ME 343: Mechanical Design-3

Design of Shaft

Aly Mousaad Aly, PhD

Assistant Professor, Dept. of Mech. Eng.
Faculty of Engineering, Alexandria University
 Outline
Practical information
Shaft design

Lecture1: Design of Shaft 2

 Instructor
Lecturer: Dr. Aly Mousaad Aly
Office: Last floor, Dept. of Mech. Eng.,
Faculty of Eng., Alexandria University
Office hours:
Thursday 8:30 to 9:35
Thursday,
Thursday, 11:00 to 12:05

Lecture 1: Introduction 3
 Course Materials
Slides: Available online.
Available at the department copy center.
Course website:
www.engr.uconn.edu/~aly/ME343
References:
Shigleys Mechanical Engineering Design,
Eighth Edition, The McGrawHill Companies,
Inc., 2006.
Lecture 1: Introduction 4
 Grading
Class participation
Assignments
Reports
Midterm exam
Final examination

Lecture 1: Introduction 5
 Policy
Attendance
d to llectures and
d exercises
i iis
compulsory.
We may check the attendance at the
g
beginning g of lessons.
Everybody should attend his scheduled classes
according to his name and student number.
number
We will be VERY STRICT about this rule.
Come
C t lessons
to l about
b t 5 mini bbefore
f th
the
starting time.
Lecture1: Design of Shaft 6
 Outline
Practical information
Shaft design

Lecture1: Design of Shaft 7

 Definition of shaft?
It is
i a rotating
i member,b iin general,l h
has a
circular cross-section and is used to transmit
power.
The shaft mayy be solid or hollow. It is
supported on bearings and it rotates a set of
ggears or pulleys
p y for the purpose
p p of p
power
transmission.
The shaft is generally acted upon by bending
moments, torsion and axial forces.

Lecture1: Design of Shaft 8

 Shaft versus axle and spindle
Axle is a non-rotating member used for
pp
supporting g rotatingg wheels, etc., and do not
transmit any torque. Spindle is simply defined as
a short shaft
shaft. However
However, design method remains
the same for axle and spindle as that for a shaft.

Lecture1: Design of Shaft 9

 What does it mean shaft
shaft design?
design ?
Material selection
Geometric layout
Stress and strength: static and fatigue
Deflection and rigidity: bending defl., torsional
g, slope
twisting, p at bearingsg and shaft-
supported elements, and shear deflection
due to transverse loading on short shafts.
shafts
Vibration: critical speed
Lecture1: Design of Shaft 10
 Material selection
M
Many shafts
h ft are made d ffrom low
l carbon,
b cold-
ld
drawn or hot-rolled steel.
Alloy steel:
steel Nickel,
Nickel chromium and vanadium are
some of the common alloying materials.
However alloy steel is expensive.
However, expensive
Shafts usually dont need to be surface hardened
unless they serve as the actual journal of a
bearing surface.
Hardening g off surface
f ((wear resistant):
) case
hardening and carburizing ; cyaniding and
nitriding.
Lecture1: Design of Shaft 11
 Geometric layout

Lecture1: Design of Shaft 12

 Geometric layout

The geometry of shaft is generally that of stepped

cylinder.
li d
There is no magic formula to give the shaft geometry
f any given
for i d
design
i situation.
it ti
Lecture1: Design of Shaft 13
 Geometric layout
The
h b best approach h iis to llearn ffrom similar
i il
problems that have been solved and combining
th b
the bestt tto solve
l your own problem. bl
A general layout to accommodate shaft elements,
e.g. gears, bearings, and pulleys, must be
specified early in the design process.
Shoulders are used for axially locating shaft
elements and to carry any thrust loads.
Common Torque Transfer Elements: keys, set
screws, ppins, ppress or shrink fits, tapered
p fits.
Lecture1: Design of Shaft 14
 Geometric layout
Small pinions are often machined onto shafts.
Sequence of assembly should be thought.
Use chamfers to ease assembly and avoid
i
interferences.
f
Consider stress risers due to ggrooves and
sharp steps in shafts.
What
Wh t can ffailil and
dhhow will
ill it h
happen??

Lecture1: Design of Shaft 15

 Shaft design based on strength
Design
i iis carried
i d out so that
h stress at any llocation
i off
the shaft should not exceed material yielding.
Stress due to torsion:
T r 1 6T
= =
d o3 (1 c )
xy 4
J
xy : Shear stress due to torsion
T : Torque on the shaft
7024 hp 9549 kW
T
Note: N (RPM ) N (RPM )

Lecture1: Design of Shaft 16

 Shaft design based on strength
Bending stress:
M y 32M
b = =
I d o3 (1 c )

M : Bending moment at the point of interest

do : Outer diameter of the shaft
c: di/do

Lecture1: Design of Shaft 17

 Shaft design based on strength
Axial
i l stress: Fa
Fa 4 Fa
a = =
A d o2 (1 c 2 )
Fa
Fa: Axial force (tensile or compressive)
: Column-action
C l ti factor(=
f t ( 1 1.0
0 for
f tensile
t il lload)
d)
arises due to the phenomenon of buckling of
l
long slender
l d members b whichhi h are acted
d upon b
by
axial compressive loads.

Lecture1: Design of Shaft 18

 Shaft design based on strength
A i l stress
Axial t ((continue):
ti )
1
= , ( = L / r ) 1 1 5
1 0 .0 0 4 4
2 s yc
= , > 115
nE
2

n = 1.0 for hinged end; n = 2.25 for fixed end

n = 1.6 for ends p partlyy restrained,, as in bearingg ,
L = shaft length
syc = yyield stress in compression
p
Lecture1: Design of Shaft 19
 Shaft design based on strength
Maximum shear stress theory (ductile mat.):
Failure occurs when the maximum shear stress
at a point exceeds the maximum allowable
shear stress for the material.
material Therefore,
Therefore
2
x
max = allowable = + xy
2

Fa d o (1 + c )
2
16 2

allowable = M + +T2
d o (1 c )
3 4


8

Lecture1: Design of Shaft 20
 Shaft design based on strength
Maximum normal stress theory (brittle mat.):
2
x x
max = allowable = + + xy2
2 2

a o ( )
16 F d 1 + c 2

allowable = M +
d o (1 c )
3 4
8



Fa d o (1 + c )
2
2

+ M + +T2
8

Lecture1: Design of Shaft 21
 Shaft design based on strength
Von Mises/ Distortion-Energy theory:
max = allowable = x2 + 3 xy2

Fa d o (1 + c )
2
16 2

allowable = 2M + + 3T 2
d o3 (1 c 4 )
ll bl
4

Lecture1: Design of Shaft 22

 Shaft design based on strength
ASME design code (ductile material):

Fa d o (1 + c )
2
16 2

+ ( kt T )
2
allowable = km M +
d o3 (1 c 4 )

8

where, km and kt are bending and torsion factors
where
accounts for shock and fatigue. The values of
th
these ffactors
t are given
i iin ASME d
design
i coded ffor
shaft.
Lecture1: Design of Shaft 23
 Shaft design based on strength
ASME design code (brittle material):

a o ( )
16 F d 1 + c 2

allowable = k m M +
d o (1 c )
3 4
8



Fa d o (1 + c )
2
2
2
+ km M + + ( kt T )
8

Lecture1: Design of Shaft 24

 Shaft design based on strength
ASME design code:
Combined shock and fatigue factors
Stationary shaft Rotating shaft
Type of load
km kt km kt

Gradualyy applied
pp load 1 1 1.5 1
Suddenly applied load, minor shock 1.5-2 1.5-2 1.5-2 1-1.5
Suddenly applied load
load, heavy shock --- --- 23
2-3 153
1.5-3

Lecture1: Design of Shaft 25

 Shaft design based on strength
ASME design
d i code: d
Commercial steel shafting
allowable = 55 MPa for shaft without keyway
allowable = 40 MPa for shaft with keyway
y y

Steel under definite specifications

allowable = 30% of the yield strength but not over
18% of the ultimate strength in tension for shafts
without keyways. These values are to be reduced by
25% for the presence of keyways.

Lecture1: Design of Shaft 26

 Standard sizes of shafts
Typical sizes of solid shaft that are available in
the market are:
diameter increments
up to 25 mm 0.5 mm
25 to
t 50 mm 1 0 mm
1.0
50 to 100 mm 2.0 mm
100 to 200 mm 5.0 mm

Lecture1: Design of Shaft 27

 Example: problem
A pulley
ll d drive
i iis ttransmitting
itti power tto a pinion,
i i
which in turn is transmitting power to some other
machine element.
element Pulley and pinion diameters are
400 mm and 200 mm respectively. Shaft has to be
designed
g for minor to heavyy shock.

A C D B

.
m m m
Lecture1: Design of Shaft 28
 Example: solution
Torsion:
TD = 6000 x (Dpinion/2)
= 6000 x (200/2)
= 6x10e5 N.mm
OR
TC = (4000 -1000) x (Dpulley/2)
= 3000 x (400/2) = 6x10e5 N.mm

Lecture1: Design of Shaft 29

 Example: solution
B di ((vertical
Bending ti l plane):
l )
A B
200 mm C 400 mm D 200 mm
RAV RBV
1000 N
6000 N

RBV= (1000x200- 6000x(400+200))/(200+400+200) = -4250 N

MDV= -4250x200
4250x200 = -8
8.5e5
5e5 N.mm
N mm
MCV= 6000x400 - 4250x600 = -1.5e5 N.mm

Lecture1: Design of Shaft 30

 Example: solution
B di (h
Bending (horizontal
i t l plane):
l )
A B
200 mm C 400 mm D 200 mm
RAH RBH
2200 N
5000 N

RBH = (5000x200 + 2200x(400+200))/(200+400+200)

= 2900 N
MDH = 2900x200
2900 200 = 5.8e5
5 8 5 N.mm
N
MCH = 2900x600 - 2200x400 = 8.6e5 N.mm

Lecture1: Design of Shaft 31

 Example: solution
Bending
di ((resultant):
l )
( M DV ) + ( M DH )
2 2
MD =
= 10.29 105 N .mm
Similarly
Similarly,
MC = (1.5 10 ) + (8.6 10 )
5 2 5 2

= 8.73 105 N .mm

Since TC = TD and MD > MC, section-D is critical.

Lecture1: Design of Shaft 32

 Example: solution
ASME
S code:
d
Under minor to heavy shock, let us consider
km= 2 and kt = 1.5. Also let us assume the shaft will
be fabricated from commercial steel, i.e. allowable =
40 Mpa.
16
d =3
o
40
( 2 10.29 10 ) + (1.5 6 10 )
5 2 5 2

d o = 65.88
65 88 mm
The value of standard shaft diameter is 66 mm.
Lecture1: Design of Shaft 33