Shafts

Mott, Chapter 12
Why use shaft?
To transmit power
Shaft geometry
Cylinder, bar, beam (length and diameter)
Load acting on shaft
Torsion (shear stress)
Bending (normal stress)
Shaft Design
 181Introduction

In machinery, the general term shaft refers to a member, usually of

circular crosssection, which supports gears, sprockets, wheels, rotors,
etc., and which is subjected to torsion and to transverse or axial loads
acting singly or in combination.
An axle is a nonrotating member that supports wheels, pulleys, and
carries no torque.
A spindle is a short shaft. Terms such as lineshaft, headshaft, stub
shaft, transmission shaft, countershaft, and flexible shaft are names
associated with special usage.

CH-18 LEC 29 Slide 4

 ConsiderationsforShaftDesign

1. DeflectionandRigidity
(a)Bendingdeflection
(b)Torsionaldeflection
(c)Slopeatbearingsandshaftsupportedelements
(d)Sheardeflectionduetotransverseloadingofshortershafts
2. StressandStrength
(a)StaticStrength
(b)FatigueStrength
(c)Reliability

CH-18 LEC 29 Slide 5

 ConsiderationsforShaftDesign

Thegeometryofashaftisthatofasteppedcylinderbending.
Gears,bearings,andpulleysmustalwaysbeaccuratelypositioned

CommonTorqueTransferElements
Keys
Splines
Setscrews
Pins
Pressorshrinkfits
Taperedfits

CH-18 LEC 29 Slide 6

CommonTypesofShaftKeys.

CH-18 LEC 29 Slide 7

CommonTypesofShaftKeys.

CH-18 LEC 29 Slide 8

CommonTypesofShaftPins.

CH-18 LEC 29 Slide 9

CommonTypesofShaftPins.

CH-18 LEC 29 Slide 10

CommonTypesofRetainingorSnapRings.

CH-18 LEC 29 Slide 11

CommonTypesofSplines.

CH-18 LEC 29 Slide 12

CH-18 LEC 29 Slide 13
CH-18 LEC 29 Slide 14
RigidShaftCoupling.

CH-18 LEC 29 Slide 15

Figure182
(a) Chooseashaftconfigurationto
supportandlocatethetwogears
andtwobearings.
(b)Solutionusesanintegralpinion,
threeshaftshoulders,keyand
keyway,andsleeve.Thehousing
locatesthebearingsontheir
outerringsandreceivesthe
thrustloads.
(c)Choosefanshaft configuration.
(d)Solutionusessleevebearings,a
straightthroughshaft,locating
collars,andsetscrewsforcollars,
fanpulley,andfanitself.Thefan
housingsupportsthesleeve
bearings.
Shaft Design
 Shaft Design
Given required power Given required power
to be transmitted to be transmitted
Calculate torque, Calculate torque,
Calculate forces, Calculate forces,
Calculate stresses (if Determine shaft
geometry is known), diameter (if the
Select material material is known)
 Shaft Design Procedure
1. Develop the free body diagram; model the
various machine elements mounted on the
shaft in terms of forces and torques
2. Develop the shear and moment diagram;
identify bending moment (leads to normal
stress) and torque (leads to shear stress)
3. Identify critical locations for stress analysis;
calculate stresses (known diameter)
4. Determine diameter or select material based
on failure theories
 Forces Acting on Shaft
Forces due to chain and sprocket
T TA TB
Fc
D2 DA 2 DB 2
Fcx Fc cos T
Fcy Fc sin T
 Forces Acting on Shaft
Forces due to V-belt and sheave
FB F1  F2
1.5T
FB |
D2
For flat belt and pulley
2.0T
FB |
D2
 Forces Acting on Shaft
Forces due to gear (spur gear)
63000hp
T
n
T
Wt
D2
Wr Wt tan I
Wx Wt tan\ (helical gear)
 Forces due to Gears

Fuerzas ejercidas sobre el engranaje B por el Fuerzas ejercidas sobre el engranaje A por el
el engranaje A. el engranaje B.
El engranaje A conduce B Fuerzas de reaccion
 Database Product Finder

6.10 Helical Gear Calculations

6.10.1 Normal System Helical Gear

In the normal system, the calculation of a profile shifted helical gear, the working pitch
diameter dw and working pressure angle wt in the axial system is done per Equations (6-10).
That is because meshing of the helical gears in the axial direction is just like spur gears
and the calculation is similar.
z1
d w1 = 2 a x
z1 + z2


z2
d w2 = 2 a x (6-10)
z1 + z2


d b1 + d b2
(
wt = cos 1
2ax
)

Table 6-1 shows the calculation of profile shifted helical gears in the normal system.
If normal coefficients of profile shift x n1 , x n2 are zero, they become standard gears.

Table 6-1 The Calculation of a Profile Shifted Helical Gear in the Normal System (1)
Example
No. Item Symbol Formula
Pinion Gear
1 Normal Module mn 3
2 Normal Pressure Angle n 20
3 Helix Angle 30
4 Number of Teeth & Helical Hand z 1, z 2 12 (L) 60 (R)
tann
5 Radial Pressure Angle t tan1( ) 22.79588
cos
6 Normal Coefficient of Profile Shift x n1 , x n2 0.09809 0
xn1 + xn2
7 Involute Function wt inv wt 2 tann ( ) + invt 0.023405
z1 + z2
8 Radial Working Pressure Angle wt Find from Involute Function Table 23.1126
z1 + z2 cost
9 Center Distance Increment Factor y
2cos coswt
(
1 ) 0.09744
z 1 + z2
10 Center Distance ax (

2cos
+ y mn ) 125.000
zmn
11 Standard Pitch Diameter d 41.569 207.846
cos
12 Base Diameter db d cost 38.322 191.611
db
13 Working Pitch Diameter dw 41.667 208.333
coswt
h a1 (1 + y xn2 ) mn
14 Addendum 3.292 2.998
h a2 (1 + y xn1 ) mn
15 Whole Depth h [2.25 + y (xn1 + xn2)]mn 6.748
16 Outside Diameter da d + 2 ha 48.153 213.842
17 Root Diameter df da 2 h 34.657 200.346

If center distance, ax, is given, the normal coefficient of profile shift xn1 and xn2 can be
calculated from Table 6-2. These are the inverse equations from items 4 to 10 of Table 6-1.

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 Database Product Finder

Gleason Straight Bevel Gear Standard Straight Bevel Gear

Pinion Gear Pinion Gear

Fig. 8-10 The Tooth Profile of Straight Bevel Gears

8.5.2. Standard Straight Bevel Gears

A bevel gear with no profile shifted tooth is a standard straight bevel gear. The
applicable equations are in Table 8-3.

Table 8-3 Calculation of a Standard Straight Bevel Gears

Example
No. Item Symbol Formula
Pinion Gear
1 Shaft Angle 90
2 Module m 3
3 Pressure Angle 20
4 Number of Teeth z 1, z 2 20 40
5 Pitch Diameter d zm 60 120
sin
6 Pitch Cone Angle
1 (
tan1
z
+cos
2 ) 26.56505 63.43495
z1
2
1
d2
7 Cone Distance Re 67.08204
2sin2
8 Face Width b It should be less than Re /3 or 10m 22
9 Addendum ha 1.00 m 3.00
10 Dedendum hf 1.25 m 3.75
11 Dedendum Angle f tan (hf /Re)
1
3.19960
12 Addendum Angle a tan1 (ha /Re) 2.56064
13 Outer Cone Angle a + a 29.12569 65.99559
14 Root Cone Angle f f 23.36545 60.23535
15 Outside Diameter da d + 2h acos 65.3666 122.6833
16 Pitch Apex to Crown X Recos h a sin 58.6584 27.3167
b cos
17 Axial Face Width Xb a 19.2374 8.9587
cosa
di 2b sin
18 Inner Outside Diameter d a a 43.9292 82.4485
cosa

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 Database Product Finder

16.1 Forces In A Spur Gear Mesh b

Fu
The spur gear's transmission force
F n , which is normal to the tooth sur- Fn Fr
face, as in Figure 16-1, can be re-
solved into a tangential component, Fu ,
and a radial component, F r . Refer to
Equation (16-1).
Fig. 16-1 Forces Acting on a
The direction of the forces ac-
Spur Gear Mesh
ting on the gears are shown in
Figure 16-2. The tangential compo-
nent of the drive gear, F u1 , is equal
to the driven gear's tangential com-
Engranaje impulsor
Drive Gear
ponent, F u2 , but the directions are
opposite. Similarly, the same is true
of the radial components.
Fr1 Fr1
F u = F n cos b
Fu2 Fu1 Fu1 Fu2
(16-1)

F r = F n sin b Fr2 Fr2

16.2 Forces In A Helical Gear Mesh

The helical gear's transmission

force, F n, which is normal to the tooth Driven Gear
su rfa ce , ca n b e re so lve d in to a
tangential component, F 1 , and a Fig. 16-2 Directions of Forces Acting
radial component, F r . on a Spur Gear Mesh
F 1 = F n cos n

(16-2)

F r = F n sin n

The tangential component, F 1 ,

can be further resolved into circular
subcomponent, F u , and axial thrust Fa
subcomponent, F a .

F u = F 1 cos

(16-3)
F1 Fu
F a = F 1 sin

Substituting and manipulating

the above equations result in: n Fr

F a = F u tan
F1
(16-4)
tan n
F r = F u Fn
cos
Fig. 16-3 Forces Acting on a
Helical Gear Mesh

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 Database Product Finder

The directions of forces Conductor

acting on a helical gear mesh pinon
Right-Hand Pinion as Drive Gear
are shown in Figure 16-4. I Left-Hand Gear as Driven Gear
The axial thrust sub-compo-
Conducido
n e n t f r o m d r i v e g e a r , F a1 ,
equals the driven gear's, F a2 ,
but their directions are op- Fr1 Giro antihorario Fr1
posite. Again, this case is the Fu2 Fu1
Fa1 Fa2
same as tangential compo-
nents F u1 , F u2 and radial com- Fa2 Fa1
Fu1 Fr2 Fu2
ponents F r1 , F r2 . Fr2

Conductor
pinon
16.3 Forces In A Straight Left-Hand Pinion as Drive Gear
Bevel Gear Mesh
II Right-Hand Gear as Driven Gear
Conducido
The forces acting on a
straight bevel gear are shown Fr1 Fr1
Fu2 Fu1
in Figure 16-5. The force Fa2 Fa1
which is normal to the central
Fa1 Fa2
part of the tooth face, F n , can Fu1 Fu2
be split into tangential com- Fr2 Fr2
ponent, F u, and radial com-
p o n e n t , F 1, i n t h e n o r m a l
plane of the tooth.

F u = F n cos

(16-5) Fig. 16-4 Directions of Forces Acting on a

F 1 = F n sin Helical Gear Mesh

Again, the radial compo-

nent, F 1 , can be divided into
an axial force, F a , and a radial F1
force, F r , perpendicular to the Fu
axis. Fn
F a = F 1 sin

(16-6) Fa

F r = F 1 cos
Fr F1
And the following can be

derived:

F a = F u tan n sin

(16-7)
Fig. 16-5 Forces Acting on a
F r = F u tan n cos
Straight Bevel Gear Mesh

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Let a pair of straight bevel gears with a shaft angle = 90, a pressure angle n = 20
and tangential force, F u , to the central part of tooth face be 100. Axial force, F a , and radial
force, F r, will be as presented in Table 16-2.

Table 16-2 Values of Axial Force, F a , and Radial Force, F r

(1) Pinion
z2
Ratio of Numbers of Teeth
z1
Forces on the Gear Tooth
1.0 1.5 2.0 2.5 3.0 4.0 5.0
Axial Force 25.7 20.2 16.3 13.5 11.5 8.8 7.1

Radial Force 25.7 30.3 32.6 33.8 34.5 35.3 35.7

(2) Gear
z2
Ratio of Numbers of Teeth
z1
Forces on the Gear Tooth
1.0 1.5 2.0 2.5 3.0 4.0 5.0
Axial Force 25.7 30.3 32.6 33.8 34.5 35.3 35.7

Radial Force 25.7 20.2 16.3 13.5 11.5 8.8 7.1

Figure 16-6 contains the directions of forces acting on a straight bevel gear mesh. In
the meshing of a pair of straight bevel gears with shaft angle = 90, all the forces have
relations as per Equations (16-8).

F u1 = F u2


F r1 = F a2 (16-8)


F a1 = F r2

Pinion as Drive Gear

Gear as Driven Gear

Fr1 Fr1
Fu1 Fu2
Fa1 Fa1
Fr2 Fr2
Fa2 Fu2 Fa2 Fu1

Fig. 16-6 Directions of Forces Acting on a

Straight Bevel Gear Mesh
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16.4 Forces In A Spiral

Bevel Gear Mesh
Concave Surface
Spiral gear teeth have
convex and concave sides.
Depending on which surface
the force is acting on, the
direction and magnitude
changes. They differ depen- Convex Surface
Gear Tooth Gear Tooth
ding upon which is the driver
and which is the driven. Right-Hand Spiral Left-Hand Spiral
Figure 16-7 presents the
profile orientations of right- Fig. 16-7 Convex Surface and Concave Surface
and left-hand spiral teeth. If of a Spiral Bevel Gear
the profile of the driving gear
is convex, then the profile
of the driven gear must be concave. Table 16-3 presents the concave/convex relationships.

Table 16-3 Concave and Convex Sides of a Spiral Bevel Gear Mesh
Right-Hand Gear as Drive Gear
Rotational Direction Meshing Tooth Face
of Drive Gear Right-Hand Drive Gear Left-Hand Driven Gear
Sentido horario Clockwise Convex Concave
Sentido antihorario Counterclockwise Concave Convex

Left-Hand Gear as Drive Gear

Rotational Direction Meshing Tooth Face
of Drive Gear Left-Hand Drive Gear Right-Hand Driven Gear
Sentido horario Clockwise Concave Convex
Sentido antihorario
Counterclockwise Convex Concave
NOTE: The rotational direction of a bevel gear is defined as the direction one
sees viewed along the axis from the back cone to the apex.

16.4.1 Tooth Forces on a

Fs m
Convex Side Profile Ft

The transmission force, Fn, can be Fu n

resolved into components F1 and Ft as: F1
F1 Fn
F 1 = F n cos n Fa

(16-9)
Fs Ft
F t = F n sin n
Fr
Then F 1 can be resolved into
components F u and F s :

F u = F 1 cos m

(16-10)

F s = F 1 sin m
Fig. 16-8 When Meshing on the
Convex Side of Tooth Face

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On the axial surface, F t and F s can be resolved into axial and radial subcomponents.

F a = F t sin F s cos

(16-11)

F r = F t cos + F s sin

By substitution and manipulation, we obtain:

Fu
F a = (tan n sin sin mcos )
cos m
(16-12)
Fu
F r = (tan n cos + sin m sin )
cos m

16.4.2 Tooth Forces on a F1

Concave Side Profile F1
Fu Fn
m
On the surface which is normal n
to the tooth profile at the central Fs
portion of the tooth, the transmission
force, F n , can be split into F 1 and F t Ft
as:

F 1 = F n cos n Fs

(16-13)
Fa
F t = F n sin n
Fr Ft
And F 1 can be separated into
components Fu and Fs on the pitch surface:

F u = F 1 cos m

(16-14)

F s = F 1 sin m Fig. 16-9 When Meshing on the
Concave Side of Tooth Face
So far, the equations are identical to the convex case. However, differences exist in
the signs for equation terms. On the axial surface, F t and F s can be resolved into axial
and radial subcomponents. Note the sign differences.

F a = F t sin + F s cos

(16-15)

F r = F t cos F s sin

The above can be manipulated to yield:

Fu
F a = (tan n sin + sin m cos )
cos m
(16-16)
Fu
F r = (tan n cos sin m sin )
cos m

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 Database Product Finder

Let a pair of spiral bevel gears have a shaft angle =90, a pressure angle n = 20, and a
spiral angle m = 35. If the tangential force, F u, to the central portion of the tooth face is 100,
the axial thrust force, F a, and radial force, Fr, have the relationship shown in Table 16-4.

Table 16-4 Values of Axial Thrust Force (F a) and Radial Force (Fr)
(1) Pinion
z
Meshing Tooth Ratio of Number of Teeth 2
z1
Face
1.0 1.5 2.0 2.5 3.0 4.0 5.0
Concave Side 80.9 82.9 82.5 81.5 80.5 78.7 77.4

of Tooth 18.1 1.9 8.4 15.2 20.0 26.1 29.8

Convex Side 18.1 33.6 42.8 48.5 52.4 57.2 59.9

of Tooth 80.9 75.8 71.1 67.3 64.3 60.1 57.3

(2) Gear
z
Meshing Tooth Ratio of Number of Teeth 2
z1
Face
1.0 1.5 2.0 2.5 3.0 4.0 5.0
Concave Side 80.9 75.8 71.1 67.3 64.3 60.1 57.3

of Tooth 18.1 33.6 42.8 48.5 52.4 57.2 59.9

Convex Side 18.1 1.9 8.4 15.2 20.0 26.1 29.8

of Tooth 80.9 82.9 82.5 81.5 80.5 78.7 77.4

The value of axial force, Fa, of a spiral bevel gear, from Table 16-4, could become negative.
At that point, there are forces tending to push the two gears together. If there is any axial play
in the bearing, it may lead to the undesirable condition of the mesh having no backlash.
Therefore, it is important to pay particular attention to axial plays. From Table 16-4(2), we
understand that axial thrust force, Fa, changes from positive to negative in the range of teeth
ratio from 1.5 to 2.0 when a gear carries force on the convex side. The precise turning point of
axial thrust force, Fa, is at the teeth ratio z1 / z 2 = 1.57357.

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 Database Product Finder

Figure 16-10 describes the forces for a pair of spiral bevel gears with shaft angle = 90,
pressure angle n = 20, spiral angle m = 35 and the teeth ratio, u, ranging from 1 to 1.57357.

= 90, n = 20, m = 35, u < 1.57357.

Left-Hand Pinion as Drive Gear
I Right-Hand Gear as Driven Gear
Driver
Fr1
Fu1
Fu2
Fa2 Fa1
Fr2

Fa1
Fr2 Fr1 Fu1
Fu2
Fa2

Right-Hand Pinion as Drive Gear

II Left-Hand Gear as Driven Gear

Driver
Fr1

Fu1 Fu2 Fa2 Fa1

Fr2

Fa1 Fr2
Fr1
Fu2 Fu1
Fa2

Fig. 16-10 The Direction of Forces Carried by Spiral Bevel Gears (1)

Figure 16-11, shown on the following page, expresses the forces of another pair of spiral
bevel gears taken with the teeth ratio equal to or larger than 1.57357.

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 Database Product Finder

= 90, n = 20, m = 35, u 1.57357

Left-Hand Pinion as Drive Gear
I Right-Hand Gear as Driven Gear
Driver

Fa1 Fu2 Fr1

Fu1 Fr1
Fr2

Fa2 Fa1
Fr2 Fu2 Fa2
Fu1

Right-Hand Pinion as Drive Gear

II Left-Hand Gear as Driven Gear

Driver
Fr1
Fu1 Fu2
Fr1 Fa1
Fr2
Fa1 Fa2
Fr2
Fu2 Fu1
Fa2

Fig. 16-11 The Direction of Forces Carried by Spiral Bevel Gears (2)

n
F1
16.5 Forces In A Worm Gear Mesh Fn

16.5.1 Worm as the Driver Fr1

For the case of a worm as the driver, Figure 16-12,

the transmission force, Fn, which is normal to the tooth
surface at the pitch circle can be resolved into components
F1
F 1 and F r1. Fu1
Fn
F 1 = F n cos n Fa1

(16-17)

F r1 = F n sin n

Fig. 16-12 Forces Acting on the

Tooth Surface of a Worm
T-146
 Example
A chain is transmitting 100 kW with the
chain speed at 6000 rpm and V = 50 m/s.
The shaft material is AISI 1040 cold
drawn. Determine the shaft diameter
required.
 Shaft Design Considerations
Stress Concentration (fillet or key seat)
1.5 < Kt < 2.5
Combined tangential and radial load (3-D)
Two shear and moment diagrams
z
Wt

M xy  M yz
2 2
My
Wr y

x
 Stress Concentration
Keyseats
Kt = 2.0 for profile keyseat
Kt = 1.6 for sled keyseat
Shoulder fillets
Kt = 2.5 for sharp fillet
Kt = 1.5 for well-rounded fillet
Retaining ring grooves
Kt = Kt = 3.0, or
Increase diameter by 6%
Forces Acting on A Shaft
 Shear and Moment Diagrams
From bottom look up Front view
 ANSI / ASME Shaft Equation
Mc 32M
a
I Sd 3
Tc 16T
Wm
J Sd 3
2 2
32M 16T
2 Kt N 3 3 N
K t a N 3 m N
2

 Sd 3  Sd
1 1

Sn ' S y Sn ' Sy

1
2 3
3 T
2
32 N Kt M
d 
S S
Sn ' 4 y
 Example 12-1 (p. 548)
The system transmitting 200 hp from
pinion P to gear A, and from pinion C to
gear Q.
The shaft rotating speed is 600 rpm.
Shaft material is AISI 1144 OQT 1000
 Example (p. 549)
Free body diagram
Shear and moment diagrams
Torque at each segment
Calculate diameter for locations A, B, C, and D
(at both left and right)

No moment No torque, no moment,

Torque = 21000 No torque vertical shear only

A B C D
 Shear and Moment Diagrams
From bottom look up Front view
Design Examples
Design Example - Torque
Design Example - Forces
Design Examples Shear and Moment