Failure analysis of Shaft

Group members

 HAMZA ALI 18PWMEC4501

 AZMAT ULLAH 18PWMEC4508
 MUHAMMAD UZAIR 18PWMEC4514
 NADIR ULLAH 18PWMEC4531
 BASIT AZIM 15PWMEC4002
INTRODUCTION

 DRIVE SHAFT
 Drive shafts are mechanical components that are widely used in
vehicle powertrain systems to transmit torque and rotation between different
components which are not in line or cannot be connected directly.
 ) Cause of failure of the element:
 The dominant cause of the drive shaft is torsional stress, this stress produce
due to maximum torque. ItThere is also fatigue stress acting on the shaft but
it does not break due to fatigue. Because the shaft have not a uniform
diameter and failure due to fatigue occurs due at point where stress
concentration is maximum (smaller diameter, non-fillet area etc) and the
failure of this element occur at larger diameter.
 it’s failure occur due to maximum load (or torque)
DIMENSIONS

 Diameter of shaft=23mm
 Length of broken part=126mm
𝑑2
 Area of cross section of shaft =𝜋 4 =415𝑚𝑚2

 PICTURE OF BROKEN PART

FAILURE ANALYSIS

 TORQUE
 Torque produced in the shaft is given by
𝑃𝑥60
 𝑇 = 2𝜋𝑥𝑁
 Where N= revolution per minute
 N=1000rpm
 P=Power of engine
 P=66 Kwatt
 Thus, by putting the values we get;
 T=0.6325 KNm

 Torsional stress


𝑻𝒄
 𝝉=
𝑱
 Where T= torque
 c= radius of shaft
 j= polar moment of inertia
0.6325𝑥0..115
 𝜏= 2.745𝑥10−8
𝑃𝑎

 𝜏 = 264 𝑀𝑃𝑎
 The direction of torsional stress on element is clockwise.
STRENGTH ANALYIS

 c) Fatigue strength / Endurance limit of the element:

 Se=KaKbKcKdKeKfSe’
 Where
 Ka=surface condition modification factor
 Kb=size modification factor
 Kc=load modification factor
 Kd=temperature modification factor
 Ke=reliability factor
 Kf=miscellaneous effect modification factor
 Se’=rotatory shaft test specimen endurance limit
 Ka= 𝑎𝑠𝑢𝑡 𝑏
 Where a=4.51
 b=-0.265
 ka=0.75
 Kb=1.24𝑑−0.107 for2.79 < d < 51mm
 Where d=0.023m
 Kb=0.88
 Kc=0.59 (torsional load)
 Kd=Ke=Kf=1
 And
 Se=0.5(Sut)
 Se=420.5MPa
 Se’=163.74MPa
PLANE STRESSES

 Plane stresses:
𝝈𝒙 +𝝈𝒚 𝝈𝒙 −𝝈𝒚 𝟐
 𝝈𝟏,𝟐 = ± ( ) + 𝝉𝒙𝒚 𝟐
𝟐 𝟐

 𝝈𝟏 = 𝟐𝟔𝟒𝑴𝑷𝒂
 𝝈𝟐 = −𝟐𝟔𝟒𝑴𝑷𝒂
MAXIMUUM DISTORTION ENERGY THEORY

 According to maximum distortion energy theory

(𝜎1 −𝜎2 )2 +(𝜎2 −𝜎3 )2 +(𝜎1 −𝜎3 )2
 𝜎𝑒 =
2

 𝜎𝑒 = 323.33𝑀𝑃𝑎
FACTOR OF SAFETY

 Safety factor based on yield strengths of the element :

𝑌𝑒𝑖𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
 𝑁=
𝜎𝑒
250𝑀𝑃𝑎
 𝑁 = 323.3326

 N=0.7731
 ) Safety factor based on Endurance limit of the element:
𝑌𝑒𝑖𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
 𝑁=
𝑆𝑒′
250𝑀𝑃𝑎
 𝑁 = 163.74𝑀𝑃𝑎

 𝑁 = 1.52
 Sustainable Design:
 Drive shaft can be manufactured from the following materials:
 1. Structural steel
 2. Aluminum alloy
 3. Polyethylene
 4. Titanium
 5. Carbon fiber


 THANKS!!!!!!!!!!!!!!