Shaft-Hub Connections for Light-weight Drive Shafts in Fiber Composite- Metal-Mixing Methods Investigation of form-fit dominated Connection Types and Development of practical Design Notes

Composite driveshafts have been proven suitable for reducing weight and enhancing the energy efficiency of mobility systems such as cars and airplanes and in general machinery. The joining technology between the mostly metallic load introductions and the tubular shaft body is crucial for the mechanical performance and also for the manufacturing and assembly cost. Aside press-fit and structural bonding, mostly form-fit dominated joining technologies such as the well established bolted connection, but also the novel Pin and 'Smoothed Spline' (SSP) Joint are available. To reduce development time, hence cost for future composite driveshafts, significantly a design guideline for the corresponding shaft-hub-connections is established. It will allow for a well funded preliminary design and dimensioning with the aim of opening new markets for those innovative lightweight components. To create the needed database, the above mentioned joining technologies are examined with analytical, numerical and experimental approaches in generic configurations. Selected results of those investigations are presented in this paper.