Data :

Power transmitted by shafts = 1500KW

Rotational speed of driving pulley = 2000rpm
Pre stress belt ratio = 2.05
Gear pressure angle = 20 deg
Safety Factor SF or ns = 1.3
Yield strength of shaft material = y=400 MPa
Ultimate tensile strength of shaft material = uts= 1000 MPa
Material of keys AISI 1020 cold drawn = y = 350 MPa
A/A student data = 64

Schematical illustration of assembly

1. General calculations for shaft 1

Calculate angular velocity for shaft 1

1 =

2 rpm 2 2000
=
=209.44 rad / s
60
60

n Rn = s Rs => 2000 150 = s 150 => s = 2000rpm

Calculate the shaft 1 input torque

Torque = power/ angular velocity
Tq1 = 1500KW/209.44 = 7162Nm

Calculate the belt tension

Belt ratio: 2.05
Pulley 2 radius: 0.15m
T1 = (2.05 T2 )
Tq1 = (2.05 T2R) - (T2 R)
7162 = (2.05T2 0.15)-(0.15 T2 )
T2 = 7162/0.1575
T2= 45.47kN
And
T1= 93.22N
Calculate the tangential and radial forces of gear 1
Radius of gear 1= Rgear1=0.16m The tangential force is given by:
Ft = torque/ Rgear1 = 7162Nm/0.16m => Ft = 44.76kN
The radial force is given by:
Fr = Fttan20o = (44.76kN)tan20o => Fr = 16.29kN

2. Shaft 1 forces and reactions

Free body diagram shaft1

Calculating the reactions on z-x plane
By taking moments at point A
(44.76kN 50mm) + (R2z 300mm) = (138.69kN 420mm)
R2z = 186.7kN
By summation of forces z-x plane
fz=0
R1z + 138.69kN = 44.76kN + 186.7kN
R1z = 92.77kN
Calculating the reactions on y-x plane
By taking moments at point A
16.29 kN 50mm = R2y 300mm
R2y = 2.715kN
By summation of forces y-x plane
fy=0
16.29kN 2.715kN - R1y = 0
R1y = 13.57kN

3. Bending moment and torque diagrams for shaft 1

290mm

130mm

150mm

Ft=550,5 N

R2z=3084,9 N

D
T1+T2=2398,63 N

R1z=1236,7 N

Mb=
-160,38Nm

Mc=
-359,77Nm

Moment diagram in z-x plane

The bending moment at B and C in Z-X plane are given by:

Mb = (-R1z 0.05m) = (-92.77kN 0.05m) = -4.64kNm
Mc = (-R1z 0.3m) + (Ft 0.25m) = -27.831kNm + 11.19kNm = -16.64kNm

290mm

130mm

150mm

Fr=200,37 N

A
R1y=138,35 N

D
R2y=62,02 N

Mb=
-18 Nm

Moment diagram in y-X plane

The bending moment at B and C in Y-X are given by:

Mb = (-R1y 0.05) = -13.57kN 0.05 = -0.6785kNm
Mc= (-R1y 0.3) + (Fr 0.25) = (-13575N 0.3) + (16.29kN 0.25) = 0Nm

290mm

130mm

150mm

Tx(Nm)
Tq=66,06

X(m)

Torque diagram

The resultant moment at b is

Mb = Mbz2 + Mby2 = (-4.64)2 + (-0.6785)2 = 4.69kNm
The moment at point C is:
Mc = Mcz2 + Mcy2 = (-16.64)2 + (0)2 = 16.64kNm

As seen from the bending moment diargams the maximum moment occurs at
point C at the bearing and has a value of 16.64kNm
The torque is constant 7162Nm between points B and D. The critical point of the
shaft is at point B.
Mx = 16.64kNm

Torque = 7162Nm

4. Determine the smallest safe diameter

Calculation of the endurance limit e for shaft 1
Data: ns = 1.3 , y = 400pa , Mc = 16.64kNm , Tc = 7162Nm , uts = 1000Mpa

e=Ka*Kb*Kc*Kd*Ke*Kf*Kg* e

e=0.504 uts = 0.504 1000 = 504Mpa

Ka=surface factor (hot rolled steel)

Ka = a utsb = 57.7 1000-0,718 = 0.4047

Kb = (d/7.62)-0,1133 = (47/7.62)-0,1133 = 0.8134

Kc = 0.897

Kb=size factor

Kc=reliability, 90%

Kd=temperature factor

Kd= 1

Ke= 1

Kf= 0.63

Kg= 1

Ke=duty cycle

Kf=fatigue stress

Kg=various

e = 0.4047 0.8134 0.897 1 1 0.63 1 504MPa e =

93.756Mpa
The smallest safe diameter for shaft 1 is given by

32 1.3
d=

3 2

16.64 10
6
93.7 10

)( (

3
7162
+
6
4
400 10

1
2 3

) ) ] =0.133 m

The smallest safe diameter for shaft1 is d=133mm

5. General calculations for shaft 2

Calculate angular velocity for shaft 2

1 =

2 rpm 2 3200
=
=335.1 rad /s
60
60

nRn = sRs => 2000160 = s100 => s = 3200rpm

Calculate the shaft 2 input torque

Torque = power/ angular velocity
Tq1=1500kW/335.1 rad/s = 4476.28 Nm

Calculate the tangential and radial forces of gear 2

The tangential and radial forces are equal and opposite to the ones on gear 2
Ft=44.76kN
Fr=16.29kN

6. Shaft 2 forces and reactions

Free body diagram shaft 2

Calculating the reactions on z-x plane
By taking moments at point B:
(-44.76kN 0.13) + (R2z 0.26) = 0
R2z = 22.38kN
By summation of forces z-x plane:
fz=0

R1 z - Ft +

R2 z = 0

R1z = 44.76 - 22.38

R1z = 22.38kN
Calculating the reactions on y-x plane
By taking moments at point B:
-16.29 x 0.13 = R2y x 0.26
R2y = 8.145kN
By summation of forces y-x plane:
fy=0
-16.29 + 8.145 + R1y = 0
R1y= 8.145kN
7. Bending moment and torque diagrams for shaft 2

The bending moment at B and C in Z-X plane are given by:

Mb = (-44.76 x 0.13) + (22.38 x 0.26) = 0Nm
Mc = R1z x 0.13 = 22.38 x 0.13 = 22.38kNm
130mm

130mm

130mm

R1z=275,25 N

R2z=275,25N

Ft=550,5 N

Mz(Nm)

Mc=35,8 Nm
X(m)

Moment diagram in Z-X plane

The bending moment at B and C in Y-X are given by:

Mb = 8.145 x 0.26 16.29 x 0.13 = 0Nm
Mc = R1y x 0.13 = 8.145kNm
130mm

130mm

130mm

R1y100,19 N

A
Mz(Nm)

R2y=100,18 N

Ft200,37 N

Mc=13,025 Nm
X(m)

Moment diagram in y-X plane

130mm

130mm

130mm

R2z=275,25N

R1z=275,25 N

B
Tx(Nm)
Tq44,04 Nm

X(m)

Torque diagram
The resultant moment at b is:
Mb = Mbz2 + Mby2 = (0)2 + (0)2 = 0Nm
The moment at point C is:
Mc = Mcz2 + Mcy2 = (22.38)2 + (8.145)2 = 23.82kNm
As seen from the bending moment diargams the maximum moment occurs at
point C at the gear and has a value of 23.82kNm
The torque is constant 4476.28Nm between points A and C. The critical point of
the shaft is at point C.
Mx = 23.82kNm

8. Determine the smallest safe diameter

Torque = 4476.28Nm

Calculation of the endurance limit e for shaft 1

Data: ns = 1.3 , y = 400pa , Mc = 23.82kNm , Tc = 4476.28Nm , uts = 1000Mpa

e=Ka*Kb*Kc*Kd*Ke*Kf*Kg* e

e=0.504 uts = 0.504 1000 = 504Mpa

Ka=surface factor (hot rolled steel)

Ka = a utsb = 57.7 1000-0,718 = 0.4047

Kb = (d/7.62)-0,1133 = (47/7.62)-0,1133 = 0.8134

Kc = 0.897

Kb=size factor

Kc=reliability, 90%

Kd=temperature factor

Kd= 1

Ke= 1

Kf= 0.63

Kg= 1

Ke=duty cycle

Kf=fatigue stress

Kg=various

e = 0.4047 0.8134 0.897 1 1 0.63 1 504MPa e =

93.756Mpa
The smallest safe diameter for shaft 1 is given by

32 1.3
d=

23.82 x 103
3
4476.28
+
6
4 400 10 6
93.7 10

)( (

1
2 3

) ) ] =0.149 m

The smallest safe diameter for shaft2 is d=149mm

9. Calculations of the keys and keyways

Keys are used to secure the pulleys and gears on the shafts. They are used to
transmit the torque from the shafts to the rotating elements. The size of the keys

depends on the shaft diameter and is taken form the British Standard Metric
Keyways for Square and Rectangular Parallel Keys table. They can fail from shear
and from bearing.
Shear stress calculation
Tdesign=P/As
P=T/0.5d=2T/d
As=b*l , Tdesign=2T/dbl
To avoid failure due to shear
Tdesign 0.4Sy/ns
Bearing stress calculation
Failure due to compressive or bearing stress
The compression or bearing area of the keys is
Ac=l*h/2

, design=P/Ac=2T/0.5*dlh=4T/dlh

To avoid failure due to compressive or bearing stress:

design 0.9*Sy/ns

Calculation of the key and the keyway for pulley 2 on shaft 1

Shaft dia= d = 133mm
Torque = T = 7162Nm

Key yield strength y = 350Mpa

Key size (mm)= 60 x 32 x 20
Keyway size (mm)= 60 x 32 x 16 (depth) (4,3 hub)

A. Failure due to shear

Tdesign = (2 x 7162) / ( 0.06 x 0.032 x 0.02) = 373.02Mpa
ns = (0.4 x Sy ) / Tdesign = (0.4 x 350) / 373.02 = 0.37

B. Failure due to bearing

design = P/Ac = (4 x 7162) / ( 0.06 x 0.032 x 0.02) = 746.04Mpa
nS = (0.9 x Sy ) / design = (0.9 x 350) / 746.04 = 0.42

Calculation of the key and the keyway for gear 1 on shaft 1

Shaft dia= d = 133mm
Torque= T = 7162Nm
Key yield strength y = 350Mpa
Key size (mm)= 60 x 32 x 20
Keyway size (mm)= 60 x 32 x 16 (depth) (4,3 hub)

A. Failure due to shear

Tdesign = (2 x 7162) / ( 0.06 x 0.032 x 0.02) = 373.02Mpa
ns = (0.4 x Sy ) / Tdesign = (0.4 x 350) / 373.02 = 0.37

B. Failure due to bearing

design = P/Ac = (4 x 7162) / ( 0.06 x 0.032 x 0.02) = 746.04Mpa
nS = (0.9 x Sy ) / design = (0.9 x 350) / 746.04 = 0.42

Calculation of the key and the keyway for pulley3 on shaft 2

Shaft dia= d = 149mm
Torque= T = 4476.25Nm
Key yield strength y= 350Mpa

Key size (mm)= 65 x 37 x 25

Keyway size (mm)= 65 x 37 x 20 (depth) (3,3 hub)

A. Failure due to shear

Tdesign = (2 x 4476.25) / ( 0.065 x 0.037 x 0.025) = 148.9Mpa
ns = (0.4 x Sy ) / Tdesign = (0.4 x 350) / 148.9 = 0.94

B. Failure due to bearing

design = P/Ac = (4 x 4476.25) / ( 0.065 x 0.037 x 0.025) = 297.8Mpa
nS = (0.9 x Sy ) / design = (0.9 x 350) / 297.8 = 1.06

Calculation of the key and the keyway for gear 2 on shaft 2

Shaft dia= d = 149mm
Torque= T = 4476.25Nm
Key yield strength y= 350Mpa
Key size (mm)= 65 x 37 x 25
Keyway size (mm)= 65 x 37 x 20 (depth) (3,3 hub)

A. Failure due to shear

Tdesign = (2 x 4476.25) / ( 0.065 x 0.037 x 0.025) = 148.9Mpa
ns = (0.4 x Sy ) / Tdesign = (0.4 x 350) / 148.9 = 0.94

B. Failure due to bearing

design = P/Ac = (4 x 4476.25) / ( 0.065 x 0.037 x 0.025) = 297.8Mpa
nS = (0.9 x Sy ) / design = (0.9 x 350) / 297.8 = 1.06

10. Calculations of the critical speed of rotation for shaft 2

The calculations for the critical speed are based on the diameter of the shaft
between points B and C. the maximum deflection is at point C.
shaft diameter d = 149mm
Yangs modulus of elasticity E = 210000 N/mm2
Find the resultant force at point C

F= Ft2+Fr2

44.76 2 +

F=

16.922 = 47.85kN

The second moment of area of the shaft for 149mm diameter is:
4

I=

d 0.149
=
=2.42 105 m4
64
64

Calculation of the maximum deflection at point C

The shaft at boints B and D behaves like a simply supported beam.
The maximum deflection is given by:

( 47.85 10 3 ) 0.13 0.13

F B X ( 2 2 2)
( 0.2620.13 20.132 )=3.45 m
l x b =
3
5
6 l E I
6 0.26 ( 210 10 ) ( 2.42 10 )

Calculation of the critical speed of rotation

The critical speed is given by:

9.81
=1.7 rad /s
3.45

The critical speed in RPM is given by:

N=

60 ( 1.7 ) ( 60 )
=
=16.1 RPM
2
2

The critical speed of rotation for shaft 2 is 16.1 RPM

So the critical rotational speed of shaft 2 is much smaller than the actual.

11.

Attachments