17.

Shaft Design Introduction

Objectives
Compute forces acting on shafts from gears, pulleys, and
sprockets.
Find bending moments from gears, pulleys, or sprockets that
are transmitting loads to or from other devices.
Determine torque in shafts from gears, pulleys, sprockets,
clutches, and couplings.
Compare combined stresses to suitable allowable stresses,
including any required stress reduction factors such as stress
concentration factors and factors of safety.
Determine suitability of shaft design and/or necessary size of
shafting.
Shaft must have adequate torsional strength to
transmit torque and not be over stressed.
Shafts are mounted in bearings and transmit power
through devices such as gears, pulleys, cams and
clutches.
Components such as gears are mounted on shafts
using keys.
Shaft must sustain a combination of bending and
torsional loads.

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Standard diameters of shafts Torsion of circular shafts

Diameter (in.) Diameter

increments (in.)
Upto 3 1/16

3 to 5 1/8

5 to 8 1/4

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Torsion of circular shafts

TL
Angle of twist, =
GJ
= the angle of twist (radians)
T = the applied torque (in-
(in-lb.)
L = shaft length (in.)
J = polar moment on inertia of the shaft cross section
(in4)
G = shear modulus of elasticity of the shaft material
(lb/in2)

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1
 Torsional Shear Stresses Shear Stress in a shaft

Torque Torque
16 T
Tc Shear stress, SS =
Torsional shear stress, SS = D3
J Where
T = torque
J = Polar moment of inertia = d
4
16 T
32 D = diameter of the shaft = 3
c = radius of the shaft SS
T = Torque
d = diameter of shaft
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Forces on spur gear teeth Forces on spur gear teeth

Ft = Transmitted force Power, P = Tn or T = 63,000 P
Fn = Normal force or separating 63,000 n
force
Torque, T = Ft r and r = Dp /2
Fr = Resultant force
= pressure angle Combining the above we can write
Fn = Ft tan
2T 2 P 63,000
Ft = =
Ft Dp Dp n
Fr =
cos
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Loads from Bevel gears Loads from Bevel gears

An additional axial force will be acting on the shaft Force transmitted, Fn = Ft tan cos
because of the bevel angle = Pressure angle
For the pinion it is relatively small, and can be = Cone angle
neglected. Axial Force, Fa = Ft tan sin
Resultant Force, Fr = 2
Ft + F2
For the larger gear it will be significant and will be
larger than the radial separating force. F = Fn or Fa depending on whichever is larger

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2
 Loads from Worm gears Loads from Worm gears
To
Driving force on the worm gear, Ft =
Axial rwg
To = Output torque
Driving Ft sin
Separating force, Fs =
cos cos - f sin
where
= lead angle
Separating
= normal pressure angle

f = coefficient of friction

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Loads from Worm gears Loads from Worm gears

Axial force on the worm gear
cos sin + f cos
Fa(gear) = Ft(gear)
cos cos - f sin
where
= lead angle

= normal pressure angle

f = coefficient of friction

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Loads from Belts and Chains Bending of circular shafts

For a belt, Total load, Ft = Ff + Fb
Net driving force, Fd = Ff Fb
Driving torque, T = Fd r
r = effective radius of pulley or sprocket
For a chain Fb = 0
Shafts transmit power through gears and
pulleys
These produce bending load in addition to
torsion
Use strength of material approach to calculate
the reaction forces and bending moments

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3
 Bending of circular shafts Bending of circular shafts

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Shaft Design Problems Example Problem 17-1: Design Stresses in Shafts

Shaft shown drives a gear set that is transmitting 5
Step 1: Calculate the torque on the shaft from power hp at 1750 rpm.
Step 2: Find the torsional stress in the shaft Shaft is supported in self-aligning ball bearings
Step 3: Calculate the loads coming from gears, belts and gears are both 10 pitch, 40 tooth, 20 spur
gears.
or chains
Find torsional and bending stresses in shaft.
Step 4: Calculate the bending moment due to the
acting forces. If necessary combine the forces.
Step 5: Calculate the bending stress in the shaft
Step 6: Combine the bending stress and the torsional
stress using the theories discussed in chapter 4
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Example Problem 17-1: Design Stresses in Shafts (contd.) Example Problem 17-1: Design Stresses in Shafts (contd.)
Find the torsional stress in the shaft.

First find Z':

Find the torsion in the shaft: (Appendix 3)

(2-6) D3
Z' =
Tn 16
hp =
63,000
(.75 in)3
Z' =
then: 16

(17-1) Z' = .083 in3

63,000 hp (3-6)
T = T
n Ss =
Z'
63,000 (5)
T = 180 in-lb
1750 Ss =
.083 in3
T = 180 in-lb
Ss = 2170 lb/in2

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4
Example Problem 17-1: Design Stresses in Shafts (contd.) Example Problem 17-1: Design Stresses in Shafts (contd.)
Find the resultant force on the shaft:
Find the load at the gear pitch circle: (12-2)
Ft
Fr =
(11-4)
cos
NT
Dp =
Pd
90 lb
Fr =
cos 20
40
Dp =
10 Fr = 96 lb

Dp = 4 inches Find the maximum moment:

(12-3) (Appendix 2)
2T FL
Ft = Mm =
DP 4

2 (180 in-lb) 96 lb (15 in)

Ft = Mm =
4 in 4

Ft = 90 lb Mm = 360 in-lb

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Example Problem 17-1: Design Stresses in Shafts (contd.) Combined Stresses in Shafts
Find the stress:

M
As seen in Chap 4
S =
Z

(Appendix 3)
D3
Z =
32

(.75 in)3
Z =
32

Z = .041in3

M
S =
Z

360 in-lb
S =
.041 in3

S = 8780 lb/in2

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Combined maximum shear stress Example Problem 17-2: Combined Stresses in

Shafts
= Maximum combined shear stress From previous example problem, find the combined stress using
the maximum shear stress theorem:
S = normal stress 2 S 2
1/2

SS = shear stress = SS + (4-5)

2 S 2
= Ss2 + 2
This can be rewritten as

Substituting stresses from previous example problem:

D3
(T + M 2 ) 1/2
5.1 2
=



2
= (2170 lb/in2) + 2
8780 2
lb/in2

T = Torque in the shaft = 4900 lb/in 2

M = Maximum moment This should be compared to shear stress allowables.

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5
 Example Problem 17-3: Combined Stresses in
Maximum Normal Stress Theory Shafts
From Example Problem 17-1, find the combined stress using the
= equivalent combined normal stress maximum normal stress theory:

S
2
S = normal stress from bending or axial loads =
S
Ss2 +
1
2
2 2

SS = shear or torsional stress
1/2 Substituting stresses from Example Problem 17-1:
S 2 S
2

= SS +
2 2 8780 in 2
2
8780 lb / in 2 1
= + ( 2170 lb / in 2 ) 2 +

2
2 2
This can be written as
= 9300 lb / in 2
5.1
[
= 3 M + (T 2 + M 2 )1/2
D
] This should be compared to the normal stress allowable.

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Solid Circular shaft Critical speeds of shafts

D =3

(T + M 2 ) 1/2
5.1 2

D= 3
5.1

[
M + (T 2 + M 2 )1/2 ]

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Critical speeds of shafts

Operating speed should be 20% away from the critical speed.
Vibration frequency, f is given by
1 kg
f=
2 W
f = frequency in cycles per second, Hz
k = force constant, force per inch of deflection
g = acceleration due to gravity, 386.4 in./s2
W = weight in pounds, lb

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6
 Change the frequency to rpm Shaft with n concentrated loads
Critical speed, Nc = 60 f
Rayleigh
Rayleighs equation is used.
Also k is weight divided by deflection
W
k=
W1 1 + W2 2 + W3 3 + ... + Wn n
60 Wg N c = 187.7 2 2 2 2
Nc = W1 1 + W2 2 + W3 3 + ... + Wn n
2 W

1
N c = 187.7

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Example Problem 17-5: Critical Speed Example Problem 17-5: Critical Speed (contd.)
Find the estimated critical speed for the shaft in Example Problem 17-1
(assume the entire shaft diameter is inch).
188
First, find deflection: Nc =
FL 3
(Appendix 2)

= 48 EI (17-14)
188
(Appendix 3)
Nc =
I =
D4 .21
64
Nc = 410 rpm
(.75 in)4
I =
64

I = .016 in4

96 lb (15 in)4
= 48 (30 x 106 lb/in2) (.016 in4) This is approximate, and additional multiples would exist at 820,
1230, and 1640 rpm.
= .21 inch

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