aa cunrren 2 sHarrs ‘The most basic point in sll of sechanteal and structural design in to have & thorouth grasp of elenentary stress analyess Mastery of the subject of shaft design for exanple is impossible without thse snderstandéng The eheory has two fundamental foundations (2) The principles of equittbrium. (2) The elsseic properties of solide. Strain causes atresa and in studying strain there are tvo eleseatary aotions of the planes of molecules (2) Wormat aoveneat (causes tensile or compressive stress). (2) Tangential movenent (causes shear stress). ‘These two can be combined to give inclined stress. The following Sa a brief sumaary of sinple stress analysis, che proofs of which caa be found in any standard book fon aachantes. Glossary of terms used in the theory leading to the derivation of the Equivalent Torque formsia on page 2.5. F = Load, censile, compressive or shear, f. T= applied congue, Noma. Mi = applied beading moment, Noam. T, = equivalent torque, Noam. 5, + a tensile stress, MPa. Sp = a second tensile stress, MP 5, = a compressive stress, MP 5, = 4 shear stress, MPa. f, = principal stress, MPa. = maximum shear stress, WP 2, = polar section modulus, aa?. 4 = shafe diameter, ma.aa (a) Sinple Tension (or compression) r Fig. 1. This not only causes tenetle (or compressive) stress but a maximum L shear stress slso, equal to helf the fenaile (or compressive) stress, 2 feting at 45" to the axis of che Joad. This forse the basis of the a saxisun-shear~stress theory. The axinua-shear-otress theory states | that yielding beping whesever the paxinim shear stresa equate the shear stress corresponding to the t sield strengeh ine sinple tension t (zefer also Chap. 1y page 1.23). () Pure shear A, {? ‘Tals condition can be produced by any of the — fhethods shown in Pig. 2. Tn the f4rst diegran a Zectangular block of unit thickness is loaded ous.1 by forces ¥, and F, doth wniforuly distributed cover the surfaces on which they ere acting. ‘he block is in equilibefun so that FL xb = Fy x a. Equtl shear stresses act on vertical ‘and horizontal planes, therefore an eleneatary cube ABCD has on ali four faces a shear stress 2g tn the second dfagram a rectangular block is subjected to equal compressive and tensile Stresser, Equal sheer stresses act on ali planes St 45" to the faces eo thet an elementary cube bcD has on s11 four faces shear atte st 8 In the third dtagran a circular shaft e under a'corque 7, Any small exbe ABCD has a shear Stress acting on each of its four faces. S ono. A simouse 5 & ‘The result of strain produced by pure shear is i shown in Fig. 2 fourth diagram. Any cube ABCD 42 deformed into a rhombohedron A'B'C'D'. From study of the Glagonale it sppeare that a shear strain does not cause only shear stresses, but Cauca tensile and compressive seresses of magnitude equal to the shear stresses Gn planes inclined at 45" with the planes of shear. These last are called "jgagonal tension” snd "diagonal compression".23 Diagonal compression ig one of the ain considerations in the design of large plate girders. Tt will cause failure at shear stresses auch lover han the gisder will apparently theoretically take. Fellure of his nature As termed Telastic shear buckling” ‘This Leads to the prinetple of Conplenentary Shear. ‘This theory states that Sf at any poise in @ aaterial under strain chere guiate a shear strest across one plane there gust exist an equal shear stress cross a second plane at right angles to the first, and there 1s a definite elation betwen the seases of the two. (e) Dixect sheer ‘made occurs when a member is subjected to a pair of equal, opposite 4nd paraliel forces which are 0 near co being co-linear chat. the material between fa restating # negligible bending moment. Rivets, eye and pine are examples of chis condition ead the shear stress ie simply taken a9 uniforaly distributed Sections (6) ond (c) are important principles to underetand in the design of concrete foundations where it is necessary to detersine ‘shether dean shear or punching shear 19 the criterion (concrete being, three times as strong in punching shear ae opposed to bean shear) (a) Bulk sSerain Hig. 3. This produces only noresl movenent of all parallel paiva of plenos and 5) | Normal movements hence fora decrease in 4444 /ot paratitplanes Voluse compressive stresses ‘ere set up and for increase in volune tensile stresses x are produced. The co pressive or tensile Stresses are qunerically qual to applied bulk stress. ai tttt (e) Theorem of Principal stress ‘This theores is of major importance. At any point ina material under strain there exists ~ tro planes at right angles to one. another, SAiz crore vhich the stresses aze entirely aoraal we/f= (Gos. there are no sheer stresses across SS Ht, those planes). The setess across one of Hite these planee is the algebreicat aesizen = = Serene ae the point, and chat acrows the ~ ited Sther plane athe slgebrofeal minimum screes — St the pore. he twp planes are knom ae Vie the "priocipal planes" ac the point, and iM the tresses across chem as che "principal stresses” at the point. Consider’ a onail portion of material under the action of Esnsile stresses §, and Sp snd conplinco~ ery shear 5, Hig. he E((orincipal stress) = s, +s, 2 ¥isp- 5 * + 48 z2a Meximum Shear Stvess ‘The maximum shear etree at 2 polat acts across principal prinedpal sere lanes inclined at 45° co the ‘equals one half of the algebrate difference between the & 5 fu caalaing the principal serene and Hil tit ReSNTaatierserss Recut fier ereatetion, ron 0 tody Non. ter == i Tewitlbesons obroun tae with wat S/o |=, tet Feseapes“eevennee (eanane 8, 5) the f Ti] |S gremest snese sevens accion fa 0 body with = Ex'Soteruied uy the geeseet principal ste Sones the valve of the shar stcece wilt é HEE TEL Seat act scrote the pane sn. ta F165 rtteuler condition is aati the Longtade ieal snd cteeunferencial stresses 102 botler shell. Extension of Theory to shafe Design lefer to Figs, 6 and 7. Lat "N" the bending sozent snd "I che torque act. fat the seme cross-section. It can be seen that Sy 48 absent. L ae = let 138 a ‘The result indfeates unlike principal stresses as the quantity under the square root sign 1s greater than 82, therefore the mixtmun shear stress 4s determined by both principal stresses.25 Ducktte shafts Ductile materiai like mild steel fats by sheer therefore the mextimu-shear= stress theory as propounded by Guest is used. Guest's theoty at tested by Practical experinents is found to err on the side of safety, nonetheless it 4s the design procedure most widely used. Te can be £10? 4, (equivalent tome) = fear = Hee operating in shaft. Ly shown that for a round shaft where £, = maximum shear stves Derivation of Squivalent Tongue Form: Refer to Figs. 6 and 7, page 2.4, Let 'M" ehe bending ment and "T" the torque act at the seme cross-section, Tecan be seen that Sy is absent. 7 stfse + 45 Fe (rinetpal stress) = 7 a et el ad fy and . Subtract (2) from (1) and divide by 2, this equale che muxiaun shear stress f, that 1s operating in the shat. Inserting values from (3) and (4) WaT Vas ht ele2.6 Devermination of Maximm Permissible Working Serese Ductile asteriels only Meximum permissible stresses for all combinations of shaft Ioadings are sgiven in Table No, L., Chapter 1, pages 1.19 ~ 1.21. (where the naximm-shear-streas theory {2 used to determine working stratses Leis alvays 7, that governs shaft size in the case of combined loading, Hye Bquivalent Bending Youent, wilt always give a enaller diameter. The theory behind thte method 1a not covered in this book.) ‘The maximin peruiseible working stress for sll rotating (or even oscillating) Ghatte ia bated on endurance Linit regardless of the operating speed. ‘the maximum permissible working stress for stationary shafts 42 based on yield poine ony if the lead 4a essentially static. Tf the load 1s reversing Of severely fluctuating the maximum peraiseible working stress should be for rotating shafts. Explafaing the probles from another viewpoint, the Snpoctant question to answer is whether the stress being considered is static or reversing (or fluctuating) Bending Moments in Two Planes Te ds sonetines convenient to consider bending eoments ia two planes vhon caloulating shaft designs. (See page 3.19, 08.) ‘These bending moments con simply be added with vectors (or by Pythagoras’ theoren if planes are at 90") at critical sections. Bactors for Bending Moment and Torque (G) Shock Factors ‘mese are given in Table Wo. 1. for stationary and rotating shafts. Note regarding rotating shafts Tn the absence of shock, no factor on B.W. te theoretically Decessary at the working stress 2 Based on endurence Limit and hence shaft faflure vill aot occur. However 4 19 a common practice throughout engineering to apply fp snail factor to the Br. This causes only a marginal increase Sn ahate eine TABLE wo 1 y Ke Re statie reversal Stationary shafts: Design procedure as Load gradually applied 10 1.0 for rotating oad suddenly apptied 152.0 152.0 shafts. Rotating shafts: Load gradually applied ons 10 Los oad Suddenly applied, winor shock —1.5-2.0 Loa.s 15-200 oad suddenly applied, heavy shock 2.0-3.0 15-3.0 210-3.0aa (4) Seroee Concentration Factors Alovance for etross concentration must be made where applicable tn che various shaft design formulas Stress concentration takes place at 2 change of diameter (erstica! section). With a live shaft @ cyclical reversal of bending stress necessitates = factor being applied to che calculated bending moment. Torque is generally static nd therefore no factor is required in most cases. As a comon rule in design s small snount of etress concentration is tolerable in s ductile material when not subject to strees reversals If reversal of torque ie present ¢ factor is necessary eo with the ending moment and these Factors can be obtained from Ghaxts 6 to 16 in Chapter 10. Anoug other conditions which can be described as “etrees raisers" are keyways, Roles and screw threads. stossaay oF Tens = Applied bending moment, Neae T= Applied torque, Nam Te = Equivalent congue, tum Ky = Shook factor sa bending F,=_Stock factor 1n torsion Ker" Ripectavely Care as for tablet page nen oe Semon Xgq = Stross concesteation factor for shaft ia bending only. Kye" Coubined stress concentration factor for shaft tn bending. Nee + _‘Strese concentration factor for shaft in torsion. Rep = St¥eee concentration factor for shaft in tension. Kpye = Combined stress concentration factor for shaft ta tension. Values for stress concentration factors can be taken from Charts 6 to 16 tn Chapter 10.” These Charts apply essentially to Eeversed loading. Mesbers stressed by static loading (moet corque Loading i static) may. ve stronger 4m practice than the theory indicates. Therefore the value of By Secoms 4 value Judgeent in scatic applications and in sone circumstances is taken Fyf, = Permissible and actual shear stress, MPa. ) chap. 1, Table No. Ls = Permissible and actual tensile stress, MPa.J pages 1.20 and 1.21. cton otata, wt, ES cote ze Mat = as a im 2 GA 2 = Mhean! section modulus, an’, a, - 4 = Retornal diameter of shaft, am2.8 Glossary of terms (Cont.) A+ 4 = arto of intern to external dtaecers, 5, = vlad pine strene of the materials MPa (Bete Ho. 25 ase 2.9 = endurance Limit of material, MPa (Table No. 2, page 2.9) w= Asal tension or coapression, W Y= Colum action factor = unity for a tensile load For 4 compressive toed 1 m to. tor < 150 1 @.0008 * fee footaate - Sy tor BE > 150 a vis toe where a = 1.0 for hinged ends (se1f-algning bearings) = 0199 for partly reserained ends (eigid deariogs) = ol6r for fixed ends k = radius of gyration (orthogonal), am = actual span of shaft, am = Young's modulus, MPa Shafts With Axisl Loading. Refer also to pages 2-12 and 2.13. The following formula is based on che maximum-shear-stress cheory. 6 Weegee + EY he ona Heth DPE + Oy? ao aFa- a) were Kg = stress concentration factor (seter page 2.7) ‘The process of designing shafts having axial loading is iterative as on both sides of the equation. Fookaote, Computer analysis has show that the ASME shaft design formas given For ¥ in previous printéngt of this text (prior co 3th reprint) had several tacon~ Statuncies. Consequently the required adjustments have dosn carried out; the re Gulting formulas ara given in the glossary of terms and specifically apply to steele having #250 £0 300 MPa. For other steels a conservative approach would de to neglect the 150 slenderness ratio limit and use the larger of the two y values. Even though the ASME code has been withdram by the U.S.A. Standards Institute the above formise for y and hence 'a" still have good practical use. appearsLo TABLE No. 2 Bogineering properties of shefting steels steed We Gy) Held Gnd. Limit (FD) Hot rolled structural steel, 410 Wa 250 wre 207 Wea Grade 250 to AS 3679. Common shafeing materials bright steel as 1443 black ateel AS 1442 = © 1020 400 we 200 wea 180 ora 2 es 1030 500 wee 250 wea 225 ora 2 es 1040 540 wee 270 wa 243 Pa ALL values are "average" values and ace Britele Matersale Brittle meteriele fail ia tension and so maxiaua principal eeress (tension) ie the design criterion. Rankine developed the following formule from thia theory. ue Vee ee oe where , is the imginery torque which Af applied alone would produce hear stress equal to the maxim principal stress. an alternative form of the above equation is now quoted. yo et Ve ee - oe fe ¥ 3 here M, is corned the Equivalent Bending Monent and Se the Sending nowent which 4F acting alone vould produce the ease maximom principal stre Stress concentrations at critical sections should be carefully checked a¢ brittle materials have ao yield point and hence plastic flow i# absent. Deflection Limite for shafts Generat Torsional. 3° per metre. lateral Stuply supported 0.8 am per aetee of apen ‘cantilever (overhung) 1.6 mn per metre of span Cont. on page 2.1020 Deflection Limits for shafts. (Goat.) Torsional 0.25* per metre between adjacent gears uounted on the sane shaft. Lateral Lsterel deflection of shafts carrying gears should be limited to contain "error in action” betveen gear teeth to the figures given in Table No. 3. ‘Tose figures apply to well cut comercial gears baving pitch Line velocities of up to'75 n/ain. and are for the purpose of keeping tolce and wear factors within reasonable bounds {Te must be realised that these Limits are for deal machine design appli: tons e.g. gear boxes. ‘The Linite cannot alvays be matntained e.g. deatgne having overhung shafts fn the latter case we Yely on ousll cooth deflectioss end "vearing in" of gear teeth, ‘mODULe TERROR Ti ACTION 25 0.12 a 2 9.10 am a 0.08 am 6 0.07 am 5 0.06 sm 4 snd ese 0.05 am Deflection Formulas orsionat 9 = EE radtane Vaterel. Use normal bean formulas. (Refer Chapter 1, page 1-17.) Torque déagran ‘A Torque Diagran 1s a diagram which gives the torque in a shaft at any section For shafee having miltiple pover take-offs, 2 Torque Diagran should be constra ted. See Exercise 23, page 2-t. inertia Loading On Shafts, (Lefer also to pages 2.36 and 14.18.) The basic safety factor of 2.0 on stress allows for inertia of starting in ‘normal design application. ‘The average starting torque given by most squirrel cage electric motors 12 ell in excess of 2.0 x torna naximm full load runing Corgue, when startin Direct~on-Line (D.0:L.).. This neans chat by standard calculation sethode © shaft may be stresced beyond yield point at the instent of starting. Wonetheless practical application proves the chosen safety factor of 2.0 ig satisfactory for the folloving reason.2a In geverel vith atesl, 22 the apeed of losding ds incrensed, the yfeld etvength hhas'a noticeable increase. "Run-op" tine with norvai noter use 18 well under one second, which correspands with "high speed" loading. This 1s effective in raising the yield point of che steel sufficiently co make the design safe. However, designers ate advised to increase the basic safety factor to at Lease 3.0 whete the prine mover places a starting torque of between 160% and. 260% fall Load torgue on the system.” (With an electric motor the reference would be aither the starting torque or the pull-owt corque, whichever is greater.) This Say svold shaft damage, eepectally in the case of @ jaz load. Other elenente in the system may neod special consideration slso. Where votor starting oF pull- fut torque of 300% to 350% full load torque ie encountered, a basic safety factor of 4.0 my be advisable, The choice of a aafety factor in non-code work Ss the Designer's decision and is a "valve. judguent" on the possible design conditions to be encountered. Generel guidance on torque~speed chavactersstics fof aqutrrel cage electric motors 1s given on pages 17-4 and 17.5. 1m the rarer cases, where dic. motors or High Torque a.c. motors are used, extremely high starting torques, up to five tinas full load torque, can be encountered. Sefecy factors for shaft design should be correspondingly incre f2¢, unless the design procedure shown in che AS 1403 Shaft Design Code 42 Methods of reducing starting torque sre discussed in Appendix C of AS. 1403. Asditionally, with excoseively high stereing torques, approprtately increased safety factore will be required on all elements in the aysten. Cotment on the safety factor for chain drives is given on peses 5.8 snd 6.9. A fluid coupling presente @ alightly different shaft loading condition. This Je discussed on pages 8.7 and €2, Zt de worth noting that che outpst torque Characteristics of « £lai@ coupling, during the starting period, can be nodi= Eled by varying the anome of oil within the coupling. ‘True inertia loeding where motor size is determined by torque of acceleration, rather than pover of normal running, vould necessitate special loading consider— ‘Ations in the shaft deripn. ‘The prolonged "runvsp” tinen (eay 2 to 5 seconde ‘of more) encountered, would suagert that the saximin torque loading imposed on the aystem, Sy the motor, doring the "run-up" period, be used ao a basis for the Gesign. This torque would be greater thin chat resulting frou he noraal maxi~ ton Feil load torgue a2 calcslated from the motor name plate pover. Basic safety factor should be 2-0 minimus, Alternatively, AS 1403 may be used. With most Snereia applications, pover requirenents at normal running speed axe negligible. Shear Stress his Ae rarely £€ ever a consideration io shaft design. If this check f= required, recommended stresses are given in Table Now i, Chap- 1, pages 1-19-21. Shore, heavily loaded stationary shafts are most Likely to be affected. The pernigeible stress levels given are applicable to ‘average’ shear stvege caleul~ Btions, i.e. £, = U/A where A= actual area. [Refer to Exercise 8(a)-] TABLE Wo. 4 Metric bar sizes in mm [Always check with manufacturer for availability at cine of design. 051020 1.6 to 250; 081030 1.6 to 150; $1040 1.6 to 250, Below are the standard afzes from 1 mm upwards: 4 17 2% 23 27 40 52 65 80 95 120 130 250 13 18 21 24 30 45 56-70. «G5 100 130 160 1 19 22 25 38 $0 60 75 50 110 140 180naz Summary of Shut Design ‘The following categories of shaft d Dactile materials ony. ign should be considered. Rocating shafts Bending only. Section 1. ‘Torque only. Section 2. Conbined bending and torque. Section 3. Any of above plus axial loading, Section 4. Statéonary Shaft Bending only. Section 5. ‘Torque only. Section 6. Combined bending and torque. Section 7. Aay of above plus axial loading, Section 4. Toads on stationary shafts must be essentially static 1f the maximum ermiscible working stress is to be based on yield point. for reversing Severely fluctuating loads raximm permissible working stress ie to be Aetermined as for rotating shatte ive. a5 an endurance application. Summary of Sections Section 1 Rotating shafts Bending only. Ky Kyg M@ =F, 2 (or %) Section 2 Rotating shafts. Torque only. KK + FL 2, (oF yd Section 3 Rotating shafts Conbined bending and torqu ay VR + HK, DF = Hz, Gry) Section & Rotating or stationary shafts. Refer aleo to page 2.8 © and/or 7 plus axial toading. 16 Re + FY Ke op a He MAC + ET? Ka Ke BY Ko or 2 8p eK ee" va wD23 ‘This de 2 formola covering all possiblities of loading. Wore: (4) TET = 0 still use F,. (i) In che aziet toad component of the shove forms neglect K, $f shafe 42 under compressive load only. Section 5 Stationary shafts. Bending only. KL Kp, Mo= PLZ Cor %) section 6 Stationary shafts. ‘torque only. Ry kye Tt Fy Cr ty ion 7 Stationary shafts. Cosbined bending and corque. ay + (eR? + BED? = Ft, Core, hee ‘on lection Foraulas ™ Toreionat. 6 = 2 radians T= Torque applied over length "£", Noam b= Length of shafe under consideration, am © = Modulus of rigidity (shear modulus), "MPa J = Polar second moment of area (polar moment of inertia), un Use noraat beam form (Refer chapter 1, page 1-17.) NOTH: Torsional and lateral deflections axe calevlated on basic loades do not include shock or service factor: Suggested deflection Limits were given on pages 2.9 and 2.10. Brcessive deflections (Lateral and/or terefonal) should be avoided because they: (1) can cause secondary stresses. (i) can result in unsatisfactory machine performsnce. Arubipping shafe can eause shock Iosdings in trasenission, (448) can in some efrounetances cause bad gear meshing. (av) ean Took vnsighely.aus SORKED XAMPLE NO. 1 Section 1 type shatte Design the shaft shown in Fig. 8. po Nea Plain bearings 95. 09° 95, FIG. 8 sosver eplect any snall enount of torsion in shaft due to bearing friction Use C5 10%, F, = 225 Wa, Table No. 2, page 2.9. x = Be nes we . he ges . Meee ne 00s mn 2 © MS. ain srom wich @ = 59.91 i ros whic! 91 am Nearest standard aize above = 60 =n, Table No. 4, page 2.11. Check lateral deflection (2) Assume shaft is restrained at che bearings 4-e. che ends are true we cantilevers; 6 = Ty (standard deflection forma.) 60 . 260s 636 172.5 a 6 «25000 x95 Te TT WOO x GH TITS 1054 am Peratestble $= 1.6 mm per m of span, page 2.9- 1.6 x 0.095 = 0.15 mm > 0.054 mm2s (44) Assune the shaft pivots at each bearing as 4¢ would with self aldgning bearings. be Gaba est oS (Standard defection forme Where w= 25.000 + 25000 = 50 000" a= 95 am b= 00 + 2 x 95 = 190m ge BOO x 95 Ges x90 - 4x 954) TEx 307 000 x 636 172-5 = 0.91 ae sresents a considerable increase {9 deflection uhen compared vith case (1) jon for this is that when the bearings do not restrain the shaft, che ‘shaft bows between che bearings and this considerably accentuates ehe end deflections. WORKED EXAMPLE WO. 2 Section 2_Type shafte A solid shaft ts to trangaie 75 ii at 150 rp.a. Determine the shaft size veing C5 1020 bright eveel. snswer we P= Too - sooo? _ 1000 » 75 x 60 n Lor = WOR, 1000 ee 6. 4974.65 3, © 1020,7, = 180 MPa, ueing the maxteum-shear-serat factor of 2.0, theory and 2 baste safety By + owe . noe Bu M6 x 1, . rea i ze 106 103.33 cot, = ME = 106 103.33 érom vasch @ = 1.45 am e Woarest standard size above = 85 am, Table No. 4, page 2-11. (Check torsional deflection Py 0 = BB assume £ = 1000 an. soe Be BEL sizes x 10% mn" 2 zHorked Example No. 2. (Cont. @ = MTss x 10? x 1000 2 gos? = 0.65" 82 700 x 5.1208 x 10° Permisetble 8 = 3*/m > 0.65%/m, page 2.9, WORKED EXAMPLE WO. 3 Section 3 Type shafts Geared motor 19, 18.75 eon, cs SO \ hain ve 1 sin ie 1 \ ‘ \ tN : Fa 4) 3] ae i 1 | mt 1 Chain drive i 1 2hupment 1 | A | 1 [ b iy FIG. 9 i 1 Fig. 9. shova the drive for gone mining equtpnent. (4) Draw a BM. diagram for the shaft. Celeulate the shaft size on the basis of strength only. aay Both sprockets are keyed to the shaft. Answer Shaft speed = 90 x G2 = 45 cpm, 8 pe me To0s tooo e _ 1000 x 4 x 60 | a te. = ot 848.83 WeWorked Example No. 3. (Cost) 88.03 x 0? x 2 | Force in chatse = 48:89 210° = 2 2 p59.40 Asoune chain forces are verticel. Refer to Fig. 10(a) for an idealised load atagran. Worente about A 7359.4 x 130 + 260 B= 7259.4 x 260 = Pa B= 6510.20.8 5 poss " Mopante about 8 7359.4 x 100 + 7359.4 x 130 = 260.4 SA = 6510,24.8 6510.26 8 6510.26 fa) ‘hock. By inspection,upward force: = dowward forces. 735 940 Nem 246 330.8 unm My = 7359.4 x 100 = 735 940 Kamm (b) 5 Mg = 7359.4 x 230 ~ 6510.24 x 130 FIG. 10 = 846 330.8 Mae Refer t0 Fig. 10(8) for eM. Diagram n+ ferr ‘46 300.8 + 948 6307 = 1198 661 Nae Use C5 1030, 7, = 225 MPa, keyway allowance to be made. 2s BS. awe 1198-661 = 26 408.29 a con, = SE = 28 600.29 from vitch d= 52.5 am Hota: the motor used in this example 49 « squtrrel cage type, Tf it is started D.d-L., then a beste F of S of 3.0 ehovld be sed because of the high starting torque: The high starting torque and/or high pull-out torque of such drive Places great losde on shafts snd other components of the driven machenien. Tyax S49 89 a8 bgh see aleo 2.8 « rated torque. ge Dll. Ifa P of § of 3.0 de used, d= 60.1wont mUMOLE Wo. 4 Section 4 Type shafts (a) Rotating ohafe Accertatn solid shaft in a food processing plant has an axial compressive Yond of Be. Consider the shafe Se pin ended and che span is 400 an. Working conditions are minor shock and there 1s a keywsy at the critical section ‘the applied moment = 4000 Tem ‘The applied torque = 2000 Hew Determine if 120 mn dianeter shaft of CS 1030 is aatiafactory. Anever a ES < ee 13.33 < 150 A 1 aoe 1 00 5) 1 TS) 68 1020, F, = 225 ura, Table Mo. 2, page 2.9. 1.0623 oe = BS x 0.75 = 42.19 mma. a1 16\/ Uae + § YEE +) + RDF = wD . 5 factors Table No. 1, page 2.6) Kya ey = LIS Table pa joy /rsaoaoeio%+ § 1.0625x.7538000—20)*4(. 25320000109" 42.19 = 104.75 < 120 am2s (@) stationary shaft Fig. 11. shows a hollow stationmry shaft which — Eofas part of sooe pechanicalequipeest. The fomiaated size de I01s6 0.0. © a-3'yell free to 20 re cabes 00 ‘| }aaoo N Check the suitability of the above tube. “te | Assoaptions: (2) the shaft (esbe) has pin ends. iI (4D. the Loads are alvays in the fl ne dfveccion (ii) the torque is reacted oot at | can l the Lover suppore. | ee. engineering detatle of tube fron Manutactorer's [ | estalogue: | | seen of cross asction «1360 ll 1.61 x 10 m* g I 3.22 x 10° an* oa 264 om tH 31.7 x 10° a? Hi a. 63.6 x 10% mn? I : a Hi eo Hy we 1250 000 Wem li . Hi 1 = Wx radius » 2000 x 600 i = 1 200 000 Bam 2. = 1.67 < 130 1 — Teoom Teens 7 = 250 wa %y Se Fy 70.26 F, 0.26 x 250 = 65 Hea2.20 a, 6 224s & , Wise 9114 W = 50042.5 x 10.7 = 526.8 kp (conservatsvely) fe Jneb yan ree wr G- a") fey {a 250 10% E406. 10. 140110)" + 1200 008 wx 65 (1 - 0.9114") Sas 78am < 101.6 a ‘Check Iateral deflection ae ML 2000 x 25002, me = 1.95 am SEE” Ge x 207 000 x 1.61 x 10° 6+ permtscible = 0.8 mm/m span, page 2.9 = 0.8 22.5 = 2.0mm > 1.95 sm tL, 1.200 000 x 1259 82 700 x 3.22 = 10° o.00se® = 0.32" Permissible @ = fe = 3128 = 275" > O32 WORKED EXAMPLE NO. 5. Section 5 Type shafts Rafer to Fig. 8. page 2-1h, Soppose now that che shaft 16 stationary and the hela axe fitted with bearings; determine the required size of shaft. Answer Use GS 1030,8, = 250 MPa, Table No. 2, page 2.9 “ORL + 0.68, = 0.6 250 = 150 He * y wos pI 25 000 x 95 | om? aoe no 3 15 623.33, 282 . 2 = ME 2 15 939.33 from whieh @ = 56.43 am22 rast standard size shove * 56m, Table No. 4, page 2.11. Chock Lateral deflection > 6 = HE Geandard deftection formis.) wet. ase : re Ee ES 02 749.7 mm 25 000 x 95% = 0.072 a 3x 207 000 x 482 749.7 Permissible 6 = 1.6 mm perm of span = 1.6 x 0,095 = 0.15 am > 0,072 un WORKED EXAMELE NO._6 Section 6 Type shafts A solid round “cheft" is required to act as an anchor to resist a torgue of 6000 Wn. The load is suidenly appited but alway in the one direction, Anover Try 65 1040, fy = 270 MPa, Table No. 2, page 2.9. .2 8, = 0.92270 = al We 03H, = 0.3 270 Faby KE, getect j= 1.5 from Table to. 1, paps 2.6. z, 1.5 x 6000 x 102 = bx 60008102 git a = ME aut antan trom which = 62.7 mm 16 Wearest standard size shove = 85 mn, Table No. 4, page 2.11. Check torstonal deflection 0+ BE, nenme t= 1600 m2 ss. ee % = = 5.1268 x 10 amt 9 ~ 6000x107 1000 gre 2 opie 82 700 x 5.1248 x 10° Pemicsible 9 = 3¢/m > 0.81", pase 2.9.WORKED EXAMPLE WO. 7 scion 7_Type shafts Determine 4 suitable size for the shaft shown in Fig. 12. Use CS 1030 material: snaver Firat deeign for strengeh 400 1000. = Mo= 250 x 400 = 100 000 Nam T = 250 x 1000 = 250 000 S.m= —= = = 12 fee = ¥/100 000% + 250 ooo 269 258.24 Nem FIG. 12 © 1030, r= 250 MPa, Table No. 2, page 2.9. = 03%, © 0.9250 = 75 He 7 Oe cone Tae 22 BBL 5550.1 ae? ee 3 me 2, tag + 3990 +1 from which @ = 26.35 am nearest standard aize above = 27 am, Table No. 4, page 2.11. Secondly check for Lateral deflection = BE. 36 087 an 64 oe Mle 3Er 5 6 880x400" a. 59 3 207 000 x 26 087 Permissible 6 = 1.6 ma/u of span, page 2.9. © 1606 = 064mm < 0.99 am ‘Try 30 na dieneter safe. roe BL OL 39 760.78 om* oe se 1 6 = ME. __250x so = 0.65.mm which 8 onty SEE «3 x 207 000 x 39 760.78 marginally in excess of the maxiaua permissible deflection of 0.64 am79 521.36 an! = 0.0152 radians = 0.87" 250.000 « 400 W700 * 1921-36 Maximum permissible @ = 3°/m = 3% 0.6 © 1.2 > 0.87, p29 EXERCISES 1. Hig. 19 shows 2 stationary axle used in a michine trolley. 45. (@) Determine the required size for the axle iF ‘051030 steel se need. | i Assume: (4) the lead 1s suddenly applied, Kym 155 (34) the loads and reactions are | concentrated. Uf (b) Calculate £5 and Fy if 20 mm stock 1s used. (©) state the actual axle deflection and che neximmn peratsaible deflection tf 20 m= Afanater stock 13 used. 0.036 mm 75MPa FIG, 13 Spur pinions. 297, 8m, 20° PA FIG. 142.28 (@) Determine the required size of shaft using CS 1020 saterial. There are two critical positions to be checked: (1) at the power input, point C. There do a keysay at this position. (a1) at point B. (b) Suppose 90 mm stock is chosen for the job: calculate the lateral Seflection at each pinto. and (c) Detornine the actual and permissible torsional deflections of the shat (4) from ¢ to the first pinion. (33) between the two pinions. ans. (e)(4) 87-61 mm (0) 0-486 um (G0LF aligning bres.) (6)(4) 0-144"; 0.9° GL) 73.22 mm 0.0225 om (piain bree.) (at) 0.492"5 0.513" A shagt in gone mechanical equipaent is subject co a bending nomont of 400 N.m, while trananiteing 5 iW at 970 r-p-m. If an axial tension load of 60 000 is then applied to the shaft which 1 50 mm dianeter of CS 1030, Getermine f, and Bee fos. 31.86 wa 36.25 MPa Fig. 15. stove # stationary’ shaft which has to resist the Ioade Indicated. If the loads are sudéenly applied, Kj = 1475, (elways in ehe direction shown) determine: (a) @ suitable dianeter for the shafe Lf-C5-1030 material is used. 1000 8 (®) the actual and meximm permissible torefonal deflections 00. Ane. (@) 28.75 mm (use tam. 30). (@) L.743"/a or dian. 30). 3.0°/8 100. 1000 N2.25 ig. 16, shove a hollov stationary shaft with an off centre load. By abate + 210 Ha ABsune ends sre pinned. (a) Draw Bua. and torque diagrams for the shaft. (®) Detersine the required section modulus. |G) Te keep defections within permissible 5008 Linite a cube 42.4 outside Gianeter x § a wall de finally chosen. Detersine: El (3) the Latersi deflection én the centre and che maxinom pernissible Seflection. “70 (6) the maximum torssonal deflection find the maine perafeaible FIG. 16 torsional deflection. From the Manufacturer's catalogues 1 = 0.0942 x 10° am 5 = 0.1884 x 10% ant Answers: 2, = 2594.45 am? (©) 015316 em 0.8 om (32) 0.1052"/a 3m A solid shaft of CS 1020 4 to eraneate 120 Mi at 250-9. Service conditions are minor shock K, = 1.5. There 1.4 Ley in the shaft. Determine: (a) the required shafe diameter. (®) the actual torsional deflection and the mexiaun permisoible torsional deglection ££ a 110 nm dianeter shaft 12 uaed. ans. (@) 101.236 am ©) 0,221"/a 3/a A rotating shaft of CS 1040 carries = bending somint of 4S Hi.m where torque ig'57 Wien. Loading conditions are ainor shock Ky = 1.5 and Ky » 1.25. ‘There 1s & keyway at the position of maxtmun moment Design the shove shaft on the basis of strength oxly. ane. 222.22.26 ‘The machine mechanism shown in Fig. 17. bas a hollow shaft at che operating end. Welded to this shafe ts « lever. When the lever is in ite Lovermost position a load "E" is attached. ‘The load 1e then raised by operating the Zope wheel. The lever has 60° of movenent and there is a holding brake in the arrangement. The overall efficiency is 95%. Determine (@) the maximum value of F. (b) the required section aodulus for the Hollow shaft. Use a steel ‘equivalent to C5 1020. (©) the sctuel an maxima permissible torsional deflection of the shaft if 53:7 outside diameter x 4.0 ‘ns. (a) 145.26 kg 4 (©) 2 = 6481161 mm? (c) 9.46%; 0.975° te e07 8(a). Fig. 17(a) shovs a stationary shaft of 50 m diameter, ($1020, subjected to'd static load of 500 kg. Refer to section XE at the support. (4) Determine the maxinun shear stre ac Band D. State F. (AE) Unéng ‘average! bean shear stress calcvlate the total resultant shear etrese at A'and C. State F (G1) Calculate the true maximum shear stregs at A and C. dos.) f, at Band D = 33.98 ra Fy = 60 Ma Gy 6, at A= 32.48 we #o at C= 27.48 1a Fy = 60 Ha t ‘Seeton X (Lt) f at A= 33.31 Wa 16. 71a) Fy at C = 26.65 Na10. 227 ‘The stationary shaft show in Pig. 18. 42 the anchor point for sone eachenicsl equipaent. The nosinated size of tube is 114.3 outside diameter # 4.9 wall Sp saterial equivalent to 65.1020. ‘The extel load és reseted out at the bese but the tube 42 torafenlly restrained fat each end. Engineering detatis of tube frow Monufscturer's catalogue. area of ‘chose section .....- 1540 an? 2.33 x 10° ae" + 4.66 x 105 mo” 2400. 38.9 om <2. kale Determine: (@) the oultabitiey of the nominated tubes (b) the spproxinate aaxisun lateral, deflection and the maxtmm permis Sble lateral deflection. (©) the setual and seximum peratesttle torsional deflections: ans. (a) 102.781 am < 114.3 om (b) 175 se 1.92 am fe) 0.16%/a 38a FIG. 18 Braminstion question, R.X.I-T., 1979. Figs. 19 and 20, page 2.29 , stov diagrannatic assemblies of « Runbling In anovering the folloving questions use minor shock factors az follove shafts 1.5 on Mand 1.25 on T, all other machine elements 1.25. (2) The drive connection {2 to be by roller chain. Determine the safety Esctor for the nominated size. (b) Determine the bending moment (excluding shock factor) a (a). the bearing support, point A. (44) the bolted stub shaft connection, poine B.1. @ cy wo a ans. 2.28 Using C$ 1030 material deternine the required: size for the drive side ‘stub shate. Fig. 20, page 2.29 shovs the suggested design for the bolted drive side ‘stub shaft conection. Determine the value of: (4) the interaction formula for the bolts, (Refer to pages 12.29 to 1243.) (2) fg and Boge Baler to pages 12.29 to 12.63.) Coleulate the following values for the drive key in the C.I. chain Wheel (aasune a 60 mm diaseter shaft 1s used). () fend for the ey. (ss) f, and @) 9.93 () (948 613.62 Nama (©) 59.386 an GD 559 643188 New @ @ 0.432 (©) (2) 44.46 mre 103.5 wee GH) 32.89 Mra 525 wa (2) 145.43 Pa 125150 wwe Authors" commence ‘the above analysis assumes the sotor i¢ not started D,0.L. In the stub shagt eonsection design, it may be advisable to use a further factor of 1. fon bolt loads to allow for endurance type loading. Refer to page 12.44. ‘the student should now repeat the question assuaing the motor is started Dik. Pull-out torque = 260 {Gli load torque. Losding conditions bpose minor shock. Folloy the instructions given in Worked Example No. 1, page 1.28. ‘The factors of 1.4 and 3.0 quoted for "Designed couplings" can be used for the design of the bolts in the atub shaft coanection. these factors wil? ‘also cover any endurance type loading thet vill occur during normal fell. Speed running, Use 16 mm diameter bolts, Peraisaible stresses for the bolts can be 1st we A, = mex Ls oo 1.6 he 7 Oe ee Fe 7 525 x Hel = 202 wa et shagt factors can be as before: aSon Mand. 1.25 0n 7. ‘the carvice factor on key design can be 1.25, Assume @ 20 x 12 x 76 key inva 70 am éianeter shaft. Ge) 9.55 QB) (4) 948 613.62 Nem Ce) 67.98 am GD 359 443.88 Nem (@) Gy 0.558 (©) 36.28 wa 69 Mea (77.63 Mea 292 Whe G3) 4.26 mPa 83-100 wee. Slightly overstressed but aot ‘seriously for crushing stressDrive key from MAK-A-KEY” steal 18x11 « 76 long . wo w= | os dl | = Ny a 307.89 Aco. MGS © of 6 of combined | mraus of dumm moter 72 rev/min 25.4 mm duplex chain ‘and product (tension side of ehain is vertical) 6-412 botts on M0 PCD. £IG. 20