Chapter 5 - Shaft Design

Department of Material and Engineering Design, p g g g ,
Faculty of Mechanical and Manufacturing Engineering,

University of Tun Hussein Onn Malaysia (UTHM) Johor.
BDA 3083 Notes Mechanical Engineering Design I
Week 6
Chapter 5
Sh ft D i Shaft Design
Prepared by: Mohd Azwir Bin Azlan
BDA 3083 Mechanical Engineering Design I
Learning Outcomes
CHAPTER 5 Shaft Design
Learning Outcomes
At the end of this topic the students would be able to apply and At the end of this topic, the students would be able to apply and
appreciate the knowledge to:
f f select suitable material for shaft design
perform load, stress, and power calculations analytically as applied to
a shaft components a shaft components.
design a shaft with some consideration on static and fatigue failure.
2
Department of Material and Engineering Design,
What you will be learn here?
What you will be learn here?
5.1 - Introduction
5 2 - Shaft Materials 5.2 Shaft Materials
5.3 - Shaft Layout
5 4 - Shaft Design for Stress 5.4 - Shaft Design for Stress
5.5 - Limits and Fits
3
5 1 Introduction
5.1 Introduction
What is shaft?! What is shaft?!
~a rotating member,
usually of circular cross
ti section
What it is used for?!
~to transmit power or
motion
~It provides the axis of ~It provides the axis of
rotation, or oscillation, of
elements such as gears,
pulleys flywheels cranks pulleys, flywheels, cranks
and the like, and controls
the geometry of their
motion.
4
motion.
5 1 Introduction cont
5.1 Introduction cont
What is axle?!
An axle is a nonrotating member
that carries no torque and
What it is used for?!
is used to support rotating
wheels, pulleys and etc.
Train wheels are affixed to a straight
axle, such that both wheels rotate in
unison.
5
5 1 Introduction cont
5.1 Introduction cont
What is spindle?!
A spindle is a short shaft. Terms
such as lineshaft, headshaft,
stub shaft, transmission shaft,
countershaft, and flexible shaft
are names associated with
special usage.
Tapered roller bearings used in a Tapered roller bearings used in a
mowing-machine spindle. This design
represents good practice for situations
where one or more torque-transfer
elements must be mounted outboard.
6
e e e ts ust be ou ted outboa d
5 2 Shaft Materials
5.2 Shaft Materials
Many shafts are made from low carbon, cold-drawn or hot-rolled steel, such as ANSI
1020-1050 steels.
A good practice is to start with an inexpensive, low or medium carbon steel for the first
time through the design calculations time through the design calculations.
If strength considerations turn out to dominate over deflection, then a higher strength
material should be tried, allowing the shaft sizes to be reduced until excess deflection
b i becomes an issue.
Shafts usually dont need to be surface hardened unless they serve as the actual journal
of a bearing surface. Typical material choices for surface hardening include carburizing
grades of ANSI 1020, 4320, 4820, and 8620.
Cold drawn steel is usually used for diameters under about 3 inches. The nominal
diameter of the bar can be left unmachined in areas that do not require fitting of diameter of the bar can be left unmachined in areas that do not require fitting of
components.
Hot rolled steel should be machined all over.
7
5 2 Shaft Materials cont
5.2 Shaft Materials cont
For large shafts requiring much material removal, the residual stresses may tend to
cause warping (bend out of shape - distortion and twisting).
If concentricity is important, it may be necessary to rough machine, then heat treat to
remove residual stresses and increase the strength then finish machine to the final remove residual stresses and increase the strength, then finish machine to the final
dimensions.
In approaching material selection, the amount to be produced is a salient factor.
For low production - turning is the suitable process.
For High production - conservative shaping method (hot or cold forming, casting), and
minimum material in the shaft can become a design goal Cast iron may be specified if minimum material in the shaft can become a design goal. Cast iron may be specified if
the production quantity is high, and the gears are to be integrally cast with the shaft.
Stainless steel may be appropriate for some environments e.g. Involved in food
i processing.
8
5 3 Shaft Layout
5.3 Shaft Layout
Various method to attach element on shaft. Various method to attach element on shaft.
clamp
collar
snap ring
taper pin
key
taper pin
y
hub
hub
step
shaft
bearing
bearing
step step
step
axial
clearance
press
fit
press
fit
A bl /Di bl i l ll di d h d
gear
sprocket
frame frame
sheave
Assembly/Disassembly progressively smaller diameter toward the ends
Axial clearance to allow machinery vibration
Keys/pins/rings to secure rotating elements ( gear, pulley, etc)
9
y p g g ( g p y )
5 3 Shaft Layout cont
5.3 Shaft Layout cont
Significant detail is required
to completely specify the
geometry needed to geometry needed to
fabricate a shaft.
The geometry of a shaft is
generally that of a stepped
cylinder.
The use of shaft shoulders is The use of shaft shoulders is
an excellent means of axially
locating the shaft elements
d t th t and to carry any thrust
loads.
10
Common shaft
l di h i loading mechanism:
11
Common torque transfer elements: Common torque transfer elements:
Keys Keys
Splines
Setscrews
Pins Pins
Press or shrink fits
Tapered fits
12
Pins: Pins:
Round pins Taper pins Split tubular
i i spring pins
- Pins are used for axial positioning and for the transfer of torque or thrust or both.
- Some pins should not be used to transmit very much torque
- Weakness will generate stress concentration to the shaft
13
Keys and keyseats: Keys and keyseats:
Keys are used to transmit torque from a component to the shaft
14
Keys are used to transmit torque from a component to the shaft.
Spline shaft and Hub: Spline shaft and Hub:
- Used when large amounts of torque are to be transferred
St t ti i ll it d t
15
- Stress concentration is generally quite moderate
Locational device: Locational device:
Nut and washer Nut and washer
Sleeve
Shaft shoulder Shaft shoulder
Ring and groove
Setscrew Setscrew
Split hub or tapered two-pieces hub
Collar and screw
Pins
16
Nut and Washer: Nut and Washer:
17
Sleeve: Sleeve:
is a tube or enclosure used to couple two mechanical components together, or
t t i t t t th thi it t ll i d d to retain two components together; this permits two equally-sized appendages
to be connected together via insertion and fixing within the construction.
18
Shaft shoulder : Shaft shoulder :
The use of shaft shoulders is an excellent The use of shaft shoulders is an excellent
means of axially locating the shaft
elements and to carry any thrust loads.
Example:
(a) Choose a shaft configuration to support and locate the two gears and two bearings.
(b) Solution uses an integral pinion, three shaft shoulders, key and keyway, and sleeve.
19
(b) Solution uses an integral pinion, three shaft shoulders, key and keyway, and sleeve.
Spring loaded Retaining Ring : Spring loaded Retaining Ring :
Most popular used because give an economical p p g
solution to some problem.
Bowed retaining rings provide restoring forces to
the components being held. p g
Flat retaining rings allow small amounts of axial
motion of the held component.
20
Set Screw : Set Screw :
is a type of screw generally used
to secure an object within another
bj Th object. The set screw passes
through a threaded hole in the
outer object and is tightened
i t th i bj t t t against the inner object to prevent
it from moving relative to the outer
object.
21
Split Hub : Split Hub :
22
Collar and Screw : Collar and Screw :
is a simple, short ring fastened over a rod or shaft
found in many power transmission applications -
most notably motors and gearboxes.
used as mechanical stops, locating components,
and bearing faces. The simple design lends itself to
easy installation - no shaft damage. easy installation no shaft damage.
Since the screws compress the collar, a uniform
distribution of force is imposed on the shaft, leading
to a holding power that is nearly twice that of set
screw collars.
23
5 4 Shaft Design for Stress
5.4 Shaft Design for Stress
Critical Location :
It is not necessary to evaluate the stresses in a shaft at every point; a few
potentially critical locations will be adequate
Critical Location :
potentially critical locations will be adequate.
Critical locations will usually be on the outer surface, at axial locations where the
bending moment is large, where the torque is present, and where stress
concentrations exist.
Most shafts will transmit torque through a portion of the shaft. Typically the torque
comes into the shaft at one gear and leaves the shaft at another gear. The torque comes into the shaft at one gear and leaves the shaft at another gear. The torque
is often relatively constant at steady state operation.
The bending moments on a shaft can be determined by shear and bending
moment diagrams Since most shaft problems incorporate gears or pulleys that moment diagrams. Since most shaft problems incorporate gears or pulleys that
introduce forces in two planes, the shear and bending moment diagrams will
generally be needed in two planes.
24
5 4 Shaft Design for Stress cont
5.4 Shaft Design for Stress cont
Critical Location :
Resultant moments are obtained by summing moments as vectors at points of
interest along the shaft In situations where a bearing is located at the end of the
Critical Location :
interest along the shaft. In situations where a bearing is located at the end of the
shaft, stresses near the bearing are often not critical since the bending moment is
small.
Axial stresses on shafts due to the axial components transmitted through helical
gears or tapered roller bearings will almost always be negligibly small compared
to the bending moment stress. They are often also constant, so they contribute
littl t f ti little to fatigue.
Consequently, it is usually acceptable to neglect the axial stresses induced by the
gears and bearings when bending is present in a shaft. If an axial load is applied g g g p pp
to the shaft in some other way, it is not safe to assume it is negligible without
checking magnitudes.
25
Shaft Stresses :
The fluctuating stresses due to bending and torsion are given by: -
Shaft Stresses :
; ;
I
c M
K
a
f a
=
I
c M
K
m
f m
=
J
c T
K
a
fs a
=
J
c T
K
m
fs m
=
I I J
Under many conditions, the axial components F is either zero or so small that it can be neglected.
J
A i lid h ft ith d ti i t t t Assuming a solid shaft with round cross section, appropriate geometry terms
can be introduced for c, I, and J resulting in
;
3
32
d
M
K
a
f a
=
3
32
d
M
K
m
f m
=
;
3
16
d
T
K
a
fs a
=
3
16
d
T
K
m
fs m
=
26
Shaft Stresses :
Combining bending and shear stresses accordance to the von Misses stress
at two stress element are given by:
Shaft Stresses :
2 / 1
2 2
2 / 1 2 2
16 32
T K M K
f f
at two stress element are given by: -
3 3
2 / 1 2 2
16
3
32
) 3 ( '
= + =
d
T K
d
M K
a fs a f
a a a

2 / 1
2 2
2 / 1 2 2
16
3
32
) 3 ( '
= + =
T K M K
m fs m f

3 3
3 ) 3 (
= + =
d d
m m m

27
Shaft Stresses : Shaft Stresses :
28
DE-Goodman : DE Goodman :
Fatigue failure curve on the modified Goodman diagram
[ ] [ ]

+ + + =
2 / 1
2 2
2 / 1
2 2
3
) ( 3 ) ( 4
1
) ( 3 ) ( 4
1 16 1
m fs m f
ut
a fs a f
e
T K M K
S
T K M K
S d n
Equation for the minimum diameter
[ ] [ ]
3 / 1
2 / 1
2 2
2 / 1
2 2
) ( 3 ) ( 4
1
) ( 3 ) ( 4
1 16
+ + + =
m fs m f
ut
a fs a f
e
T K M K
S
T K M K
S
n
d

This criteria does not guard against yielding, so required separate check for possibility of static
failure (yield occur) in the first load cycle
29
failure (yield occur) in the first load cycle.
DE-Gerber : DE Gerber :
Fatigue failure curve on the Gerber diagram
where
+ + =
2 / 1
2
3
2
1 1
8 1
ut
e
e
AS
BS
S d
A
n
2 2
) ( 3 ) ( 4
a fs a f
T K M K A + =
ut e
2 2
) ( 3 ) ( 4
m fs m f
T K M K B + =
3 / 1
2 / 1
2
2
1 1
8

e
BS nA
d
This criteria does not guard against
yielding so required separate check for
1 1
+ + =
ut
e
e
AS S
d
yielding, so required separate check for

possibility of static failure (yield occur)
in the first load cycle.
30
DE-ASME Elliptic :
2 / 1
DE ASME Elliptic :
Fatigue failure curve on the ASME Elliptic diagram
2 / 1
2 2
2 2
3
3 4 3 4
16 1
=
y
m fs
y
m f
e
a fs
e
a f
S
T K
S
M K
S
T K
S
M K
d n

y y e e
3 / 1 3 / 1
2 / 1
2 2
2 2
3 4 3 4
16
=
m fs m f a fs a f
S
T K
S
M K
S
T K
S
M K
n
d
This criteria takes yielding into account, but is not entirely conservative, so also required
separate check for possibility of static failure (yield occur) in the first load cycle

y y e e
S S S S
31
separate check for possibility of static failure (yield occur) in the first load cycle.
DE-Soderberg : DE Soderberg :
Fatigue failure curve on the Soderberg diagram
[ ] [ ]

+ + + =
2 / 1
2 2
2 / 1
2 2
3
) ( 3 ) ( 4
1
) ( 3 ) ( 4
1 16 1
m fs m f
yt
a fs a f
e
T K M K
S
T K M K
S d n
3 / 1
[ ] [ ]
3 / 1
2 / 1
2 2
2 / 1
2 2
) ( 3 ) ( 4
1
) ( 3 ) ( 4
1 16
+ + + =
m fs m f
yt
a fs a f
e
T K M K
S
T K M K
S
n
d
This criteria inherently guards against yielding, so it is not required to check for possibility of
static failure (yield occur) in the first load cycle

32
static failure (yield occur) in the first load cycle.
Check for yielding :
S
Check for yielding :
max
'
y
y
S
n =
Factor of safety
( )
2 / 1
2 2
' ' ' + =
where
( )
max m a
+ =
2 / 1
2 2
) ( 16
3
) ( 32
+
+
+
=
T T K M M K
m a fs m a f
3 3
3
=
d d
33
For a rotating shaft with constant bending and torsion, the bending stress is
completely reversed and the torsion is steady. Therefore
0 =
m
0 =
a
These will simply drops out some of previously terms.

34
Example 5-1 : Example 5 1 :
At a machined shaft shoulder the small diameter d is 28 mm the large diameter At a machined shaft shoulder the small diameter d is 28 mm, the large diameter
D is 42 mm, and the fillet radius is 2.8 mm. The bending moment is 142.4 Nm
and the steady torsion moment is 124.3 Nm. The heat-treated steel shaft has an
ultimate strength of S
ut
= 735 MPa and a yield strength of S
y
= 574 MPa. The ultimate strength of S
ut
735 MPa and a yield strength of S
y
574 MPa. The
reliability goal is 0.99.
(a) Determine the fatigue factor of safety of the design using each of the ( ) g y g g
fatigue failure criteria described in this section.
(b) Determine the yielding factor of safety.
35
Solution 5-1 : Solution 5 1 :
4 . 142 =
a
M 0 =
m
M Nm
Nm
0 =
a
T 3 . 124 =
m
T Nm Nm
a) Determine the fatigue factor of safety of the design:
42 D
q = 0 85 (figure 4 1)
10 0
8 . 2 r
50 . 1
28
42
= =
d
D
K
t
= 1.68 (figure A-15-9)
K
ts
= 1.42 (figure A-15-8)
r = 2.8
q = 0.85 (figure 4-1)
S
ut
= 0.735 GPa
q
s
= 0.92 (figure 4-2)
10 . 0
28
= =
d 58 . 1 ) 1 68 . 1 ( 85 . 0 1 = + =
f
K
39 . 1 ) 1 42 . 1 ( 92 . 0 1 = + =
fs
K
36
) (
265 0
k
5 . 367 ) 735 ( 5 . 0 ' = =
e
S
205 ) 5 . 367 )( 814 . 0 )( 87 . 0 )( 787 . 0 ( = =
e
S
MPa
787 . 0 ) 735 ( 51 . 4
265 . 0
= =

a
k
87 . 0
62 7
28
107 . 0
=
=

b
k
MPa 05 ) 5 . 367 )( 8 . 0 )( 87 . 0 )( 787 . 0 (
e
S
Applying Eq. DE-Goodman criteria gives

62 . 7

b
0 . 1 = = =
f d c
k k k
[ ] [ ]

+ =
2 / 1
2
2 / 1
2
3
) ( 3
1
) ( 4
1 16 1
m fs
ut
a f
e
T K
S
M K
S d n
[ ] [ ]

2 / 1 2 / 1
814 . 0 =
e
k
[ ] [ ]
+ =
2 / 1
6
2
2 / 1
6
2
3
10 735
)) 3 . 124 ( 39 . 1 ( 3
10 205
)) 4 . 142 ( 58 . 1 ( 4
) 028 . 0 (
16
x x
604 . 0 ) 10 407 . 0 10 195 . 2 ( 232004
6 6
= + =

x x
65 . 1 = n
37
Similarly, apply same technique for other failure criteria,
87 . 1 = n DE-Gerber
88 1 = n
DE ASME Elliptic
88 . 1 = n
DE-ASME Elliptic
56 . 1 = n
DE-Soderberg
) 3 124 )( 40 1 ( 16 ) 4 142 )( 58 1 ( 32
2 2

b) Determine the Yield factor of safety :
4 . 125
) 028 . 0 (
) 3 . 124 )( 40 . 1 ( 16
) 028 . 0 (
) 4 . 142 )( 58 . 1 ( 32
'
3 3
max
=
58 . 4
4 . 125
574
'
max
= = =
y
y
S
n
38
5 5 Limits and Fits
5.5 Limits and Fits
3 types of fitting
Cl Fit
3 types of fitting
Interference Fits.
An interference fit is the condition that exist when,
due to the limits of the
Clearance Fits.
No interference occur.
due to the limits of the
dimensions, mating parts
must be pressed together.
Transition Fits.
The fit can have either
clearance or interference.
39
5 5 Limits and Fits cont
5.5 Limits and Fits cont
Definitions applied to a cylindrical fit.
Capital letters always refer to the hole; p y
lowercase letters are used for the shaft.
D = basic size of hole
d = basic size of shaft
u
= upper deviation
l
= lower deviation
F
= fundamental deviation
F
D = tolerance grade for hole
d = tolerance grade for shaft
Note that these quantities are all deterministic Note that these quantities are all deterministic.
Thus, for the hole,
D
max
= D + D D
min
= D
For shafts with clearance fits c d f g and h For shafts with clearance fits c, d, f, g, and h,
d
max
= d +
F
d
min
= d +
F
d
For shafts with interference fits k, n, p, s, and u,
d = d + d = d + + d
40
d
min
= d +
F
d
max
= d +
F
+ d
Table 51
Descriptions of Preferred
Fits Using the Basic
Hole System
Source: Preferred Metric Limits Source: Preferred Metric Limits
and Fits, ANSI B4.2-1978.
See also BS 4500.
41
Table A11
A Selection of International Tolerance GradesMetric Series
(Size Ranges Are for Over the Lower Limit and Including the
Upper Limit. All Values Are in Millimeters)
Source: Preferred Metric Limits and Fits ANSI B4 2 1978 See also BSI 4500 Source: Preferred Metric Limits and Fits, ANSI B4.2-1978. See also BSI 4500.
42
Table A12
Fundamental
Deviations for
ShaftsMetric Series
(Size Ranges Are for ( g
Over the Lower Limit
and Including the
Upper Limit.
All Values Are in
Millimeters)
Source: Preferred Metric Limits
and Fits , ANSI B4.2-1978. See
also BSI 4500.
43
Example 5-2 :
Find the shaft and hole dimensions for a loose running fit with a 34-mm basic size.
Solution 5-2 : Solution 5 2 :
From Table 51, the ISO symbol is 34H11/c11. From Table A11, we find that tolerance
grade IT11 is 0 160 mm The symbol 34H11/c11 therefore says that D = d = 0 160 mm grade IT11 is 0.160 mm. The symbol 34H11/c11 therefore says that D = d = 0.160 mm.
Using Eq. (D
max
= D + D) for the hole, we get
D 34 + 0 160 34 160 mm D D 34 000 mm D
max
= 34 + 0.160 = 34.160 mm D
min
= D = 34.000 mm
The shaft is designated as a 34c11 shaft. From Table A12, the fundamental deviation is
F
0 120 U i E f h ft ith l fit t th h ft di i = 0.120 mm. Using Eq. for shaft with clearance fits, we get the shaft dimensions
d
max
= d +
F
= 34 + (0.120) = 33.880 mm
d = d + d = 34 + (0 120) 0 160 = 33 720 mm
44
d
min
= d +
F
d = 34 + (0.120) 0.160 = 33.720 mm

Chapter 5 - Shaft Design

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Chapter 5 - Shaft Design

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Department of Material and Engineering Design, p g g g ,

Faculty of Mechanical and Manufacturing Engineering,

yielding, so required separate check for

These will simply drops out some of previously terms.

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