Optimizing Half Shaft Design: Balancing Forces, Materials, and Cost

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Discussion Overview

The discussion revolves around the design of a half shaft (drive axle) for a small racing car, focusing on the forces acting on the shaft, material selection, and cost considerations. Participants explore various aspects of shaft design, including sourcing components and understanding the mechanical forces involved.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Mathematical reasoning

Main Points Raised

  • One participant seeks assistance with understanding the forces acting on a half shaft and notes a lack of specific literature on the topic.
  • Another participant inquires about the intended application, specifically the engine type and horsepower.
  • A participant mentions the car's weight and engine model, indicating it is a small racing car.
  • Suggestions are made to source rear differentials and half shafts from a Subaru WRX, with a focus on the strength and suitability of the components.
  • There is a recommendation to consider a differential and suspension setup similar to that of a quad for appropriate sizing.
  • A later reply emphasizes the importance of creating a free body diagram (FBD) to analyze forces and torques acting on the shaft, highlighting the need to consider the entire mechanical support system.
  • Another participant compares the weight of the car to their own vehicle, suggesting that common designs like the Caterham Seven or Ariel Atom might provide useful insights or components.
  • Cost, weight, and available gear ratios are noted as critical factors in the design process.

Areas of Agreement / Disagreement

Participants express various viewpoints on sourcing components and the design considerations for the half shaft, with no consensus reached on specific solutions or approaches. Multiple competing views regarding suitable components and design strategies remain present.

Contextual Notes

Participants mention the need for specific vehicle dimensions, masses, and accelerations to fully understand the forces acting on the half shaft, indicating that assumptions and approximations may be necessary.

wasfy8
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I am going to design a half shaft (drive axle) which connects the differential with the wheel hub, the diameter and its material.
And i have some problems with the forces which act on it.
I didn't find any book about this topic, i found only lot of books which talk about shaft design in general.
So, can anyone help ?
thanks
 
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what is this to be used on? V8? how much horsepower?
 
for a small racing car about 200 kg weight
the engine is Suzuki GSXR-600-750k6
 
For that car, I would try to source the rear differential and halfshafts from a subaru WRX.

The R160 differentials are plenty strong enough for your car's weight and size and come with a few different flavors of limited slip goodness (helical, clutch, and viscous).

Me? I would go further and get the entire rear suspension setup and use what I needed concerning uprights, hubs, brakes...etc...and sell off the rest.

http://memimage.cardomain.com/ride_images/2/4810/1641/24523320013_large.jpg
 
Sounds like a diff/suspension the size of a quad's would be more appropriate.
 
wasfy8 said:
I am going to design a half shaft (drive axle) which connects the differential with the wheel hub, the diameter and its material.
And i have some problems with the forces which act on it.
I didn't find any book about this topic, i found only lot of books which talk about shaft design in general.
So, can anyone help ?
thanks

Draw a(n) FBD to determine the forces and torques that act on the shaft. It will be necessary to look at more than just the shaft in order to understand the problem (review the mechanical support system including all elements that interface with the shaft). Vehicle dimensions, masses and accelerations all need to be known (or approximated) to some degree. Consider static forces from the weight of chassis, torque transferred during acceleration, forces involved in turning and suspension action.
Get an idea what the shaft is doing before you use an existing design or part.
 
With a 200 kg weight I am guessing this is a bike engined car and a very light one at that - my Caterham is 500 kilos.

There's a few common ones out there you might like to look at e.g. Caterham Seven and Ariel Atom. Caterhams in particular are available in DIY kit form with a large build community, and the drive shafts will be available separately if you need them.
 
It's going to boil down to the ratios that are available, cost, and weight.
 

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