MANE-4030: Elements of Mechanical Design: Worksheet #15

4/11/11: Topic: Shaft Design

The speed reducer shaft shown in the figure is designed to support a pulley and a worm. The shaft is made of plain carbon steel, heat-treated to HB = 226, resulting in the strengths Su = 113 kpsi and Sy = 86 kpsi. All surfaces of the shaft are finished by grinding. The worm and the pulley are secured to the shaft with sled runner keys in keyways as indicated in the figure. A free body diagram showing the shaft loads is given. The pulley subjects the shaft to a radial bending load of 618 lb and a torque of 3640 in-lb. The worm receives the torque and, in addition, subjects the shaft to a 3200 lb axial load, which is to be taken by the right-hand bearing, and a radial bending load of 335 lb. The shaft rotates at 60 rpm and is to have a life of 10 hours. You are to compute the factor of safety. (a) Draw shear and bending moment diagrams for the shaft. (b) Considering all the loading conditions on the shaft (axial, bending and torsion), where the shaft has a smaller diameter (and therefore higher stresses), and where there are stress concentrations, decide where the critical locations on the shaft will be. (Since the shaft has a high bending moment, plus a torque and an axial load acting on the section supporting the pulley, we can expect the maximum stresses here. The question is then, will the critical point be right at the pulley, where the bending moment is maximum and where there is a stress concentration due to 13 the keyway, or at the shoulder where the shaft goes from a 1 1 8 in diameter to a 1 1 6 in diameter, where there is also a high bending moment and a stress concentration due to the fillet.) (c) Which part of the stress is alternating? Remember, fatigue stress concentration factors only affect the alternating part of the stress. You can find the fatigue stress concentration factor at the keyway in your book (Table 8.3, treat it as hardened steel). What is the fatigue stress concentration factor at the shoulder? From this information, determine which of the locations decided in part (b) will be the most critical location on the shaft. (d) Compute the alternating and mean effective stresses (von Mises) at the critical location. (e) Compute the equivalent, completely reversed stress. (f) Compute the fully modified fatigue limit, Sf. (g) Compute the number of cycles and use this to compute the fatigue strength, SN. (h) Compute the safety factor.

= 3200 lb = 584.25 lb = 368.75 lb

EMD worksheet solutions #15

April 11, 2011 (a) Figure below.

Figure 1: Shear & bending moment diagrams. Figure 1: shear & bending moment (b) Stresses caused by bending moment is a major factor to be considered, so the critical locations EMD worksheet solutions #20 are at the top or bottom points of cross-section A: the place where the pulley is mounted; or of the Nov.19, 2004 cross-section B: the shoulder llet 3 inches left of A. At both points, there is a mean axial compression stress caused by the axial loading, an alternating axial stress caused by bending moment, (a). Figure attached. and constant shear stress caused by constant torque. The only loading dierence between critical (b). Stresses caused by bending moment is a major factor to be considered, so the Critical point at A and B is the alternating stress and the stress concentration factor. locations are at the top or bottom points of cross-section A: the place where the pulley is mounted;

or of cross-section B:mounted the shoulder llet inches key: left of A. Table At both points, is a mean (c) At the A, where pulley is with a sled3runner using 8.3, get Kfthere key = 1.6. At axial stress caused by the axial loading, alternating axial bending B, thecompression shoulder llet 3 inches to the left of A: using an Figure 5.4), D/d =stress 1.61, caused r/d = by 0.056, get moment, an constant shear stress caused by constant torque. The only loading dierence between Kt = 2.1; using Figure 5.46, r = 0.0625, Su = 113ksi, get q = 0.84. Thus critical point at A and B is the alternating stress. Kf f illet = Table 0.84(28.3 .1 1) + 1 = 1.K 92 (1) (c). At A, where pulley is mounted: using (P349), get key = 1.6; at B, the shoulder llet 3 inches left of A: using Figure 4.17(P214), D/d = 1.61, r/d = 0.055, get Kt = 2.1; using Figure Calculating the alternating stress caused by bending at A and B: 4.27(P221), r = 0.0625, Su = 113ksi, get q = 0.84, (32)(2921.25 in-lb)(1.6) 32MA (1.6) = = 33, 437 psi (2) aA = 3 3 dk = 0.84(2.1( )(1 .+ 125 in) 1) 1 = 1 . 92 (1) f (32)(2, 820in-lb)(1.92)) aB = = 38, 734 psi (3) )(1.125 )3 calculating the alternating stress (caused byin bending at A and B:
so we see location B is more critical. 32(2921.25)(1.6) 32M (1.6) = = 33437psi aA = 3 D 3.14159(1.1253 ) 32(2820)(1.92)) 1 aB = = 38734psi 3.14159(1.1253 )

(2) (3)

(d) Considering the axial location B. eqa = aB = 38, 734 psi (4)(3, 200 lb) axial = = 3, 219 psi ( )(1.125 in)2 (16)(3, 640 in lb) xt = = 13, 020 psi ( )(1.125 in)3 1 eqm = [2(3, 219 psi)2 + 6(13, 020 psi)2 ]1/2 = 22, 780 psi 2 (e) eqCR = eqa 38, 734 psi = 22,780 = 48, 514 psi 1 (eqm /Su ) 1 113 ,000 (8) (4) (5) (6) (7)

(f) Modifying factors are: ksr = 0.9 (using Figure 5.33), ksz = 0.9, and kr = 0.9 (assuming 90% reliability). Approximating Sf = 0.5Su = 56.5 ksi, then Sf = Sf (0.9)(0.9)(0.9) = 41.2 ksi (g) The number of cycles is: N = 60 rev/min 60 min hr (10 hr) = 3.6 104 cycles. (10) (9)

The fatigue strength at this number of cycles is (approximating as a straight line on semi-log graph): SN = 113 ksi (113 41.2) ksi log(3.6 104 ) = 58.5 ksi 6 (11)

(h) The safety factor at 10 hours is then nf = 58.5 = 1.21 48.5 (12)