14 at both ends and the core member 18, which in the illustrated embodiment protrudes from both of the end fittings 14.
In the manufacture of a shaft assembly, the individual fibre rovings are wound helically along the mandrel 1 7 and the external surface of the shank portion of one of the end fittings 14, and are continued around the external surface parts 1 6a, of the end fitting, back along the mandrel 17, around the external surface parts 1 spa of the other end fitting 14 and back along the mandrel 17, until the desired thickness of the wall of the tubular portion has been built up.
Following curing of the assembly, withdrawal of the core member 18 through one of the end fittings 14 allows segment 1 7a to drop into the area vacated by the core member 18 to facilitate removal of segment 1 7a through the hollow end fitting 14. This then permits withdrawal of all of the remaining sements 1 7b to 179 in a similar manner.
Thus, the present provides a fibre-reinforced shaft assembly having dual load paths for the transfer of operational loads from the single piece end fittings 14 to the tubular fibrereinforced shaft portion 12. The primary load path comprises the bond formed during curing between the matrix material and the external surface of the shank portion 1 5 of the end fitting 14, and the secondary load path is formed by the wrapping of the fibre filaments around the external surface parts 1 6a of the end fittings 14.
The winding of the fibre filaments alternately around the end fittings and along the shaft portion provides for an unbroken flow of fibres throughout the assembly which improves the integrity of the assembly. The angle of winding can be varied to provide varying degrees of flexural and torsional stiffness and strength. For use in critical areas such as in the drive to a helicopter tail rotor it is preferred that the matrix material consists of a thermo-plastic polymer because of its damage tolerance capabilities and since it assists the fibres in taking up non-geostable paths to facilitate the wrapping of the fibres around the external surface parts 1 6a of the end fittings as well as in achieving an even covering throughout the shaft portion.
The simple single piece end fittings reduce cost and minimise the weight of the assembly.
Whilst one embodiment has been described and illustrated it will be understood that many modifications can be made without departing from the scope of the invention. For example the external surface parts may be flat or generally concave and the actual shape of the end fittings can be varied to suit any particular application. The number of external surface parts around which the fibres are wound can be varied accordingly as long as a minimum requirement of one such surface part is provided. The helically wound fibres can be supplemented with longitudinally extending fibres to increase the tensile/compressive strength of the assembly.
Claims (8)
1. A fibre-reinforced shaft assembly including a tubular fibre-reinforced shaft portion having a longitudinal axis and comprising a plurality of helically wound fibre filaments embedded in a synthetic plastics matrix material and at least one metal end fitting, characterised in that the metal end fitting has at least one external surface part located gener ally perpendicular to the longitudinal axis of the shaft portion, and the helically wound fibre filaments extend from the shaft portion around said external surface part of the end fitting and back along the shaft portion.
2. A shaft assembly as claimed in Claim 1, further characterised in that the or each said external surface part comprises the external surface of an attachment arm extending generally radially from one end of said end fitting.
3. A shaft assembly as claimed in Claim 2, further characterised in that said attachment arm extends from one end of a hollow shank portion of the end fitting, the hollow shank portion being located internally of the shaft portion.
4. A shaft assembly as claimed in any preceding Claim, further characterised in that the or each external surface part comprises a convex surface.
5. A shaft assembly as claimed in any preceding Claim, further characterised in that the matrix material comprises a thermo-plastic polymer material.
6. A method of manufacturing a tubular fibre-reinforced shaft assembly, characterised by the steps of locating an end fitting at each end of a longitudinally segmented mandrel, the end fittings each having at least one external surface part extending generally perpendicular to a longitudinal axis of the mandrel; winding pre-impregnated fibre filaments helically around the mandrel towards one of the end fittings, continuing the winding of the filaments over and around said external surface of the end fitting and helically back along the mandrel, over and around the said external surface part of the other end fitting, and back along the mandrel; repeating the above winding process until the desired thickness of pre-impregnated fibre-reinforced material has been applied; curing the resin to form an integral assembly; and removing the mandrel.
7. A method as claimed in Claim 6, further characterised in that the mandrel includes a central core member adapted to protrude through an aperture in one of the end fittings, one of the segments of the mandrel having side surfaces tapered outwardly towards the core member whereby, following curing of the assembly and withdrawal of the core member, the said segment is movable into the space vacated by the core member for removal through the aperture in the said one of the end fittings followed in turn by removal of the remaining segments.
8. Every novel feature and every novel combination of features disclosed herein.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8323604A GB8323604D0 (en) | 1983-09-02 | 1983-09-02 | Fibre-reinforced shaft assembly |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8421594D0 GB8421594D0 (en) | 1984-10-17 |
| GB2146097A true GB2146097A (en) | 1985-04-11 |
| GB2146097B GB2146097B (en) | 1986-09-17 |
Family
ID=10548256
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8323604A Pending GB8323604D0 (en) | 1983-09-02 | 1983-09-02 | Fibre-reinforced shaft assembly |
| GB8421594A Expired GB2146097B (en) | 1983-09-02 | 1984-08-24 | Fibre-reinforced shaft assembly and method of manufacture |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8323604A Pending GB8323604D0 (en) | 1983-09-02 | 1983-09-02 | Fibre-reinforced shaft assembly |
Country Status (1)
| Country | Link |
|---|---|
| GB (2) | GB8323604D0 (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0222660A1 (en) * | 1985-11-14 | 1987-05-20 | Spiflex S.A. | Method of reinforcing a cylindrical element against torsional forces, and relative cylindrical element |
| GB2187819A (en) * | 1986-03-15 | 1987-09-16 | Uni Cardan Ag | Drive shafts |
| US5605507A (en) * | 1993-06-02 | 1997-02-25 | Institut Francais Du Petrole | Mechanical linking device made of wound fiber-reinforced resin manufacturing process |
| US5683300A (en) * | 1994-02-17 | 1997-11-04 | Kabushiki Kaisha Toyoda Jidoshokki Seisakusho | Drive shaft made of fiber reinforced composite material and method of manufacturing the same |
| AT411787B (en) * | 2001-10-31 | 2004-05-25 | Siemens Sgp Verkehrstech Gmbh | HOLLOW SHAFT |
| WO2014006134A1 (en) * | 2012-07-06 | 2014-01-09 | Wethje-Beteiligungs-Gmbh | Fibre-reinforced driveshaft and eyelet winding process for production thereof |
| US20220025922A1 (en) * | 2018-09-21 | 2022-01-27 | Tirsan Kardan Sanayi Ve Ticaret A.S. | Production assembly and method for hybrid composite driveshaft tube |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1330313A (en) * | 1970-09-23 | 1973-09-19 | British Aircraft Corp Ltd | Composite structures |
| EP0019494A1 (en) * | 1979-03-26 | 1980-11-26 | Skf Compagnie D'applications Mecaniques-Adr | Control or force transmitting link |
-
1983
- 1983-09-02 GB GB8323604A patent/GB8323604D0/en active Pending
-
1984
- 1984-08-24 GB GB8421594A patent/GB2146097B/en not_active Expired
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1330313A (en) * | 1970-09-23 | 1973-09-19 | British Aircraft Corp Ltd | Composite structures |
| EP0019494A1 (en) * | 1979-03-26 | 1980-11-26 | Skf Compagnie D'applications Mecaniques-Adr | Control or force transmitting link |
Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0222660A1 (en) * | 1985-11-14 | 1987-05-20 | Spiflex S.A. | Method of reinforcing a cylindrical element against torsional forces, and relative cylindrical element |
| GB2187819A (en) * | 1986-03-15 | 1987-09-16 | Uni Cardan Ag | Drive shafts |
| FR2595772A1 (en) * | 1986-03-15 | 1987-09-18 | Uni Cardan Ag | TRANSMISSION SHAFT, ESPECIALLY ARTICULATED TRANSMISSION SHAFT, MADE OF FIBER REINFORCED PLASTIC MATERIAL, AND METHOD AND DEVICE FOR MANUFACTURING THE SAME |
| DE3608754A1 (en) * | 1986-03-15 | 1987-09-24 | Uni Cardan Ag | DRIVE SHAFT, ESPECIALLY DRIVE SHAFT, MADE OF FIBER REINFORCED PLASTIC, AND METHOD AND DEVICE FOR PRODUCING THE DRIVE SHAFT |
| JPS62270810A (en) * | 1986-03-15 | 1987-11-25 | ジー・ケー・エヌ・オートモーティヴ・アクチエンゲゼルシャフト | Driving shaft consisting of fiber-reinforced synthetic resinand method and device for manufacturing said driving shaft |
| US4773891A (en) * | 1986-03-15 | 1988-09-27 | Uni-Cardan Aktiengesellschaft | Drive shaft of fibre-reinforced plastic material |
| GB2187819B (en) * | 1986-03-15 | 1989-11-15 | Uni Cardan Ag | Drive shaft of fibre-reinforced plastics material |
| JPH0742975B2 (en) | 1986-03-15 | 1995-05-15 | ジー・ケー・エヌ・オートモーティヴ・アクチエンゲゼルシャフト | Drive shaft made of fiber reinforced synthetic resin and method and device for producing the drive shaft |
| US5605507A (en) * | 1993-06-02 | 1997-02-25 | Institut Francais Du Petrole | Mechanical linking device made of wound fiber-reinforced resin manufacturing process |
| US5683300A (en) * | 1994-02-17 | 1997-11-04 | Kabushiki Kaisha Toyoda Jidoshokki Seisakusho | Drive shaft made of fiber reinforced composite material and method of manufacturing the same |
| AT411787B (en) * | 2001-10-31 | 2004-05-25 | Siemens Sgp Verkehrstech Gmbh | HOLLOW SHAFT |
| WO2014006134A1 (en) * | 2012-07-06 | 2014-01-09 | Wethje-Beteiligungs-Gmbh | Fibre-reinforced driveshaft and eyelet winding process for production thereof |
| US20220025922A1 (en) * | 2018-09-21 | 2022-01-27 | Tirsan Kardan Sanayi Ve Ticaret A.S. | Production assembly and method for hybrid composite driveshaft tube |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2146097B (en) | 1986-09-17 |
| GB8421594D0 (en) | 1984-10-17 |
| GB8323604D0 (en) | 1983-10-05 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 732 | Registration of transactions, instruments or events in the register (sect. 32/1977) | ||
| PCNP | Patent ceased through non-payment of renewal fee |