Numerical Laminate Screening of Pin-Loaded CFRP Driveshaft Joints Using Progressive Damage Analysis and Multi-Criteria Evaluation.

Abstract

Carbon fiber-reinforced polymer (CFRP) driveshafts offer significant lightweight potential, but the performance of pin-loaded joints is strongly affected by laminate architecture. To support laminate selection beyond peak strength alone, a numerical screening framework combining finite-element analysis, Hashin-based progressive damage modeling, and multi-criteria evaluation was developed. Seven representative layups were compared under axial compression considering off-axis fiber orientation, stacking order, hoop restraint, and mid-plane symmetry. The results showed that Layup 3 achieved the highest peak load of 28.38 kN but exhibited abrupt brittle failure, whereas Layup 1 reached 22.02 kN with more gradual post-peak degradation and localized progressive damage. Removal of hoop-oriented plies promoted longitudinal splitting-type deformation, while asymmetric stacking reduced deformation stability. By integrating peak load, effective energy absorption, and failure safety, Layup 1 achieved the highest comprehensive evaluation index of 0.612 and remained preferred when the safety weight exceeded approximately 0.2. Within the present numerical framework, the proposed approach provides a practical basis for preliminary laminate screening of CFRP driveshaft joints.