Design, Structural Failure Analysis, And Optimization of Automotive Propeller Shaft Using Finite Element Method in Ansys

ABSTRACT This paper presents a comprehensive study on the design, failure analysis, and optimization of a propeller shaft using ANSYS software. The research focuses on reducing weight, enhancing durability, and improving performance by evaluating conventional metallic shafts against advanced composite alternatives such as E-glass/epoxy and HM carbon/epoxy. The methodology integrates finite element analysis (FEA) to simulate static and dynamic conditions, assess stress distribution, and predict failure modes under torsional and bending loads. Comparative analysis of materials based on deformation, elastic strain, safety factor, and cost highlights the potential of composites to deliver superior strength-to-weight ratios, improved fatigue resistance, and higher natural frequencies compared to traditional steel shafts. Optimization strategies employing ply orientation and laminate stacking sequences are applied to achieve maximum weight reduction without compromising safety and design requirements. The study concludes that composite shafts not only enhance fuel efficiency by reducing vehicle weight but also contribute to sustainable automotive design. Furthermore, the work demonstrates that ANSYS, combined with emerging AI-driven optimization tools, provides a powerful framework for predicting failures, preventing breakdowns, and refining designs. The outcomes support broader applications in the automotive, marine, and aerospace sectors, emphasizing efficiency, reliability, and cost-effectiveness. Keywords- Propeller Shaft; ANSYS; Failure Analysis; Optimization; Composite Materials; Stress Analysis; Weight Reduction; Automotive Engineering