Prediction of curing-induced distortion in integrated CFRP drive shafts considering non-uniform resin distribution

doi:10.19936/j.cnki.2096-8000.20260928.005

Abstract

Abstract: Integrated carbon fiber reinforced polymer (CFRP) drive shafts featuring a flange-membrane disk-tube structure have emerged as a significant development direction for lightweight, high-performance transmission components, owing to their excellent specific strength/stiffness ratio and weight reduction potential. Addressing the unresolved challenge that existing models struggle to accurately characterize the influence of non-uniform resin distribution on cure-induced deformation and residual stresses within integrated CFRP drive shafts, this study proposes a novel cure deformation prediction method that incorporates resin distribution heterogeneity. Representative volume element (RVE) models with varying resin contents are established to predict the composite mechanical properties, thermal expansion, and chemical shrinkage characteristics. These predicted properties are then mapped onto a macroscopic finite element (FE) model of the drive shaft to simulate deformation behavior and stress distribution during the curing process. The research results demonstrate that non-uniform resin distribution significantly impacts deformation and residual stresses in integrated CFRP drive shafts. Specifically, for every 1% increase in the difference in resin volume fraction between the upper and lower sides of the shaft, the maximum cure-induced deformation increases by 0.63 mm, and the maximum residual stress rises by 1.05 MPa. Notably, when the resin volume fraction difference between the upper and lower composite sections reaches 40%, the maximum bending deformation of the tube section can reach 23.67 mm (without membrane disks) and 22.45 mm (with membrane disks). Concurrently, residual stresses are concentrated predominantly in the fillet regions of the integrated flange and membrane disk, exhibiting a maximum stress increase of 102.4%. Based on these findings, the paper further discusses deformation suppression strategies suitable for implementation in engineering. This work provides a crucial theoretical foundation and pathways for process optimization in the manufacturing of high-precision integrated CFRP drive shafts.

Key words: CFRP drive shaft, integrated molding, resin non-uniformity, curing deformation, RVE modeling, performance prediction

CLC Number:

TB332

NIE Huiyang, ZHOU Jintao, GUO Jiawei, LONG Junmi, LIU Shuting. Prediction of curing-induced distortion in integrated CFRP drive shafts considering non-uniform resin distribution[J]. COMPOSITES SCIENCE AND ENGINEERING, 2026, 0(9): 38-50.

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