Strength-to-Weight Optimization of Driver Shafts: A Comparative Analysis of Material Selection, Manufacturing Methods, Generative Design, and Topology Optimization using Fusion 360

Abstract

This study presents a comprehensive comparative analysis of strategies for optimizing the strength-to-weight ratio of driver shafts in automobile applications. The research focuses on four key areas: material selection, manufacturing methods, generative design, and topology optimization. Firstly, a range of materials commonly used in driver shaft manufacturing is evaluated, considering factors such as strength, weight, durability.. Various manufacturing methods, including traditional techniques and advanced processes like additive manufacturing, are assessed for their impact on shaft performance. The study also delves into the application of generative design and topology optimization techniques. Generative design algorithms are employed to explore innovative shaft geometries that enhance structural integrity while minimizing weight. Topology optimization algorithms are utilized to optimize material distribution within the shaft, further improving strength-to-weight characteristics. The findings highlight the potential benefits of integrating advanced design methodologies with appropriate material selection and manufacturing processes. This research contributes valuable insights for optimizing driver shafts, enhancing automobile performance, and achieving efficient utilization of materials in automotive engineering. Key Words: Driver Shaft design, Strength and weight optimization, Generative Design, Topology Optimization, Material and manufacturing Consideration.