ME 343: Mechanical Design-3

Design of Shaft (continue)

Dr. Aly Mousaad Aly

Department of Mechanical Engineering
Faculty of Engineering, Alexandria University
 Objectives
At the end of this lesson, we should be able to
Understand design method for variable load
Define equivalent stresses on shaft
Design shaft based on stiffness and
g y
torsional rigidity
Understand critical speed of shafts

Lecture 2: Design of Shaft 2

 Shaft design based on fatigue
Any rotating shaft loaded by stationary
bendingg and torsional moments will be
stressed by completely reversed bending stress
while the torsional stress will remain steady
(i.e., Ma = M; Mm = 0; Ta = 0; Tm = T).
A design method
h ffor variable
bl lload (f
(fatigue),
)
like Soderberg, Goodman or Gerber criteria
can be followed.

Lecture 2: Design of Shaft 3

 Shaft design based on fatigue

Design under variable normal load (fatigue)

Lecture 2: Design of Shaft 4
 Shaft design based on fatigue
A is the design point for which the stress
p
amplitude is a and the mean stress is m. In
the Soderberg criterion the mean stress
material property is the yield point Sy,
whereas in the the Goodman and Gerber
criteria the material property is the ultimate
strength Sut. For the fatigue loading, material
property is the endurance limit Se in reverse
bending.
Lecture 2: Design of Shaft 5
 Shaft design based on fatigue
SSoderberg
d b criterion
it i mod-Goodman
dG d criterion
it i
FS a FS m FS a FS m
+ =1 + =1
Se Sy Se Sut
Gerber criterion 2
FS a FS m
+ =1
Se Sut
where
a = stress amplitude (alternating stress); Se =
endurance limit (fatigue limit for completely reversed
loading); m = mean stress; Sy = yield strength; ut =
g and FS= factor of safety.
ultimate tensile strength y
Lecture 2: Design of Shaft 6
 Shaft design based on fatigue

Design under variable shear load (fatigue)

Lecture 2: Design of Shaft 7
 Shaft design based on fatigue
It is most common to use the Soderberg
criterion.
FS K f a FS m
+ =1 Kf = fatigue stress
Se Sy
Sy K f a Sy concentration factor
+m =
Se FS
Sy K f a S ys K fs a
+ m = eq + m = eq
Se Ses
Normal Stress Equation Shear Stress Equation
Lecture 2: Design of Shaft 8
 Shaft design based on fatigue
Sy K f a S ys K fs a
+ m = eq + m = eq
Se Ses

eq and eq are equivalent to allowable stresses

(Sy/FS) andd (Sys/FS),
/FS) respectively.
i l
Effect of variable stress has been effectivelyy
defined as an equivalent static stress.
Conventional
C ti l ffailure
il th
theories
i can bbe used
d tto
complete the design.
Lecture 2: Design of Shaft 9
 Shaft design based on fatigue
Max. shear stress theory + Soderberg line
((Westinghouse
g Code Formula))
2
eq
max = allowable = + 2
eq
2
2 2
Sy Sy K f a S y K fs a
= +m + +m
2 FS Se Se
2 2
332 FS K f M a M m K fs Ta Tm
d = + + +
S S S S
e y e y
Lecture 2: Design of Shaft 10
 Shaft design based on rigidity
Deflection is often the more demanding
constraint. Manyy shafts are well within
specification for stress but would exhibit too
much deflection to be appropriate
appropriate.
Deflection analysis at even a single point of
interest requires complete
l geometry
information for the entire shaft.

Lecture 2: Design of Shaft 11

 Shaft design based on rigidity
It is desirable to design the dimensions at
critical locations to handle the stresses, and fill
in reasonable estimates for all other
dimensions before performing a deflection
dimensions,
analysis.
Deflection
fl off the
h shaft,
h f b both
h llinear and
angular, should be checked at gears and
bearings.

Lecture 2: Design of Shaft 12

 Shaft design based on rigidity
Sl
Slopes, llateral
t ld deflection
fl ti off th
the shaft,
h ft and/or
d/ anglel off ttwist
it
of the shaft should be within some prescribed limits.

Crowned
tooth

Diametral pitch, P = number of teeth/pitch diameter. 1 in = 25.4 mm.

Lecture 2: Design of Shaft 13
 Shaft design based on rigidity
In case off sleeve
l b
bearings,
i shaft
h f ddeflection
fl i across
the bearing length should be less than the oil-film
thi k
thickness.
T ( N .mm ) L ( mm )
( radd ) =
Twist angle: G ( N / mm 2 ) J ( mm 4 )

G: shear modulus; J: polar moment of inertia

The limiting value of varies from 0.3
0 3 deg/m to 3
deg/m for machine tool shaft to line shaft
respectively.
respectively
Lecture 2: Design of Shaft 14
 Shaft design based on rigidity
L t l deflection:
Lateral d fl ti

Double integration
Moment-area
Energy (Castigliano Theorem)
= f (applied load, material property, moment of
inertia and given dimension of the beam).
From the expression of moment of inertia, and
k
known design
d parameters, including
l d , shaft
h f
dimension may be obtained.

Lecture 2: Design of Shaft 15

 Double Integration Method
d2y M dy M ( x)
= ( x) = = dx
dx 2
EI dx EI ( x)

M (x) 2
y(x) = EI (x)
dx

Use boundary conditions to obtain integration

constants

Lecture 2: Design of Shaft 16

 Conjugate beam method
Was developed by Otto Mohr in 1860
Slope (real beam) = Shear (conj. beam)
Deflection (real beam) = Moment (conj. beam)
Length of conj. beam = Length of real beam
The load on the conjugate beam is the M/EI
diagram of the loads on the actual beam

Lecture 2: Design of Shaft 17

 Conjugate beam method
R lb
Real beam

Conjugate beam

Real beam

Conjugate beam

Lecture 2: Design of Shaft 18

 Example 1
Determine the slope
and deflection at the
tip of a cantilever using
the conj
conj. beam
method.
Sol:l 2
PL
B =
2 EI
2EI
PL3
yB =
3EI
Lecture 2: Design of Shaft 19
 Example 2
Compute theh maximum
i d
deflection
fl i and d the
h
slopes at the bearings. EI is constant.

(a) (b)

Lecture 2: Design of Shaft 20

 Critical speed of rotating shaft
Critical speed of a rotating shaft is the speed
y
where it becomes dynamically y unstable.
The frequency of free vibration of a non-
rotating shaft is same as its critical speed
speed.

N critical ( RPM ) =
60
g
( w11 + w2 2 + .... + wn n )
2 ( 11 22
w 2
+ w 2
+ .... + wn n )
2

Lecture 2: Design of Shaft 21

 Critical speed of rotating shaft
W1, W2. : weights of the rotating bodies (N)
1, 2 . : deflections of the respective bodies
(m)
For
F a simply
i l supported d shaft,
h f hhalf
lf off iits weight
i h
may be lumped at the center for better
accuracy.
For a cantilever shaft,
shaft quarter of its weight
may be lumped at the free end.

Lecture 2: Design of Shaft 22

 Shaft design: general considerations
Axial
i l thrust
h lloads
d should
h ld bbe taken
k to groundd
through a single thrust bearing per load
direction.
Do not split
p axial loads between thrust
bearings as thermal expansion of the shaft can
overload the bearings.g
Shaft length should be kept as short as
possible to minimize both deflections and
possible,
stresses.

Lecture 2: Design of Shaft 23

 Shaft design: general considerations
A cantilever beam will have a larger deflection
p y supported
than a simply pp ((straddle mounted))
one for the same length, load, and cross
section.
section
Hollow shafts have better stiffness/mass ratio
and higher
h h naturall ffrequencies than
h solid
l
shafts, but will be more expensive and larger
in diameter.

Lecture 2: Design of Shaft 24

 Shaft design: general considerations
Slopes, lateral deflection of the shaft, and/or
g of twist of the shaft should be within
angle
some prescribed limits.
First natural frequency of the shaft should be
at least three times the highest forcing
f
frequency. ((A ffactor off ten times or more is
preferred, but this is often difficult to achieve).

Lecture 2: Design of Shaft 25

 Example 3
Determine the diameter of a shaft of length L
y g a load of 5 kN at the center if the
=1m, carrying
maximum allowable shaft deflection is 1mm.
What is the value of the slope at the bearings
bearings.
Calculate the critical speed of this shaft if a disc
weighting 45 kg is placed at the center
center. E=209
E 209
GPa. st = 8740 kg/m^3.

Lecture 2: Design of Shaft 26

 Example 3: solution
Maximum deflection:
PL3
y=
48 EI
5000 (1000 )
3

1=

48 ( 209 10 ) 3
d4
64
d = 56.45 mm
From a standard shaft size, d = 58 mm

Lecture 2: Design of Shaft 27

 Example 3: solution
Slope at bearings:
5000 (1000 )
2 2
PL
1 = 2 = =
16 EI 16 209 103 58 4
( ) 64 ( )
= 0.0027 rad

which is much for tapered and cylindrical

roller bearings. However, this value may be
acceptable for deep-groove ball bearing.
Lecture 2: Design of Shaft 28
 Example 3: solution
Critical
C iti l speed:
d
Shaft weight = rho x A x L = 7840 x A x 1 = 20.7 kg

( 0.5 20.7 + 45 ) 9.807 (1000 )

3
PL3
= = = 0.097 mm

48 EI 48 ( 209 103 ) ( 58 )
4

64
60 9.807
N critical = = 3030 RPM
2 0.097 10 3

The operating speed of the shaft should be well

below this value ((sayy less than 1000 rpm).
p )
Lecture 2: Design of Shaft 29
 Example 4
FFor th
the same problem
bl solved
l d iin th
the previous
i llesson,
determine the following:
1 Lateral deflection at D (using Conj
1. Conj. Beam method)
2. Slope at bearings A and B (using Conj. Beam method)
3. Critical speed

A C D B

.
m m m
Lecture 2: Design of Shaft
d sh = 66 mm 30
 Shaft design: summary
Shaft design means material selection,
ggeometric layout,
y stress and strength
g (static
(
and fatigue), deflection and slope at bearings.
Conjugate beam method for slope and
deflection calculations.
Some design considerations: (axial load, shaft
length, support layout, hollow shafts, slopes
and deflection, operating speed)

Lecture 2: Design of Shaft 31

 Report
Write
W it a short
h t reportt on material
t i l selection
l ti forf
shaft manufacturing. Talk briefly about heat
treatment processes that may be considered.
considered
Deadline: Thursday, April 7, 2011
How to submit:
Send attachment to mosaadaly2000@yahoo.com
Pl
Please give
i a title
titl to
t th
the emailil as your student
t d t
number followed by your name, e.g.
999 Name Surname
Print out: not recommended

Lecture 2: Design of Shaft 32

 Slides and sheets

Available for download at:

http://www engr uconn edu/~aly/Courses/ME343/
http://www.engr.uconn.edu/ aly/Courses/ME343/

Lecture 2: Design of Shaft 33