Manufacturing and Unbalance Testing of Rotationally Moulded Hybrid Composite Drive Shafts

One effective way of reducing greenhouse gas emissions is through the consistent use of lightweight construction. By decreasing the moving mass, energy requirements can be lowered. Fibre-reinforced plastic composites are par-ticularly suitable for lightweight components with very high mechanical require-ments and a long service life. This article presents the manufacture and investi-gation of unbalance in rotationally moulded parts using a drive shaft as an exam-ple. The aim is to examine the influence of process parameters on the properties of the shaft and to identify potential applications. The hybrid components are manufactured using a rotational moulding process in which braided preforms and load introduction elements are processed in a single step. The elements are co-cured by a thermoset matrix under the influence of temperature and centrifugal force. Various process parameters, such as rotational speed, matrix temperature, mould temperature, and mould unbalance, are varied, and their influence on the component properties is investigated. Furthermore, the unbalance of the manu-factured shafts is determined using a two-plane balancing machine. ... mehrIt is shown that the unbalance of the shafts is sufficient for use as drive shafts or crankshafts without the need for additional balancing processes