D2 Definitions: Shaft —a rotating member transmitting power Axle ~a stationary member carrying rotating wheels, pulleys, ete Spindle ~ a short shaft or axle on machines Machine Shaft ~ shaft which is used to transmit power between the source and the machine absorbing the power Lineshaft or Mainshaft — transmission shaft driven by the prime mover Countershaft, jackshaft, headshaft, shortshaft — transmission shaft intermediate between the lineshaft and the driven shaftShafting design diagram Commercial Sizes of shaft, inches (Faires p. 269; Vallance p. 181) 19511313715 3 7 11 15 S168 161 16'3 Te lige 7 15 6 y Te 22 2p 2G 38 TE 5o,522,665,7 16" 162" ‘Materials for Transmission shaft: cold rolled, hot rolled, forged carbon steel Relation of Power, Torque and Speed P=2nTN ‘Where: P = power transmitted (kw)que or torsional moment (KN-m) = F xr N= speed (rev/see) F = transmitted load or tangential force (KN) R= radius (m) Te TL Ss=7 and @ = 7¢(radians) isr Ss =< (for solid circular shaft) 16TDo 8 = age a pa [er hollow circular shaft Ss =; for solid circular shaft 16MDo $8 = Foot D) for hollow circular shaft ‘Where: Ss = torsional shear stress torque or torsional moment lstance from neutral axis to the outermost fiber = radius (for solid circular shaft) ‘I= polar moment of inertia c ~(n/32)D“4 for eiteular shaft {x/32)(Do"4-Di4) for hollow circular shaft D= diameter of shaft length of shaft © = angular deformation in length L, radians G~ modulus of rigidity in shear 11 500 000 psi to 12 000 000 psi for steel Do = outside diameter Di= inside diameter ‘M>~ bending moment s 18 ue TE seman = Ds 16 gpa + VM? +7?) Stmax Where:Ssmax = maximum shear stress St max = maximum tensile or compressive stress M-=bending moment T= torsional moment Strength of Shaft with assumed allowable stresses (PSME Code p.18) For Main Power transmitting shafts: pa pa? /80P aa Oy For Lineshafis carrying pulleys: DN 535 °° For Small, Short shafts paP® oy. pa? PP 38 OF Fw Where: power transmitted in HP D = diameter of shaft in inches N= speed in RPM Shafting formulas from machinery*s handbook Diameter of shaft: A. for allowable twist not exceeding 0.08 deg per ft length [ur D=029VT or D ser Where: D=shaft diameter, inches T= torque, Ib-in HP = horsepower N=speed, rpm In $.T units (allowable twist 0.26 deg per meter length) D=226\T or D asa‘ V N Where: D= shaft diameter, mm N= speed, rpmB. for allowable twist not exceeding | deg per20D length [ae N D6 horsepower speed, 1pm C. For short, solid shaft subjected only to heavy transverse shear N Where: ‘V = maximum transverse shearing loads, Ibs Ss ~ maximum torsional shearing stress, Ib’/sq. in Linear Deflection of shafting For steel lineshafting, it is considered good practice to limit the linear deflection to a maximum, of 0.010 inch per foot length Maximum Distance: A. For shafting subjected to no bending action except its own weight: L=8.95VD? B. For shafting subjected to bending action pulleys, etc. L=5.2YD? ‘Where: L = maximum distance between bearings, ft D = diameter of shaft, inches Note: 1. Pulleys should be placed as close to the bearings as possible 2. In general, shafting up to three inches in diameter is almost always made from cold-rolled steelDa SOLVED PROBLEMS 1, What power would a spindle 55 mm in diameter transmit at 480 rpm, Stress allowed for short shaft is 59 MPa (ME Bd. Apr 97) A412 kW C. 96.88 KW B. 50.61 kW D. 39.21 kW Solution: 16T Ss am 50 = 18" ~7(55)* T=1 927 390 N-mm = 1.92739 KN- P= 2aTN = 2a(1.92739)(480/60) = 96.88 kW 2. Determine the torque received by the motor shaft running at 4250 rpm, transmitting 11 H. through a 10 in diameter, 20° involute gear. The shaft is supported by ball bearing at both ends and the gear is fixed at the middle of 8 in shaft length. (ME Bd. Apr 97) A. 163 in-Ib C. 132 inlb B. 167 in-lb D. 136 in-lb Solution: P=2IN 11(33000) = 22 T(4250) T= 13.594 ft-lb = 163.128 in-tb 3. Compute the lineshaft diameter to transmit 12 HP at 180 rpm with torsional deflection of 0.08 degree per foot length. (ME Bd. Oct 96) A3in C. 2.35 in B. Sem D.62 mm Solution: P=2nIN 12(33000) = 2nT(180) T= 350.14 fi-lb = 4201.68 in-Ibs L=1ft=12inDs y= ® Dé for solid circular shaft G = 12 000 000 psi for steel oath =u 4201.68(12 0.08 (2) = 201680) _ 180" ~ ($) 24(42,000,000) D=2.35in 5. Compute the nominal shear stress at the surface in MPa for a 40 mm diameter shaft that ‘transmit 750 kw at 1500 rpm. Axial and bending loads are assumed negligible. Torsional shearing stress is 28 MPa A218 ©. 232 B.312 D. 380 Solution: 2aTN 750 = 2xT(1500/60) T=4,775 kN-m l6T 16T ~ D3 ~ 7(0.040)° Ss = 379 982 kPa = 380 MPa Ss 6. A hollow shaft has an inner diameter of 0.035 m and an outer diameter of 0.06 m. Compute for the torque if the shear stress is not to exceed 120 MPa in N-m (ME Bd. Oct 95) A. 4500 €. 4300 B.4100 D. 4150 Solution: So = _tetv0 Ss ‘m(Do*—Di*) 167 (0.06) 120,000,000 = T=4500N—m 77(0.06* = 0.035") 7. Design the size of a solid steel shaft to be used for a 500 hp, 250 rpm application if the allowable torsional deflection is 1° and the allowable stress is 10,000 psi and modulus of rigidity is 13 x 1096 psi (ME Bd. Oct 95) A. Sindia C.4 7/8 in dia B.4 5/8india D.4 % india Solution:Solving for the shaft diameter D based on stress: P=2a1N 500(33,000) = 2T(250) T = 10,504,226 fi-lb = 126,051 in-Ib Dy 5. 167 Spe 10,000 = 26(426.051 \ =D? D=4in Solving for the shaft diameter D based on torsional deflection: The shaft length is not given. The common practice for torsional deflection is 1° per 20D @= 1° x (180/x) rad 126,051 in-Ibs L=20D @/32)D°4 13,000,000 psi =m oR iG . 10) = ap 0058200 80 (%)(4)(43,000,000) D=4.85 in Therefore: use D = 4 7/8 in 8. A2 in solid shaft is driven by a 36 in gear and transmits power at 120 mpm. If allowable shearing stress is 12 ksi, what horsepower can be transmitted? (ME Bd. Oct 95) 29.89 C. 39.89 B. 35.89 D. 34.89 Solution: za T= 18,850 in-lbs = 1,570.8 ft-lbs 2nTN = 2n(1570.8)(120/60)(hp/350) = 35.89 HP 9. A short 61 mm shaft transmit 120 HP. Compute the linear speed of a pulley 55 cm mounted on the shaft. (ME Bd, Oct 95) A. 1796 fm C. 1856 fpm. B. 1766 fpm D. 2106 fm Solution: For short shaft (PSME Code)D=61 mm=2.4 in DN pa2k N =330rpm ‘D-10 DN = 2(0.55 x 3.28)(3.28)(330) = 1870 ft/min 10. A hollow shaft has an inner diameter of 0.035 m and outer diameter of 0.06 m. determine the polar moment of inertia of the hollow shaft (ME Bd Oct 95) A.1.512x 10% m! ©. 1.152 x 10% mt B.1.215 x 10° m* D. 1.125 x 10% m* Solution: J = (po! - dit 2 1 yy (0.064 — 0.0354) = 1.125x 10-m* 11, Compute the speed of the gear mounted on a 52.5 mm diameter shaft receiving power from a driving motor with 250 HP. (ME Bd. Apr 95) A. 2185 RPM C. 2265 RPM B. 2071 RPM D. 2341 RPM Solution: From PSME CODE: 250 30 N=2265 RPM 11, A3 in diameter short shaft carrying two pulleys close to the bearings transmits how much horsepower if the shaft makes 280 RPM? (ME Bd. Apr 95) A. 199 HP C.200 HP. B. 198 HP D.210 HP Sotution: From PSME CODE: D®N _ (3)2280 P= = = 199HP 3838 12. A rectangular key was used in a pulley connected to a lineshaft with a power of 7.46 kw at a speed of 1200 rpm. If the shearing stress of the shaft and key are 30 MPa and 240 MPa, respectively. What is the diameter of the shaft? (ME Bd. Oct 2006) A. 116mm C, 21.6 mm B.15.6mm D. 32.2 mm.Solution: P=2nIN 7.46 = 2nT(1200/60) T= 0.059365 kN-m = 59,365 N-mm er ssa Dal — 1069365) a1 g =“ =21.6mm 13. Determine the torque received by the motor shaft running at 4250 rpm, transmiting 11 hp, through a 10 in diameter, 20° incolute gear. The shaft is supported by ball bearings at both ends and the gear is fixed at the middle of 8 in shaft length (ME Bd Apr 2006) A. 163 in-Ib C.132 inelb B. 167 in-lb D. 138 in-lb Solution: P=2nIN 11(33,000) = 2nT(4250) T= 13,594 ft-lb = 163.128 in-Ib 14, Compute for the diameter in inches of a conveyor head pulley SAE 4130 solid steel shaft being driven by a 11HP drive motor through a gear reduces with 180 xpm output, the torsional deflection is 0.08 degree/foot of shaft length. (ME Bd, Apr 2006) Solution: 2nTN 11(33,000) = 2xT(180) 321 felbs = 3852 in-lbs 3952(12) Byera1.500.000) D=2.327 in, say 2.3/8 inches pulley 15. The power that can be transmitted by a spindle of $5 mm diameter running at 1200 rpm and allowable stress of 5 MPa is equal to : (ME Bd Apr 2006) A103 kw C.23 kw B. 20.5 kw D.35.2 kw Solution: 5000 = T= 0.16334 KN-m 7(0.055)"P= 2x TN = 2n(0.16334)(1200/60) = 20.5 kw 16. Determine the diameter in inches of a steel countershaft that delivers 13.31 HP at a speed of 15.7 rad/see, the allowable material shear stress is 8.5 ksi. (ME Bd. Oct 2005) Alin C.2in B.1 %in D.1 Min Solution: N= 15.7 rad/see = 149.9 rpm _ DN HP = for countershaft 38 1331-20) D=1.5i: 31s Sin 17. Compute for the torsional deflection in degrees of 110 mm diameter, 1.4 meter long shaft subjected to a twist moment 3 x 10°6 N-mm. the torsional modulus of elasticity is 83.000 MPa. (ME Bd. Apr 2003) ‘A.0.27 C.0.20 B.031 D.0.24 Solution: _ TL _ (3x10°N —mmm)(1400mm) 180 deg =e or ie @) (210) mm(83,000 5 y rad 0=0.2deg 18, Two parallel shaft connected by pure rolling turn in the same direction and having a speed ratio of 2.75. what is the distance of the two shatt if the smaller cylinder is 22 em in diameter? (ME Bd. Apr 2005) A. 16.60.em ©. 25.25 em B. 30.25 em D. 19.25 em Solution: DINI = D2N2 2.75 = (NUN2) = (D2D1) 2.75 = (D2/D1) D2=60.5 cm Cylinder 2 is an internal cylinder, therefore, the center distance will be: D2-D1_ 605-22 = =P 2 19.25cmDAB 19. Itis desired to check the design of a 2 in medium steel shaft subjected to a turning moment of 40,000 in-Ib, Ultimate stress is 50,000. Determine the factor of safety applied. (ME Bd. Apr 2004) A. c.25 B. 0.509 D.1.96 Solution: FS = 1.9635 20. How much torque can be safely transmitted by a | 7/16 in, diameter shaft if safe stress is 7000? (ME Bd Apr2004) A. 28142 KN-m C. 28000 KN-m B. 3500 in-lbs ‘D. 4100 in-Ibs Solution: D=1 7/16 in= 1.4375 in ss a2 72° sor 7000 = aaa7a T = 4082.73 in — lbs 21. A shaft with a 1.125 in diameter receives 400 in-Ibf of torque through a pinned sleeve. The pin is manufactured from steel with a tensile yield strength of 73.9 ksi. Using a fictor of safety of 2.5 compute for the following: (ME Bd. Apr 2004) A. For the yield strength in shear, assume that by using the distortion energy failure theory, the equation is Sys = 0.577 Syt. What will be the maximum allowable shear stress? A. 71.06 ksi C.17.06 ksi B. 60.71 ksi D. 32.17 ksi Solution: Sys = 0.577 Syt = 0.577(73.9) = 42.6403 Sys _ 42.6403 Fs is 7.056 ksiB, What is the total shear force in the pin? A.37L.L bf C1171 Ibe B. 711.1 Ibf D.311.1 lbf Solution: T=Fx1.25/2 TAL. 11 It C. What pin diameter is needed? A. 0.361 in C.0.631 in B. 0.316 in D.0.23 in Solution: Ss =F (wi4 x d’2) 17,056 = 711. 11/ (n/4.x 42) d= 0.23 in D. If the pin has a tensile yield strength of 50 MPa, manufactured from steel, what will be the yield strength in shear? A. 71.06 ksi C. 60,71 ksi B. 117.7 x 10%6 Pa D. 294.3 x 10°6 Pa Solution: Sys = 0.577 Syt = 0.577 x (510 x 10°6) = 294.27 x 10°6 Sys/FS = 294 x 10°6/2.5 = 117.7 x 10%6 Pa E. Assume that the shaft torque becomes 45 N-m, compute for the total shear tthe pin. A.9641.3N C. 3149.6 N B. 1177 bf D. 571.7 Ibf Solution: D=1. 125 inx 2.54 envin x my/100 cm = 0.028575 m T=FxD2 x 0.028575/2 F=3149.6N 22. A marine turbine developing 15,000 hp and it tums the shaft at 300 rpm. The propeller which is attached the shaft develops a thrust of 150,000 Ibs. A hollow steel shaft with an outside diameter of 14 in will be used. (ME Bd. Apr 2004) A. Compute for the torque. A. 622,000 ft-lb C. 486,600 ft-lb B. 826,000 ft-lb D. 262,600 ft-Ib Solution: P= 2xTN = 15,000 = 2aT (300) T= 262,605.65 ft-lb B. determine the inside diameter of the shaft if the maximum shearing stress based on torsion alone is not to exceed 7,500 psi.Solution: Ss = 16TDo / x [Dod - Di] = 7500 = 16 x 262,605.65 x 14 /x [144 — Dis] Di= 9.589 in C. what will be the propeller’s thrust that is develop in kilogram? 68, 180 kg C. 86,880 kg B. 26.810 kg D. 186,000 ke Solution: Ft= 150,000 lbs x kg/2.2 Ibs = 68, 18182 kg. D. what is the diameter of the solid shaft? A. 1.88 in C.6, 128 in B, 12.886in D. 8.621 in Solution: Ss = 16T/aD*3 = 7,500 = 16 x 262,605.65 x 12 /tD*3 D= 12.886 in E. What is the percentage saving in weight over the solid shaft? A.92.3% €.37.3 % B. 73.3% D. 67.3 % Solution: Ws — weight of solid shaft = volume x density =AxLxp=q4x 12.8862 xL p= 130.41 Lp weight of hollow shaft = 7/4 [14°2 -9.59°2] L p=81.70L p % savings = Ws-Wh / Ws x 100 = 130.41L p ~ 81.701 p/ 130.41L p = 37.35% 23. A shell with an outside diameter of 406 mm and a wall thickness of 2.54 mm is subjected to 280 MPa tensile load and 45 KN-m. What is the maximum shear stress in MPa? A. 69.73 MPa C. 296 MPa B. 156 MPa D. 16.4 MPa Solution: Do = 0.406 m Di 406 — (2x0.00254) = 0.40092 m Ss = 16TDo / x [Do4 — Di*4] = 16 x 45 x 0.406 / x [0.4064 — 0.400924] = 69,721.3 KPa = 69.721 MPa 24. A torque of 3142 foot-pounds is applied to one end of a solid cylindrical shaft of 4 inches in diameter fastened at the other end. The maximum shearing stresses closest to? A. 2500 psi €. 3,000 psi B. 3500 psi D. 3142 psiSolution: Ss = 16T/aD*3 = 16x 3142 x 12/ 0x 4" = 3,000 psi 25. A hollow bronze tube has an outer diameter of 2 inches and an inner diameter o 1% inches and 12 inches long. A crank 15 inches long is keyed to one end, and the other is held rigid. The modulus of rigidity is 10,000,000 psi. A. Compute for J A. 3.73 in™4 3.781 in4 B. 1.0733 in4 D. 1.738 in’4 Solution: J = W/32 (Do“4 -Di'4) = w/32 (24 ~ 1.5°4) = 1.073 in “4 B. What force must be applied to the end of the crank to produce a torsional shear of 5.000 psi? A. 835 Ibs €. 358 Ibs: B. 853 bs D. 583 Ibs Solution: Ss = 16TDo/x [Do“4 - Di*4] = 5 T= 5,368.93 in-lb=FL=F x15 357.92 Ibs 100 = 16T x 2/7 [24-154] C. What will be the angular moment of the end of the crank when this load is applied? A. 0.344 degree C. 0.544 degree B. 0.543 degree D. 0.434 degree Solution: = TLIG = [(5368.93 x 12) / (1.073 x 10x10°6)] x 180/n = 344 degree D. The torsional shear can be express as? A. 543 bars ©. 453 bars B. 935 bars D. 345 bars Solution: Ss = 5,000 psi x 101.325 KPa /14,7 psi x 1 bar’ 100 KPa = 344.64 bars E. The force required at the end of the crank is equivalent to? A. 900 ke C. 163 kg B. 887 ke D. 788 ke Solution: F = 358 Ibs x kg/2.2 Ibs = 162.72 kg26. A taper pin with a minimum mean diameter of 6.2 mm will be applied to fix a lever to a 2 inches shaft with an allowable design stress of 15 ksi. Compute for the transmitted maximum torque in in-lbs. use a factor of safety of 2. A600 C. 700 B. 800 D. 780 Solution: Empirical formula from Machinery Handbook p. 186 d= 1.13(7/DS) *1/2 d= mean diameter of taper pin (in) S = safe unit stress (psi) mmm = 0.244 in T = torque (in-Ibs) D = shaft diameter (in) 0.244 = 1.13 (T/2 x 15,000) “1/2 T= 1,398.8 in-lbs Applying the factor of safety 2: T = 1,398.8/2 = 699.4 in-Ibs 27. Determine the power transmitted by main power transmitting steel shaft with 2 7/8 inches in outside diameter, SAE 1040 driving conveyor head pulleys at a shaft speed of 130 rpm. A.40 C45 B.50 D.38 Solution’ P=D°3xN/80=2.875°3 x 150/80 = 44.6 HP 28. Find the diameter of a main power transmitting shaft in mm to transmit 100 KW at 400 rpm. A48 C76 B.67 D.85 Solution’ P= 100 KW=134 HP N= 400 pm D°3.xN/80= 134 =D*3 x 400/80 D=2.99 in=76 mm 29. Design a safe shaft diameter for a power transmitting shaft to transmit 30 HP at a shaft speed of 180 rpm. ©.3.25 D.23/8 Solution: P=D°3xN/80=134=D"3 x 180/80 D=2.37 in=23/8in 30. What would be the diameter in mm of a main power transmitting steel shaft SAE 1040 to transmit 100 KW at 600 rpm? A 67 C76 B47 D.56Solution’ P=D°3xN/80=134=D°3 x 600/80 D2.614 in = 66.4 mm. 31. Compute the power in HP of a line shaft having a diameter of 1 7/8 inches with a speed of 200 mm. 5 ©.32 B.27 D.35 Solution’ Power = D3 x N/ 53.5 = 1.875°3 x 200 / 53.5 = 24.6 HP 32. A short 40 mm diameter shaft having a rotational speed of 300 rpm. Determine the power transmitted by the shaft A.31 HP C. 45 HP B. 38 HP D. 49 HP. Solution’ Power = D3 x N/ 38 =(40/25.4) “3 x 300 / 38 = 30.8 HP 33. Determine the diameter of a line shaft transmitting 25 HP and having a speed of 225 rpm. The shear stress of the shaft is 6 ksi ALL 7/8 in C.1LiSin B. 1% in D.1 “in Solution: Power =D*3xN/53.5=D°3x 225/535 D=1.811 insay1 7/8 in 34. Compute the angular deflection of a shaft in degrees having a diameter of 4 5/8 inches, length 60 inches, transmit 12 HP, at 180 rpm. Use G = 11.5x10%6 psi. A. 0.028 degree C. 0.089 degree B. 0.125 degree D. 0.890 degree Solution: 2a TN = 12 x 33,000 = 2aT x 101.68 in-lbs = TLIG = [(4,201.68 x 60)/ (w/32 x 4.6254 x 11.5x10°60)] x 180/n = 0.028 degree 35. Compute for the diameter in inches of SAE 1030 steel shaft to transmit 12 HP at 120 rpm with torsional deflection below 0.08 degree/foot length as required. A.27/8in C.2 Yin B.25/8in D.23/8 in Solution: 2nTNT =(12 x 550) / (2 x 120/60) = 525.21 lb-ft Using G = 12x10°6 psi = TLIIG = 0.08 x 1/180 = 525.21 / (1/32 x D4 x 12x10%6 x 144) D= 0.217 ft = 2.604 im say 2 5/8 in 36. A 3 inches diameter short shaft carrying to pulleys close to bearing to transmit how much horsepower if the shaft makes 280 rpm. A.199 BP C. 200 HP. B. 198 HP. D.210 HP Solution: P=D3xN/38=(393 x 280)/38 = 199 HP 37. Compute the speed of gear mounted on $2.5 mm diameter shait receiving power from a driving motor with 250 HP. A. 2,182 pm C. 2,282 rpm. B. 2,071 rpm D. 2.341 1pm Solution: From PSME code P=D°3xN/80=250= {(5: 2265 rpm 5/25.4y°3 N] / 80 38. A solid cylindrical shaft 48.2 em long is used for a transmission of mechanical power at a rate of 37 KW running at 1,760 rpm. The Ss is 8.13 MPa. Calculate the diameter. A30mm C.40 mm B.35 mm D.50 mm Solution: P= 2a IN = 37 =2nT x 1,760/60 T=02KNm 16T/aD*3 = 8130 = 16 x 0.2/mD*3 D=0.050 m= 50 mm 39. A hollow shaft with outside diameter of 14 em and wall thickness of 0.80 cm transmit 200 KW at 400 rpm. What must be the angular deflection of the shaft if the length is 5 meters? The material of the shaft is C4140 steel. A. Ld degree C. 1.41 degree B. 1.84 degree D. 0.09 degree Solution’ P= 2a IN = 200 = 24 T x 400/60 T=4.77465 KN-m 32 (Do™4 —Di*4) = w/32 (0.144 — 0.1244) = 1.45042x10°-5 m4 Use G = 82,741,285.71 KPa = TLIG = 4.77465 x 5 / 1.45042x10°-5 x 82,714.285.7 1.14 degree40. A short 61 mm diameter shaft tansmits 120 HP, Compute the linear speed of a pulley $5 em diameter mounted on the shaft. A.1,796 fpm C.1,870 fpm B. 1,766 fpm D.2,016 fpm Solution: For short shaft: = D°3xN/38= 120=(61/25.4)°3xN/38 0 mpm aDN= N v x0, x 330 = 1870 fpm 41. Find the power in watts transmitted by a main power transmitting shaft with a diameter of 55 mm and speed of 200 rpm. AL 15.45 c.254 B. 18.926 D.307 Solution: For main power transmitting shaft: P=D3xN/80 D=55/25.4 = 2.165 P= 2.165°3 x 200 / 80 = 25.37 x 746 = 18.926 watts 42. Compute for the torsional deflection in degrees of a 3 5/8 inches diameter, 1.2 m long shaft subjected to a twist moment of 3x10°6 N-mm. the torsional modulus of elasticity is 80,000 MPa. A. 0.365 C..0.653, B. 0.985 D. 1.025 Solution: D=3 5/8 in-92.075 mm © = TLIG = [(3x10°6 x 1200) / (a/32 x 92.0754 x 80,000)] x 180/x = 0.365 degree 43. Compute for the torsional deflection in degrees of a 110 mm diameter, 1.4 m long shaft subjected to twist moment of 3x10°6 N-mm. The torsional modulus of elasticity is 83,000 Nimm?2 A. 0.27 B.O31 Solution: = TLIG = [(3x10°6 x 1400) / (w/32 x 1104 x 83,000)] x 180/n = 0.2 degree 44, Find the torsional moment in Newton-millimeter developed when the shaft delivers 20 KW at 200 rpm, A. 0.85x10°6 C. 1.20x10°6 B. 1.0x10°6 D.2.10x10°6Solution: P= 2aTN = 20 = 2aT x 200/60 T = 0.955 KN-m = 0,955x10%6 N-mm_ 43. A 102 mm diameter shaft is driven at 3000 rpm by a 300 HP prime mover. The shatt drives a 121.9 em diameter chain sprocket having 86% output efficiency, Compute the torque in in-Ib develop in the shaft. A. 5,600 C. 8,150 B. 7,100 D. 6,300 Solution: P= 2x TN = 300 x 33,000 = 2nT x 3,000 = 525.21 ft-lb = 6,302.5 in-lb 46. Compute for the twisting moment in in-Ib developed when the shaft delivers 20 HP at 1,200 rpm. A. 1,166 €.1,050 B.915 D.945 Solution: P = 2a TN = 20 x 33,000 = 2nT x 1,200 = 87.535 ft-lb = 1,050.4 in-Ib 47. Determine the diameter in inches of a steel countershaft that delivers 13.31 HP at a speed of 15.7 rad/s, the allowable material shear stress is 8.5 ksi. Alin C.2in B.1%in D.1 Min Solution: N= 15,7 rad/s x rev/2arad x 60s/min = 149.9 rpm HP =D*3N / 38 for countershaft = 13.31 = (D'S x 149.9)/38 = 1.5 in 48. In SAE 1030 steel 2 inches diameter solid shaft with a deflection not to exceed 0.06 degree ft length. Modulus of rigidity of 12,000,000 psi. Determine the power transmitted if the shaft rotates at 280 rpm. A.7.3 HP C.8.3 HP B.3.7HP D. 3.8 HP Solution: = TLIG = 0.06 x n/180 = T x12 / (w/32 x 24x 12x10°6) T = 1644.9 in-lbs = 137 ft-lbs 2nTN = 2a x 137 x 280 x HP/33,000 = 7.3 HP49. A hollow shaft has an inner diameter of 0.035 m and an outer diameter 0.06 m. Compute for the torque if the shear stress is not to exceed 120 MPa in N-m. A. 4,400 ©4500 B. 4,300 D. 4,200 Solution: Ss = 16TDo / tx (Do™4 -Di*4) 120x10°6 = 16T x 0.06 / rx (0.064 — 0.035 T=4,500 N-m 50. What power would a spindle shaft is $9 N/mmy*2. mm in diameter transmit at 480 rpm stress allowed for short A. 98.68 KW C. 68.98 KW B, 96.88 KW D. 68.89 KW Solution: Ss = 16T/aD93 = 59x10°3 = 16T / xx 0.055°3 T= 192739 KN-an P = 2nTN = 2 x 1.92739 x 480/60 = 96.88 KW $1. A3 inches diameter short shaft carrying two pulleys close to bearings transmits how much power if the shaft makes 280 rpm? A991 199 B.919 D. 260 Solution: P=D°3xN/38 x 280/38 = 198.9 HP. 52. Compute the speed of the gear mounted in $2.5 mm diameter shaft receiving power from a prime mover with 250 HP. A. 2,182 pm ©.2,287 rpm B. 2,081 rpm D. 2,341 1pm Solution: D=52.5mm =2.06 in From PSME code: HP = D°3 x N/ 80 (0 = 2.06°3 xN/ 80 N= 2,287 rpm 53. A 3% inches diameter solid circular shaft transmitting a torque of 1,500 fi-lb, Compute the ‘maximum normal stress in the shaft A. 3,238 38 B. 2,138 D. 1,228 Solution:Ss = 16T/aD°3 = (16 x 1,500 x 12) / wx 3.5°3 = 2,138 psi 54. A small countershaft is 1% inch in diameter and has an allowable stress of 8,500 psi. Find the horsepower delivered by the shaft at a speed 15.7 rad/s. C.13.31 D.14.72 Solution: Ss = 16T/xD"3 = 8,500 = (16 x T) / (wx 1.5°3) T = 5,632.78 in-Ibs = 469.4 ft-lbs 5.7 x 60 / 2m = 150 rev/min P = 2a TN = (2x x 469.4 x 150)/33,000 = 13.39 HP. . A 16 ft steel line shaft has no bending action except its own weight. What power in HP can the shaft deliver at a speed of 200 rpm? Consider that the torsional deflection will not exceed 0.08/ft length, 13.2 C244 B.158 D.14.6 Solution: Reference: Machinery Handbook 24" edition p. 267 D/2/3 = L8.95 = D = (16/8.95)°3/2 = 2.39 in HP = (D/4.6) *4 x N= (2.39/4.6)4 x 200 56. The torsional deflection of a SAE 1040 steel shaft is to 0.8 degrees in a length of ' m, The shear stress is 69 MPa. Compute the diameter of a shaft in mm. steel modulus of elasticity is 79,000 MPa. ASL B.50 Solution: Ss = 16T/aD/3 = 69,000 = 16T/nD*3 T= 13,548D°3 KN-m_ © = TLIG 0.8 x n/180 = 13,548D°3 x 0.5 / [(7 D3 / 32) x 79,000,000] D= 0.062 m= 62 mm 57. Compute the diameter of a solid shaft transmitting 75 HP at 1,800 rpm. The nature of load and the type of service is such that the allowable Ss based on pure torsion is 6,000 psi. A.17/8in C.15/16 in B.2 1/6 in D.3 1/8 in Solution: P= 2a IN = 75 x 33,000 = 2aT x 1,800 218.838 fi-lbs = 2,626.06 in-Lbs 16T/AD*3 = 6,000 = 16x 2,626.06 / x x D3 1.306 say 1 5/16 in58. The shaft is subjected to a steady load of 36,000 in-Ib at a shear stress of 10,000 psi. Compute the diameter of the said shaft in inches. A.17/8 in C.3in B.2 “in D.2%in Solution: T = 36,000 x D/2 = 18,000D in-Ibs Ss = 16T/aD*3 =10,000 = (16 x 18,000D) / xx D*3 D= 3.027 in use 3 in 59. A solid transmission shaft is 3.5 inches in diameter. It is desired to replace it with a hollow shaft of the same material and same torsional strength but its weight should only be half as much as the solid shaft. Find the outside and outside diameter of the hollow shaft in mm, Solution: Solid shaft: Ss = 16T/nD’3 Hollow shaft: Ss = 16TDo/x x (Do“4 -Di*4) Equating the stress: 16T/xD"3 = 16TDo/x x (Do"4 -Di*4) Do“4 -Di*4 = 42.875Do Equation 1 Let L = length of shaft, p = density Solid shaft: v= n/4 D'2 L Hollow shaft: v~ 2/4 x (Do”2 -Di"2) L ¥4 (w/4) (3.502) Lp = w/4(Do*2 —Di*2) Lp Do"2-Di'2=6. 125 Equation 2 Di’ 02 — 6.125 or Di*4 = (Do*2 -6, 125) “2 Substituting in Equation 1: Do"4 — (Do*2 — 6.125) *2 = 42.875Do. Do"? ~ 3.5Do ~ 3.0625 =0 By quadratic formula: Do=4.225 in= 107 mm, Di~ sqrt (4.225°2- 6, 125) = 3.424 in = 87 mm 60. A 76 mm solid shaft is to be replaced with a hollow shaft of equal torsional strength. Find the inside diameter and the percentage of weight saved if the outside diameter of the hollow shaft is 100 mm. Solution: For solid shaft: $s = 16T/D*3 For hollow shaft: Ss = 16TDo/x (Do“4 —-Di*4) Equating the torsional stress: 16T/aD*3 = 16TDo/x (Do"4 —Di*4) Di Let v= volume weight nid (76) °2L w/4 (100°2 — 86.55°2) L (4 x 76°2 x Lw)— w4(100°2 ~ 86.55°2) Lw] / (2/4 x 76°2 x Lw) 0.5656 =56.56% = 86.55 mm v % of weight saved61. A solid shaft is to be used to transmit 75 KW at 550 rpm. If the shaft design stress will not exceed 26 Nimm2, determine the diameter of the solid shaft. Power = ax IN=75 =2nx Tx 550/60 T=1302177K) 302,177 Ss = 16T/aD%3 D=63.42 mm 62. A 500 rpm shaft is fitted with a 30 inches (76.2 mm) diameter pulley weighing 250 Ib (113.6 kg). This pulley delivers 35 HP (26.1 KW) to a load. The shaft is also fitted 24 inches (61 cm) pitch diameter gear weighing 200 Ib (90.9 kg). This gear delivers 25 HP (18.65 KW) to a load. Assume that the tension of the tight side of the belt is twice that of the slack side of the belt, determine the concentrated loads produced on the shaft by the pulley and the gear in Ib and in ‘Newton, Solution: The relative positions of the belt and gear are not specified. therefore the positions that will produce maximum on the shaft will be assumed. For the pulley: 2aT! 35 x 33,000 = 2a x Tx 500 T = 367.548 ft-lbs (FL-F2)r=T (2F2 -F2) x 15/12 = 67.648 F2 = 204. 118 lbs, Fl = 588.236 Ibs Fp = 588,236 + 250 = 1,132,354 Ibs = 5,038 N For the gear: = 2nTN = 25 x 33,000 = 22x T x 500 T= 262.606 ft-lbs Tir = 262.606/1 Fg~ 262.606 + 200 162.606 Ibs. 162.606 Ibs = 2,058 N 63. A steel is subjected to a constant torque of 2260 N-m. The ultimate strength and yield strength of the shafting material are 668 MPa and 400 MPa respectively. Assume a safety factor of 2 on the yield point and endurance strength in shear, determine the diameter of the shaft in inches, Solution: Maximum shear stress = 1/2 tensile stress Sy max = 1/2 (4,000) = 2,000 KPa With factor of safety of 2, the allowable torsional stress is Ss = 200,000/2 = 00.000 KPa Solving for the Shaft diameter, D Ss= 16T/aD*3 = 16 x 2.260 / x D'S D = 0.048644 mm = 1.915 in64. A solid steel shaft is to be design to limit the maximum twist of not more 2.5 degrees in a 5 m length when acted upon by a torque of 18 KN-m, Determine the maximum diameter of the shaft. (G = 83 GPa) Solution: [© = 180/a (TL/IG)] degree Where: G=83x0°3 MPa xD*4/32 D=[(180 x 18x10°%6 x 5,000 x 32) / (2.5 x #2 x 83x10°3)] * 44 = 126 mm 65. From the previous problem, determine the maximum shearing stress induced in the shaft if the modulus of elasticity in shear is 83 GPa. Solution: Ss max = 16T/aD*3 16x 18x10°6 / wx 1263 = 45.8 MPa 66. Determine the power that can be transmitted by a solid shaft 6 m long and running at 180 rpm. The maximum shear stress induced is 70 MN/m*2 When twisted through 3 degrees. G = 83 GN/mm*2. Solution: Ss max = 16T/aD’3 70 Nimm’2 T=ax D3 x 70/16 = 13.744D°3, [@ = 180/x (TLIIG)] degree © =3 degree G=83x10°3 Nimm’2 T=(3 x D4 x 83x103) / (180 x 32 x 6,000) = 0.071 LID“4 Equating the torque: 0.0711 1D"4 =13.744D'3 D=193.2 mm T=0.07111 x 19: 9,907.3x10°% N-mm = = 2nTN = 2 x 9,907.3 x 10-x 150/60 = 1,556,235 W = 1,556.2 KW 67. Determine the diameter of a steel marine propeller to transmit a shaft power of 5.000 KW at 200 rpm. Design shear stress is 50 MPa and maximum allowable twist is not more than 1 degree in 25 diameter of propeller length. Axial load is negligible. Solution: T= (9.55x10°6 x 5,000KW)/220 rpm = 217.045x10°%6 N-mm Ss max = 16T/aD/3 = 50 Nimm”2 D = [(16 x 217.045x10"6 x 25 x 32) / (wx 83x10*3)] “1/3 = 280 mm © = 180 nx (TLIG) O= 1 degree L=25D x D/32 G=83x10°3 Nimm*2 D = [(180 x 217.045x10°6 x 25 x 32) / (wx 83x10°3)] “1/3 = 493 mm Therefore use: D = 493 mm68. Determine the maximum twisting moment that can act on a composite stepped steel shaft which consists a hollow section 2 m long, 70 mm ID, and 100 mm OD rigid attached to a solid portion 1.5 m long and 70 mm in diameter, if the design stress in shear is 80 MN/m*2 and the total twist is not to exceed 2.0 degree. Solution: For strength: $s max = Tr/ T Hollow section: Ss max = 80 MN/mm"2 OD/2 = 0.100/2 = 0.050 m /32 x (OD“4 — ID“4) = 1/32 x (0. 100°4 — 0.0704) =7.4603x10"-6 m4 T =(80 x 7.4603x10*-6) / 0,05 = 11.936x10°-3 MN-m Solid section Ss max = 16T/aD*3 = 80 MN'm’2 r= D/2 =0.07/2 = 0.035 m /32 x 0,07°3 = 2.3572x"10-6 m“4 T= (80x 2.3572x10"6) / 0,07 = 5.3878x10°-3 MN-m For tigidity: 0 = 180/7 x (TL/JG) degree The total twists of the composite shaft is equal to the sum of the twist of the hollow and solid sections, Ot= Os + Oh 2.x w/180 = [(Tr x 2)(7.4603x10-6 x 83x10°3)] + [(Tr x 1.50)/(2.3572x10%-6 x 83x1093)] Tr=3.2x10*-3 MN-m = 3.2 KN-m The smallest of the torque is Tr, therefore: Tmax = 3.2 KN-m 69. Determine the maximum length of a flexible steel wire shaft encased in a stationary tube that fits closely enough to impose a frictional torque of 2 N-nvm. The wire has a diameter of 10 mm and the induced stress must not exceed 140 MN/m*2. Solution: T =2L = 2x10%-6 MN-m/m (Lm) = (Ss x tx D3) / 16 = (140 x xx 0.010°3) / 16 L=13.74m 70, From the previous problem, what will be the angular rotation of one end with respect to the other end? Solution: © = integration from 0 to © (d0) = integration from 0 to L [(2x10%-6 x LAL)/JG] (2x10*-6/JG) x (L*2/2) 132 x 0.014 = 9.817x10°-10 m4 G = 83x10*-3 MN/m*2 © = (2x10%6 x 13.742) / (2 x 9.817X10°-10 x 83x10°3) = 2.316 rad = 132.75 degree71. A hollow shaft is slipped over a solid steel shait 60 mm in diameter. The shafts are of equal length and are fastened rigidly together at their ends. If the hollow bronze shaft has an outside diameter of 90 mm, what would be the maximum shearing stress induced in the solid steel by a torque of 3000 N-m applied at the ends? For bronze, GPa; for steel 83 GPa. Solution: T, = torque acting on steel shaft To = torque acting on bronze shaft T.=+Tp=3x 10° MN-m OD = Outside diameter of bronze shaft ID = inside diameter of bronze shaft D = diameter of steel shaft ID 8s = twist of steel shaft 8b = twist of bronze shaft 1 - oe ase I(steel) = (wy (60% 32 723 x 10° mm* = 1.2723 x 106 mt I(bronze) = (71904 — 60°) 32 1689 x 10° mm? 1689 x 10% m* 3 = 6b T) = Th (1.2723)(83)_(5.1689)(35) T,= 0.5837, T.+Tp=3x 103 MN-m Ty = 1.894 x 10? MN-mTb T.= 1.106 x 103 MN-m For the steel shafting: (max) ~ 161. = (16)(1.106 x 10: xD> (n)(0.06*) lo7 MPa 72. From the Previous Problem, What would be the maximum shearing stress induced in the hollow bronze? Solution: For the bronze shafting: SHAFT OD = 90 mm; ID= 60mm;ID 009.667, O90 K=0.1975 Seam = —16Te _ 16)(1.894 x 193): yp ves “(@MOD*)\(I-K*) ()(0,090°)(1-0.1975) 73. A solid circular shaft transmits $0 KW at 900 xpm. It is supported by a bearing and a pinion 100 mm pitch diameter is attached to it. With the tooth load uniformly distributed over the face of the gear and the shaft is assumed to be rigidly supported, determine the torsional moment transmitted by the shaft Solution: 2nTN 50,000 = (Ee) T= 530.5 N-m 60 74, from the Previous Problem, Assuming 20° involute teeth, what is the maximum bending moment on the shaft? Solution: F = tangential load = 21/D = 10510 M= maximum bending moment ‘ace width x F = 0.074 (10.610) = 371.35 N-m 75. From the Previous Problem, What is the diameter of the shaft if the allowable shear stress is 43 MPa? Solution: S.=43 MPa Di=_16 VIP+M*= 16 V(S30.5x 10° = 71.35 x 10°? NS.) (43) D=42.48 mm Use D=43 mm 76. A keyed fiange coupling connects two 80-mm diameter commercial shaftings. If the shafis Were to run at 300 spm and to transmit power supplied from a 4-cylinder gasoline engine, determine the power that can be transmitted. Assume the shafting with a keyway with a shear sttess of 41 MP a and a shock factor of 1.3. Sier LOTR)(xy(D") 41)(3.1416)(80°) Tex3 3170x108 P=2nTN= rar Pepe P= 99,588.5 W = 99.5 kw 77. A hollow circular shaft whose inside diameter, ID, is one-half its outside diameter, OD, can transmit a torque of 2500 N-m clockwise and a torque of $00 N-m counterclockwise, Determine the shaft outside diameter if the design factor is 2 based on the yield strength and the endurance limit in shear. Material of shaft is SAE 1095 annealed (endurance limit in tension = 358.53 MPa and yield strength in shear = 227.53 MPa). Solution: K=ID=05 oD K+ =0,0625 L-K*= 0.9375, otow shat Sn = endurance limit in shear 5 (Sa) = 0.5(358.53) = 179.3 MPa Tn = mean torque ‘Max. torque ~ Min, torque 2 lternating torque fax. torque — Min. torque = 2500 —(-500) = 1500 N-m. 2 500 — (-500) = 1500 N-m ny Ts Sm = __16Tm, 16(1000) 32.5 (@OD*\I-K*) —@(OD*V(0.9375)_ OD* Ss=__16Ta = __16(1500)_ = 8148.7 (@OD\L-K*) (@(OD*(0.9375) OD? 227.53 MPa = 227.53 x 106 Nim* 79.3 MPa = 179.30 x 10° Nim? ~_54325__ +_81487__ OD? (227.53x10°)OD*) | (179.3x10°(OD*)78. From the Previous Problem, determine the inside diameter of the hollow shaft. Solution: ID QD =5L75 2°72 79. A 58.7375 mm cold-rolled shafting running at 350 pm is driven by an ovethanged flat pulley having a diameter of 1320.8 mm, under this condition this shaiting transmits 70 Hp (52.22 kw). Assuming that the maximum bending moment is 1.45 as the shearing moment, determine the maximum shearing moment. Solution: T= maximum torsional (shearing) moment P-2aTN apo 52,220 T= 1427.75 N-m = 1427.75 x 107 N-mm 80. From the Previous Problem, Determine the maximum bending moment. Solution: M = maximum bending moment = 1 4ST = 1.45(1424,75) = 2065.89 N-m = 2065.89 x 10° N-mm. 81. Find the power that can be transmitted bya cast iron shaft 76.2 mm in diameter when making 20 revolutions per minute, the value of S, not to exceed 10.522 MPa. Solution: T= (n\D*V(S.) = (4)(76.2°)(10.522) = 914 x 10° N-mm = 914 Nem 16 16 P=2a1N= mom) 20 = 1914.2 W 82. Find the diameter of a steel shaft which will be used to carry a 118.1-kw motor rotating at 265 rpm if the distance between bearings is 1.2192 m. assume the torsional stress to be 92 MPa. Solution: P=2aIN 118,100 =2 mp dt T= 4255.74 N-m = 4255.74 x 10° N-mm Di = 16T = 16(4255.74 x 10° (@S.) nx 92 D=61.76 mm, use 62 mm83. From the Previous Problem, If a coupling is used to transmit the power, find the diameter of the bolts to be used if the radius of the bolt circle is 120mm and the number of bolts is 8. Assume the torsional stress of the bolts to be 55 MPa. Solution: The bolts are under single shear. = diameter of the bolts, mm ‘N= number of bolts = R~ radius of bolt circle = 120 mm S = torsional (shear) stress of the bolts 33 MPa~ 55 N'imm? A = cross-sectional area of one bolt, mm? = 0.78540? shearing force per bolt acting normal to bolt axis, N §.74 x 10° / (120) (8) 3(0.7854)(55) d=11.7 mm Use = 12-mm bolts 84, There are three parallel shafts A, B and C. shaft A has a 28-tooth gear of module, ms = 6.35 meshing with a large gear of shaft B having 80 teeth. A smaller gear of 22 teeth and m = 8.467 of shaft B- meshes with a 54 tooth gear of shaft C. if the shafts are on a level plane, find the distance between shafts A and C. Solution: Pitch diameter = (Module) (Number of teeth) itch diameter of gear on shaft A, mm Da = (6.36) (28) = 177.8 mm itch radius of gear on shaft A, mm 4/2 = 88.9 mm pitch diameter of gear on shaft B, with 80 teeth Dai = (6.35) (80) = 508 mm Rai = pitch radius of gear on shaft B, with 70 teeth 508/2 = 254 mm Dp» = pitch diameter of gear on shaft B, with 20 teeth Dp = (8.467) (22) = 186.2 mm Ra: = piteh radius of gear on shaft B, with 20 teeth 186.2/2 = 93.1 mmDe = pitch diameter of gear on shaft C De= (8.467)(54) = 457.21 mm Re = itch radius of gear on shaft C Re = 457.21/2 = 228.6 mm D = distance between shafts A and C =Ra + Rai + Rap Re = 88.9 + 254+ 93.1 + 228.6 = 664.6 mm 85. From the Previous Problem, Find the rpm of shaft C if shat A turns 1500 rpm. Solution: RPM of C= 1560 Je 3” = 214 8 86. From the Previous Problem, Find the rpm of shaft C if shaft A turns 1500 rpm. Solution: P=2aIN 41,000(0.93)(0.93) = 2 ] 214 a T= 1582.3 Nm 87. A steel shaft is transmitting 41 kw at 1100 rpm. The nature of the load and the type of service of the shaft is such that the allowable shearing stress based on pure torsion is 29.256 MPa. Compute the diameter of the shaft to the nearest commercial size of shafting. Solution: P=2zTN 41,000 = mm ij ca 335,928 N-amm (29.256) D=395 mm Use D = 39.5 mm shafting 88. From the Previous Problem, Calculate the torsional deflection of the shaft in degrees per foot of the shaft. Use G = 83 GPa. Solution, 180 deg x-994,7(83]000) KEYS Contents: A. Definitions B. Types of Keys C. Stresses in Keys D. Compressive Stress E. Shearing Stress F. Solved Problems Definitions: Key—a machine member employed at the interface of a pair of mating male and female circular cross-sectional members to prevent relative angular motion between these mating members. Keyway —a groove in the shaft and mating member to which the key fits. Splines ~ permanent keys made integral with the shaft and fitting into keyways broached into the mating hub. Types of Keys: 1 Square key ~ has a square cross-section with half of its depth sunk the shaft and half in the hub. 2Flat key — has rectangular cross-section with the smaller dimension placed in the radial direction with half sunk in the shaft and half in the hub and is used where the weakening of the shaft by the keyway is seirous. 3.Round key — has a circular cross-section. 4.Barth key — is a square key with bottom two comers beveled. $.Woodruff key — consists of one-half of a circular disk fitting into a rectangular keyway in the female member and a semi-circular keyway in the male member. 6.Gibd-head taper key — is a flat with a special gib-head to facilitate easy driving and removal of, the key. 7.Saddle key — is a flat key used without a keyway in the shatt. 8.Kennedy keys — are tapered square keys with the diagonal dimension in a circumferential direction 9.Feather key — is one which has a tight fit into one member and a loose sliding fit in the other mating member thus allowing the hub to move along the shaft but prevents rotation on the shaft. ODES Ei i NS ae Square Key Flat Key Wood ey ie ae ; BS g&> 7 ia aa cclea ee aa acaiStresses in Keys 22TN SE. oS a + Where: D = diameter of the bolt circle D, - diameter of the shaft t= thickness of the flange 4 = diameter of the bolt CO» Torque Capacity of Coupling (One Concentric Row) T-FRo=FDa 2 Torque Capacity of Coupling (Two Conceptrie Rows); T =FiRim + F2Rone D1 mt _+ F2 D2 m 2 Where: o T = torque capacity of coupling or torque” transmitted by hd F = shearing force of one bolt radius of bolt circle D = diameter of bolt circle umber of bolts 5 " Relations of Shear Strain, Radial Distance and Shear Stress: Relation of Shear Strain and Radial distances from the axis of the shaft: Ys =¥2 Ri =RRelation of Shear Stress and Radial distances from the axis of the shaft: Where: Y = shear strain R = radius of bolt circle Ss G = modulus of rigidity SOLVED PROBLEMS 1.4 flanged bolt coupling has ten (10) steel 25.4 mm diameter bolts evenly tighten around a 415 mm bolt circle. Determine the torque capacity of the connection if the allowable shearing stress in the bolt is 50 MN/m’, (ME Bd. Oct 97). A. 59.95 Nm B. 52.6 kN-m* C. 46.15 KN-m D. 43.8 KN Solution: Sw = shearing stress per bolt = Fo “Av = 50,000 KN/m? Sw» = 50 MN/m? Fy (0.0234)? 50,000 force on all bolts = 25.335 x 10 = 253.35 KN. T =torque =F x bolt circle radius = 52.57 kN-m 2.A flange coupling has an outside diameter of 200 mm and connects two 40 mm shafts. There are four 16 mm bolts on a 140 mm bolt circle. The radial flange thickness is 20 mm. if the torsional stress in the shaft is not to exceed 26 MPa, determine the shearing stress in the bolts if uniformly distributed. (ME Bd. Oct 90). A. 8.5. Nimm? B. 5.8 Nimm’* C. 6.5 Nimm? D.7.5 Nimm?* Solution: S, =_16T shearing stress of the shaftxD* 26,000 =__16T (0.40)? T = 0.3267256 kN-m_ F = force on bolts = Torque = 0.3267256 20142 F =4.6675KN = 4,667.5 N Fe = 4.667. 1,167 N 4 Shearing Stress on bolt = Fy = 1,167 “GQ (6F 3. flange coupling connects two 2” diameter shafts. The flanges are fitted with 6 bolts of SAE 1040 steel on a 7” bolt circle. The shaft runs at 300 rpm and transmits 45 Hp. Assume a factor of safety of 5, ultimate tension of 70,000 psi, and ultimate shear of 55,000 psi, what is the torque transmitted? Solution: Power -22TN 45(33,000) = 2 aT (300) T =787.817 ft-lbs 53.8 in-lbs *T 4 4.From the Previous Problem, Determine the diameter of bolts required. Solution: T =Fi) F =9453.8/3.5 = 2701 Ibs F per bolt = 2701/6 = 450.17 Ibs S =FA 3.000 = 450.17 d = 0.228 in, 3 (iA? 5.From the Previous Problem. How thick should the flange be? Solution: S =F/A 70,000 = 450.17 t=0.141 In 5 1(0.228) 6.4 flange coupling is to connect two 57 mm shafts. The hubs of the coupling are each 111 mm in diameter and 92mm thick and the flange webs are 19 mm thick. Six 16 mm bolts in a 165 mm diameter circle connect the flanges. The keyway is 6 mm shorter than the hub’s thickness and key is 14 mm x 14 mm, coupling is to transmit 45 KW at 160 rpm. For all parts, yieldpoint value in shear is one-half the yield point in tension or compression which is 448 MPa. Find the stress and factors of safety based on yield points hear in key. Solution: pom Length of key = 92-6 = 86 mm. _ Power =22TN 7 sfarom) 45 =2 xT (160/60) san irean T =2.686 KN-m : | 2 Radius =57 =28.5 mm ee Ye om Force on shafts_= torque = 2.686 = 94.246 KN _ Radius 0.0285 Shear in key = foree _= 94.246 = 78,277 KPa= 78,277 MPa Shear area 0.014(0.086) FS. <_224 86 78.277 7.From the Previous Problen in the key. Find the stress and factors of safety based on yield point bearing Solution: Bearing stress in key = ___force = 94.246 = 156,555 KPa = 156.555 MPa bearing area 0.007(0.086) FS. =_448 = 2.86 156. 8.Find the stress and factors of safety based on yield point shear in bolts Solution: Force on coupling = torque radius where: radius =165 = 82.5 mm =0.0825 m Force on coupling = torque =2.686 = 32.557kN Tadius 0.0825 32.557/6 426 kN foree_= 5.426 5426 = 26,987 KPa = 26.987 MPa Shear area (n/4(d?_— (n/4)(0.016F FS.=_24 = 83 Force per bolt Shear in bolts 9.Two short shafts having identical diameters of 38.1 mm and rotating at 400 mpm are connected by a flange coupling having 4 bolts with a 100 mm bolt circle. The design shearing stress of thebolt is 12 N/mm? and design compressive stress of the flange is 15 N/mm”. What is the power transmitted by the shaft in KW? Solution: Using PSME Code, Eq, 6a, p. 18: 100 em (400) 26.502 KW 10. From the Previous Problem, What diameter of bolt should be used? Solution: P =2n1N 26.502 T = 0.632689 kN-m radius 00 = 50 mm =0.050m 2 For = force jorque = 0.632689 = 12.654 kN = 12,654 N radius 0.050 Force per bolt = 12,654/4 = 3,163.5 N Ss L = FIA ur 4 d = 18.32 mm=0,72 in, From Table 6-1, p. 130, Doughtie and Vallance: Bolt Diameter = % in. (19.05 mm) 11. From the Previous Problem, How thick should be the flange in mm? Solution: S =FA 15 = 3,163.5 t = 11.07 mm thickness of flange 19.05 t 12. A flanged bolt coupling has a bolt circle 360 mm in diameter where eight steel 25-mm- diameter bolts are evenly spaced. Determine the torque transmitted by the coupling if the design shearing stress in the bolts is 60 MPa. Solution’ T= torque transmitted by the coupling = PRn =a (°)(Sqs)(Rn) = 0.7854(252(60) 360 (8) = 4241.15 x 10* N-mm 4 2 T = 42411 Nm13. A solid circular shaft 90 mm in diameter is connected by a rigid coupling to a hollow shaft 100mm in outside diameter and 90 mm in inside diameter. If the allowable stress in shear in the shafts and bolts is 70 MPa, determine the number of 12-mm-diameter steel bolts to be used on a 240-mm-diameter bolt circle so that the coupling will be as strong as the weaker shat Solution: Sx 7 For the hollow shaft r= 100 =50mm 5 =x (OD*~ ID*) = x (100% 90%) = 337,623 x 10 mm* 32 Tp = torque that could be transmitted by the hollow shaft = 60 (337.623 x 10) = 405.1476 x 10 Nemm = 30 5 kN-n For the solid shaft: 90/2 = 45 mm J = (90%) = 644.125 x 10% mm Ts torque that can be transmitted by the solid shaft, =__60(644.125 x 10+) = 7.7295 x 10° Nemm = 7.72 45 kN-m Hollow shafting is weak A =area of one bolt = 0.7854 (12°) Solving for the force per bolt: F =S, (A) = 70(113A) =7917 N Total foree on bolts = 405.1476 x 10* = 33,762.29 N 120 29 = 13.1 mm? No. of bolts = 33. 762 7, oa Use 5 bolts 14, Eight 10-mm-diameter steel bolts on a bolt circle 150 mm in radius and six 20-mm- diameter steel botls on a concentric bolt circle 100 mm in radius were used in a rigid coupling If the design stress in the bolts is 60 MPa, determine the torque capacity of the coupling, Solution: "His DI a Where the subscripts 1 and 2 refer to the bolts in the outer and inner circles: 0 Ly Fi =2.667F:10 150 Ay Su = 0,7854(10°)(60) = 4712.4 N T = torque capacity of coupling T =FrRim + F2Rom = 4712.4(150)(8) + (2.66)(4712.4)(100)(6) = 13.175 x 106 N-mm = 13.175 kN-m_ 15, A flanged coupling having an outside diameter of 190 mm connects two 40-mm shafts ‘There are three 16-mm bolts on a 134-mm bolt circle, The radial flange thickness is 20 mum. if the torsional stress in the shaft is not to exceed 30 MPa, determine the power that can be transmitted at 900 rpm. Solution: T =Torque transmitted = x D'S. = n(40°\(30) = 376.991 x 10° N-mm = 376.991 N-m 16 16 Power transmitted, P= 2 xTN = na 76201 900 = 35,530.56 W 5.53 kw 16. From the Pervious Problem, determine the shearing stress in the bolts if uniformly distributed. Solution: F = shearing force per bglit.= _T_= (376,991) = 1875.57N D4 3{ 3 ats shearing stress in the bolts =F =_ 187.57 =9.3 MPa A _ x (16? 17. From the Previous Problem, determine the maximum shearing stress induced in the bolts. Solution: 4F 3A (9.3) = 12.43 MPa Secoas) 18. From the Previous Problem, determine the bearing pressure in the bolts. Solution: Shearing force =_1875.57 = 5.8 MPa Bearing Pressure: Projected area of bolt 16x20 19. Two 38.1 mm shafts are connected by a flanged coupling. The flangs are fitted with 6 bolts of SAE 1020 steel on a 152.4 mm bolt circle. The shafts run at 260 rpm and transmit a torque of 950,000 N-mm. assuming a factor of safety of S, ultimate tension, 430 MPa, and ultimate shear, 330 MPa, what power is transmitted? Solution: P =2n1N “26h Po? = 3,143 W = 23.1 kw0 20. From the Previous Problem, Determine the diameter of the bolts required. Solution: 1 = number of bolts = 6 De~ diameter of bolt circle = 152.4 mm F = shearing force per bol = T Q F = 850,000) = 1859.14 {12 \4 Design stress, Sa = 330 = 66 MPa F =A(Sa) 1859.14 =n d (66) 4 d =5.98 mm use 6 mm bolt 21. From the Previous Problem, How thick should the flange be? Solution: Sa =430 = 86 MPa F = 1859.14 N per bolt, F =d(t) (Sa) 1859.14 =3.6 mm 6x86 22. Two solid shafts 120 mm in diameter are coupled by bolts 30 mm in diameter with centers 120 mm from the axis. How many bolts arg necessary? Solution: D = diameter of bolts = 30 mm Pe] oe 200mm De = diameter of bolts circle = 120 x 2= 240 D> shaft diameter= 120 mm n =number of bolts T =torque transmitted by bolts_- 2 x dS. 5 220mm T = torque of shaft D's, 16 a (120) 4 120(0.784 x 30°)(16) Use 4 bolts