SHAFT STRESSING and DESIGN

Zsolt Tiba

Design Guidelines
2018
Shaft stressing and design
Design the shaft I. of the transmission machinery, see Fig. 1.
The transmission machinery has continuous operation in a milling plant driven by a short-
circuited asynchronous motor.
The nominal power of the transmission machinery is Pgn=43.6 kW; the ration between the
electric motor and the shaft in question im-t = 7.1.
Calculate the reaction forces at the bearing supports; after choosing the material of the shaft
determine the minimum diameter of the shaft based on static load.
Further tasks:
1. Draw the draft of the shaft; design the supporting shoulders and the necessary shaft
diameter steps and the torque transmitting joints.
2. Design the shaft bearing system, select the rolling bearings from brand catalogue based
on the journal pin diameters and the prescribed service life.
3. Determine the length of the torque transmitting joint on the shaft of which diameter was
fixed before. The gear 1 joins to the shaft I by a splined joint, and gear 2 joins by a
keyed joint.

Figure 1.
Data of the electric motor:
 nominal power: Pmn = 45 kW
 nominal rpm: nmn =2960 1/min = 49.33 l/s

Mi Mb
 torque ratios:  2.0 ,  3 .1
Mn Mn

 moment of inertia J = 0.30 kgm2

 mass: m = 340 kg
Under normal operation circumstances the load alteration may be described by the operation
factor: kop=1.3 provided by the designing normative. The overload arises at starting which is
considered by the stalling torque of the motor. Accordingly, the overload factor kov = 3.1.
The stressing of the shaft (preliminary design and fatigue calculation) is based on normal
operation circumstances (kop=1.3) however the plastic and residual deformation is checked
under overload (kov = 3.1).
Clarifying the correlations explained above, the stressing of the shaft may be carried out.
Steps of stressing:
I. Preliminary design
II. Strength analysis
I. Preliminary design
1. Determining the longitudinal dimension of the shaft.
2. Calculating the preliminary diameter of the shaft.
a. clarifying (measuring, modelling, or calculating) the loads,
b. drawing the load diagrams,
c. choosing shaft material,
d. stressing
3. Construction of shaft parts
a. designing the torque transmitting joints,
b. designing the journal pins of the shaft; choosing rolling bearings
c. shop drawing of the shaft.
II. Strength analysis (not detailed in this guide)
1. Checking the service life; fatigue calculation,
2. Checking for residual and elastic deformation,
3. Calculating the critical rpm.

I.1. Longitudinal dimensions

The longitudinal dimension of the shaft and position of the gears and journal pins relative to
each other are determined and located by the construction of the gearing house which is given
in this task.

I.2. Determining the preliminary shaft diameter

I.2.a. Clarifying the loads
The nominal torque of the motor:
P 3
M  mn  45.10  145.18  146 Nm
mn 2n 2  49.33
mn
The rpm of the shaft I. being aware of the ratio:
n 49.33 1
nt  mn   6.95
i 7.1 s
mt
Torque subjecting to the shaft I.:
P
gn 43.6  103
M tI    1000 Nm
2n 2  6.95
t
The shaft I. transmit the torque to the shaft III. by a mashing gear pair in the form of peripheral
tooth force which is one of the component of the normal tooth force (Fn) acting on the pressure
line. Its another component is the radial tooth force.
The own weights of the parts are disregarded since their order of magnitude is small compared
to the acting forces. Since the gears on the shaft I. are straight gears, no axial tooth forces arise;
thus the normal tooth forces (Fn1 and Fn2) can be divided on the working pitch diameters only
into radial and peripheral forces in the x-y-z coordinate system, see Fig. 2.

Figure 2

The nominal normal tooth forces may be calculated by the well-known formula. If the reference
diameters of the gears are: d1 = 400 mm and d2 = 306 mm, than:

2M tI 2  1000  103 2M tI 2  1000  103

Fn1    5320 N Fn 2    6950 N
d1 cos  400  0.94 d cos  306  0.94
2
since the transverse pressure angle  = 20.
The peripheral forces:
2M tI 2  1000  103 2M tI 2  1000  103
Ft1    5000 N Ft 2    6536 N
d1 400 d 306
2
The radial forces:
Fr1 = Fn1 sin  = 5320 0.342  1820 N Fr2 = Fn2 sin  = 5950 0.342  2050 N
Being aware of the longitudinal dimensions and the tooth force components, the load diagrams
may be drawn in y-x and z-x planes, see Fig. 3.
I.2.b. The load diagrams
On the load diagrams the longitudinal dimensions, tooth forces and torque are indicated.

Figure 3.
Calculation of the reaction forces components:

y - x plain:
180  5000  60  2050
M Ay = 0 = 60 Fr 2 + 180 Ft1 - 410 FBy  FBy   2496N
410
230  5000  470  2050
M By = 0 = -230 Ft1 + F Ay 410 + 470 Fr 2  FAy   455N
410
z - x plain:
60  6536  180  1820
M Az = 0 = 60 Ft 2 + 180 Fr1 - 410 FBz  FBz   1756N
410
470  6536  230  1820
M Bz = 0 = 230 Fr1 + 410 FAz - 470 Ft 2  FAz   6472 N
410
The reaction forces:
2  F2  64722  4552  6488N
FA  FAz Ay
2 2
FB  FBz  FBy  17562  24962  3052 N

I.2.c. Choosing shaft material

Considering the operation circumstances and the load of the shaft St 44-2 general-purpose
structural steel (acc. to DIN 17100) may be used without heat treated condition. Its material
properties: - ultimate strength Su = 500 MPa
- yield point Sy = 245 MPa
I.2.d. Stressing
The load diagrams show the place of the maximum stress at the gear 1, this is why the minimum
shaft diameter is determined here.
The nominal bending moment subjecting to this cross section area:
2  M 2  5742  4042  702 Nm
M  M hjy hjz

For determining the minimum shaft diameter, we apply the overload factor (kop=1.3) to
calculate the maximum bending moment and torque.
M max  kop .M hj  1.3  702  910 Nm

M t max  kop M t  1.3  1000  1300 Nm

The resultant moment according to the H-M-H theorem:

2  3M2
M res max  M max  910 2  3 1300 2  1450 Nm
4 t max 4

Combined static load (maximum energy of distortion)

M2 M 1 3 sy
 e   2  3 2  2
 3 2t  3
M 2  M t2   allow 
K K p 0.1d 4 n

n  23
d 3
KP  K 2  2  2 0.1d 3
32
3
M 2  M t2
d min 
3 4
0.1 allow
Choosing the preliminary safety factor for n=2.8, the minimum shaft diameter may be
calculated for static load with the following formula:
M resmax n pre
 3 145010 2.8  55mm
3
d min  3
0.1S 0.1245
y

Counting in the weakening effect of the torque joint, the shaft diameter is chosen for d= 65 mm.

I.3. Construction of shaft parts

The shop drawing of the shaft may be made after designing the torque transmitting joints; the
shaft journals; supporting shoulders; and the axial retaining devices.

I.3.a. Designing the torque transmitting joints

The gear 1 is connected to the shaft I by a splined joint; and the gear 2 by a keyed joint.
Considering the calculated minimum shaft diameter and the required diameter steps to provide
supporting shoulders, the shaft dimensions are fixed according to the Fig. 7 hence the nominal
diameter of the keyed joint is 55mm, and the splined shaft is 65 mm.
Parallel keyed joint (acc. to DIN 6885)
Shaft diameter: d = 55mm
Torque: M t  1000 Nm
Parallel key dimensions b x h = 16 x 10mm
t1 = 6mm
Key material: St 44-2 Su = 500 MPa
Sy = 275 MPa

Figure 4.
2
Sy 275Nmm
pallowed    135MPa
n 2
0.5S y 0.5  275Nmm2
 allowed    65MPa
n 2
factor of safety: n
- for steady loads: 2
- for minor to high shock loads: 2.5 - 4.5
a. Stressing for shear stress
M 1000 103 Nmm
peripheral force (tangential) F=   36.3KN
d /2 55 / 2mm
F
shear stress   allowed
leff b
the required length of the parallel keyed joint in terms of shear stress:
F 36.3 103 N
leff    35mm
b  allowed 16mm  65 Nmm 2
b. Stressing for bearing stress:
F
bearing stress p  pallowed
leff  h  t1 
the required length of the parallel keyed joint in terms of bearing stress:
F 36.3 103 N
leff    66mm
h  t1  pallowed 10  6mm 135Nmm2
From the detailed stress calculations, it may be seen that the design stress is the bearing stress
hence the required key length:
l  leff  b  66  10  76  80 mm

Splined joint (acc. to DIN 5464)

Splines are ,,built-in keys” they can transform more torque than can be handled by keys while
axial movement between shaft and hub is required.
The applied spline profile: straight sided splines-medium series (8-65x56x10)
Shaft diameter: D = 65mm
Torque: M tI  1000 Nm
Spline dimensions 65x56x10 (D x d x b)
(outer diameter x inner diameter x spline with)
Number of splines z=8
Shaft material: St 42-2 Su = 500 MPa
Sy = 255 MPa
Sy 245Nmm2
pallowed    120MPa
n 2
0.5S y 0.5  245Nmm2
 allowed    60MPa
n 2
factor of safety: n
- for steady loads: 2
- for minor to high shock loads: 2.5 - 4.5
a. Stressing for bearing stress:
Torque capacity based on bearing stress:
dm
M  pallowed A z
2
A  h  2c l
Dd
h  4.5mm
2
Dd
dm   60.5mm
2 Figure 5.
the required length of the splined joint in terms of bearing stress:
2M
l
d m h  2c  pallowed z
2 1000 103 Nmm
l  9.8mm
60.5mm  4.5mm  2  0.5mm 120 Nmm2  8

a. Stressing for shear stress

Torque capacity based on shearing
d
M   allowed bl m z
2
the required length of the splined joint in terms of shear stress:
2M 2 1000 103 Nmm
l   6.9mm
 allowed bd m z 60Mnn2 10mm  60.5mm  8
From the detailed stress calculations, it may be seen that the design stress is the bearing stress
hence the spline length is the width of the gear 2.
l  30mm
I.3.b. Designing the journal pins of the shaft; selecting rolling bearings for service life
The diameter of the shaft journal pins, based on the draft of the shaft, is 60mm.
In the gear drive house, the shaft bearing system is cross located, the applied bearings are single
row deep grooved ball bearings. The selection of the rolling bearings based on its S-N curve,
see Fig. 6. The reference point of the S-N curve is C (basic dynamic load rating) that permits
the bearing life to be predicted at any level of actual load applied.
C: basic dynamic load rating: constant radial load that bearing can take for a rating life of
1 million revolutions of the inner ring (outer ring does not rotate).

Figure 6.
The basic dynamic load rating according to the Fig. 6:
C  3 LP for ball bearing
P equivalent dynamic bearing load
P=Fr if Fa/Fr  e
P=VXFr + YFa if Fa/Fr  e, (V is rotation; X,Y are load factors)
since no axial force acts, Fa=0, therefore
P=Fr
 min   1  1
L  60  Lh hn 
 h   min  10
6

Lh 4 - 8000 machines used intermittently

14 – 20,000 used in 8 hours/day service
50 – 60,000 for continuous 24 hours service

Lh = 18,000 hours, the prescribed service life.

n = 2960 1/min
min 1 1
L  60 18,000h  2960  6  3200
h min 10
Selecting the bearing A
d = 60mm
PA =FrA= 6488N
C  3 3200 6488N  96KN
The selected bearing: 6412, C = 108 KN, bearing dimensions: DxdxB = 150 x 60 x 35
Selecting the bearing B
d = 60mm
PB =FrB= 3052N
C  3 32003052N  45KN
The selected bearing: 6212, C = 55.3 KN, bearing dimensions: DxdxB = 110 x 60 x 22

I.3c. Shop drawing of the shaft

Figure 7.