Shaft Design

ENTC 463
Mechanical Design Applications II
 Next Thursday
4/3/2008
Meet @ Thompson 009B

Allen to Hagan – 2:20 to 3:00 PM

Higginbotham to Winniford– 3:00 to 3:35 PM

ENTC 463
Mechanical Design Applications II
ATTENTION: MMET Students, the IAC members
would like to meet YOU on April 11th !
WHO? IAC Members
WHAT? Meet and Greet
WHERE? 510, 5th Floor Rudder Tower
WHEN? April 11th 3:30-5:00pm
WHY? They will also be available to review your resume
and help you improve it for potential employers. Please sign
up with Courtney in THOM 117

Deadline to sign up is April 8th.

 MMET IAC Meeting
April 11th 2008
STUDENTS NEEDED!!
MMET Majors ONLY

Come join us for the 2008 Spring IAC Meeting

Great DOOR PRIZES!
I-POD NANO and much more!
(Must Be Present to Win)

Sign up with Courtney in THOM 117

 ENTC 463
• Lab 3 Due 4/10
• Homework HW 12 Due 4/15
– Chapter 12 – 2, 4, 25, 27
 Shafts
• Mott, Chapter 12
• Why use shaft?
– To transmit power
• Shaft geometry
– Cylinder, bar, beam (length and diameter)
• Load acting on shaft
– Torsion (shear stress)
– Bending (normal stress)
Shaft Design
Shaft Design
 Shaft Design
• Given required power • Given required power
to be transmitted to be transmitted
– Calculate torque, – Calculate torque,
– Calculate forces, – Calculate forces,
– Calculate stresses (if – Determine shaft
geometry is known), diameter (if the
– Select material material is known)
 Shaft Design Procedure
1. Develop the free body diagram; model the
various machine elements mounted on the
shaft in terms of forces and torques
2. Develop the shear and moment diagram;
identify bending moment (leads to normal
stress) and torque (leads to shear stress)
3. Identify critical locations for stress analysis;
calculate stresses (known diameter)
4. Determine diameter or select material based
on failure theories
 Forces Acting on Shaft
• Forces due to gear (spur gear)
63000hp
T=
n
T
Wt =
D2
Wr = Wt tan φ
Wx = Wt tanψ (helical gear)
Forces due to Gears
 Forces Acting on Shaft
• Forces due to chain and sprocket
T TA TB
Fc = = =
D 2 DA 2 DB 2
Fcx = Fc cos θ
Fcy = Fc sin θ
 Forces Acting on Shaft
• Forces due to V-belt and sheave
FB = F1 − F2
1.5T
FB ≈
D2
For flat belt and pulley
2.0T
FB ≈
D2
 Example
• A chain is transmitting 100 kW with the
chain speed at 6000 rpm and V = 50 m/s.
The shaft material is AISI 1040 cold
drawn. Determine the shaft diameter
required.
 Shaft Design Considerations
• Stress Concentration (fillet or key seat)
1.5 < Kt < 2.5
• Combined tangential and radial load (3-D)
– Two shear and moment diagrams
z
Wt

M y = M xy + M yz
2 2

Wr y

x
 Stress Concentration
• Keyseats
– Kt = 2.0 for profile keyseat
– Kt = 1.6 for sled keyseat
• Shoulder fillets
– Kt = 2.5 for sharp fillet
– Kt = 1.5 for well-rounded fillet
• Retaining ring grooves
– Kt = Kt = 3.0, or
– Increase diameter by 6%
Forces Acting on A Shaft
 Shear and Moment Diagrams
From bottom look up Front view
 Shaft Design/Analysis Example
MSST :
Sy
σ1 − σ 3 ≤
N
16
πd 3
(
M + M 2
+ T 2
−
16
)
πd 3
M − M 2
+ (
T 2
≤
Sy
N
)
32
πd 3
(M 2
+ T 2
≤ )
Sy
N
Mc M (d 2) 32 M
σx = = =
1

I (
πd 64
4
)
πd 3 ⎛ 32 N
d ≥⎜
⎜ πS
⎞
M 2 +T 2 ⎟
⎟
3

Tc T (d 2 ) 16T ⎝ y ⎠
τ xy = = =
J ( )
πd 4 32 πd 3 ⎛ ⎛M ⎞ ⎛ T ⎞ ⎞⎟
2 2
1
3
⎜ 32 N ⎜ ⎟ +⎜ ⎟ ⎟
( )
d ≥⎜
σx
⎛σ ⎞
2
16 ⎜ π ⎜S ⎟ ⎜S ⎟ ⎟
σ1 = + ⎜ x ⎟ + τ xy = 3 M + M 2 + T 2
2
⎝ ⎝ y ⎠ ⎝ y⎠ ⎠
2 ⎝ 2 ⎠ πd
σx
⎛σ ⎞
( )
2
16 Is this correct ?
σ1 = − ⎜ x ⎟ + τ xy = 3 M − M 2 + T 2
2

2 ⎝ 2 ⎠ πd
 Fatigue Failure Criterion
• Cyclic loading due to shaft rotation
– Find mean and alternating stresses
– Construct Mohr’s circles for mean stress and
alternating stress
– Derive effective mean and alternating
stresses (based on MSST or DET)
– Use Soderberg or Goodman for design and
analysis
 Fatigue Failure of Shaft
Mean : Alternating :
σ mx = 0 32M
σ ax = 3
32 M σ my = 0 πd
σx = ± σ my = 0
πd 3 16T
σy =0
τ mxy = 3
τ mxy = 0
πd
16T
τ xy = 32T
πd 3 σm'= 3
πd ANSI/ASME equation for
32 M fully reversed bending and steady torsion :
σa '=
πd 3 ⎛ σa ⎞
2 2
⎛ τm ⎞
⎜⎜ ⎟⎟ +⎜ ⎟ =1
Soderberg : ⎜S ⎟
⎝ Sn ' ⎠ ⎝ ys ⎠
K tσ a ' σ m ' 1
+ =
Sn ' Sy N
ANSI Shaft Design Equation

For repeated reversed bending and constant torque

 ANSI/ASME Shaft Equation
Fully reversed bending and steady torsion :
2
⎛ τm ⎞
2
⎛ σa ⎞
⎜⎜ ⎟⎟ +⎜ ⎟ =1
⎜S ⎟
⎝ Sn ' ⎠ ⎝ ys ⎠

Consider safety factor :

2
⎛ σa ⎞ ⎛ τm ⎞
2

⎜⎜ ⎟⎟ + ⎜ ⎟ =1
⎜ ⎟
⎝ S n ' ⎠ ⎝ S ys ⎠
2 2
⎛ σa ⎞ ⎛ τm ⎞ ⎛ σa N ⎞ ⎛ τm N ⎞
2 2

⇒ ⎜⎜ ⎟⎟ + ⎜ ⎟ = 1 ⇒ ⎜⎜ ⎟⎟ + ⎜ ⎟ =1
⎜ ⎟ ⎜ ⎟
⎝ S n ' N ⎠ ⎝ S ys N ⎠ ⎝ S n ' ⎠ ⎝ S ys ⎠
 ANSI / ASME Shaft Equation
Use DET (pure shear for torsion) :
2
⎛ ⎞
2
⎜ ⎟ ⎛ ⎞
2
⎛ σa N ⎞ ⎛ τm N ⎞
2 2 2
⎛ ⎞ ⎛ σa N ⎞
⎜⎜ ⎟⎟ + ⎜ ⎟ = 1 ⇒ ⎜ σa N ⎟ + ⎜ τm N ⎟
⎜
⇒⎜ ⎟ + ⎜ 3τ m N ⎟
=1
⎜ ⎟ ⎜ S ' ⎟ ⎜ 1 ⎟ ⎟ ⎜ ⎟
⎝ S n ' ⎠ ⎝ S ys ⎠ ⎝ n ⎠ S ⎝ Sn ' ⎠ ⎝ S y ⎠
⎜ y ⎟
⎝ 3 ⎠

Consider stress concentration :

2 2
⎛ 3τ m N ⎞ ⎛ K t σ a N ⎞ ⎛ 3τ m N ⎞
2 2
⎛ σa N ⎞
+⎜ ⎟ =1⇒ ⎜ ⎜ ⎟ =1
⎜⎜ ⎟⎟
⎜ S ⎟ ⎜ S ' ⎟⎟ + ⎜ S ⎟
⎝ Sn ' ⎠ ⎝ y ⎠ ⎝ n ⎠ ⎝ y ⎠
 ANSI / ASME Shaft Equation
Mc 32M
σa = =
I πd 3
Tc 16T
τ m= = 3
J πd
2 2
⎛ ⎛ 32M ⎞ ⎞ ⎛ ⎛ 16T ⎞ ⎞
2
⎛ 3τ m N ⎞
2 ⎜ Kt ⎜ 3 ⎟
N ⎟ ⎜ 3⎜ 3 ⎟ N ⎟
⎛Kσ N⎞ πd ⎠ ⎟ + ⎜ ⎝ πd ⎠ ⎟ = 1
⇒ ⎜⎜ t a ⎟⎟ +⎜ ⎟ =1⇒ ⎜ ⎝
⎜ S ⎟ ⎜ ⎟ ⎜ Sy ⎟
⎝ Sn ' ⎠ ⎝ y ⎠ Sn '
⎜ ⎟ ⎜ ⎟
⎝ ⎠ ⎝ ⎠

1
⎡ 2 ⎤ 3
3 ⎛⎜ T ⎞⎟
2
⎢ 32 N ⎛ Kt M ⎞ ⎥
d= ⎜⎜ ⎟⎟ +
⎢ π ⎝ Sn ' ⎠ 4 ⎜⎝ S y ⎟⎠ ⎥
⎢⎣ ⎥⎦
ANSI / ASME Shaft Equation
Fully reversed bending and steady torsion
1
⎡ 2 ⎤ 3
3 ⎛⎜ T ⎞⎟
2
⎢ 32 N ⎛ Kt M ⎞ ⎥
d≥ ⎜⎜ ⎟⎟ +
⎢ π ⎝ Sn ' ⎠ 4 ⎜⎝ S y ⎟⎠ ⎥
⎢⎣ ⎥⎦

Static
1
⎡ ⎛M ⎞ 3 ⎛ T ⎞ ⎤⎥
2 2 3

⎢ 32 N ⎜ ⎟ + ⎜ ⎟
d≥
⎢ π ⎜S ⎟ 4⎜S ⎟ ⎥
⎢⎣ ⎝ y ⎠ ⎝ y ⎠ ⎥⎦
 ANSI Shaft Design Equation

Fully reversed bending and steady torsion :

2
⎛ σa ⎞ ⎛ τm ⎞
2

⎜⎜ ⎟⎟ + ⎜ ⎟ =1
⎜ ⎟
⎝ S n ' ⎠ ⎝ S ys ⎠

Fully reversed bending and steady torsion

1
⎡ 2⎤ 3
⎞ 3⎛ T ⎞ ⎥
2
32 N ⎛ Kt M
d≥⎢ ⎜⎜ ⎟⎟ + ⎜ ⎟
⎢ π ⎜ ⎟
⎢⎣ ⎝ Sn ' ⎠ 4 ⎝ S y ⎠ ⎥⎥
⎦

Can we use Soderberg or Goodman criterion?

 Example 12-1 (p. 548)
• The system transmitting 200 hp from
pinion P to gear A, and from pinion C to
gear Q.
• The shaft rotating speed is 600 rpm.
• Shaft material is AISI 1144 OQT 1000
 Example (p. 549)
• Free body diagram
• Shear and moment diagrams
• Torque at each segment
• Calculate diameter for locations A, B, C, and D
(at both left and right)

No moment No torque, no moment,

Torque = 21000 No torque vertical shear only

A B C D
 Shear and Moment Diagrams
From bottom look up Front view
Design Examples
Design Example - Torque
Design Example - Forces
Design Examples – Shear and Moment