SHAFT DESIGN

MDPN354

October 23 Ahmed H. Mokhtar 1

What to revise?
• Machine Drawing
 Fits and Tolerances
 Surface Roughness
 GD&T

• Stress Analysis

• Machine Design I

October 23 Ahmed H. Mokhtar 2

FORCE ANALYSIS

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Gears

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Pulleys

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Chain
Sprockets

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SOLVED EXAMPLE

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A transmission shaft supporting a spur gear B and the
pulley D is shown in Figure. The shaft is mounted on
two bearings A and C. The diameter of the pulley and
the pitch circle diameter of the gear are 450 mm and
300 mm respectively. The pulley transmits 20 kW
power at 500 rpm to the gear. 𝑃𝑃1 and 𝑃𝑃2 are belt
tensions in the tight and loose sides, while 𝑃𝑃𝑡𝑡 and 𝑃𝑃𝑟𝑟
are tangential and radial components of gear tooth
force. Assume, 𝑃𝑃1 = 3 𝑃𝑃2 . The gear and pulley are
keyed to the shaft. The material of the shaft is steel
50C4 (𝑆𝑆𝑢𝑢𝑢𝑢 = 700 and 𝑆𝑆𝑦𝑦 = 460 N/mm2). The factors 𝑘𝑘𝑏𝑏
and 𝑘𝑘 𝑇𝑇 of the ASME code are 1.5 each. Determine
the shaft diameter using the ASME code.

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Solution
Given:
𝑃𝑃 = 20 𝑘𝑘𝑘𝑘
𝑛𝑛 = 500 𝑟𝑟𝑟𝑟𝑟𝑟
𝑆𝑆𝑢𝑢𝑡𝑡 = 700 𝑁𝑁/𝑚𝑚𝑚𝑚2
𝑆𝑆𝑦𝑦 = 460 𝑁𝑁/𝑚𝑚𝑚𝑚2
𝐷𝐷𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 = 300 𝑚𝑚𝑚𝑚
𝐷𝐷𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 = 450 𝑚𝑚𝑚𝑚
𝑘𝑘𝑏𝑏 = 𝑘𝑘 𝑇𝑇 = 1.5

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Solution
20𝑥𝑥103
𝑇𝑇 = 2 𝜋𝜋500 = 382 𝑁𝑁𝑁𝑁
60
For the Pulley:
382𝑥𝑥103
𝑃𝑃1 − 𝑃𝑃2 = = 1698
225
𝑃𝑃1 = 3𝑃𝑃2
𝑃𝑃1 = 2.55 𝑘𝑘𝑘𝑘
𝑃𝑃2 = 0.85 𝑘𝑘𝑘𝑘
For the Gear:
382𝑥𝑥103
𝑃𝑃𝑡𝑡 = = 2.55 𝑘𝑘𝑘𝑘
150
𝑃𝑃𝑟𝑟 = 𝑃𝑃𝑡𝑡 tan 20 = 0.93 𝑘𝑘𝑘𝑘
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Solution

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Solution

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Solution
𝑀𝑀𝑟𝑟𝑟𝑟𝑟𝑟. = 𝑀𝑀𝑥𝑥𝑥𝑥 2 + 𝑀𝑀𝑥𝑥𝑧𝑧 2

ASME code:

3 16 𝛼𝛼𝐹𝐹𝑎𝑎 𝑑𝑑𝑜𝑜 (1+𝐾𝐾 2 ) 2 2

𝑑𝑑𝑜𝑜 = 𝑘𝑘𝑏𝑏 𝑀𝑀𝑏𝑏 + + 𝑘𝑘 𝑇𝑇 𝑇𝑇
𝜋𝜋 𝜏𝜏𝑎𝑎𝑎𝑎𝑎𝑎 (1−𝐾𝐾 4 ) 8

Where: 𝐾𝐾 = 𝑑𝑑𝑜𝑜 /𝑑𝑑𝑖𝑖 and 𝛼𝛼 = 1 for tension.

For solid shaft and no axial load:

𝟑𝟑 𝟏𝟏𝟏𝟏 𝟐𝟐 𝟐𝟐
𝒅𝒅 = 𝒌𝒌𝒃𝒃 𝑴𝑴 + 𝒌𝒌𝑻𝑻 𝑻𝑻
𝝅𝝅 𝝉𝝉𝒂𝒂𝒂𝒂𝒂𝒂

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Solution
460
𝜏𝜏𝑎𝑎𝑎𝑎𝑎𝑎 = = 115 𝑀𝑀𝑀𝑀𝑀𝑀
2∗𝑓𝑓.𝑠𝑠.

Moment Torque Diameter (mm) Diameter (mm)

(Nm) (Nm)
A 0 0 29.4 30
B 710 382 37.7 38
C 1400 382 45.9 50
D 0 382 29.4 30

Shaft diameters at bearings

should be in the order of 5

Shaft diameters should be

rounded for manufacturability
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 Shaft elements should rest on
shoulders

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 Shoulder diameters are relative
to mating parts.

𝑫𝑫 + 𝒅𝒅
𝒅𝒅𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔 ≤
𝟐𝟐

Minimum shoulder step = 10

Maximum shoulder
diameter

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 Moment Torque Diameter (mm)
(Nm) (Nm)
A 0 0 30
B 710 382 38
Shoulder 70
C 1400 382 50
D 0 382 30

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Shaft Fillets/undercuts

𝑟𝑟𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝

𝑟𝑟𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠

𝑟𝑟𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 < 𝑟𝑟𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 Fillets replaced by undercuts for

manufacturability
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 Chamfers should be done for easy
assembly

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 Keyways should be perpendicular to
Key-Keyway each other

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Splines

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Locking Mechanisms
Retaining Rings

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Locking Mechanisms
Retaining Rings

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Locking Mechanisms
Locknut and
lockwasher

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 Bearings should NOT be fitted on long
shoulders or threads

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Bearings Arrangements

1. Locating-floating arrangement
2. Floating bearing arrangement
3. Adjusted bearing arrangement

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Sealing

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Sealing

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 Sealing
1. Static Sealing

O-ring

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 Sealing
1. Static Sealing

Gasket

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 Sealing
1. Dynamic Sealing

Radial lip seal

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Working Drawing

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Working Drawing

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Working Drawing

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Working Drawing

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