Ghulam Ishaq Khan Institute of Engineering

Sciences and Technology, Topi, Pakistan

ME – 364

Design of Machine
Elements – II

Instructor
Muhammad Ilyas, PhD

Faculty of Mechanical Engineering

 Nomenclature

➢ Shaft
➢ In general, a long narrow rotating member, usually having a circular cross-
section, used to transmit power or motion.

➢ Also used for mounting elements such as gears, pulleys, sprockets,

flywheels, cranks, etc.

➢ Provide an axis of rotation (or oscillation) for these elements

➢ Axle
➢ A non-rotating member that carries no torque and is used to support
rotating wheels, pulleys, and such elements

➢ Spindle
➢ Refers to a short shaft or to the end of a shaft where an element such as a
hub, rotor, chuck, etc. is mounted (e.g., in machining equipment)

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 Shaft Design
➢ Material Selection
➢ Geometric Layout
➢ Stress and strength
➢ Static strength

➢ Fatigue strength

➢ Deflection and rigidity

➢ Bending deflection

➢ Torsional deflection

➢ Slope at bearings and shaft-supported elements

➢ Shear deflection due to transverse loading of short shafts

➢ Vibration due to natural frequency

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 Shaft Materials

➢ Deflection primarily controlled by geometry, not material

➢ Stress controlled by geometry, not material
➢ Strength controlled by material property
➢ Shafts are commonly made from low carbon, CD or HR steel, such as
AISI 1020–1050 steels.
➢ Fatigue properties don’t usually benefit much from high alloy content
and heat treatment
➢ Surface hardening usually only used when the shaft is being used as a
bearing surface

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 Shaft Materials
➢ Cold drawn steel typical for 𝑑 < 3 in.
➢ Hot rolled steel common for larger sizes. Should be machined all over.
➢ Low production quantities
➢ Lathe machining is typical

➢ Minimum material removal may be design goal

➢ High production quantities

➢ Forming or casting is common

➢ Minimum material may be design goal

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 General rules of thumb

➢ Mminimize both deflections and stresses, keep the shaft length as short
as possible and overhangs minimized
➢ A cantilever beam will have a larger deflection than a simply supported
(straddle mounted) one for the same length, load, and cross section, so
straddle mounting should be preferred whenever possible
➢ A hollow shaft has a better stiffness/mass ratio (specific stiffness) and
higher natural frequencies than a comparably stiff or strong solid shaft,
but will be more expensive and larger in diameter
➢ Try to locate stress-raisers away from regions of large bending moment
and minimize their effects with generous radii and reliefs

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 General rules of thumb
➢ Deflections at gears carried on the shaft should not exceed about
0.13mm (0.005) in and the relative slope between the gear axes should
be less than about 0.03°
➢ If plain (sleeve) bearings are used, the shaft deflection across the
bearing length should be less than the oil-film thickness (see Chapter
12) in the bearing
➢ If non-self-aligning rolling element bearings are used, the shaft’s slope
at the bearings should be kept to less than about 0.04°
➢ Axial thrust loads should be taken to ground through a single thrust
bearing per load direction. Do not split axial loads between thrust
bearings, thermal expansion of the shaft can overload bearings
➢ The first natural frequency of the shaft should be at least two/three
times the highest forcing frequency expected in service, and preferably
much more. (A factor of 10 × or more is preferred, but this is often
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difficult to achieve in mechanical systems).
 Shaft Layout
➢ Issues to consider for shaft
layout
➢ Axial layout of components

➢ Supporting axial loads

➢ Providing for torque

transmission

➢ Assembly and Disassembly

https://koyo.jtekt.co.jp/en/support/bearing-knowledge/5-3000.html
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 Axial Layout of Components

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 Axial Layout of Components

Norton RL, Machine Design–An Integrated Approach, Prentice Hall, 5th edition, 2010

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 Supporting Axial Loads
➢ Axial loads must be supported through a bearing to the frame.
➢ Generally best for only one bearing to carry axial load to shoulder
➢ Allows greater tolerances and prevents binding

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 Providing for Torque Transmission

➢ Common means of transferring torque to shaft

➢ Keys

➢ Splines

➢ Setscrews

➢ Pins

➢ Press or shrink fits

➢ Tapered fits

➢ Keys are one of the most effective

➢ Slip fit of component onto shaft for easy assembly

➢ Positive angular orientation of component

➢ Can design key to be weakest link to fail in case of overload

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 Assembly and Disassembly

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 Assembly and Disassembly

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 Reading Assignment

➢ Shaft Materials
➢ Shaft layout

15
 Shaft Design for Stress

➢ Stresses are only evaluated at critical locations

➢ Critical locations are usually
➢ On the outer surface

➢ Where the bending moment is large

➢ Where the torque is present

➢ Where stress concentrations exist

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 Shaft Design for Stress
➢ Standard stress equations can be customized for shafts for convenience
➢ Axial loads are generally small and constant, so will be ignored in this
section
➢ Standard alternating and midrange stresses

➢ Customized for round shafts

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 Shaft Stresses

➢ Combine stresses into von Mises stresses

2 2 1/2
32𝐾𝑓 𝑀𝑎 16𝐾𝑓𝑠 𝑇𝑎
𝜎𝑎′ = 𝜎𝑎2 + 3𝜏𝑎2 1/2 = +3 (7–5)
𝜋𝑑 3 𝜋𝑑 3

2 2 1/2
32𝐾𝑓 𝑀𝑚 16𝐾𝑓𝑠 𝑇𝑚
′
𝜎𝑚 = 2
𝜎𝑚 + 2 1/2
3𝜏𝑚 = +3 (7–6)
𝜋𝑑 3 𝜋𝑑 3

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 Shaft Design
➢ Substitute von Mises stresses (Eq. 7–5 and 7–6) into failure criteria
equation. For example, using modified Goodman line,
1 𝜎𝑎′ 𝜎𝑚
′
= +
𝑛 𝑆𝑒 𝑆𝑢𝑡
1 16 1 2 2 1/2 1 2 2 1/2
= 4 𝐾𝑓 𝑀𝑎 + 3 𝐾𝑓𝑠 𝑇𝑎 + 4 𝐾𝑓 𝑀𝑚 + 3 𝐾𝑓𝑠 𝑇𝑚
𝑛 𝜋𝑑 3 𝑆𝑒 𝑆𝑢𝑡
(7–7)

➢ Solving for 𝑑 is convenient for design purposes

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 Shaft Design

➢ Similar approach can be taken with any of the fatigue failure criteria
➢ Equations are referred to by referencing both the Distortion Energy
method of combining stresses and the fatigue failure locus name e.g.
DE-Goodman, DE-Gerber, etc.
➢ In analysis situation, either use these customized equations for factor of
safety, or use standard approach from Chapter 6.
➢ In design situation, customized equations for shaft diameter, 𝑑, are
much more convenient.

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 Shaft Design
➢ DE-Gerber

2 1/2
1 8𝐴 2𝐵𝑆𝑒
= 1+ 1+ (7–9)
𝑛 𝜋𝑑 3 𝑆𝑒 𝐴𝑆𝑢𝑡

1/3
2 1/2
8𝑛𝐴 2𝐵𝑆𝑒
𝑑= 1+ 1+ (7–10)
𝜋𝑆𝑒 𝐴𝑆𝑢𝑡

where

2 2
𝐴= 4 𝐾𝑓 𝑀𝑎 + 3 𝐾𝑓𝑠 𝑇𝑎

2 2
𝐵= 4 𝐾𝑓 𝑀𝑚 + 3 𝐾𝑓𝑠 𝑇𝑚

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 Shaft Design
➢ DE-ASME Elliptic

➢ DE-Soderberg

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 Stresses for Rotating Shaft

➢ For rotating shaft with steady bending and torsion

➢ Bending stress is completely reversed, since a stress element on the
surface cycles from equal tension to compression during each rotation
➢ Torsional stress is steady
➢ Previous equations simplify with 𝑀𝑚 and 𝑇𝑎 equal to 0

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 Checking for Yielding in Shafts

➢ Always necessary to consider static failure, even in fatigue situation

➢ Soderberg criteria inherently guards against yielding
➢ ASME-Elliptic criteria takes yielding into account, but is not entirely
conservative
➢ Gerber and modified Goodman criteria require specific check for
yielding

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 Check for Yielding in Shafts

➢ Use von Mises maximum stress to check for yielding

′ 2 2 1/2
𝜎𝑚𝑎𝑥 = 𝜎𝑚 + 𝜎𝑎 + 3 𝜏𝑚 + 𝜏𝑎
2 2 1/2
32𝐾𝑓 𝑀𝑚 + 𝑀𝑎 16𝐾𝑓𝑠 𝑇𝑚 + 𝑇𝑎
= +3 (7–15)
𝜋𝑑 3 𝜋𝑑 3
𝑆𝑦
𝑛𝑦 = ′ (7–16)
𝜎𝑚𝑎𝑥
➢ Alternate simple check is to obtain conservative estimate of 𝜎𝑚𝑎𝑥
′
by
summing 𝜎𝑎′ and 𝜎𝑚′

′
𝜎𝑚𝑎𝑥 ≈ 𝜎𝑎′ + 𝜎𝑚
′

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 Example 7–1

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 Example 7–1 (continues)

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 Example 7–1 (continues)

6-5

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 Example 7–1 (continues)

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 Example 7–1 (continues)

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 Example 7–1 (continues)

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 Estimating Stress Concentrations

➢ Stress analysis for shafts is highly dependent on stress concentrations

➢ Stress concentrations depend on size specifications, which are not
known the first time through a design process
➢ Standard shaft elements such as shoulders and keys have standard
proportions, making it possible to estimate stress concentrations factors
before determining actual sizes

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 Estimating Stress Concentrations

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 Reducing Stress Concentration at Shoulder Fillet
➢ Bearings often require relatively sharp fillet radius at shoulder
➢ If such a shoulder is the location of the critical stress, some
manufacturing techniques are available to reduce the stress
concentration
a) Large radius undercut into shoulder

b) Large radius relief groove into back of shoulder

c) Large radius relief groove into small diameter of shaft

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 Safety standards for rotating components

Ref: Juvinall RC, Marshek KM - 2011, Fundamentals of Machine Component Design

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 Example 7–2

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 Example 7–2 (continued)

68

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 Example 7–2 (continued)

= 876.6 N
= 2403 N
= 3938 N

= 10818 N

(lbf-in)

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 Example 7–2 (continued)
(lbf)

𝑡 𝑅𝐵𝑧
𝑅𝐴𝑧 𝑊23
50mm

55mm
𝑡
𝑊54

𝑟 𝑟
𝑊23 𝑊54
145mm

𝑅𝐴𝑦 250mm 𝑅𝐵𝑦

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 Example 7–2 (continued)

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 Example 7–2 (continued)

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 Example 7–2 (continued)

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 Example 7–2 (continued)

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 Example 7–2 (continued)

A-15-8

A-15-9

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 Example 7–2 (continued)

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 Example 7–2 (continued)

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 Example 7–2 (continued)

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 Example 7–2 (continued)

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 Setscrews
➢ Resistance to axial motion of
collar or hub relative to shaft
is called holding power

➢ Typical values listed in Table

7–4 apply to axial and
torsional resistance

➢ Typical factors of safety: 1.5

to 2.0 for static, and 4 to 8 for
dynamic loads

➢ Length should be about half

the shaft diameter

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 Keys and Pins
➢ Used to secure rotating
elements and to transmit
torque

➢ Taper pins are sized by

diameter at large end

➢ Small end diameter is

𝑑 = 𝐷 − 0.0208𝐿

➢ Table 7–5 shows some

standard sizes in inches

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 Keys

➢ Failure of keys is by either direct shear or bearing stress

➢ Key length is designed to provide desired factor of safety

➢ Factor of safety should not be excessive, so the inexpensive key is the weak link

➢ Key length is limited to hub length

➢ Key length should not exceed 1.5 times shaft diameter to avoid problems from
twisting

➢ Multiple keys may be used to carry greater torque, typically oriented 90º from
one another

➢ Stock key material is typically low carbon cold-rolled steel, with dimensions
slightly under the nominal dimensions to easily fit end-milled keyway

➢ A setscrew is sometimes used with a key for axial positioning, and to minimize
rotational backlash

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 Stress Concentration Factors for Keys
➢ For keyseats cut by standard end-mill cutters, with a ratio of r/d = 0.02,
Peterson’s charts give
➢ 𝐾𝑡 = 2.14 for bending

➢ 𝐾𝑡 = 2.62 for torsion without the key in place

➢ 𝐾𝑡 = 3.0 for torsion with the key in place

➢ Keeping the end of the keyseat at least a distance of 𝑑/10 from the
shoulder fillet will prevent the two stress concentrations from
combining.

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 Tolerances and Fits

➢ Suggested reading: page 624 of Machinery's Handbook, 30th

Edition by CJ McCauley and E Oberg, Industrial Press 2016.

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