DESIGN OF MACHINE ELEMENTS

DESIGN OF SHAFT
Shaft Design : Worked Examples 1& 2
Introduction
• In this lecture we shall employ the design considerations and equations
developed in lecture 1 to solve the main example (Example 1).

Learning Objectives:
After studying this lecture a student should be able to:
• Analyse a shaft and its mountings to generate shear force and bending
moment diagrams for the shaft in two perpendicular planes
• Compute the minimum shaft diameters at relevant section of the shaft.
• Compute the standard size specifications of the shaft.

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 Example 1
Design the shaft shown in Figures P2. It is to be machined from AISI1144 OQT
1000 steel. The shaft is part of the drive for a large blower system supplying
air to a furnace. Gear A receives 200hp from Gear P. Gear C delivers the
power to Gear Q. The shaft rotates at 600rpm.

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• Given Shaft Design Solution Steps:
• The properties of the steel are: Sy = 572 MPa, Sut = 813 MPa and the percent
elongation is 19%.

• Assumptions:
• A size factor should be applied to the endurance strength because the shaft
will be quite large to be able to carry 200hp.

• Since the material has a good ductility, estimate the Sn = (290 – 310)Mpa
(approx.)
• Although we do not know the actual size at this time, we might select Cs =
0.80 from Figure 12 as an estimate.
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 Solution
• The endurance strength is then computed as:
S n = S n C s C R
= (290MPa )(0.80)(0.81) = 187.92MPa

• Compute for the torque in the shaft.

 N .m / sec 
200hp 746 
P
T= =  hp 
= 2.37kN .m
  2rad / sec 
600rpm 
 60rpm 
Note that part of the shaft from A to C is subjected to this torque.
There is zero torque from the right of Gear C over to Bearing D.

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Torque Distribution:

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Forces exerted on shaft by Transmission
elements: Forces on Gear A

Forces on Gear C,

WtC = 2
TC
=2
(2.37kN ) = 18.7kN
DC (0.254m)
WrC = WtC tan C
( )
= (18.66kN ) tan 20 o = 6.8kN

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Proposed Shaft Geometry

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Shear Force and Bending Moment of
shaft

F y = 0  − 3.4 + 2.0 + 6.8 + RDx  = 0

 RDx = −5.4kN

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Shear Force and Bending Moment of
shaft

F y  
= 0  − 9.4 + 20.6 − 18.7 + RBy = 0
 RDy = 7.5kN
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• Draw the shaft and indicates the force at their proper positions. The free-body, shear force and
bending moment diagrams are presented below.

For XZ-Plane
For YZ-plane

3 . 4 kN 5 . 4 kN 9 . 4 kN 18.7 kN

2 . 0 kN 6 .8 kN 7 . 5 kN
20.6kN

5.4kN
11 . 2 kN

0
− 1 . 4 kN
3
.4
kN

− 3 . 4 kN
− 7.5kN
0
1 . 9 kN . m
− 0 . 86 kN . m

− 1.37kN.m 14
− 2.4kN.m
Bending Moment Calculations

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 Bending Moments at Various Points
xz plane yz plane Resultant
Point A 0.00 0.00 0.00
Point B -860.00 -2400.00 2549.43
Point C -13700.00 1900.00 13831.12
Point D 0.00 0.00 0.00

Torque at Various Points

Point A 2370.00
Point B 2370.00
Point C 2370.00
Point D 0.00

Forces at Various Points

xz plane yz plane Resultant
Point A -3400.00 -9400.00 9996.00
Point B 2000.00 20600.00 20696.86
Point C 6800.00 -18700.00 19897.99
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Point D -5400.00 7500.00 9241.75
 Computing for diameter at various points on
the shaft.

Points A
There are no forces or moments, because it is the free end of the shaft. There is only
torque present at A. Neglecting the stress concentration, the diameter can be found
as:

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Point B
The point B is the location of a bearing with a sharp fillet to the right of B and a well-
rounded fillet to the left.

It is a desirable to make D2 at least slightly smaller than D3 at the bearing seats to permit
the bearing to be slid easily unto the shaft up to the place where it is pressed to its final
position.

There is usually a light press fit between the bearing bore and the shaft seats. To the left of
B (diameter D2): T = 2.37kN.m
MB = (M 2
+ M By
2
)
M B = of(M By )
Bx
The bending moment at B is the resultant the
2
moment
+ M 2
in the x and y planes from the
= (2.37kN .m ) + (0.86kN
Bx 2
figure below.
= (2.37kN .m ) + (0.86kN .m ) = 2.53kN .m
2 2
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Kt = 1.5 (rounded fillet) Using the equation we have 1
 
3
2
 TB 
2
32 N  Kt M B  3
D2 =    + 
 S 


   S n  4  Y  
 
1
  1.5(2.37kN .m )  
3
2
   
 32(3)  187.92MPa  
=   = 85mm

 3  2.37kN .m 
2

+  
 4  572MPa  
 

For D3, Kt = 2.5 (sharp fillet), then, 1

 
3
2
 TB 
2
32 N  Kt M B  3
D3 =    + 
S 


   S n  4  Y  
 
1
  2.5(2.37kN .m )  
3
2
   
 32(3)  187.92MPa  
=   = 101mm

 3  2.37kN .m 
2

+  
 4  572MPa  
  19
• Point C
• The point C is the location of a Gear C with a well-rounded fillet to the left
and a retaining ring groove to the right of C.

• The use of a well rounded at this point is actually a design decision that
requires that the design of the bore of the gear accommodate a large fillet.

• Usually, this means that a chamfer is produced at the ends of the bore.

.
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• The bending moment at C is the resultant of the moment in the x and y planes given as:

To the left of C the torque, exist with the profile key seat given Kt = 2.0. Then,

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To the right of C, there is no torque but the ring groove suggests Kt = 3.0 for
design, and there is reverse bending. Using the equation, we have
1
 32 N  Kt M C 
3

D5 =   
   S n 
 32(3)  3(2.35kN .m ) 
1
3

=   = 104.68mm
   187.92MPa 

This value is higher than that computed for the left of C, so it governs the
design at C

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Point D
The point D is the seat for Bearing D and there is no torque or bending moment here.
However, there is a vertical shearing force equal to the reaction at the bearing. Using
the resultant of the x and y plane reactions, the shearing force is

VD = (V 2
Dx + V Dy
2
)
= (5.4kN )2 + (7.4kN )
2
= 9.2kN

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 4V
 =
• The vertical shear stress for circular shaft is
S y 572MPa 3A
 =  d = 0.577 = = 110MPa
• but N 3

• The required area of 4(9is.2kN )

4V shaft
A= the = = 111.52 mm2
3 d 3(110MPa)

A = 14 D62

• The area A Dis given

4 A as: 4(111.52 mm 2
)
6 = = = 11.9mm
 
• Solving for D ,6 with the other computed diameters, and it will usually be so.
There is very small compared
In reality the diameter at D will probably be made much larger than this computed value
because of the size of a reasonable bearing to carry the radial load of 9.2kN. 24
 Summary
The computed minimum required diameters for the various part of the shaft
in Figure PB2 are presented in the Table (to the nearest ½ - in
Min. Spec.
Mating Part Dia # Dia. Dia
(mm) (mm)
Gear A D1 47.86 50.8
Nothing @ B D2 85 101.6
Bearing B D3 101 101.6
Gear C D4 104.68 127.0
Bearing D D5 11.9 50.8
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 Thank You

End of Lecture 2 of 2_Unit 1

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