Muhannad Al_Waily_Machines Systems Design

Shaft Design

Stress Concentration Effect Gear Forces Effect

Under Under
Spur Helical Bevel Worm
Static Dynamic
gears gears gears gears
Load Load

Maximum Stress Result

Stress Bending stress

concentration Normal stress
Axial stress
Minimum area
Direct shear
Shear stress
Maximum load
Torsion shear
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Stress Concentration

 max  K t . nom
 max  K ts . nom

Kt

stress-concentration factor
for normal loading

Kts

Photo-elastic Measurement of stress Concentration in flat, stopped, notched bar in bending.

stress-concentration factor
for shear loading

nom & nom are the nominal stresses calculated for the particular applied loading and net cross-section assuming
a stress distribution a cross the section that would obtain for a uniform geometry
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The theoretical stress-concentration

factor at the edge of the hale

a
Kt 1  2 
c

Stress Concentration at the Edge of an Elliptical hole in a plate.

exponential function

represents the
independent variable

b
K t  Ax
the coefficient A and exponent b for any one
value of ' ' are determined by nonlinear
regression on several data points taken from
Geometric stress-concentration factors and functions for stepped flat bar in
the experimental data bending.
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r/d r/d

r/d r/d
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r/d r/d

d/D
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Stress Concentration Under Dynamic Loading

Fully reversed Repeated Fluctuating

Mean or    min
average stress
 m  max stress range    max   min
2
   min  min a
variable stress  a  max ratios R
 max
A
m
2
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Kb= load correction factor for

endurance limit for  eb   e .K b   e
the reversed bending load. Its
reversed bending load
value is usually taken as unity

Effect of Loading
Ka= load correction factor for
on Endurance endurance limit for
Limit-Load the reversed axial load. Its
reversed axial load
 ea   e .K a
Factor value may be taken as 0.8

Ks= load correction factor for the endurance limit for

reversed torsional or shear load. reversed torsional or  es   e .K s
Its value may taken as 0.55 shear load

For steel  e  0.4 u

For cast iron  e  0.35 u

For non-ferrous
metal and alloys
 e  0.3 u

Factor of Safety for Fatigue Loading

Endurance Limit Stress 

F .S .   e
Design or Working Stress  d
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Notches and Stress Concentration (Notch Sensitivity)

K f 1 fatigue (dynamic) stress-

' notch sensitivity ' q q
Kt  1 concentration factor

1 K f  1  q.( K t  1)
q
a
1
r
Stresses

  K f . nom
  K fs. nom

for Annealed)b( for Hardened )c(

Aluminum aluminum
for steels)a(
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Combined Steady and Variable Stress

Goodman method Soderberg method

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Goodman Method for

Combination of Stresses
a m
1
e u
F .S . F .S .

e  m   1  
a  1   e  m
F .S .   u   F .S .  u 
 F .S . 

1  
 m  a
F .S .  u  e
' the fatigue stress concentration factor ' Kf
1  m  a .K f
 
F .S .  u e

ductile materials brittle materials

1   a .K f 1  .K  a .K f
bending  m  m t  bending
F .S .  u  eb F .S . u  eb
1   a .K f  .K  a .K f
axial loading  m 1
 m t  axial loading
F .S .  u  ea F .S . u  ea
torsional or shear 1   a .K f 1  .K  a .K f torsional or shear
loading  m  m t  loading
F .S .  u  es F .S . u  es
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Soderberg Method for

Combination of Stresses
a m
1
e y
F .S . F .S .
   1
e  m   
a  1 e   m
F .S .   y 
 F .S .  y 
 F .S . 

1  
 m a
F .S .  y  e
' the fatigue stress concentration factor ' Kf
1  m  a .K f
 
F .S .  y e

ductile materials

bending axial loading torsional or shear

loading
1

 m  a .K f
 1  m  a .K f
  1   a .K f
F .S .  u  eb F .S .  u  ea  m
F .S .  u  es
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Combined Variable Normal Stress and Variable

Shear Stress

equivalent normal torsional or shear

stress due to equivalent normal loading
reversed bending stress due to reversed
axial loading

 a . y .K fb  a . y .K fs
 neb   m   a . y .K fa  se   m 
 eb  nea   m   es
 ea

total equivalent normal stress

y
 ne   neb   nea 
F .S .

Maximum shear stress theory Maximum normal stress theory

2 2 y y
 se(max)  1
2
 ne   4 se    ne(max)  1  ne  1  ne 2  4 se 2 
F .S . 2 2 F .S .
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mean or average Mm
bending stress m 
Simple
Z
  y  
bending  b  323 
M m   
.K f .M a 
d  
 e 
variable bending Ma
stress
a 
Z

mean or average F Fm   y  F
axial stress m  m a    .K f . a
Axial
A A  e  A
Loading  y 
variable axial Fa Fm   .K f .Fa
stress a   e 
A 
A
mean or average 16.Tm
shear stress m  16.Tm   y  16.Ta
3
Simple  .d    .K .
 .d 3   es 
fs
 .d 3
torsion
variable shear 16.Ta 16  y  
a   . T  
 m   fs a .K .T
stress  .d 3    es 
 .d 3 
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Designing to Avoid Stress

Concentrations (Methods of
Reducing Stress Concentration)
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Gear Forces

Spur Gear Straight Tooth

Bevel Gear

Tangential force
Bevel Gear

radial force Spiral Bevel

Gear

Helical Gear
Tangential force

Tangential force The pinion thrust

force
Separating force
The gear thrust
force
Thrust force Worm Gearing

Tangential force on the worm

Tangential force on the worm gear

The separating force

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Mt
Tangential force Ft 
r
Spur Gear

radial force Fr  Ft . tan 

Tangential force
Mt
Ft 
If the pressure angle r
is measured in a Separating force
plane perpendicular
Fr  Ft . tan 
to the axis of the gear
Thrust force
Fa  Ft . tan 
tan n
Helical Gear tan  
cos
Tangential force
M
Ft  t
If the pressure angle is r
measured in a plane Separating force
perpendicular to a F . tan n
tooth Fr  t
cos
Thrust force
Fa  Ft . tan 
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Direction of Thrust loading

Bevel Gear

Straight Tooth Bevel Gear The tangential force

Spiral Bevel Gear The pinion thrust force

The gear thrust force

The tangential force Mt

Ft 
r

The pinion thrust force F p  Ft . tan  .sin 

The gear thrust force Fg  Ft . tan .cos 

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(c)
(a)

(b) (d)
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Worm Gearing

Tangential force on the worm Tangential force on the worm gear The separating force
Mt  1  f . tan    sin n 
Ft ( worm)   cosn  Fr  Ft ( gear ) . 
rw Ft ( gear )  Ft ( worm) .  cos  . cos   f . sin 
 
 tan   f
n

 cosn   sin n 
 Ft ( worm) . 
 cos  . sin   f . cos  
 = lead angle of the worm (which is the same as the lead n

helix angle of the worm gear) tan  

 .Dw

Direction of Tangential forces on Worm and Worm gear