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Prepared by: Salih Alan The total normal stress and the shear stresses are:
Room: B‐175 Phone: 5256 4· 32 16
E‐mail: asalih@metu.edu.tr Date: 05/12/2008
ME 307 – MACHINE ELEMENTS I Using the distortion‐energy theory,
TUTORIAL 9
4· 32 16
“DESIGN OF SHAFTS” 3· 3
th
The material properties from Table A‐18 (Shigley 8 Edition)
Problem 1: 620 , 340
The shaft in the figure is subjected to the loadings shown. The material of the shaft is
AISI 1050 HR. The surface of the shaft is machined. Determine the diameter of the The diameter of the shaft can be found using the safety factor value.
shaft for:
a.) a factor of safety of 2.5, if the loads are static.
b.) a factor of safety of 2 if the loads are completely reversed with the 2.5
given magnitudes. Take 0.85 and the reliability is 95 percent. 4· 32 16
3
y T 340
T 2.5
x 4 · 100 32 200 · 10 16 400 · 10
3
F F
z which gives 31.1 , by iteration.
M M Note that, taking the axial force as 0, 31.0 can be found. This value can be
100 , 200 · , 400 · used as an initial value to the iterations.
b.)
Solution: For the fatigue case the critical points are the upper and the lower points on the outer
a.) surface of the shaft. The stress formulations used above will be the alternating stress for
The normal stress due to axial force is uniform over the area: this case. The mean components of the stresses will be zero.
4· 4· 32 16
The maximum stresses due to the bending moment and the twisting torque, for the Alternating component of the von Mises stress is:
static case, at a point on the surface of the shaft are:
4· 32 16
3· 3
Maximum torsional shear due to the twisting torque stress occurs at the outer Endurance limit of the shaft is needed. The endurance limit of the test specimen is:
surface of the shaft and maximum normal stress due to bending occurs at the upper 0.5 · 0.5 · 620 310
point of the outer surface. So this point is the critical point. The stresses at this point
due to these loadings are: The endurance limit modifying factors are:
32 16 0.75 for 620 and machined surface.
0.85 given in the problem.
METU – ME 307 Machine Elements I – Fall 2008
2
0.868 for 95% reliability. Problem 2: Figure 1 shows a shaft with two gears and a drum mounted on it with keys
1 nothing machined. and profiled keyways. Gears 1 and 2 are identical helical gears driven by another pair of
1 no stress concentration. helical gears. The forces acting on gear 1 are shown in figure 3. Same forces act on gear 2
1 nothing machined.
in the same directions, except the axial force being in the opposite direction. The force
acting on the drum can be seen in figure 2. The material of the shaft is AISI 1095 HR
0.75 · 0.85 · 0.868 · 1 · 1 · 1 · 310 172
steel, the shaft is annealed and the surface of the shaft is machined. For the loadings and
The diameter of the shaft can be found using the safety factor value. the dimensions given below; find the factor of safety of the shaft for 99% reliability using
Since mean stress is zero: Distorsion‐Energy Theory and Soderberg Criteria.
80 , 120 , 240 , 70 , 80 , 90
2 0.15
4· 32 16
3 160 , 120
172 60 , 40 , 15.50 , 14.56
2
L3
4 · 100 32 200 · 10 16 400 · 10
3 L2
y L1 Drum
which gives 36.2 , by iteration.
x G1 G2
d3 d2 d1 A B C
Figure 1
y y
x
z Drum
z G1
G1&G2
Fax
Fdrum Ft Fr
Figure 2
G3
Figure 3
METU – ME 307 Machine Elements I – Fall 2008
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Solution: 2
10
The material properties from Table A‐18 (Shigley 8th Edition) 2
830 , 460 · 80 · 10 3200 ·
To find the stresses on the shaft, the moment and the torque distribution over the · 120 · 10 · 40 · 10 4400 ·
shaft is needed. The torque on the shaft is transmitted from the drum to the gears My
through the shaft. The torque applied by the drum force has a value of:
160 · 10 z 4400 Nm
60000 4800 · 3200 Nm
2 2
The torque exerted to the gears 1 and 2 are the half of this value 2400 · due x
to symmetry. The torque diagram over the shaft can be drawn as in the figure below.
x
Tx 80 120 160
2400 Nm Note that there is a tensile axial force throughout the shaft. The normal stress due to this
axial force is the same for all positions. The magnitude of the torque is the same over the
120 240 shaft. The maximum bending moment occurs at section C. So this section should be
x
checked in the safety factor analysis. Section B should also be checked, since the
-2400 Nm diameter of the shaft is smaller compared to the one at section C. The diameter is the
smallest at section A, however there is no bending moment at this section, so this
The reaction forces are needed to obtain the moment diagram of the shaft. The section does not need to be checked.
reaction forces will be calculated and the bending moment diagram will be drawn in
two orthogonal planes x‐y and x‐z planes. The analysis in the x‐y plane is as follows: Analysis in section B:
y The magnitude of the bending moment at section B is the sum of the moment in x‐y and
x‐z planes:
x 1240 3200 3432 ·
Fr FBy FBy Fr The axial force and the torque values are:
15.50 14.56 , 2400 ·
· 80 · 10 1240 · The shaft is rotating, so the constant bending moment gives fully reversed bending stress
and the constant torque gives mean torsional shear stress. The axial force gives mean
y Mz 1240 Nm normal stress.
x Using the Distortion‐Energy Theory, the alternating and the mean components of the
von Mises stress are:
160 x 3 · where 0 therefore
80
3 · where
The analysis in the x‐z plane:
32 32 · 3432 · 10
68.3
z · 80
4 4 · 14.56 · 10
x 2.9
Ft FBz Fdrumz FBz Ft · 80
16 16 · 2400 · 10
23.9
· 80
METU – ME 307 Machine Elements I – Fall 2008
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68.3 16 16 · 2400 · 10
16.8
3· 2.9 3 · 23.9 41.5 · 90
The endurance limit of the test specimen is, 63.9
0.5 · 0.5 · 830 415 3· 2.3 3 · 16.8 29.2
Figure 7.8 in the formula sheet gives the surface factor, 0.7 for machined shaft The only different endurance limit modifying factor is the stress concentration factor.
with 830 . The drum at section C is mounted on the shaft with a profiled type keyway. For annealed
The size factor is: 0.75 for 80 50 . material with a keyway under bending, the fatigue strength reduction factor is: 1.6
For 99% reliability, the reliability factor is: 0.814. from the useful information link on the website of the course:
As nothing mentioned, the temperature factor 1. http://www.me.metu.edu.tr/courses/me307/images/drawings/drwg05.jpg
To determine the stress concentration factor ; and values are needed. The
Then, the stress concentration modifying factor is: 0.625
notch sensitivity can be read as 0.9 for 0.15 · 80 12 4 and .
830 from Figure 7‐13 in the formula sheet. The theoretical stress The endurance limit at section C:
concentration factor has the value, 1.5 for 0.15 and
D
1.125 from 0.7 · 0.75 · 0.814 · 1 · 0.625 · 1 · 415 110.8
The factor of safety at section C:
Figure A‐23‐9 in the formula sheet. 1
1 1 1 0.9 1.5 1 1.45
1 1
0.69 1 63.9 29.2
1.45
110.8 460
As nothing mentioned, the miscellaneous effects factor 1. 1.56
Then, can be calculated as: The safety factor for section B is slightly lower than that of the section C. So section B is
0.7 · 0.75 · 0.814 · 1 · 0.69 · 1 · 415 122.4 more critical and the safety factor of the shaft analyzed is 1.54.
The Soderberg criteria give the factor of safety as:
1
1 68.3 41.5
122.4 460
1.54
Analysis in section C:
The bending moment, the axial force and the torque values are:
1240 4400 4571 ·
14.56 , 2400 ·
The alternating and the mean components of the von Mises stress are:
3 · where 0 therefore
3 · where
32 32 · 4571 · 10
63.9
· 90
4 4 · 14.56 · 10
2.3
· 90
METU – ME 307 Machine Elements I – Fall 2008
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Problem 3:
The figure shows a shaft with two gears and a drum mounted on it. Gears 1 and 2 are A B
identical of weight 70N. The weights of the shaft and the drum are 140N and 100N,
F1 F2 F3 F4 F5 Figure 4
respectively. Find the first critical speed of the shaft using Rayleigh’s equation. Take
the flexural rigidity of the shaft as 4 · 10 · .
70 , 100 50
280 280
140 80 40 100 140
20
100 Drum 280
G2 The shaft in the problem can be considered as an overhanging simply supported beam.
G1 To find the deflections at position 3, the forces outside the supports will be replaced
with equivalent force and moment system at the supports. The deflections will be
determined by using the formula from the deflection table for simply supported and
cantilever beams.
F3
Meq
Figure 1 A B Meq
A B
Solution: F1 F2 F3 F4 F5 Figure 5
The Rayleigh’s equation gives the first critical speed of a shaft as: FR FR Feq FR FR Feq
∑ th
∑
where is the weight of the i element on the shaft and is the 70 50 120
deflection at the ith body location. The shaft can be analyzed by dividing it into 3 · 80 · 50 70 · 80 50 · 50 8100
elements as in Figure 2. The deflection of the gears, drum and each element on the Using the equivalent system in Figure 5, the deflection at position 3 can be calculated.
shaft are to be determined. Superposition of the three loadings; two end moments and the center load will give the
total deflection. Also for the positions outside the supports, the slopes at the supports
50 50 40 40 50 50
due to these loads are needed.
A B F3
Meq Meq
A B B
1 2 3 4 5 Figure 2 A
Meq
Meq F3 Feq Feq
The positions 1 and 5 are the positions of the gears. The positions 2, 3 and 4 are the A B
centers of the 3 elements of the shaft. Position 3 is also the position of the drum.
Note that the lowest critical speed of the shaft is related with the first bending mode Feq Feq A B A B
of the shaft. The shape of the first mode is given in Figure 3. Figure 6
Figure 6 shows the superposition of the loads over the shaft. Note that equivalent force
Figure 3
due to overhanging forces will not make any deflection or slope, since they are acting on
The deflections at the specified positions will be calculated considering the weights the supports.
are acting in the directions shown in Figure 4, that will result in the deflection curve The deflection at 3 and the slopes at A and B due to end moment at B:
of the first mode shape given in Figure 3. , (from beam deflection tables)
8100 · , 4 · 10 · , 80 , 40
8.1 · 10
METU – ME 307 Machine Elements I – Fall 2008
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Note that the sign of the end moment is taken as negative due to the sign 7.6 · 10
convention used in beam deflection formulas. The deflections at 4 and 5 due to the concentrated force at 4:
(from beam deflection tables) 3 , 50 , 50
2.7 · 10 ·
1.563 · 10
(from beam deflection tables) 2
5.4 · 10
The deflections at 3 and the slopes at A and B due to end moment at A: 9.896 · 10
The deflections at 4 and 5 due to the concentrated force at 5:
Using the symmetry,
8.1 · 10 3 , 70 , 80
5.4 · 10 1.385 · 10
2.7 · 10 3 , 70 , 80
The deflections at 3 and the slopes at A and B due to the center load:
2.987 · 10
4 3 , (from beam deflection tables), 140 The total deflections at 4 and 5:
3.733 · 10 6.656 · 10
1.4 · 10 (from beam deflection tables) 1.357 · 10
The total deflections at 1 and 2:
1.4 · 10 (from beam deflection tables) 1.357 · 10 6.656 · 10
1.993 · 10
1.4 · 10 The weight at each position is also needed.
1.4 · 10 100 80
70 50 140
280 280
To find the deflections outside the supports, the slope at supports A and B of the The first critical speed of the shaft can be calculated using the Rayleigh’s equation. Note
simply supported beam given in Figure 6 is obtained and the deflection of the that during the calculation of all the deflections, y axis has been selected as pointing
overhanging locations due to these forces are obtained by simply multiplying the upwards. However, since Rayleigh’s equation is obtained from the equality of potential
distance with the slope. In addition to this, the overhanging forces are considered as energy and kinetic energy all the forces and deflections used in Rayleigh’s equation
they are acting on a beam cantilevered at the support locations. Therefore, the total should be taken as positive. Note that energy is a positive quantity and it cannot be
defections at the overhanging parts are obtained by simply adding the deflections negative.
due to the slope of simply supported beam (including moments) and the cantilever 70 · 1.357 · 10 50 · 6.656 · 10 140 · 1.993 · 10 50 · 6.656
beam.
It will be sufficient to find the deflections at positions 4 and 5, because of symmetry. · 10 70 · 1.357 · 10 2.845 · 10 ·
These deflections will be the same as that of 2 and 1, respectively. 70 · 1.357 · 10 50 · 6.656 · 10 140 · 1.993 · 10
F4 F5 50 · 6.656 · 10 70 · 1.357 · 10
3.078 · 10 ·
θB Figure 7 9.81 · 2.845 · 10 9522
9522 1515 90920
The deflections at 4 and 5 due to the forces inside the supports: 3.078 · 10 2
, 50 The analysis can be simplified if the shaft masses for the overhanging locations are
4.75 · 10 lumped onto the positions of the gears. This way, deflections of only 3 locations are to
, 80 be found, i.e. the locations of the gears and the drum.
METU – ME 307 Machine Elements I – Fall 2008