Chapter 11: Shafts

When a man has a vision, he cannot obtain the power from that vision until he has performed it on the Earth for the people to see. Black Elk Hamrock Fundamentals of Machine Elements

Shaft Design Procedure

1. Develop a free-body diagram by replacing the various machine elements mounted on the shaft by their statically equivalent load or torque components. To illustrate this, Fig. 11.1(a) shows two gears exerting forces on a shaft, and Fig. 11.1(b) then shows a free-body diagram of the gears acting on the shaft. Draw a bending moment diagram in the x-y and x-z planes as shown in Fig. 11.1(c). The resultant internal moment at any section along the shaft may be expressed as

2.

Mx =
3.

2 + M2 Mxy xz

4. 5. 6.

Develop a torque diagram as shown in Fig. 11.1(d). Torque developed from one power-transmitting element must balance the torque from other power-transmitting elements. Establish the location of the critical cross-section, or the x location where the torque and moment are the largest. For ductile materials use the maximum-shear-stress theory (MSST) or the distortion-energy theory (DET) covered in Sec. 6.7.1. For brittle materials use the maximum-normal-stress theory (MNST), the internal friction theory (IFT), or the modied Mohr theory (MMT), covered in Sec. 6.7.2.

Hamrock Fundamentals of Machine Elements

z Az A P1 B Ay x T P2 (a) My Mz (b) P2 By

y T P1 Bz

Shaft Assembly

x Moment diagram caused by loads in x-z plane (c) Tx Moment diagram caused by loads in x-y plane

T x (d)

Figure 11.1 Shaft assembly. (a) Shaft with two bearings at A and B and two gears with resulting forces P1 and P2; (b) free-body diagram of torque and forces resulting from assembly drawing; (c) moment diagram in xz and xy planes; (d) torque diagram.

Hamrock Fundamentals of Machine Elements

160 mm

40 mm

Example 11.1
Chain

(a) y

RA

160 mm

40 mm

M x

RB
P (b)

Figure 11.2 Illustration for Example 11.1. (a) Chain drive assembly; (b) free-body diagram; (c) bending moment diagram.

80 N-m (c)

Hamrock Fundamentals of Machine Elements

z 0.250 m 0.250 m A y 0.050 m C 0.150 m 300 N B 200 N x 550 N 400 N 0.075 m D

z 0.250 m 150 N y 475 N 950 N 650 N 475 N 0.250 m 7.5 N-m

0.150 m 500 N x 7.5 N-m

Example 11.2

(a) A C B D A C

(b) B D

0.250 m 0.250 m 0.150 m 475 N 950 N 475 N My(N-m) My = 118.75 N-m

0.250 m 150 N Mz (N-m)

0.250 m 0.150 m 650 N 500 N

Mz = 37.5 N-m x(m) (c) A C 7.5 N-m B D (d)

My = 75 N-m x(m)

7.5 N-m 0.250 m Tx(N-m) 0.250 m 0.150 m

x(m) 7.5 (e)

Figure 11.3 Illustration for Example 11.2. (a) Assembly drawing; (b) free-body diagram; (c) moment diagram in xz plane; (d) moment diagram in xy plane; (e) torque diagram.

Hamrock Fundamentals of Machine Elements

Fluctuating Stresses on Shafts

TFa
Sm pKfSa Tm pKfsTa

Tm pKfsTa

Sm pKfSa

Se/2ns D G

(a) y

SF

A sin F
Sm +KfSa

F Sy/2ns

TFm

TF F

Tm +KfsTa

x (b)

A cos F

Tm +KfsTa

Figure 11.5 Soderberg line for shear stresses.

Figure 11.4 Fluctuating normal and shear stresses acting on shaft. (a) Stresses acting on rectangular element; (b) stresses acting on oblique plane at angle . Hamrock Fundamentals of Machine Elements

Derivation in Eq. (11.29)

sin 2! A = tan 2! = cos 2! 2B

4( ~ B) 2

2 ~ 2B

Figure 11.6 Illustration of relationship given in Eq. (11.29). Hamrock Fundamentals of Machine Elements

(A ~ )2 +

~ A

Shaft Design Equations

Using DET and Soderberg Criteria
ns = 32 !d 3Sy Sy Mm + K f Ma Se
2

Sy 3 + Tm + K f sTa 4 Se

32ns d= !Sy

Sy Mm + K f Ma Se

Sy 3 + Tm + K f sTa 4 Se

1/3

Hamrock Fundamentals of Machine Elements

Example 11.4

d3 d1

d2

Figure 11.7 Section of shaft in Example 11.4.

Hamrock Fundamentals of Machine Elements

Critical Frequency of Shafts

Single Mass
!= k = ma W /y = W /g g "

Multiple Mass - Raleigh Equation

ma y W(t)
!cr = g "i=1,...,n Wi#i,max "i=1,...,n Wi#2 i,max

Figure 11.8 Simple singlemass system.

Multiple Mass - Dunkerly Equation

1 1 1 1 = 2 + 2 ++ 2 2 !cr !1 !2 !n

Hamrock Fundamentals of Machine Elements

Example 11.5

y x1

PA x2 A

PB x3 B R2 x

R1

Figure 11.9 Simply supported shaft arrangement for Example 11.5.

Hamrock Fundamentals of Machine Elements

Keys and Pins

Figure 11.10 Illustration of keys and pins. (a) Dimensions of shaft with keyway in shaft and hub; (b) square parallel key; (c) flat parallel key; (d) tapered key; (e) tapered key with Gib head, or Gib-head key. The Gib head assists in removal of the key; (f) round key; (g) Woodruff key with illustration of mountingl (h) pin, which is often grooved. The pin is slightly larger than the hole so that friction holds the pin in place; (i) roll pin. Elastic deformation of the pin in the smaller hole leads to friction forces that keep the pin in place. Hamrock Fundamentals of Machine Elements

w w

Plain Parallel Keys

d

w 2 w w l

Shaft diameter in. 0.500 0.625 0.750 0.875 1.000 1.125 1.250 1.375 1.500 1.675 1.750 1.875

Key width in. 0.125 0.1875 0.1875 0.1875 0.25 0.25 0.25 0.3125 0.375 0.375 0.375 0.50

Distance from keyseat to opposite side of shaft, in. 0.430 0.517 0.644 0.771 0.859 0.956 1.112 1.201 1.289 1.416 1.542 1.591

Shaft diameter in. 2.000 2.250 2.500 2.750 3.000 3.250 3.500 3.750 4.000 4.500 5.000 6.000

Key width in. 0.50 0.50 0.625 0.625 0.75 0.75 0.875 0.875 1.00 1.00 1.25 1.50

Distance from keyseat to opposite side of shaft, in. 1.718 1.972 2.148 2.402 2.577 2.831 3.007 3.261 3.437 3.944 4.296 5.155

Table 11.1 Dimensions of selected square plain parallel stock keys.

Hamrock Fundamentals of Machine Elements

Tapered Keys

Shaft diameter in.

0.5-0.5625 0.625-0.875 0.9375-1.25 1.3125-1.375 1.4375-1.75 1.8125-2.25 2.3125-2.75 2.875-3.25 3.375-3.75 3.875-4.5 4.75-5.5 5.75-6

Square type Width Heighta w h in. in. 0.125 0.125 0.1875 0.1875 0.25 0.25 0.3125 0.3125 0375 0.375 0.5 0.5 0.625 0.625 0.75 0.75 0.875 0.875 1.00 1.00 1.25 1.25 1.50 1.50

Flat type Width Heighta w h in. in. 0.125 0.09375 0.1875 0.125 0.25 0.1875 0.3125 0.25 0.375 0.25 0.5 0.375 0.625 0.4375 0.75 0.50 0.875 0.625 1.00 0.75 1.25 0.875 1.50 1.00

Available lengths, l Minimum Maximum Available in. in. increments in. 0.50 2.00 025 0.75 3.00 0.375 1.00 4.00 0.50 1.25 5.25 0.625 1.50 6.00 0.75 2.00 8.00 1.00 2.50 10.00 1.25 3.00 12.00 1.50 3.50 14.00 1.75 4.00 16.00 2.00 5.00 20.00 2.50 6.00 24.00 3.00

Table 11.2 Dimensions of square and flat taper stock keys.

Hamrock Fundamentals of Machine Elements

Woodruff Keys
Key No. Suggested shaft sizes, in. 0.3125-0.375 0.4375-0.50 0.6875-0.75 0.8125-0.9375 0.875-0.9375 1.00-1.1875 1.25-1.3125 1.25-1.75 1.25-1.75 1.25-1.75 1.8125-2.5 1.875-2.5 Nominal key sizea , in. wl 0.062 0.500 0.094 0.625 0.125 0.625 0.156 0.750 0.156 0.875 0.188 1.000 0.250 0.875 0.250 1.125 0.250 1.250 0.250 1.500 0.312 1.500 0.375 1.500 Height of key, in. h 0.203 0.250 0.250 0.313 0.375 0.438 0.375 0.484 0.547 0.641 0.641 0.641 Shearing Area, in.2 0.030 0.052 0.072 0.109 0.129 0.178 0.198 0.262 0.296 0.356 0.438 0.517

204 305 405 506 507 608 807 809 810 812 1012 1212

Table 11.3 Dimensions of selected Woodruff keys.

Hamrock Fundamentals of Machine Elements

Set Screws

Screw Diameter (in.) 0.25 0.375 0.50 0.75 1.0

Holding Force (lb) 100 250 500 1300 2500

Table 11.4 Holding force generated by setscrews.

Hamrock Fundamentals of Machine Elements

Flywheel

Tl

Tm

Figure 11.11 Flywheel with driving (mean) torque Tm and load torque Tl.

Hamrock Fundamentals of Machine Elements

Coefcient of Fluctuation
Type of equipment Crushing machinery Electrical machinery Electrical machinery, direct driven Engines with belt transmissions Flour milling machinery Gear wheel transmission Hammering machinery Machine tools Paper-making machinery Pumping machinery Shearing machinery Spinning machinery Textile machinery Coecient of uctuation, Cf 0.200 0.003 0.002 0.030 0.020 0.020 0.200 0.030 0.025 0.030-0.050 0.030-0.050 0.010-0.020 0.025

Table 11.5 Coefcient of uctuation for various types of equipment.

!max !min 2 (!max !min) Cf = = !avg !max + !min

Hamrock Fundamentals of Machine Elements

Design Procedure for Sizing a Flywheel

1. Plot the load torque Tl versus for one cycle. 2. Determine Tl,avg over one cycle. 3. Find the locations max and min. 4. Determine kinetic energy by integrating the torque curve. 5. Determine avg. 6. Determine Im from Eq. (11.72).
Ke Im = C f !2 ave

7. Find the dimensions of the ywheel.

Hamrock Fundamentals of Machine Elements

Example 11.7

160 Torque, T, N-m 120 80 40 0 0 12 N-m

144 N-m

12 N-m

3 2

Figure 11.12 Load or output torque variation for one cycle used in Example 11.7.

Hamrock Fundamentals of Machine Elements

Materials for Flywheels

Performance index, Mf kJ/kg 200-2000 (compression only) 200-500 100-400 300 100-200 100-200 100-200 100-200 3 8-10

Material Ceramics Composites: Ceramic-ber-reinforced polymer Graphite-ber-reinforced polymer Berylium High-strength steel High-strength aluminum (Al) alloys High-strength magnesium (Mg) alloys Titanium alloys Lead alloys Cast iron

Comment Brittle and weak in tension. Use is usually discouraged The best performance; a good choice. Almost as good as CFRP and cheaper; an excellent choice. Good but expensive, dicult to work, and toxic All about equal in performance; steel and Al-alloys less expensive than Mg and Ti alloys High density makes these a good (and traditional) selection when performance is velocity limited, not strength limited.

Table 11.6 Materials for ywheels.

Hamrock Fundamentals of Machine Elements