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:
• Shigley’s Mechanical Engineering Design,
Eighth Edition, The McGraw−Hill 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 don’t 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
τ = =
π d o3 (1 − c )
xy 4
J
τxy : 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
σ b = =
I π 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 4α Fa
σ a = =
A π d o2 (1 − c 2 )
Fa
Fa: Axial force (tensile or compressive)
α: Column-action
C l ti factor(=
f t ( 1 1.0
0 for
f tensile
t il lload)
d)
α 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
α = , (λ = L / r ) ≤ 1 1 5
1 − 0 .0 0 4 4 λ
λ 2 s yc
α = , λ > 115
π 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
⎛σx ⎞
τ max = τ allowable = ⎜ ⎟ + τ xy
2

⎝ 2 ⎠

α Fa d o (1 + c ) ⎞⎟
2
16 ⎛ 2

τ allowable = ⎜M + +T2
π d o (1 − c )
3 4
⎜
⎝
8 ⎟
⎠
Lecture1: Design of Shaft 20
 Shaft design based on strength
Maximum normal stress theory (brittle mat.):
2
σx ⎛σx ⎞
σ max = σ allowable = + ⎜ ⎟ + τ xy2
2 ⎝ 2 ⎠

a o ( )
16 ⎡ ⎛ α F d 1 + c 2
⎞
σ allowable = ⎢ ⎜M + ⎟
π d o (1 − c ) ⎢⎜⎝
3 4
8 ⎟
⎠
⎣
⎤
α 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:
σ max = σ allowable = σ x2 + 3τ xy2

α Fa d o (1 + c ) ⎞⎟
2
16 ⎛ 2

σ allowable = ⎜ 2M + + 3×T 2
π d o3 (1 − c 4 ) ⎜ ⎟
ll bl
4
⎝ ⎠

Lecture1: Design of Shaft 22

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

α Fa d o (1 + c ) ⎞⎟
2
16 ⎛ 2

+ ( kt T )
2
τ allowable = ⎜ km M +
π 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 ⎡ ⎛ α F d 1 + c 2
⎞
σ allowable = ⎢⎜ k m M + ⎟
π d o (1 − c ) ⎢⎜⎝
3 4
8 ⎟
⎠
⎣
⎤
α 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
τallowable = 55 MPa for shaft without keyway
τallowable = 40 MPa for shaft with keyway
y y

Steel under definite specifications

τallowable = 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. τallowable =
40 Mpa.
16
d =3
o
40 × π
( 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