Machine Design 1: BASAEN, RV

Maximum Flexural Stress

9. SHAFTING
𝟑𝟑𝟑𝟑𝟑𝟑
𝑺𝑺𝒇𝒇 = ⇒ 𝑺𝑺𝒅𝒅 : (solid shaft)
Shaft – a rotating member, usually of circular section, 𝝅𝝅𝑫𝑫𝟑𝟑
used to transmit power or motion. Its primary load is 𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑
torsion. 𝑺𝑺𝒇𝒇 = ⇒ 𝑺𝑺𝒅𝒅 : (hollow shaft)
Axle – a non-rotating member which carries no torque 𝝅𝝅(𝑫𝑫𝟒𝟒 − 𝒅𝒅𝟒𝟒 )
and is used to support wheels, pulleys, and the like. It is or,
primarily loaded with bending. 𝟑𝟑𝟑𝟑𝟑𝟑 𝟏𝟏 𝑑𝑑
𝑺𝑺𝒇𝒇 = 𝟑𝟑
� 𝟒𝟒
� ⇒ 𝑺𝑺𝒅𝒅     :     𝐵𝐵 =
Spindle – a short shaft or axle. 𝝅𝝅𝑫𝑫 𝟏𝟏 − 𝑩𝑩 𝐷𝐷

Terms such as lineshaft, headshaft, transmission shaft, Shaft Deflection

machinery shaft, countershaft, and flexible shaft are names 𝑃𝑃𝐿𝐿3
𝑦𝑦 = : (For special cases only) ∗
associated with special usage. 𝐶𝐶𝑠𝑠𝑠𝑠 𝐸𝐸𝐸𝐸

Most machine design books generally use the term Case 1) Shaft acts as a cantilever with load P at free end
*

shaft to mean all of the above terms.

P
L
♦ SHAFT UNDER PURE TORSION y 𝐶𝐶𝑠𝑠𝑠𝑠 = 3

T T
Case 2) Shaft is simply supported with load P at midspan
*

D d D
L/2 P
y 𝐶𝐶𝑠𝑠𝑠𝑠 = 48
Solid shaft T Hollow shaft T
L
Maximum torsional stress

𝟏𝟏𝟏𝟏𝟏𝟏 Case 3) Shaft has fixed supports with load P at midspan

*
𝑺𝑺𝒔𝒔 = ⇒ 𝑺𝑺𝒔𝒔𝒔𝒔 : (for a solid shaft)
𝝅𝝅𝑫𝑫𝟑𝟑 L/2 P
𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 y 𝐶𝐶𝑠𝑠𝑠𝑠 = 192
𝑺𝑺𝒔𝒔 = ⇒ 𝑺𝑺𝒔𝒔𝒔𝒔 : (for a hollow shaft)
𝝅𝝅(𝑫𝑫𝟒𝟒 − 𝒅𝒅𝟒𝟒 ) L
or
𝟏𝟏𝟏𝟏𝟏𝟏 𝟏𝟏 𝑑𝑑
𝑺𝑺𝒔𝒔 = � � ⇒ 𝑺𝑺𝒔𝒔𝒔𝒔 : 𝑤𝑤ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝐵𝐵 = Two General Classifications of Shafts
𝝅𝝅𝑫𝑫 𝟏𝟏 − 𝑩𝑩𝟒𝟒
𝟑𝟑 𝐷𝐷
1. Transmission shaft – shaft that connects a prime
Angle of twist (torsional deformation) mover to a machine.
𝑇𝑇𝑇𝑇
𝜃𝜃 = : in radians 2. Machinery shaft – shaft that is an integral part of
𝐽𝐽𝐽𝐽
where: a machine
𝜋𝜋 4
𝐽𝐽 = 𝐷𝐷 : for solid shafts A.S.M.E. Formulas
32
and Shaft Design Stresses (Only Sy and Su are known)
𝜋𝜋 Shear design stress:
𝐽𝐽 = (𝐷𝐷4 − 𝑑𝑑4 ): 𝑓𝑓𝑓𝑓𝑓𝑓 ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑠𝑠ℎ𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 whichever is smaller:
32 Ssd = 0.3 Sy
Ssd = 0.18 Su If shaft has a keyway,
♦ SHAFT UNDER PURE BENDING consider a strength
reduction factor of 0.75
M M M M
Normal design stress:
Sd = 0.6 Sy whichever is smaller:
D d Sd = 0.36 Su If shaft has a keyway,
consider a strength
Solid shaft Hollow shaft reduction factor of 0.75

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 Machine Design 1: BASAEN, RV

Allowable deformations and

Angle of Twist 16
𝑆𝑆𝑚𝑚𝑚𝑚𝑚𝑚 = [𝐾𝐾 𝑀𝑀 +�(𝐾𝐾𝑠𝑠 𝑇𝑇)2 + (𝐾𝐾𝑚𝑚 𝑀𝑀)2 ] ⇒ 𝑆𝑆𝑑𝑑
Transmission shaft: 𝜋𝜋𝐷𝐷3 𝑚𝑚
θ𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 1𝑜𝑜 in a length of 20 diameters
Machinery shaft: … then solve for the diameter D from each of the formulas,
θ𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 0.08𝑜𝑜 𝑡𝑡𝑡𝑡 1𝑜𝑜 per foot of length and use whichever is larger!
between supports
If Km and Ks are not specified, use 𝐾𝐾𝑚𝑚 = 𝐾𝐾𝑠𝑠 = 1.0.

Note:
Transverse Deflection - If the shaft material is ductile, use the first
Transmission shaft: equation. A ductile material for a shaft is more
𝑦𝑦𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 0.01 inch per foot of length common than a brittle material.
between supports - If uncertainty arises as to the shaft material, use
Machinery shaft: the more conservative result of first and second
𝑦𝑦𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 0.002 inch per foot of length equations (e.g. for the shaft diameter, 𝐷𝐷, use the
between supports greater diameter from the equations).
- If the axial load is tensile 𝛼𝛼 = 1.0.
♦ COMBINED STRESSES - If loading conditions are not specified, the factors
𝐾𝐾𝑠𝑠 & 𝐾𝐾𝑚𝑚 become insignificant.
M T M 𝐾𝐾𝑠𝑠 = 𝐾𝐾𝑚𝑚 = 1.0
- If some loads are considerably low, they may
F F become negligible, thus, the first and second
D d equations may be simplified.
- From the possible loads on the shaft, bending
moment M is oftentimes the most difficult load to
compute.
T
From the Maximum Shear Stress equation
𝟏𝟏𝟏𝟏 𝟏𝟏 ♦ Transmission shafts from the PSME Code,
𝑺𝑺𝒔𝒔 𝒎𝒎𝒎𝒎𝒎𝒎 = � �
𝝅𝝅𝑫𝑫 𝟏𝟏 − 𝑩𝑩𝟒𝟒
𝟑𝟑
Machinery’s handbook, Kent’s M.E. handbook,
𝜶𝜶𝜶𝜶𝜶𝜶(𝟏𝟏 + 𝑩𝑩𝟐𝟐 )
𝟐𝟐
etc.
��(𝑲𝑲𝒔𝒔 𝑻𝑻)𝟐𝟐 + �𝑲𝑲𝒎𝒎 𝑴𝑴 + � � ⇒ 𝑺𝑺𝒔𝒔𝒔𝒔
𝟖𝟖

and, from the Max. Normal Stress equation Main Power

𝑺𝑺𝒎𝒎𝒎𝒎𝒎𝒎 = Transmitting
Shaft
𝟏𝟏𝟏𝟏 𝟏𝟏 𝜶𝜶𝜶𝜶𝜶𝜶�𝟏𝟏 + 𝑩𝑩𝟐𝟐 �
= 𝟑𝟑
� 𝟒𝟒
� �𝑲𝑲𝒎𝒎 𝑴𝑴 + Line
𝝅𝝅𝑫𝑫 𝟏𝟏 − 𝑩𝑩 𝟖𝟖
Shaft
𝟐𝟐
𝜶𝜶𝜶𝜶𝜶𝜶(𝟏𝟏 + 𝑩𝑩𝟐𝟐 )
+ ��(𝑲𝑲𝒔𝒔 𝑻𝑻)𝟐𝟐 + �𝑲𝑲𝒎𝒎 𝑴𝑴 + � �� ⇒ 𝑺𝑺𝒅𝒅
𝟖𝟖
Machine
where shaft
α = factor for column action Driven
Ks = combined shock and fatigue factor for Countershaft
Machine A
shear
Km = combined shock and fatigue factor for
bending Driven
B = ratio of inside to outside diameters of Machine B
hollow shaft

Note:
Main Power Transmitting Shafts
For combined torsion and bending on a solid shaft,
𝑫𝑫𝟑𝟑 𝑵𝑵
above formulas can be reduced to 𝑷𝑷 =
𝟖𝟖𝟖𝟖
16 Line Shafts Carrying Pulleys
𝑆𝑆𝑠𝑠 𝑚𝑚𝑚𝑚𝑚𝑚 = �(𝐾𝐾𝑠𝑠 𝑇𝑇)2 + (𝐾𝐾𝑚𝑚 𝑀𝑀)2 ⇒ 𝑆𝑆𝑠𝑠𝑠𝑠 𝑫𝑫𝟑𝟑 𝑵𝑵
𝜋𝜋𝐷𝐷3 𝑷𝑷 =
𝟓𝟓𝟓𝟓. 𝟓𝟓
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 Machine Design 1: BASAEN, RV

Small, Short Shaft and Countershafts For standard sizes of shafts in mm

𝑫𝑫𝟑𝟑 𝑵𝑵
𝑷𝑷 = Shaft size, mm Increment
𝟑𝟑𝟑𝟑
where 4-10 1mm
P = horsepower transmitted 12,,15,17
N = angular speed in rpm 20 - 110 5mm
D = shaft diameter in inches 110 - 200 10mm
200 -280 20mm
Note:
Above formulas were based on design stresses ♦ Cases of Shaft Problems (Stress Based)
of: 1. 𝑆𝑆𝑠𝑠𝑠𝑠 𝑜𝑜𝑜𝑜 𝑆𝑆𝑑𝑑 is given � 𝑆𝑆𝑦𝑦 , 𝑆𝑆𝑢𝑢 , 𝑎𝑎𝑎𝑎𝑎𝑎 𝑁𝑁�
- 4 ksi for main power transmitting shafts
- 6 ksi for line shafts, and For Pure Torsion,
- 8.5 ksi for small / short shafts, and 16𝑇𝑇 𝑆𝑆𝑦𝑦𝑦𝑦 𝑜𝑜𝑜𝑜 𝑆𝑆𝑢𝑢𝑢𝑢
countershafts 𝑆𝑆𝑠𝑠 = 3
⇒ 𝑆𝑆𝑠𝑠𝑠𝑠 =
𝜋𝜋𝐷𝐷 𝑁𝑁
(𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑠𝑠ℎ𝑎𝑎𝑎𝑎𝑎𝑎)
16𝑇𝑇𝑇𝑇 𝑆𝑆𝑦𝑦𝑦𝑦 𝑜𝑜𝑜𝑜 𝑆𝑆𝑢𝑢𝑢𝑢
♦ Empirical Formulas from Machinery Handbook 𝑆𝑆𝑠𝑠 = 4 4
⇒ 𝑆𝑆𝑠𝑠𝑠𝑠 =
𝜋𝜋(𝐷𝐷 − 𝑑𝑑 ) 𝑁𝑁
Required Shaft diameter: Also,
a) for an allowable angle of twist not exceeding 16𝑇𝑇 1 𝑆𝑆𝑦𝑦𝑦𝑦 𝑜𝑜𝑜𝑜 𝑆𝑆𝑢𝑢𝑢𝑢
0.08º per foot of length 𝑆𝑆𝑠𝑠 = 3
� 4
� ⇒ 𝑆𝑆𝑠𝑠𝑠𝑠 =
4 𝜋𝜋𝐷𝐷 1 − 𝐵𝐵 𝑁𝑁
𝐷𝐷 = 0.29   √𝑇𝑇 (ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑠𝑠ℎ𝑎𝑎𝑎𝑎𝑎𝑎)
b) for an allowable angle of twist not exceeding 1º
in a length of 20 diameters where
3
𝐷𝐷 = 0.1   √𝑇𝑇 𝑑𝑑
c) for short, solid shaft subjected only to heavy 𝐵𝐵 =
𝐷𝐷
transverse shear
1.7𝑉𝑉 For Pure Bending
𝐷𝐷 = � 32𝑀𝑀 𝑆𝑆𝑦𝑦 𝑜𝑜𝑜𝑜 𝑆𝑆𝑢𝑢
𝑆𝑆𝑠𝑠 𝑆𝑆𝑓𝑓 = 3
⇒ 𝑆𝑆𝑠𝑠𝑠𝑠 =
𝜋𝜋𝐷𝐷 𝑁𝑁
where (𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑠𝑠ℎ𝑎𝑎𝑎𝑎𝑎𝑎)
D = shaft diameter in inches 32𝑀𝑀𝑀𝑀 𝑆𝑆𝑦𝑦 𝑜𝑜𝑜𝑜 𝑆𝑆𝑢𝑢
T = torque in in-lb 𝑆𝑆𝑓𝑓 = 4 4
⇒ 𝑆𝑆𝑠𝑠𝑠𝑠 =
𝜋𝜋(𝐷𝐷 − 𝑑𝑑 ) 𝑁𝑁
V = maximum transverse shear load, lb 32𝑀𝑀 1 𝑆𝑆𝑦𝑦 𝑜𝑜𝑜𝑜 𝑆𝑆𝑢𝑢
Ss = maximum torsional shearing stress, psi 𝑆𝑆𝑓𝑓 = � � ⇒ 𝑆𝑆𝑠𝑠𝑠𝑠 =
𝜋𝜋𝐷𝐷3 1 − 𝐵𝐵 4 𝑁𝑁
(ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑠𝑠ℎ𝑎𝑎𝑎𝑎𝑎𝑎)
♦ Shaft Supported length VS. Shaft Diameter
(Deflection is limited to 0.01 inch per foot of length) 2. Only 𝑆𝑆𝑦𝑦 , 𝑎𝑎𝑎𝑎𝑎𝑎 𝑆𝑆𝑢𝑢 are given but no factor of
a) Shafting subjected to no bending action except safety, 𝑁𝑁
its own weight Use the ASME Code for Shaft Design
3
𝐿𝐿 = 8.95   √𝐷𝐷2 Shear design stress Normal design
stress
b) Shafting subjected to bending action due to Ssd = 0.3 Sy or Sd = 0.6 Sy or
pulleys Ssd = 0.18 Su Sd = 0.36 Su
3
𝐿𝐿 = 5.2   �𝐷𝐷2 … whichever is smaller … whichever is
where smaller
L = maximum distance between
bearings, feet Note:
D = shaft diameter in inches - Above 𝑆𝑆𝑠𝑠𝑠𝑠 and 𝑆𝑆𝑑𝑑 are based on the ASME
Code (p. 278 DME Faires shows estimation
♦ Standard Sizes of Shafts formulas)
For standard sizes of shafts in inches: - If the shaft is described to have a keyway,
refer to p. 269 of DME Faires multiply above design stresses by 0.75.

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 Machine Design 1: BASAEN, RV

3. No 𝑆𝑆𝑢𝑢, 𝑆𝑆𝑦𝑦, 𝑜𝑜𝑜𝑜 𝑁𝑁 given. The shaft is described to Then,

be any of the following transmission shafts, 𝑫𝑫𝟒𝟒 − 𝒅𝒅𝟒𝟒
𝑫𝑫𝒔𝒔 𝟑𝟑 − � �
MPTS – main power transmitting shafts 𝑫𝑫
% 𝑹𝑹. 𝑻𝑻. 𝑪𝑪. =
LS – line shaft carrying pulleys 𝑫𝑫𝒔𝒔 𝟑𝟑
SS – short, small shaft or counter shaft 𝑫𝑫𝟒𝟒 − 𝒅𝒅𝟒𝟒
% 𝑹𝑹. 𝑻𝑻. 𝑪𝑪. = 𝟏𝟏 −
�𝑫𝑫𝒔𝒔 𝟑𝟑 �(𝑫𝑫)
For each of the above shafts, design
handbooks give the following shear design
stresses, Example 1:
Ssd= 4 ksi (MPTS) A 76 mm solid shaft is to be replaced by a hollow
Ssd= 6 ksi (LS) shaft of equal length and equal torsional strength, but its
Ssd= 8.5 ksi (SS) weight should only be one half that of the solid shaft.
Determine the diameter D and d of the hollow shaft.
4. Shaft is under combined stresses
Use the derived formulas for Ssmax and Smax Solution:
T T
Combined Stresses in Shafts
a. Axial & Flexural Loads
b. Axial & Torsional Loads D d D
c. Flexural & Torsional Loads
d. Axial, Torsional, & Flexural Loads
Solid shaft T Hollow shaft T
Note:
These combinations are treated with the aid of Conditions given for the shafts include equal length,
maximum stress equations in the previous chapters. equal torsional strength and that hollow shaft should weigh
only half as much as the solid shaft. It is then assumed that
- Maximum Shear Stress Equation. The equation is the shaft are made of the same material.
more generally applicable to shaft made of ductile
material. • Equal torsional strength, 𝑺𝑺𝒔𝒔𝒔𝒔
16𝑇𝑇
𝑺𝑺 𝟐𝟐 𝑆𝑆𝑠𝑠(𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠) = ⇒ 𝑆𝑆𝑠𝑠𝑠𝑠
𝑺𝑺𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔 = �𝑺𝑺𝒔𝒔 𝟐𝟐 + � � → 𝑺𝑺𝒔𝒔𝒔𝒔 𝜋𝜋𝐷𝐷𝑠𝑠3
𝟐𝟐 16𝑇𝑇𝑇𝑇
𝑆𝑆𝑠𝑠(ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜) = ⇒ 𝑆𝑆𝑠𝑠𝑠𝑠
- Maximum Normal Stress Equation. The equation 𝜋𝜋(𝐷𝐷4 − 𝑑𝑑4 )
is more applicable to brittle materials. Thus,
16𝑇𝑇 16𝑇𝑇𝑇𝑇
𝑺𝑺 𝑺𝑺 𝟐𝟐 =
𝑺𝑺𝒎𝒎𝒎𝒎𝒎𝒎 = + �𝑺𝑺𝒔𝒔 𝟐𝟐 + � � → 𝑺𝑺𝒔𝒔𝒔𝒔 𝜋𝜋𝐷𝐷𝑠𝑠3 𝜋𝜋(𝐷𝐷4 − 𝑑𝑑4 )
𝟐𝟐 𝟐𝟐
- If uncertainly arises as to the material, use the And, with equal power being transmitted, torque is
more conservative results from both equations also constant.
above. 16𝑇𝑇 16𝑇𝑇𝑇𝑇
= : 𝐷𝐷4 − 𝑑𝑑4 = 763 𝐷𝐷 → (1)
𝜋𝜋(76 ) 𝜋𝜋(𝐷𝐷4 − 𝑑𝑑4 )
3

Conversion from Solid to Hollow Shaft

• 50% weight reduction
• Percent Saving Weight 𝜋𝜋 𝜋𝜋
𝑾𝑾𝒔𝒔 − 𝑾𝑾𝒉𝒉 𝑊𝑊s = 𝛾𝛾 � 𝐷𝐷𝑠𝑠2 � 𝐿𝐿: 𝑊𝑊ℎ = 𝛾𝛾( (𝐷𝐷2 − 𝑑𝑑2 )𝐿𝐿
4 4
% 𝑺𝑺. 𝑾𝑾. = Thus,
𝑾𝑾𝒔𝒔 𝜋𝜋 𝜋𝜋
𝑫𝑫𝒉𝒉 𝟐𝟐 − 𝒅𝒅𝒉𝒉 𝟐𝟐 𝛾𝛾( (𝐷𝐷2 − 𝑑𝑑2 )𝐿𝐿 = 0.5 �𝛾𝛾 � (762 )� 𝐿𝐿�
% 𝑺𝑺. 𝑾𝑾. = 𝟏𝟏 − 4 4
𝑫𝑫𝒔𝒔 𝟐𝟐 𝐷𝐷2 − 𝑑𝑑2 = 2888 ∶ 𝑑𝑑2 = 𝐷𝐷2 − 2888 → (2)
Note:
Applicable to equal length and same material. Substituting eqn. (2) into equation (1)
𝐷𝐷4 − [𝐷𝐷2 − 2888]2 = 763 𝐷𝐷 ∶ 𝐷𝐷 = 91.74 𝑚𝑚𝑚𝑚
• Percent Reduction in Torque Capacity
𝑻𝑻𝒔𝒔 − 𝑻𝑻𝒉𝒉 And, from eqn. (2), 𝑑𝑑 = 74.35𝑚𝑚𝑚𝑚. Thus, as a replacement
% 𝑹𝑹. 𝑻𝑻. 𝑪𝑪. =
𝑻𝑻𝒔𝒔 shaft, the hollow shaft should have the following
Where, diameters:
𝑇𝑇𝑠𝑠 = torque that the solid shaft can transmit 𝑫𝑫 = 𝟗𝟗𝟗𝟗. 𝟕𝟕𝟕𝟕 𝒎𝒎𝒎𝒎; 𝒅𝒅 = 𝟕𝟕𝟕𝟕. 𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑 (𝑨𝑨𝑨𝑨𝑨𝑨. )
𝑇𝑇ℎ = torque that the hollow shaft can transmit
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Example 2: Solution:
A shaft is made of steel whose Sy = 300 MPa and Su a) Maximum Power
= 400 MPa, it is to transmit 300 kW at 600 rpm. (a)
Calculate the diameter of the shaft if the load is gradually
applied. Consider the effect of keyway on the shaft. (b) The
same as a), except that the load is suddenly applied.

Solution:

T Keyway

Solid shaft T

b) Min. diameter required for a main power

transmitting shaft
From the PSME Code formulas for transmission
shafts:

♦ Bending Load Calculation for Shaft

1. Bending Load from Belts and Pulley

𝑎𝑎 𝑏𝑏 Driving Pulley
𝑇𝑇 𝑇𝑇
𝜃𝜃 Dp

Example 3: 𝑇𝑇
Shaft 𝛾𝛾 𝛾𝛾
a) What maximum horsepower can a 3-inch 𝐹𝐹1 𝐹𝐹2
diameter short shaft transmit at 600 rpm? 𝐹𝐹𝐵𝐵 𝐹𝐹𝐵𝐵
b) What diameter in mm is required by a main power
transmitting shaft to transmit 500 kW at 200 rpm?

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 Machine Design 1: BASAEN, RV

Useful Relations: 𝐹𝐹1 = tight side tension in the belt

𝐷𝐷
[Σ𝑀𝑀+ = 0]: 𝑇𝑇 = (𝐹𝐹1 − 𝐹𝐹2 ) � 2 � 𝐹𝐹2 = slack side tension in the belt
2𝑇𝑇 𝐹𝐹𝐵𝐵 = bending load on shaft
𝐹𝐹1 − 𝐹𝐹2 = → (1) ∶ (Net Belt Pull) 𝐹𝐹𝑐𝑐ℎ = chain tension
𝐷𝐷
where,
T = torque transmitted by the shaft 3. Bending Load from Spur Gears
𝐹𝐹1 = tight side tension in the belt 𝑇𝑇
𝐹𝐹2 = slack side tension in the belt
𝐹𝐹𝐵𝐵 = bending load on shaft
𝐹𝐹𝑟𝑟 𝜙𝜙
𝐷𝐷
Belt tension ratio: 𝑭𝑭𝑹𝑹 line of action
𝐹𝐹1 𝜙𝜙
= 𝑒𝑒 𝑓𝑓𝑓𝑓 → (2) 𝐹𝐹𝑡𝑡
𝐹𝐹2
where, where
𝑓𝑓 = coefficient of friction 𝜙𝜙 = pressure angle of the gear teeth
𝜃𝜃 = contact angle between belt and pulley (14.5°, 20°or 25°)
(based on the small pulley, where belt slip is 𝐹𝐹𝑡𝑡 = tangential force on the gear
more likely to take place) 𝐹𝐹𝑟𝑟 = radial force on the gear
𝐹𝐹𝑅𝑅 = resultant force on the gear
𝜃𝜃 = 180 − 2𝛾𝛾
For tangential load, 𝐹𝐹𝑡𝑡
From Machine Elements 2, 𝐷𝐷𝑔𝑔
𝐷𝐷𝑝𝑝2 − 𝐷𝐷𝑝𝑝1 Σ𝑀𝑀+ = 0]: 𝑇𝑇 = 𝐹𝐹𝑡𝑡 � �
𝛾𝛾 = 𝑠𝑠𝑠𝑠𝑠𝑠−1 � � 2
2𝐶𝐶 𝟐𝟐𝟐𝟐
where, 𝑭𝑭𝒕𝒕 =
𝐷𝐷𝑝𝑝2 , 𝐷𝐷𝑝𝑝1 = pulley diameter 𝑫𝑫𝒈𝒈
(tangential load of the gear tooth)
𝐶𝐶 = center distance between the pulleys

Thus, the bending load is, For radial load, 𝐹𝐹𝑟𝑟

𝐹𝐹𝑟𝑟
𝑭𝑭𝑩𝑩 = (𝑭𝑭𝟏𝟏 + 𝑭𝑭𝟐𝟐 ) 𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄 = 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡
(bending load on the shaft) 𝐹𝐹𝑡𝑡
𝑭𝑭𝒓𝒓 = 𝑭𝑭𝒕𝒕 𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕
From the set-up as shown, the bending moment 𝑀𝑀 is (radial load or separating force between gears)

𝑭𝑭𝑩𝑩 (𝒂𝒂)(𝒃𝒃) 𝑭𝑭𝑩𝑩 (𝒂𝒂)(𝒃𝒃) For the resultant load, 𝐹𝐹𝑅𝑅

𝑴𝑴 = =
(𝒂𝒂 + 𝒃𝒃) 𝑳𝑳 𝑭𝑭𝑹𝑹 = � 𝑭𝑭𝒕𝒕 𝟐𝟐 + 𝑭𝑭𝒓𝒓 𝟐𝟐

2. Bending Load Chains and Sprockets (resultant tooth load)

𝑇𝑇 This resultant tooth load 𝐹𝐹𝑅𝑅 becomes the bending load on
Ds , pitch the shaft,
diameter of 𝑭𝑭𝑩𝑩 = 𝑭𝑭𝑹𝑹
sprocket
Note:
If the shaft has complex bending loads, the bending
moment 𝑀𝑀 is generally determined with the aid of shear
and moment diagrams.
𝐹𝐹1 = 𝐹𝐹𝑐𝑐ℎ 𝐹𝐹2 = 0
𝐹𝐹𝐵𝐵 Other gear types (helical, bevel, worm gears, etc.)
Note: result in a more complicated loading on the gear and on the
For chains, the slack side tension 𝐹𝐹2 is practically zero. supporting shaft.
The bending load then becomes,
𝑭𝑭𝑩𝑩 = 𝑭𝑭𝟏𝟏 = 𝑭𝑭𝒄𝒄𝒄𝒄

[Σ𝑀𝑀+ = 0]:
𝟐𝟐𝟐𝟐
𝑭𝑭𝑩𝑩 = 𝑭𝑭𝒄𝒄𝒄𝒄 =
𝑫𝑫𝒔𝒔
where
T = torque transmitted by the shaft
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Example 4: b) Bending load from spur gear, 𝐹𝐹𝐵𝐵 =?

a) Determine the bending load 𝐹𝐹𝐵𝐵 at the shaft from the
given set up. The driven pulley is 400 mm and is 𝐹𝐹𝑟𝑟
800 mm away from the driving pulley. 𝐹𝐹𝑡𝑡

𝐷𝐷𝑔𝑔 = 150
200 mm 𝐷𝐷
𝐹𝐹2
𝑇𝑇 𝛾𝛾 𝑭𝑭𝑩𝑩 = 𝑭𝑭𝑹𝑹
𝑇𝑇𝐷𝐷 = 𝑇𝑇𝐴𝐴 = 𝑇𝑇 = 1 591 500

Power = 20 kW
n = 600 rpm
𝑓𝑓 = 0.3
𝛾𝛾
𝐹𝐹1

b) The same as a. except that the pulleys are replaced by

spur gears (𝜙𝜙 = 20𝑜𝑜 ) and the diameter of the driving
gear is 100 mm. Also compute for the bending
moment on the shaft to simply supported and the gear
is replaced midway between the bearings that are
100 mm part.

Solution:
a) Bending load from belt and pulley, 𝐹𝐹𝐵𝐵 =?

Example 5:
A 150mm diameter spur pinion transmits 20 kW at 600
rpm. Considering a pressure angle of 20o and the distance
between bearing supports as shown, recommend the
standard shaft diameter necessary if Ssd = 60 MPa.

𝐓𝐓
𝐷𝐷𝑔𝑔 = 150mm

𝐓𝐓

100mm 150mm

Solution:

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 Machine Design 1: BASAEN, RV

Example 7:
A centrifugal pump is directly coupled to a motor. The
pumping rate is 3600 li/min, against a total head of 8 meters
of water. The pump efficiency is 65% at a shaft speed of
about 500 rpm. Determine the motor shaft diameter if the
shear design stress of the shaft is 60 MPa. Neglect the
bending load from the centrifugal force due to the coupling.

Water
Coupling 𝜂𝜂𝑝𝑝 = 65%
Example 6: Shaft
The shaft of a heavy tractor transmits 120 kW at 600
rpm. It acts as a cantilever supporting a load of 2800 N
located 60 cm from the supporting bearing. The allowable Motor Pump
stresses are 137 MPa for normal stress and 62 MPa for Water IN
shear. If axial load is negligible, find the shaft diameter. 𝑄𝑄 = 3600𝑚𝑚 3/𝑚𝑚𝑚𝑚𝑚𝑚

Solution:
Sketch of shaft loading from the description:
Solution:
F =2800 N
T
𝐴𝐴 300 𝐵𝐵
M
T
L=600mm
𝑹𝑹

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 Machine Design 1: BASAEN, RV

Example 8:
A transmission shaft ‘𝑥𝑥’ carries a pulley and a pinion at
points A and D, respectively. The shaft is supported by
bearings at B and C. Dimensions given are in mm.
Recommend the diameter of this shaft ‘𝑥𝑥’. Use 𝑆𝑆𝑦𝑦 =
300 𝑀𝑀𝑀𝑀𝑀𝑀 & 𝑆𝑆𝑢𝑢 = 400 𝑀𝑀𝑀𝑀𝑀𝑀 and the given load factors
𝐾𝐾𝑠𝑠 = 1.2, 𝐾𝐾𝑚𝑚 = 1.5 and coefficient of belt friction 𝑓𝑓 =
0.3. Also consider the effect of keyway in the shaft:

150 300 150

60 kg pulley wt. to driven

= 588.6 N machine
300

shaft 'x'
𝐴𝐴 𝐷𝐷 150
400
𝐵𝐵 𝐶𝐶

15 kg pinion
wt = 147.2 N
motor
50 kW
600 rpm
200

spur gears
𝜙𝜙 = 20𝑜𝑜
90 𝑘𝑘𝑘𝑘 pulley
15 𝑘𝑘𝑘𝑘
i i

𝐶𝐶𝑑𝑑 800

motor 60𝑜𝑜
50 kW
600 rpm
𝑓𝑓 = 0.3

Solution:
Shaft ‘x’ is under combined torsion and bending.

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 Machine Design 1: BASAEN, RV

Example 9:
A transmission shaft made of steel whose Sy = SHAFT SIZES AND MATERIALS:
300 MPa & Su = 400 MPa is subjected to a torque of • Transmission shafting comes in the following
500,000 N − mm & a bending moment of 400 N − m, sizes:
simultaneously. Determine the following: 15 3 7 11 15 3 7 15 7
,1 ,1 ,1 ,1 ,2 ,2 ,2 ,3
a. Equivalent twisting moment of the shaft. 16 16 16 16 16 16 16 16 16
Determine the diameter of the shaft using this
moment and the pure torsion formula. 15 7 15 7 15 1 1
3 ,4 ,4 ,5 ,5 ,6 , 7 ,7 ,8
b. Equivalent bending moment of the shaft. 16 16 16 16 16 2 2
Calculate the shaft diameter using this bending
moment & the pure bending formula. • Transmission shafting has the following typical
c. Is the shaft diameter in (a) satisfactory on the basis sizes:
of the angle of twist of a transmission shaft? 1
d. Determine the outside diameter of the hollow By 16 " increments in this range
1
shaft described above if d = 0.5D & the loads to 1 in. with tolerance of -0.002 in.
2
are to be suddenly applied with minor shock. 1
1 16 to 2 in. with tolerance of -0.003 in.
Consider the effect of keyways in the shaft.
1 1
e. If the above shaft has a negligible bending 2 16 to 2 2 in. with tolerance of -0.004 in.
moment and is described to be a line of shaft, what
1
solid shaft diameter in inches is necessary at By 8 " increments in this range
300 rpm? 5
2 8 to 4 in. with tolerance of -0.004 in.
1
T 4 4 to 6 in. with tolerance of -0.005 in.
M M 1
6 4 to 8 in. with tolerance of -0.006 in.
D • Material for shafting:
The most commonly used stock material for
T
shafting is carbon steel with 30 to 40 points of carbon.
However, all kinds of materials, including
Example 10: nonferrous metals and mon metallic materials are also
The shaft loaded as shown, used.

100 100 100

FB1 = 6000 N FB2 = 4000 N

Required:
Shaft diameter necessary if 𝑆𝑆𝑠𝑠𝑠𝑠 = 90 MPa and 𝑆𝑆𝑑𝑑 =120
MPa. The power in the shaft is 50 kW at 1000 rpm. Use the
following factor:
𝐾𝐾𝑠𝑠 = 1.0, 𝐾𝐾𝑚𝑚 = 1.5

TYPICAL VALUES OF 𝑲𝑲𝒔𝒔 AND 𝑲𝑲𝒎𝒎

Nature of Loading 𝑲𝑲𝒎𝒎 𝑲𝑲𝒔𝒔
Stationary shafts (bending stress
not reversed:
Gradually applied 1.0 1.0
Suddenly applied 1.5 to 2.0 1.5 to 2.0
Rotating shafts (bending stress
reversed):
Gradually applied or steady 1.5 1.0
Suddenly applied, minor shocks 1.5 to 2.0 1.0 to 1.5
Suddenly applied, heavy shocks
2.0 to 3.0 1.5 to 3.0
124