In this study, we changed the existing S45C steel shafts applied to the drive shaft for power train of automotive to Al7003-T6 aluminum material. For this purpose, the optimal inner diameter of the aluminium shaft is established. And, analysis of the stresses and vibration characteristics of shafts were analyzed through finite element analysis. The final aluminum drive shaft was evaluated through the static torsional torque test and the frequency test. The Al7003-T6 aluminum drive shaft's weight is 67% comparing from 100% of shaft with existing steel, and with the performance of 3,276 N-m and 236 Hz, it satisfies requirements of the torsional torque of 3,000 N-m and vibration characteristic over 150 Hz required for drive shaft.

To estimate fuel consumption of a vehicle, a car can be tested on chassis dynamometer. In this case, test causes a lot of time and money. To predict the fuel efficiency of vehicles in the design stage or early stage of development, the development of computer simulation model is necessary. Using simulation to predict the fuel consumption, the driving model which consists of time-velocity profile and time-grade profile is necessary In this study, vehicle model is developed in MatLab/simulink to estimate real driving fuel consumption rate with time-velocity profile, time-shift gear profile and time-grade profile. Vehicle model consists of driver model, engine model, power train model, and so on. On-road vehicle tests to verify the vehicle model are carried out for analyzing the result of simulation and comparing with those of the experiments.