MACHINE DESIGN – DAY 2

I. SHAFTS
1. Shaft - is a rotating member that is used to transmit power. MOTOR Machine Shaft
2. Axle - a stationary member carrying rotating wheels, pulleys.
3. Line shaft - transmission shaft driven by prime mover. Main Shaft
4. Machine shaft - shaft which is an integral part of the machine.
Counter Shaft
5. Counter shaft - transmission shaft intermediate between the line
shaft and the driven machine.
6. Spindles - are short axles and shafts.
7. Transmission shaft - is a shaft used to transmit power between
the source and the machines absorbing the power, and include
countershafts, line shafts, head shafts, and all factory shafting.

Driven Machine 1
FORMULAS: Driven Machine 2

1. Power Formula in SI unit:

P = 2 p T N where: P = power, KW T = torque, KN-m N = speed, rps

P = 2pTN where: P = power, Hp T = torque, ft-lb N = speed, rpm

33,000

2. Torque, T T = FxR
F
where: F = applied force R = radius = D/2
R
3. Stresses in shaft when subjected to pure torsion (Ss)

A. For solid shaft: Ss = Tc = 16T

J pD3

16TDo
B. For hollow shaft: Ss =
p(Do 4 - Di 4 )

C. For designed shearing stress and compressive stress with given Sy and Su.
SHEARING: Ss = 0.18 Su, Ss = 0.3 Sy
COMPRESSIVE: Sc = 0.36 Su Sc = 0.6 Sy
Note: Choose whichever is smaller
where:
Do = outside diameter Di = inside diameter J = polar moment of inertia
c = is the distance of the farthest fiber from neutral axis T = torque
d = diameter of shaft

4. Torsional deflection (q), rad

q = TL , rad where: L = length of shaft
JG
4
J = polar moment of inertia = pd (for solid shaft) J =
p(Do 4 - Di 4 ) (for hollow)
32 32
G = modulus of rigidity in shear = 11.5 x 106 psi for steel
 FROM MACHINERIES HANDBOOK:

584 T L
A. For solid shaft: Θ = , deg
D4 G
584 T L
B. Using ALCORCON’S FORMULA for hollow shaft: Θ = , deg
(Do 4 - Di4 ) G

Θ Degrees Degrees degrees

T in-lb N-mm KN-m
L in mm m
D in mm m
Do, Di in mm m
G Psi MPa KPa

5. Stress in shaft when subjected to Torsion and Bending loads:

a. For solid shaft:

Ss = 16 (K mM)2 + (K t T )2
pd3

16 é 2 2ù
St =
êKmM + (KmM) + (K t T ) úû
pd3 ë

Note: Km and Kt not known, assume 1.0

where: T = torque
M = moment
Ss = maximum shear stress
St = maximum tensile or compressive stress

b. For hollow shaft:

16Do 16Do é 2ù
Ss = (K mM)2 + (K t T )2 St = 2
êëKmM + (KmM) + (K t T ) úû
p(Do 4 - Di4 ) 4
p(Do - Di ) 4

6. Strength of shaft with assumed allowable stresses (PSME Code p. 18)

3
a. For Main Shafts: (S = 4000 psi) P = D N
80

b. For Line Shafts: (S = 6000 psi) P = D3N

53.5
3
c. For short shafts: (S = 8500 psi) P = D N
38

where: P = power, Hp N = speed, rpm D = diameter, inch

7. From Machineries Handbook Formula

A. Shaft diameter for 0.08 degrees per foot of length of shaft deflection.

P
For English units: D = 0.29 4 T or D = 4.6 4
N
Where: D = diameter, in T = torque, in-lb
P = horsepower N = speed, rpm
 P
For SI units: D = 2.26 4 T or D = 125.70 4
N

Where: D = diameter, mm P = power, watts

N = speed, rpm T = torque, N-mm

B. Shaft deflection of 1 degree for a length of 20 times its diameter.

P
D = 0.10 3 T or D = 4.0 3
N

Where: P = power, hp D = diameter, in

N = speed, rpm T = torque, in-lb

C. Linear deflection of shafting

a. Shafting subjected to no bending action of pulleys except its own weight L = 8.95 3 D2
b. Shafting subjected to bending action of pulleys, etc L = 5.2 3 D2

Where: L = shaft length, ft D = shaft diameter, in

II. KEYS
A key is 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.

Types of keys:
1. Square key
2. Flat key
3. Round key
4. Barth key
5. Woodruff key
6. Gib-head key
7. Saddle key
8. Kennedy key
9. Feather key
FORMULAS:

1. Power of key: P = 2p T N, KW

2. Force transmitted, F F = T = T
r d/ 2

where: d = shaft diameter

3. Compressive Stress (Sc) of key Sc = Fc

(h / 2)L

Fs
4. Shearing Stress (Ss) of key Ss =
wL

where: L = length of key

w = width of key
h = height of key

5. Relation of key and shaft for the same material:

D
w = L = 1.2 D
4

6. Force tangent to pulley rim T = T’ F . r = F’ . R

7. Ff = force tends to remove key from the hub and shaft = 2 f F

F = force tangent to the key

F’ = force tangent to pulley rim
R = radius of pulley

III. SPLINE SHAFT

Is recommended when the power transmitted is too high that three keys are not enough.

1. Types of Fits

Types of 6 Splines 4 Splines 10 Splines

Fits
Permanent d = 0.9D d = 0.85D d = 0.91D
Fit w = 0.25D w = 0.241D w = 0.156D
h = 0.05D h = 0.075D h = 0.045D
To slide d = 0.85D d = 0.75D d = 0.86D
when not w = 0.25D w = 0.24D w = 0.156D
under load h = 0.075D h = 0.125D h = 0.07D
To slide d = 0.80D d = 0.81D
when w = 0.25D w = 0.156D
under load h = 0.10D h = 0.095D

Where: d = minor diameter, in or mm

D = major diameter, in or mm
r = radius, in or mm = d/2; R = D/2
w = width, in or mm
L = length of spline
2. Rm = mean radius = r + R
2
Note:
If L is not given use the recommended, L = 1.5 D,
from Vallance, Machine Design

3. Calculations for safe dimensions of splines:

3.1 Based on shearing of splines

F F
Ss = =
A s Ns w L

Since Ts = Fæç d ö÷ or F = 2 T
è2ø d

3.2 Based on Compression between splines and hub. Flange

T
F F
Sc = = F
Ac h L Ns

NS = number of splines
Dc
Ac = compressive area

r +R ) r +R)
Tc = F Rm = F( or F = 2Tc / (
2 2 Shaft
Bolt
F = compressive force

16 Tt
3.3. Based on Torsion of splined Shaft Ss =
p d3

Tt
Note: For torque capacity, T for one spline is: T= (1.1)
Ns

This recommendation is based by shearing one spline only.

T
IV. FLANGE COUPLING
Fb
1. Coupling - is a mechanical device which is used to connect length of shafts permanently.

Dc
FORMULAS:

1. Power transmitted: P = 2 p T N , KW

T T
2. Total force transmitted, (F) F = = Shear Area
r Dc / 2
 F
3. Force transmitted per bolt, (Fb) Fb =
n Flange

where: n = no. of bolts Dc = bolt circle diameter

Fb
4. Shearing of bolts(Ss) Ss =
p 2
d Dc
4

5. Compressive stress on bolts and flange (Sc)

F
Sc = b
td
Compressed Area
where: t = thickness of flange d = bolt diameter

PROBLEMS:

SHAFTING

1. A line shaft is to transmit 200 HP at 900 rpm. Find the diameter of the shaft.
A. 2.18 in B. 2.28 in C. 3.18 in D. 3.28 in

2. A 1/4 in diameter solid shaft has an allowable stress of 6000 psi and is subjected to pure torsion. If its rotational
speed is 1800 rpm, how much horsepower can it transmitted safely?
A. 0.425 hp B. 0.225 hp C. 0.316 hp D. 0.525 hp

3. Determine the thickness of hollow shaft having an outside diameter of 100 mm if it is subjected to a maximum
torque of 5,403.58 N-m without exceeding a shearing stress of 60 MPa or a twist of 0.5 degree per meter length
of shaft G=83,000 MPa
A. 15 mm B. 86 mm C. 76.8 mm D. 69.96 mm

4. An 80 mm solid shaft is to be replaced with a hallow shaft of equal torsional strength. Find percentage of weight
saved, if the outside of the hallow shaft is 100 mm.
A. 56.53% B. 67.31% C. 48.49% D. 52.90%

5. A round steel shaft to a torque 200 rpm and is subjected to a torque of 226 N-m, the allowable shearing stress
41.4 MPa. It is also subjected to a bending moment of 339 N-m. The allowable tensile stress is 55 MPa. Find the
diameter.
A. 37 mm B. 41 mm C. 45 mm D. 51 mm

KEYS & COUPLING

1. A rectangular key was used in a pulley connected to a line shaft with a power of 10 KW at a speed of 1200 rpm.
If the shearing stress of the shaft and key are 30 N/mm2 and 240 N/mm2, respectively. What is the key length if
the width is 10 mm?
A. 18.7 mm B. 21.7 mm C. 25.8 mm D. 30.2 mm

2. A flange bolt coupling consists of eight steel 20 mm diameter steel bolts spaced evenly around a bolt circle 300
mm in diameter. if the coupling is subjected to a torque of 15.1 KN-m, determine the maximum shearing stress in
the bolts?
A. 40450 kPa B. 63320 kPa C. 40054 kPa D. 31298 kPa
3. A flange coupling having 180 mm bolt circle and 19 mm thick uses 8 bolts, 16 mm diameter to connect two shafts.
It is used to transmit 60 kw at 180 rpm. Determine the factor of safety in compression if yield point in compression
is 448 MPa.
A. 15.6 B. 30.8 C. 18.5 D. 25.4

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