Shaft design and its application

‫مصطفى محمود عيال ابراهيم‬ : ‫االسم‬

II ‫تصميم ميكانيكي‬ : ‫المادة‬
‫ هندسة ميكانيك طائرات‬/ ‫ الفرع الثالثة‬/ ‫المرحلة‬
Najmuldeen yousif / Ali Husein /Ali ‫المشرف‬
Yasir / Dr.Imad AbdulHussein
Mohanad Yousif/ Shaimaa Hilal

-: INTRODUCTION

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Shaft is the most vital component used in almost every mechanical
system and machines. Out of all power transmission components shaft is
the main component which must be desinged carefully for efficient
working of machine. The conventional design procedures employed for
shaft design has its own significance. The shaft is designed for various
loading conditions for purpose of applications. Different The shaft has
different types as per the application purpose. discontinuities present in
shaft are prime cause for failure of shaft. Discontinuities results in the
reduction in strength of shaft. Discontinuities are stress raisers which are
responsible for the cause of fracture. The shaft design for combined
loading is most critical problem in practical applications. In most of the
applications shaft must be designed for combined loadings . The whole
load of machine is withstood by shaft. Design of shaft is quite important
.. part in mechanical design
Transmission shafts, or just shafts, are used in virtually every piece of
rotating machine to transmit rotary motion and torque from one location
to another. Thus the machine designer is often faced with the task of
designing shafts [Norton, 1]. A shaft is a rotating member, usually of
circular cross section used to transmit power or motion. It provides the
axis of rotating , or oscillation, of elements such as gears, pulleys,
flywheels, cranks,sproket and the like and controls the geometry of their
motion [Shigley, 2]. The loading on rotating transmission shafts is
principally one of two types: torsion due to transmitted torque or bending
from transverse load at gears, sheaves, and sprockets. These loads often
occur in combination since, for example, thetransmitted torque may be
associated with forces at teeth of gears or sprockets attached to the
shafts. The character of both torque and bending loads may either be
steady (constant) or may vary with time. Steady and time varying torque
. and bending loads can also occur in any combination on the same shaft

? What it mean shaft design

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 . Material selection _
. Geometric Layout _
. Stress and strength: static and fatigue _
Deflection and rigidity: bending defl., torsional twisting, slope at _
bearring and shaft - supported elements, and shear deflection due to
. transverse loading due to transverse loading on short shafts
. Vibration: critical speed _

Shaft materials And Applications :-

The choice of steel for a particular application can sometimes be a
bewildering experience. Within the current British Standard alone for
steels (BS970), there are several hundred steel specifications. In practice,
relatively few steels are used for the majority of applications, and some of
the popular specifications are listed below.
Steels can be divided into seven principal groupings.
1. Low carbon free cutting steels. These are the most popular types of
steel for the production of turned components, where machinability and
surface finish are important. Applications include automotive and general
engineering. The principal specification is 230M07.
2. Low carbon steels or mild steels. These are used for lightly stressed
components, welding, bending, forming, and general engineering
applications. Some of the popular specifications are 040A10, 045M10,
070M20, 080A15, and 080M15.
3. Carbon and carbon manganese case hardening steels. These steels are
suitable for components that require a wear resisting surface and tough
core. Specifications include 045A10, 045M10, 080M15, 210M15, and
214M15.
4. Medium carbon and carbon manganese steels. These offer greater
strength than mild steels and respond to heat treatment. Tensile strengths
in the range of 700e1000 MPa can be attained. Applications include
gears, racks, pinions, shafts, rollers, bolts, and nuts. Specifications
include 080M30, 080M40, 080A42, 080M50, 070M55, and 150M36.
5. Alloy case-hardening steels. These are used when a hard wear resisting
surface is required but, because of the alloying elements, superior
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mechanical properties can be attained in comparison with carbon and
carbon manganese case-hardening steels. Typical applications include
gears, cams, rolled, and transmission components. Types include
635M15,
655M13, 665M17, 805M20, and 832M13.
6. Alloy direct hardening steels. These steels include alloying elements
such as Ni, Cr, Mo, and Vand are used for applications where high
strength and shock resistance are important. Types include 605M36,
708M40, 709M40, 817M40, and 826M40.
7. Stainless steels. There are three types of stainless steels: martensitic,
ferritic, and austenitic.
Martensitic stainless steels can be hardened and tempered to give tensile
strengths in the range from 550 to 1000 MN/m2. Applications include
fasteners, valves, shafts, spindles, cutlery, and surgical instruments.
Specifications include 410S21, 420S29, 420S45, 431S29, 416S21,
416S41, 416S37, and 441S49.
Ferritic stainless steels are common in strip and sheet form, and
applications include domestic and automotive trim, catering equipment,
and exhaust systems. They have good ductility and are easily formed.
Specifications include 403S17 and 430S17. Austenitic stainless steels
offer the highest resistance to corrosion, and applications are affiliated
with the food, chemical, gas, and oil industries, as well as medical
equipment and domestic appliances. Specifications include 302S31,
304S15, 316S11, 316S31, 320S31, 321S31, 303S31, 325S31, 303S42,
and 326S36.

: As gear shaft
As gear shaft manufacturers, AmTech has the production line capabilities
to supply OEM customers with precision machined gear shafts with a
diameter of 50mm to 205mm and a length of 76mm to 915mm. Gear
shafts provide the rotation that allows one gear to engage with and turn
another and contain gear teeth integrated into the shaft.

A gear shaft with the gearing profiles at each end are called intersecting
shaft gears. Spiral Bevel gears are examples of the gear profiles used on
these types of precision made shafts .

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Advantages of gear shaft manufacturing :-

Gear profiles include straight bevel gears, zerol bevel gears and spiral –
.gears
Designed for highly efficient motion controls and power transmitting –
.between intersecting shafts at an angle
Perfect for projects that require a speed / strength work capacity and the –
.ability to change the angle of power flow

Pulley
A pulley is a wheel on an axle or shaft that is designed to support
movement and change of direction of a taut cable or belt, or transfer of
power between the shaft and cable or belt. In the case of a pulley
supported by a frame or shell that does not transfer power to a shaft, but
is used to guide the cable or exert a force, the supporting shell is called a
.block, and the pulley may be called a sheave.[3]

A pulley may have a groove or grooves between flanges around

its circumference to locate the cable or belt. The drive element of a pulley
.system can be a rope, cable, belt, or chain

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-: Types of Shafts

The following two types of shafts are important from the subject point of
: view
Transmission shafts. These shafts transmit power between the source  .1
and the machines absorbing power. The counter shafts, line shafts, over
head shafts and all factory shafts are transmission shafts. Since these
shafts carry machine parts such as pulleys, gears etc., therefore they are
.subjected to bending in addition to twisting
Machine shafts. These shafts form an integral part of the machine  .2
itself. The crank shaft is
an example of machine shaft

-: Shaft design considerations

:Shaft design considerations include

Size and spacing of components (as on a general assembly drawing), .1
,tolerances
,Material selection, material treatments .2
,Deflection and rigidity .3
,a. Bending deflection         
,b. Torsional deflection         
,c. Slope at bearings         
,d. Shear deflection         
,Stress and strength .4

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,a. Static strength         
,b. Fatigue         
,c. Reliability         
, Frequency response .5
, Manufacturing constraints .6

-: Basic Equations
The various equations required to evaluate the stresses and strains in a loaded shaft and to
arrive at safe operating loads are to be found in books or web . The simple equations below
related to the estimating the torque resulting from a transmitted power and the surface shear
stresses resulting from a transmitted torque.

where :
T : shaft torque (Nm) .
𝜔 : angular velocity (Rads/sec) .
n : RPM (revs /min) .

P = Power transmitted (kW) .

where :
σ = Direct stress (N/m²)

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τ = Shear stress (N/m²)
M = Applied bending moment (N.m)
D = Shaft diameter(m)
I = Moment of Inertia (m⁴ - more normally cm⁴)

This is very relevant to ductile metals. It is conservative and relatively

easy to apply. It assumes that failure occurs when a maximum shear
stress attains a certain value. This value being the value of shear strength
at failure in the tensile test. In this instance it is appropriate to choose the
yield point as practical failure. If the yield point = Sy and this is obtained
from a tensile test and thus is the sole principal stress then the maximum
shear stress Ssy is easily identified as Sy /2 .
Ssy = Sy /2
where :
Ssy = Shear yield strength (N/m²)
Sy = Tensile yield strength (N/m²)
Maximum Shear Stress = τ max = Greatest of ( σ1 - σ2 ) / 2 : ( σ2 - σ3 ) /
2 : ( σ1 - σ3 ) / 2 = ( σ1 - σ3 ) / 2
The factor of safety selected would be
FoS = Sy / ( 2 . τ max ) = Sy / ( σ1 - σ3 )

For the simple case of a tensile stress σx combined with a shear

stress τ xy . with the principal stress σ3 = 0. and σy ,σz τxz , τzy = 0. ..
(ref to notes on Mohrs circle) .. Mohr's Circle The two non-zero principal
stresses are :

: where
σ1 ,2, 3 = Principal Stresses(N/m²)
σx ,y, z = Direct stress z ,y and z directions(N/m²)
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τxy = Shear stress in xy plane (N/m²)
The resulting FoS = 

Or in terms of Torque and bending moments.

For a typical application of a shaft subject to direct stress, torque, and a

bending moment the mohrs circle is as follows

Where :
D = Shaft diameter(m) .
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Km = Shock fatigue factor. ( Moments ) .
. Kt = Shock / fatigue factor. (Torques)

-: forces on shafts examples

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-: CONCLUSION
A critical review is carried out on design of shaft, failure analysis, fatigue
and fracture consideration in shaft design. Many researchers have
worked on shaft design subjected to different loadings in various
applications. The conventional and modern design procedures are
adopted by several researchers. Some of them have also given new
concepts in this area But, the work regarding combined loading is less
observed. Also, when shaft is subjected to combined loading of axial,
bending and torsion with multiple discontinuities present in single shaft
than it becomes the complex case to study. The study regarding combined
loading and multiple discontinuities in single shaft is still an open area
for researchers. By using conventional techniques as well as . developed
techniques the new insights can be found out in this area Also, fatigue
and fracture considerations can also be combined and applied on the same
case so , for new researchers this paper is helpful and gives new domain
to carry out research in desing of shaft for combined loading with
. multiple discontinuities in machine design

-: References

Norton, R. L. (2006) “Machine design: an integrated Approach”, ]1[

third edition, Pearson Education, Upper Saddle River, NJ

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Shigley, J. E. and Michke, C. R. (2008) “Mechanical engineering ]2[
,(design”, eighth edition Tata McGraw Hill, New Delhi, India)
Arnold, Dieter (1991). Building in Egypt: Pharaonic Stone Masonry. ]3[
. Oxford University Press. p. 71. ISBN 9780195113747
https://mechasource.blogspot.com/2019/02/introduction-to-shaft-types-
design.html?m=1

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