a aa Unit 2.4 2.1 DESIGN OF SHAFTS 2.4.1. INTRODUCTION Shaft is a rotsting machino clement which transmits power from one point to another point. It is one of the most common and basic machine elements which are used ia a vaticey of ways in mochanical equipments. It is used with power wansmission elements like gears, pulleys, lywheels, cranks, eto. These shafts are designed to transmit the required torque and to suppott the rotating loments like gears and pulleys. These elements produce bending moment in addition to torque. A. shaft must be strong enough to sustain static and dynamic loding, 2.4.2 TYPES OF SHAFTS ‘hats ate classified as follows according t their industial applications: Line Shaft: Iisa shaft which tensmits power to several mechine elements Spindle: A spindle is a short revolving shaft. Example: Headstock spin, Drill pres spindles, eo Stub shaft: A shaft that is integral ith an engine, motor or prime mover is known 8th shaft Counter shaft: A short shaft that connects a prime mover to line shaft of @ machine is nov as counter shaft According to the applications, shafts may be divided into two typos. © Transmission shafts: ‘These shafis transmit power between the source and the machines and absorbing power, ‘Counter shafts and line shafts ace transmission shafts,22 Design of Machine Elements (i) Machine shafts: "These shafts form an intogral part ofthe machine itself. Example: Crank shaft stub shaft 2.4.3 SHAFT MATERIALS ‘The material commonly uscd for shaft is cold dravwn low cacbon steel with carbon content 0.1 _ to 0.35 peresat. When greater stength is required, as in high-speed machinery, en alloy stool such ~' a5 nickel, nickel chromium or chrome vanadium steels are used. When resistance to corrosion is desired, some copper alloys are used. Table 2.1.1 lists tome materials commonly ased for shaft ~ and their mechanical properties, Table 2.1.1 Ullimate tensile | Wield strength, aves strength, Ninn? Nini Plain carbon sels c cor 320-400 200 7 cw 340-420 210 - cas 370-490 240 . C20 440 ~ 520, 20 os 460 ~ $50 280 o 30 500 - 600 300 cao 580-680 | 330 : cas 60-750 | 380 50 660-780, 380 40Ni3 750 ~ 1050 600 A 30 Nit Cry 1000 ~ 1150 600 c 40 Cr3. Mol 120 1350 120 : 40Cr 700-850 540 Commercial shafts ace avaiable in the following preferred sizes (im mm) as per IS 3688-197 5,6, 7, 8, 10, 11, 12, 14, 16, 18, 20, 22,25, 28, 32, 36, 40, 45, 50, 60, 63, 65, 70,71, 75, BO, > 85,90, 95, 100, 122, 140, 160, 180, 200, 260, 280 and 300. > 2.1.4 DESIGN OF SHAFT BASED ON STRENGTH AGAINST STATIC LOADING Shafts may be subjected to folloxsing types of loads ()Simpic torsion (ii), Combined torque and bending moment (iv) Combined axial load, torsional moment and bending moment. Gi Simple bonding moment Design of Shafts 23 (0) Shafts subjected to simple torsion: ‘When a shaft is subjected to pure torsional momeat the shat diamter can be found ftom the torsional shear strength equation given by 16M, Shear strength, for solid shaft for hollow stat Where, Mj torsional moment or torque (Vn) d_ ~diamotor of th solid chaft 4, ~ outside diameter ofthe hollow shat 4, ~inside diameter of the hollow shaft <= sallowable shear strength = (0,5 t0 0.577}o, (i) Shaft subjected to simple bending Moment: ‘When a shaft is subjected to a pure bending load, the principal strsses induced in the shaft ate tension and compression. The maxinnam stress induced in the shaft can be deteraiined by the theory of simple bending Its givon by the relation 22M, = for solid shaft aa Md. 32M, 4, for hollow shaft. Where, (My bending moment (Gi) Shaft subjected to combined torque and bending moment: ‘When a shat is subjected fo combined loading, the desiga is usually basod on the maxiraun shear stress theory, since the shafts are usually made of ductile materials. According to maximum shear stress theory, the fllowing relation must be satisfied ae Ya xd? | TM? for solid shaft 1 Ginae Ta 2h YG? + 4 ve Simplifying, we have , +...24 Design of Machine Elements 16 =a From solid shaft relation, Bt td eG ‘The expression YM} ix called equi! visting moment andi denctdby 4, for hollow shaft M,=(MaoM? (io) Shafts subjected o fluctuating loads: The ASME (American Society of Mechanical Engincers) has worked out special procedure for design of sha. The ASME design is based on maximum shear sicess theory and employed combined shock and fatigue factors as multiplying cosicints. This factor i used to accoust for the nae of load. This factor shoud be applied to compute bending moment and torcue, Thus he design equation for combined loading isa fellows: F&F for sold shaft = AG] [EMF AG ALY orton san nd? 1-| je ‘The recommended values of Ai, and Kare listed in table 2.1.2 Table 2.1.2 Nature of toading Kk ‘Stationary shalt Gradualty applied load | 1 1 Sacidenly applied load _ | 1.5.2.0 | 15-20 Revolving shaft Steadity applied toad = [18 [a Minor shock lord 15-20 | 145 Heavy shock load 2030 ] 15-30 Design of Shafts 25 (0) Shaft subjected to combined axial load, bending moment and torsion: Ifthe shaft is subjected to an axial load in addition to tosional and bending moment a¢ in propeller shafts, then the average axial stress should be added fo the bending stress and then the maximum shear stress induced in the shaft may be calculated. When the length of the shaft is smal, the axial force will prodace either tensile or compressive stresses only. When the shaft is ‘quite long, it may behave like a column and hence start buckling. Ifthe axial force 2 is present and buckling of the shaft is scsonnted for, then the busking stasis ivan by o= 50% fr said hat AF for hollow shaft | 4 a [H(3) | Wer, = alana sn tor feed 1 for! cus owe?) ’ s, (ty i sal) : Where ‘= length ofthe shaft r= radius of gyration Gy yietd stronget ‘n= constant for types of column condition = 1 for both ends hinged =2.25 for fixod ends = 1.6 for both end pinned, guided and parily restrained For the bi-axial stress element subjected to direc stess , bending sitess o and torsional shear stress + , maximum sheac stress is given by sa eaeDesign of Machine Elements Design of Sats ae Substitng 3, os and + vals inthe bow oqo, ve et san, cai! ad* %, FTI 584M, fe oe for hollow shaft. : ~h { } Gas - 45) : ern ‘Wen vl of mite her ses () a te llonble nge of tis (0) ae seid, Wes, 0=Colnn tn ter eng gc ead stant 0 = 22! : teeter ad Gt “Ene = Length ofthe shaft r= radius of gyration ‘oy = yield strength ‘n= conctant for types of column condition = [for both ends hinged 2.25 fer fixed ends, "= 1.6 for both end pinned, guided and party restrained. (> 24.5. DESIGN OF SHAFT FOR RIGIDITY In many cases, the shaft is to be designed from rigidity point of view. We should consider = sorsional rigidity a well as lateral rigidity > ( Design for torsional rigidity: ‘be angle of twist an radians fora sold cicular shaft of uniform diameter aud Fength is given by ML IG Where, M,~Torque on the shaft ~ Polar memento neta onthe shatt= et" a : 32 (G— Modulus of rigidity forthe shaft material C 2 length of the shaft ‘When the angle of twist is measured in degrees, the equation is modified to For standard applications, the torsional deflection must not exceed 1° for @ length of shaft ‘equal 9 20 times the diameter, In case of camshaft of IC. engines, it should be less than 0.5° regardless of the shaft length. In line shafts, 2.5°to 3.5° per moter nay be taken as the limiting valve (9) Design for lateral rigidity: 1k is another important design criterion. The value of lateral defletion of a shaft duc to various transverse forces is very importaat because iti used to establish the minimum permissible clearance between the pulley, gears, bearings and housing for the shaft assembly. Ifthe clearance ‘increases or deereascs due to lateral deflection, it wil esult in uneven distribution of force, which ttimately causes early failure. Lateral deflection of a shaft con be controlled by the following, @ Reducing the span length Gi) Increasing the number of supports (Gi) Selecting the cross-section in which the eres moment of i of tubular or hallow shaft ria is large as in case Itis desirable to limit the permissible maximum transverse deflection ofthe shaf & For machine shafts, maninuin pormissible deflection is generally taken as (0.U01 to 0.006), where Ps the span between wo bearings. ‘For shaft mounting « good quality spar gear, the deflection at the gear should not exceed 0.01m and slope should be limited to 0.0286°. Where, m-inodule of the ear, ‘+ The permissible misaligament tolerance for doop groove ball bearing is i 25° 2.4.6 CRITICAL OR WHIRLING SPEED OF SHAFT Whon a shaft is mounted with gears or pulley, the center of gravity of the palley or gear may not coincide with the centerline of the bearings or axis of tho shaft, when the shaft is stationary.28 Design of Machine Elements ‘Due to this, the shaft is subjected to centrifugal force. This force will bend the shaft further whea the shat rotates, This effect ie cumulative and ultimately the shaft fails, ‘The speod at which the shaft runs so thatthe ational deflection ofthe shaft from the axis of rotation becomes infinite, is known 3s critical o whirling speed. Critical speed of whirling speed is given by ok Vm VS ‘Where, 02, , ... nate the critical speeds ofthe shaft when cach mass is consideved. 2.1.7. DESIGN OF SHAFT FOR VARIABLE LOADING ‘When 2 shaft is subjected to fotigue losding which varies between maximum to minimum values ie. Par 19 Prin Maximum stress, Mean tress, ‘Amplitude stress, 16M, = and aa? ‘Maximum shear stes5, te 15M i, aad Minimum shear sites, Tig = Design of Shafts 29 ‘Mean shear sites, Amplitude shear stress, Using Soderberg equation, Equivalent stresses, 6, ‘According to maximum shear stress theary, equivalent maximum shear stress is given by mda F VO 4 BAF 2.8. SOLVED PROBLEMS A shaft of 7mm lng is subjected to shear srs of 40MPe and has an angle of tis equa to 0.01 7radian. Determine the diameter of the shaft. Take G=0.8 x 10°MPa. Given Dt Leth of th sh, = 750mm ‘Shear stress, t= 40MPa = 40N/nm* [Angle of vs, © =0017radlan Modulus of igtiy, G= 08» 10°MPa= 0.8% 10m? To finds Diameter ofthe shaft, © Solution: ‘We know thatthe torsional moment of the shaft > M,=Zoxexd? aad Myxt EERPE oy GI Tea)” Gad 5 ol S| Angle of twist240 Design of Machine Elements 240% 750, 08x10 xd d=44.Limm ‘The standard diameter is, d= 45mm Ans. w 0.017 = Result: : Diameter ofthe shaft, d= 4Srant Rem ee A feed pump of a binary vapour eycte is of ceneifugal type and delivers 20nt min at 750rpm against a dynamic head of fm. Determine the power required to drive the motor, ifthe pump efficiency is 90%. Ifthe maximum torque on the motor shaft is 30% more than the average torque, determine the diameter ofthe motor shafe The permissible shear sires inthe shaft ‘material should not exceed SOMPa, Given data Discharge, Q = 20m'/min Speed, N= 750rpm Hood, I= 8 Pump efficiency, np = 90% = 0.9 ‘Maximum torque = 30% more than average torque Permissible shear st288, tae ™ SOMPa = SON vn? To finds Power oquied to drive the moter. P Dinter ofthe shal, © Sotution: over equited to drive the motor, Pawon-o9 2 8 (= 9.8LkN in? for water) P= 26.1667" Pump efiieny is 90%, terete, th power required to dive the motor, 9.x 10M Ans, xD P60 _29.1%10" x60 nN 2xx 780 Torque, Design of Shafs 2u1 Since, maximum torque is 30% more than the average torque Mx org Mf, = 1 «3701 ~491.1No= 481.1 10m Weknow that, M, = xt xd? es” 168 Ta 481 « 10'= x 50xd? 16 d=36.59mm ‘The nearest standard sio is Omun Ans. 3 Result: Diameter of the sha, o'= 40mm The propeller shaft of a marine engine ist tansmit SOW at 1000rpm witha significant bending. The efficiency af the propeller i 73% a 20knots (Iknot ~ 108Skn/hr). Ifthe Sendsnes ratio sles than 40 and the permissible shear snes shoul not exceed $SMPa, determine the diameter of shaft. Given data: Power, P= SOK Spood, N'=1000pm Eificieney, n= 75% = 0.75 ‘Velocity = 208mous = 20 % 1085 = 21700knvinr = 6.028n/s Senden an, <4 Permissible shear stress, += 5SMPa = $SNinm? To find: Diameter of shaft, © Soluti _28NM, oo x 1000 500» 192 = 2% 100044, oo M.= 4794 65m Power2k Deslgn of Machine Elements Let P be the axial load on the shai then Px Velocity 1” Px 6.028 075 P= 620097 500 x 10? = ves £115 cst oniter Loon = 1.2136 5 Tondo Direct stress, APa _ 4x622097%1.2136_ 961266 > AEG = 4622097 11.2136, Wi a xd’ a Si, 1654746510? ad? ad Shear stress, t= ‘Maximum shear stress, By trial and error methed, d= 76.Smnm ‘The nearest standard size of the shaft, d= 8Onam An. Result Diameter ofthe shaft, d= 0mm A solid shaft is subjected to a bending moment of 3.46 kN-m and a torsional moment of I1.S AN. The shaft is made of C45 steel and factor of safety is 6, Find the diameter of shaft {MU-OCT 1999] Given Data: Mex 3.46 Em =3.46 x 10° Neinm Me 11S BN-m = 115 « ME Nem Design of Shafts 23 Factor of safety, 2 6 Shaft matoriak: C45 Steo! Tofind: Diameter of shaft © Solution: For CAS stel, Yield strength, oy 380 Winn? 380 According to maximum shear stress theory, +, = 190m Paine arin = 5222 167A Equivalent visting moment, M,= fit +, = {CAG + 15x10 M,, =12x108N mm We also ow that, M, =Zxtxd? 16 12x10’ =e 3167ed? 16 d= 124.53 mm “The standard sizeof the shaft, d= 140 mon Am. oo Result: Diameter ofthe shaft, d= 140 mm, A factory fine shaft is 45m long and is transmit 7SEW at 200rpm. The allowable ress in shear is 49MPa and the maximum allowable ovis isl ina length of 20 diameter. Determine the required shaft diameter. {MU OCT 2000] Given data: Length of shaft, = 4.5 m = 4500 mm Power, P = 75K = 75 x 10? We 75 « 10° Nmm/s2M Design of Machine Elements Spood, N= 200 rpm Allowable shear stress t= 49.MPa Maximum allowable twist, 8= 1° = 1 x ==>" 0.0174 rad in a length of 20 diameter. Tofind: Diameter ofthe shaft, d © Solution: 358x108 =x 49d? 16 d-119 mm “The standard diameter, The allowable twist is 1° in a length of 20 diameter ie 20% 75=1500mm Total length of the shat is 4.5m, Therefore, total allowable twist for 4.5m diameter is 800 ge ry TGR = 0.052300 ‘The design equation relating to angular twist is ML @ =75 mn 8 3.58 10° 4500 oanto'f | 0.0523 = (Assume G = 0.8 « 10° Nimo) #=39.17 x 10° d= 791mm Design of Shafts 2u5 ‘The standacd diameter of the shaft, = 80mm. Take largest ofthese two values, d= 80 mm Ans, Result: Diameter ofthe shaft, d= 80mm “An cleric generator rotates et 2rpm and receives SOUKW from the driving engine. The armature ofthe generator is 60am long and located between hearings 120em center to center Owing tothe combined weight of armature and the magnetic pul, the shafe is subjected to 9000Kg acting at right angles to the shaft. The ultimate stress for the shaft is 4480kg/cm’ and shear stress i 3920Kg/e, Find the damer ofthe shaft fora factor of safety of 6 ‘(MU-Apr 05) Given data: Speed, N= 200m Power, P= 300897 = 300% 10°18" Amature length, D = 60cm = 600mm Distance, != 120em= 1200mm Weight of armature ~ 9000 ~ 90000 Shear ateess, «= 3920hg/em? = 392N/mni* Ultimate stress, c= 480K = 448M mu® Factor of safety = 6 Tofind: Diameter of shaft, © Solution: We know that Px 60 _ 300% 10" x60 dexN 2mx200 14323.94 > LOA 14323, 94m va ‘We know thatDesign of Machine Elements | 216 Design of Shafts 207 Bending moment, | Wt 900004200 _ 99 105K mm ‘A 10mm: diameter solid circular shaft can carry a torque T without exceeding a certain _ ‘maximum shear stress. What portion of this torque T can a hollow shaft having a wall thickness ‘We know that the equivalea twisting moment | of 10mm and the seme outer diameter carry? Both the shafs should have the same maximum M, fant = fon) aaa shear ses. (960 APR 1999) a Given data: Me stoi aa | Diameter of shal, d= 100 mm ‘We also know thatthe equivalent wistng moment | Thickness of wall, ¢= 10 mm zx Outer diameter, d= d (solid shaft diameter) M, =xcxd? i6 Tofind: 7 Portion of torque fr hollow shaft 305 * 10% Ex 65.330" aa a 8 Solution: 4=133504Tmm Maxioum shear stress ofthe slid shaft~ x, ‘The standard diameter ofthe shat, d= 140mm 16M, According to the maximum normal stress theory, ex 100" Equivalent bending moment, 0929 10-¢h¢, Nine 0) 1 4 30.5x10" i sng [Mediae las ae J gfe! ososst Maxinun shar soe ol sh 1M, =285 10" Internal diameter (d)) = dy~20= 100-20 = 80mm ( ‘We also know that equalant bending moment, pe LOAM de 16nd 100 a . md,’ ~4,") —-m((100)* ~(60)*) Mo Exo, ea 8626 10%) Winn?) ass 10" = Zara 00x0° Given thet the maximum shear stress of solid shatt (x2) is equal to the maximum a =15131mm - @ shear sues ofthe hollow sha) ‘Taking the larger of the two values (i) and (ii), we get ’. Equating (1) and (2). =15731mm q 5.0929 » 10*(M, 8.626 « 10°4(M,, ) “The standard diameter of shat, d= 160% An. a 09210 esl Dismeter ofthe shaft, d= 160mm Mu Foea0* 3.626410 M,, "059 M4, Ans a 0.59 portion of solid shaft torque can be safely ceried by the hollow shaft