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    Fatigue analysis of shaft of marine gearboxes

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    AGMA 94FTM1

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    Fatigue analysis of shaft of marine gearboxes

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    49 views16 pages

    Agma 94FTM1

    Uploaded by

    smhos
    Fatigue analysis of shaft of marine gearboxes

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 16
    STD-AGMA S4FTML-ENGL 1994 MM Ob87575 OOO4SOS 31] mM 94FTM1 Fatigue Analysis of Shafts for Marine Gearboxes by: E. William Jones and Anying Shen, Mississippi State University and Robert E. Brown, Caterpillar, Inc. American Gear Manufacturers Association TECHNICAL PAPER STD-AGMA S4FTML-ENGL 1994 MM Ob47575 OOONSOL 256 mm Fatigue Analysis of Shafts for Marine Gearboxes E. William Jones and Anying Shen, Mississippi State University and Robert E. Brown, Caterpillar, Ine. [The statements and opinions contained herein are those of the author and should not be construed as an official action or ‘opinion of the American Gear Manufacturers Association} Abstract ‘The design of shafts for marine gearboxes, which may include the effects of torsional vibration, is presented. The influence of the vibratory torque on the values of shaft diameter and safety factor is discussed. Use ofthe Finite Element ‘Method to evaluate unknown stress concentration factors is illustrated. A program for the design of shafts, which are subjected to fatigue, has been developed. Copyright © 1994 ‘American Gear Manufacturers Association 1500 King Street, Suite 201 ‘Alexandria, Virginia, 22314 October, 1994 ISBN: 1-55589-635-9 Copyrighl by Ube American Ceor Manufolurers Association fi Dec 29 17:30:59 2006 STD-AGMA S4FTML-ENGL L994 Ml Ob87575 OO04SO7 194 mm FATIGUE ANALYSIS OF SHAFTS FOR MARINE GEARBOXES B, William Jones, Ph.D., P.-E. Anying Shen, Graduate Student Department of Mechanical Engineering Mississippi state University, Mississippi state, Hs 39762 Robert B. Brown, Project Engineer--Gear Design caterpillar, Inc. NOMENCLATURE | notch sensitivity factor for torque Wy alternating reversed-bending monent, Gy notch sensitivity factor for tension ib in shaft fatigue Limit modification Mp mean bending moment, 1b in ky shaft ourface finish factor 7, alternating shaft torque, 1b in ky shaft size factor Th mean shaft torque, 1b in We shaft reliability factor P, alternating axial force, 1b kg shaft temperature factor Ph ean axial force, 1b ke shaft life factor vi Giternating shear force, 1b ke shaft miscellaneous factor vi, mean shear force, 1b Sf shaft fatigue (endurance) Limit of of alternating normal stress, pei Polished, unnotched test specimen in Om mean normal stress, psi Feverse bending, pai te alternating shear stress, psi s, shaft ultimate tensile strength, pet t™ mean shear stress, pai Sf shaft fatigue limit, psi 2” von Mises equivalent egress, psi Sy shaft tensile yield strength, psi X Gross section area, in Fy shaft factor of safety for fatigue Peer Regu ote ere oetcrteeasc a a polar moment of inertia of shaft, in‘ yielding © fadiue of the shaft, in #, shaft rotation frequency Gy, shaft outside dianeter, in | vibration frequency @y shaft inside dianeter, in #” phase angle Kp fatigue strees concentration factor in bending NmRODUCTION Ky fatigue stress concentration factor The traditional method for designing foie ABS formuiall artough te is eaey touse, iq farigue ‘stress concentration factor MBS £0 tomy acocaper pire’ the'visets ry torque is not included in the calculs vy nealfving’ tector for stress concen- Fy _tergue ie not toctuded in the calcula, ration torsional analysis and its magnitude is Fe TROret cae ndtegene Concentration the major contributor to the value of the act endin« . AGMA application factors, and ¢, theoretical stress concentration Second, the stress concentration factors, factor in torsion surface ‘finish factor and size factor, Hp theoretical stress concentration finich may vary significantly from shaft co factor in tension shaft, are, fot ‘treated as independent 4 notch sensitivity factor for bending Sei gh vae tat Copyrighl by Ube American Ceor Manufolurers Association fi Dec 29 17:30:59 2006 STD-AGHA SHFTHL-ENGL 1994 MM Ob87575 OOD4S08 O20 a This paper presents shaft design formula which explicitly includes vibra- tory torque and stress concentration factors A sensitivity atudy of the influence of the vibratory torque on the shaft diameter and sented. A computer program, written in C, is developed to facilitate the use of this method of shaft fatigue analysis. An example of stress concen— tration factor evaluation by the Finite Element Method is given to illustrate the modeling procedure. SHAFT LOADING ‘The shaft load includes the bending moment (M), shaft torque (T), axial force (P), and horizontal shear force (V). If the’ forces due to longitudinal and trans: verse vibrations are neglected, the M, P, and V are linear functions of 7. ‘The maximum shaft torque may be ex- pressed as T=Tq + Ta a ‘The amplitude of the shaft torque, T(t), at any time t is: P(t) = Tysin(atts) + Tm @ where ‘Tm = mean torque, 1, = alternating torque, w, = vibration frequency, ¢'= phase angle. The value T, may be primarily due to torsional vibrations, which are functions of the prime mover and driven machinery. ‘The amplitude of the vibrating torque may be computed by torsional vibratipy analy- sis. The Military standard 167 ©! gives limiting values for vibratory torques which suggests values for 1, for this class of vet ‘The application factors © and K, used in calculation of compr sive and bending stresses for gear teeth are load modifiers, which account for the increase in tooth’ load due to external effects including torsional yjprations According to Det Noreke Veritas!®l, ~cener- ally, the torsional vibrations shall not cause the maximum cyclic torques to exceed the approved K, times the approved rated torque. Further, the highest permissi application factor for gears is K, (Note the application factor used in this connection only refers to the influence of torsional vibrations.)". Hence, when the gear designers select the values of c, and Copyrighl by Ube American Ceor Manufolurers Association fi Dec 29 17:30:59 2006 K,, the values suggest magnitudes for the alternating torque T,. The torque due to torsional vibra- tions depends on 5; not uniformly distributed across system, but the system is usually ill defined when the gearbox is being de~ signed. For a stationary shaft, the bending moment ie a linear function of torque xmcyr a) where ¢; is a constant. Strictly speaking, Equation(3) is true only for a constant torque T. If the torque T includes vibratory torque, the value of the bending moment M is no longer the simple function of torque T, then Cy will depend on the system characteristics and the frequency of the torque T,. For a rotating shaft, the moment may be expressed at H = C,T(t) singt ) where by = shaft rotation frequency. Substituting (2) into (4) yields: A= Cy (2m +Tqsin(ayt +p) ain (ot) ) The vibration frequency wy is usually 0.5 to 12 times that of shaft rotation fre quency 0. ¢ is not always 0. vari with frequency and phase angle. The fol- lowing formula gives the bending moment for the worst possible combination. H = Cy (Tm4%q) sin (at) (6) For the rotating shaft the mean component of moment, M,, is usually zero. Mm = 0 m Hence, the alternating moment, M,, is: Mg Cm *CiPa (8) Bquation(8) implies that if vibratory torque 7, is 25% of mean torque T,,, then M, will “increase to 1258 of the value Produced by the mean torque acting alone. If axial vibration is neglected, the axial force P is also a linear function of torque T P= C2(TmtTgsin( ery) ) ) where C) is a constant. Therefore Pim = Com (20) Pg = CoTgsin(yt+9) If vibratory torque 7, increases 25%, then P, increases 258. DISTRIBUTION OF STRESSES IN SHAFTS Figure 1 shows the distribution of four types of stresses over a cross sec- tion of the shaft. From left to right these stresses are: normal stress due to bending, normal stress due to axial force, shear stress due to torsion, shear atreas due to bending. a oe Figure 1, Stress Distribution in the shaft The value of Q and b for a solid circular-section shaft per Figure 2 are: 2 ¢R2-y2)32 a= F(R) bo ayaa For a hollow shaft per Figure 2 with y, < ay 372 az) For a hollow shaft per Figure 2 with y, > Copyrighl by Ube American Ceor Manufolurers Association fi Dec 29 17:30:59 2006 STD-AGMA S4FTML-ENGL 1994 MM OL87575 OOO4SO9 TL? a o= Fenty)? (33) r= shaft inside radiu ¥, = distance from the center to the point where the shear stress, tp, is evaluated. (see Figure 2). Figure 2. shaft cross section For this complex stress state, the distortion-energy theory will be used to obtain the equivalent von Mises stress. Generally, the maximum equivalent stres: occurs atthe point A in Figure 2 because the bending stress is dominant. However, for a very short shaft, the maximum equiv- alent stress may occur between point A and B. An example is given in Appendix A. DERIVATION OF SHAFT DESIGN FORMULA Given the ernating bending moment M,, mean bending moment M,, alter- nating torque 7, and mean torque Tm, the stress components for a solid round shaft qa) STD-AGMA SHFTMI-ENGL 1994 MM Ob87575 OOOWSLO 789 Ma Instead of using kei/K; = 1/(1+4(5~ 1)) to reduce the material’s strengthUl, which ignores the differences in stress concentration factors between bending, torsion, and tension, the fatigue concen- tration factors, Kp, and Ka, are applied in the calculation of alternating stresse: as) where Kp = 1+96(Rp-2) be oe (ae) Kp = L4a4K,-2) Complex stress components are combined by using von Mises equivalent stress: oy = [3 (Com 2ym)?+ (Cy Seyn)?# (Sem 2i)™ 5 + 60m + on * on 1] 3 © (@a-2ya)?*(9y—~za)?*(@raSxa)™ 5 $6 (ee hy 2] FD The von Mises stress due to alternating moment and alternating torque Ma? 1,205 = (kp 22 2 "43 (Kg 38 2) 4 3 a os (a8) 743 (Kp a)71°% 16 = 8, ace doe When applying the von Mises equation for equivalent alternating stress, it is assumed that the alternating moment and torque are at the same frequency. This jgumption is usually not true. But for infinite life shaft design, the above formula is assumed to be valid since the alternating torque occurs at a frequency which is a multipl speed. The von Mis sf the critical mean stress is aft Copyrighl by Ube American Ceor Manufolurers Association fi Dee 29 17:30:59 20 5 a= 8 [an?, + a2) (as) The following ASME elliptic equation will be used to predict fatigue: (a) 2a y24¢ 2m y2ey (20) FY If the factor of safety, F,, is based on a linear relationship between M,, T,, My and Tr the variable F, may be separated per Equation(21). t6 jf2 2. 2, wae awe +3(KpT a)? os | Sp (ay pein geet |e alt 2mm 2B y 's ‘A more convenient form of this equation may be in terms of shaft outs: 23 2 2 apes Retire 43(KgTa)7) 22 1 2 an? VE ve in For a hollow shaft, yey Genre To ey ldas dis) © ytos(I( gay) (23) Hence ofa 16 1 a oe md, (1 (dis/ dog) *) + (4 pita) 243 (TQ) 71°5 J. 16 2 24372 05 ofr 15 —__1__ - pasar) da, (1~(4is/ dog) (2a) Substituting into ASME elliptic equation yields the following equation which may be Solved by iteration for the outside shaft diameter. STD-AGNA SUFTMI-ENGL apt 25-933, (4 (Kp a)™43 (Kp Q)?] s t (25) 2 cay2 ean? V6 a + BM anhsar2y M6 2 = (4g/ dag) where the fatigue strength, S, is esti a by St Kaky Sip. Equations (22) and (25) give shaft diameters based on fatigue failure mode. However, the shaft may fail by yielding when the full load is first applied. This static failure mode is discussed in the following section. ALGORITHM FOR SHAFT DESIGN PROGRAM WITH AXIAL FOR (1) Factor of fatigue mode of For given load and shaft dimen- use the following formulas to get sion: the factor of safety. Alternating normal stress: ge Mee, KPa * Tr a where dos zr nia) er md2,-a2) cian aent Alternating shear stress: KA ac te where ndt-aty ea Von Mises alternating stres Copyrighl by Ube American Ceor Manufolurers Association fi Dee 29 17:30:59 20 4994 MMH Ob87575 OOONSL 425 mm . Mean stresses: Me, Pm ates Tne aa von Mist mean atrese: eto sae2y¥2 The factor of safety for fatigue ii (2) Factor of safety evaluation for the general yielding mode of failure (static failure mode Maximum normal stress: = MatMm)e , (PatPm) max = A + A Maximum shear str (2m+Pa)e - Seat maximum stresi diag * (hat 2)! The factor of safety for yielding i Sy = (3) Design procedure based on fatigue failure moder Figure 3 shows the steps for shaft diameter design. (4) Design procedure based on ABS shaft Gianeter equations STD-AGMA S4FTML-ENGL 1994 MM Ob87575 OOOWSL2 55] Ma 6 a=0.2 [(br)2+(mi)?) where b=0.073 + (27,800/Sy), m=172,000/(60,000 +S). yes Fs

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