Design and Structural Performance Assessment of a Shaft-Driven Transmission System for Low-Maintenance Two-Wheelers

Abstract

The evolution of automobile transmission systems has significantly influenced the efficiency and reliability of modern vehicles. Early developments in automotive engineering focused on basic mechanical power transfer mechanisms, with chain-driven systems becoming widely adopted in two-wheelers due to their simplicity and cost-effectiveness. However, traditional chain drive systems suffer from several limitations, including frequent maintenance, lubrication requirements, wear and tear, and power transmission losses. These drawbacks create a need for more efficient and durable alternatives in modern drivetrain design. This project addresses these challenges by proposing a shaft-driven transmission system for a two-wheeler main shaft assembly. The study focuses on improving performance, reliability, and maintenance efficiency by replacing the conventional chain mechanism with a shaft drive system. The proposed system is designed and modelled using SolidWorks, followed by detailed structural analysis using ANSYS to evaluate its mechanical behaviour under realistic loading conditions. Finite Element Analysis (FEA) is employed to analyse parameters such as stress distribution, deformation, strain, and fatigue life. A comparative analysis is conducted using three different materials structural steel, aluminium alloy, and grey cast iron to determine the most suitable material for the shaft system. The results indicate that structural steel offers superior performance with reduced deformation and improved load-bearing capacity. The proposed system demonstrates enhanced durability, smoother power transmission, and reduced maintenance requirements. This work contributes to the development of efficient and reliable drivetrain systems, supporting advancements in modern two-wheeler design and engineering.