Machine Design II

Chapter 7 Shafts and Shaft Components

Prepared by

Adeel Nizami
Assistant Professor of Mechanical Engineering The University of Lahore

Machine Design II by Adeel Nizami

7 Shafts and Shaft Components

Chapter Outline
7-1 7-2 7-3 7-4 7-6 7-7 7-8 Introduction Shaft Materials Shaft Layout Shaft Design for Stress Critical Speeds for Shafts Miscellaneous Shaft Components Limits and Fits

Machine Design II by Adeel Nizami

Shafts
A shaft is a rotating member, usually of circular cross section, used to transmit power or motion and to support components like gears, cams, pulleys, sprockets, wheels, couplings etc An axle is a non rotating member that carries no torque and is used to support rotating wheels, pulleys, and the like A spindle is a short shaft that imparts motion either to a cutting tool (e.g. drill press spindles) or to a work piece (e.g. lathe spindles). Short axles or shafts are also called Spindles There are notches, keyways and fillets in shafts, so care must be taken to reduce stress concentration Transmission shafts : counter shafts, line shafts, over head shafts Machine shafts : crank shaft

Machine Design II by Adeel Nizami

Shaft Materials
Necessary strength in shaft to resist loading stresses affects the choice of materials and their treatments A good practice is to start with an inexpensive, low or medium carbon steel for the first time. Then a higher strength material is tried, allowing the shaft sizes to be reduced until excess deflection becomes an issue. Shafts usually dont need to be surface hardened unless they serve as the actual journal of a bearing surface. Cold drawn steel is usually used for diameters under about 3 inches. Cold worked shafts have higher strengths but with more residual stresses For low production, turning is the usual primary shaping process with minimum material removal as goal, high production may permit a volume-conservative shaping method (hot or cold forming, casting), and minimum material in the shaft can become a design goal Most are made from low carbon, cold drawn or hot rolled like ANSI 1020-1050 steels For high strength applications, alloy steel like nickel, nickel chromium or chrome vanadium steel is used otherwise mild steel for normal applications. Similarly, stainless steel may be used for certain applications.

Machine Design II by Adeel Nizami

Shaft Layout
Issues to consider for shaft layout
Axial Layout of Component:
It is best to support load-carrying components between bearings. Usually only two bearings should be used unless shaft length is extremely long Shafts should be kept short to minimize bending moments and deflections.

Supporting Axial Loads

When axial loads are not trivial, it is must to provide a means to transfer the axial loads into the shaft, then through a bearing to the ground is necessary. It is generally best to have only one bearing carry the axial load. Common torque-transfer elements are : Keys Splines Setscrews Pins Tapered fits Press or shrink fits In addition to transmitting the torque, many of these devices are designed to fail if the torque exceeds acceptable operating limits, protecting more expensive components. When components are to be press-fit to the shaft, the shaft should be designed so that it is not necessary to press the component down a long length of shaft. Consideration should also be given to the necessity of disassembling the components from the shaft.

Torque Transmission

Assembly and Disassembly

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Stresses in shafts
Shear stresses due to the transmission of torque i.e. due to torsional load Bending stresses due to forces acting upon machine elements like gears, pulleys etc and due to weight of the shaft itself. Bending stresses could either be tensile or compressive in nature Stresses due to combined torsional and bending moments Axial stresses due to axial components transmitted through helical gears or tapered roller bearings.

Machine Design II by Adeel Nizami

Shaft Design for Stress : Critical Locations

Stresses are only evaluated at critical locations Critical locations will usually be
on the outer surface at axial locations where the bending moment is large where the torque is present, and where stress concentrations exist

Most shafts will transmit torque through a portion of the shaft. The shear stress due to the torsion will be greatest on outer surfaces. The bending moments on a shaft can be determined by shear and bending moment diagrams. Axial stresses on shafts due to the axial components transmitted through helical gears or tapered roller bearings will almost always be negligibly small compared to the bending moment stress. Axial loads are generally small and constant, so will be ignored

Machine Design II by Adeel Nizami

Cases of Shafts Design

1) Shafts subjected to Torque only
The diameter of the shaft is obtained by using torsion equation which is given as

T/J = /r
Where T = torque acting upon shaft J = polar moment of inertia of shaft about axis of rotation = torsional shear stress r = distance from neutral axis to the outer most fibre ( r= d/2, if d= shaft diameter)

Polar moment of inertia (for round shaft)

J= /32 x d4

Now, the Torque is given by

T= /16 x xd3

Machine Design II by Adeel Nizami

Hollow Shafts
Polar moment of inertia (for round shaft)

J= /32 x [(do)4 -(di)4 ]

Where do = outer dia di = inner dia

Now, the Torque is given by

T= /16 x x [(do)4 -(di)4 ]/do

Sometimes, we may define k = ratio of inside diameter and outside diameter of the shaft

= di / do

Torque is also related to power transmitted by the shaft

T = Px60/2N T = Px4500/2N (SI units; N-m) (MKS units; kgf-m)

Where N = speed of the shaft in r.p.m P = power in watts (SI) and horse power (MKS)

Machine Design II by Adeel Nizami 1

Machine Design II by Adeel Nizami

2) Shafts subjected to Bending Moment only

The diameter of the shaft is obtained by using torsion equation which is given as

M/I = /y
Where M = bending moment I = moment of inertia of cross sectional area of shaft about axis of rotation = bending stress y = distance from neutral axis to the outer most fibre (y= d/2, if d= shaft diameter)

Moment of inertia (for round solid shaft)

I= /64 x d4

Now, the Bending moment is given by

M= /32 x xd3

Machine Design II by Adeel Nizami

Hollow Shafts
Moment of inertia (for round shaft)

I= /64 x [(do)4 -(di)4 ]

Where do = outer dia di = inner dia

Now, the Bending moment is given by

M= /32 x x [(do)4 -(di)4 ]/do Sometimes, we may define k = ratio of inside diameter and outside diameter of the shaft = di / do Notes:
1) The bending moments on a shaft can be determined by shear and bending moment diagrams. 2) Resultant moments are obtained by summing moments as vectors at points of interest along the shaft. The phase angle of the moments is not important since the shaft rotates

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Combined torsional and bending moments along with axial stresses

Bending, torsion, and axial stresses may be present in the form of both midrange and alternating components For analysis, it is simple enough to combine the different types of stresses into alternating and midrange von Mises stresses Axial loads are generally small and constant, so will be ignored in this section Standard stress equations can be customized for shafts for convenience Fluctuating stresses (produced due to bending and torsion) are given as Standard alternating and midrange stresses

Customized equations for round shafts

Machine Design II by Adeel Nizami

Mm = midrange bending moment Ma = alternating bending moment Tm = midrange torque Ta = alternating torque Kf and Kfs are the fatigue stress concentration factors for bending and torsion

q = Notch sensitivity (usually from 0 to 1) and is defined by

Machine Design II by Adeel Nizami

Combining these stresses in accordance with the distortion energy failure theory, the von Mises stresses for rotating round, solid shafts, neglecting axial loads, are given by

Substitute von Mises stresses into failure criteria equation. For example, using modified Goodman line

n = factor of safety

Machine Design II by Adeel Nizami

Main Failure Criterions

1

Machine Design II by Adeel Nizami

Solving for shaft diameter (d) is convenient for design purposes

Similar approach can be taken with any of the fatigue failure criteria. Equations are referred to by referencing both the Distortion Energy method of combining stresses and the fatigue failure locus name. For example, DE-Goodman, DE-Gerber, etc

Machine Design II by Adeel Nizami

DE-Gerber

where

Machine Design II by Adeel Nizami

DE-ASME Elliptic

DE-Soderberg

Machine Design II by Adeel Nizami

Shaft Stresses for Rotating Shaft

Particular Case
For rotating shaft with steady bending and torsion, Bending stress is completely reversed, since a stress element on the surface cycles from equal tension to compression during each rotation Torsional stress is steady Previous Equations can be simplified by setting Mm = 0 and Ta = 0, which simply drops out some of the terms

Checking for Yielding in Shafts

Machine Design II by Adeel Nizami

Soderberg criteria inherently guards against yielding and ASME-Elliptic criteria takes yielding into account, but is not entirely conservative. Gerber and modified Goodman criteria require specific check for yielding, as they do not guard against yielding and hence A von Mises maximum stress is calculated for this purpose. Use of von Mises maximum stress to check for yielding

Machine Design II by Adeel Nizami

Alternate simple check is to obtain conservative estimate of 'max by summing 'a and 'm

max = a + m

Example 7-1

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Shaft Design for Stress : Stress Concentration

Stress concentrations for shoulders and keyways are dependent on size specifications that are not known the first time through the process. Since these elements are usually of standard proportions, it is possible to estimate the stress concentration factors for initial design of the shaft. These stress concentrations will be fine-tuned in successive iterations, once the details are known. A keyway will produce a stress concentration near a critical point where the load-transmitting component is located. Some typical stress concentration factors are used for the first iteration in the design of a shaft. A look through bearing catalogs shows that a typical bearing calls for the ratio of D/d to be between 1.2 and 1.5. For a first approximation, D/d =1.5 can be assumed

Machine Design II by Adeel Nizami

In cases where the shoulder at the bearing is found to be critical, the designer should plan to select a bearing with generous fillet radius, or consider providing for a larger fillet radius on the shaft by relieving it into the base of the shoulder as shown in Fig. 7-9a. This effectively creates a dead zone in the shoulder area that does not carry the bending stresses, as shown by the stress flow lines. A shoulder relief groove as shown in Fig. 7-9b can accomplish a similar purpose. Another option is to cut a large-radius relief groove into the small diameter of the shaft, as shown in Fig. 7-9c

Fig. 7-9 (a-c) Arrangements for stress concentration control

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Fig. 7-10

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Critical Speeds for Shafts

When a shaft is turning, eccentricity causes a centrifugal force deflection, which is resisted by the shafts flexural rigidity E I. At certain speeds, critical speeds, the shaft becomes unstable. In other words, critical speed is the speed of shaft at which its deflection reaches to infinity which causes shaft failure. The shaft, because of its own mass, has a critical speed as
where m is the mass per unit length, A cross-sectional area and specific weight.

For an ensemble of attachments, Rayleighs method for lumped masses gives

An influence coefficient is the transverse deflection at location i on a shaft due to a unit load at location j on the shaft. For simply supported beam with single unit load.

where y is the deflection

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Machine Design II by Adeel Nizami

Miscellaneous Shaft Components

Setscrews : Setscrew depends on compression to develop the clamping force, due to frictional resistance of the contacting portions of the collar and shaft as well as any slight penetration of the setscrew into the shaft. Keys and Pins : Keys are used to enable the transmission of torque from the shaft to the shaft-supported element. Pins are used for axial positioning and for the transfer of torque or thrust or both. Retaining Rings : A retaining ring is frequently used instead of a shaft shoulder or a sleeve to axially position a component on a shaft or in a housing bore.

Machine Design II by Adeel Nizami

Limits and Fits

In the standard if limits and fits, capital letters always refer to the hole; lowercase letters are used for the shaft. For the hole For shafts with clearance fits c, d, f, g, and h, For shafts with interference fits k, n, p, s, and u,

Machine Design II by Adeel Nizami

QUIZ #1 Monday, March 5, 2012 (09:30 ~11:00) M-104 Chapter 7 (all articles and examples covered in lectures)

Homework Prob # 7.1, 7.2, 7.4, 7.7, 7.8, 7.14, 7.20, 7.21, 7.22, 7.23 Shigleys Mechanical Engineering Design