MECH3403 Assignment 1

Shaft Design



Prepared by



Group 52
Robin Kwan - 2089 2346
Thanh Cong Le - 2087 2108
Mu Hua Sun - 2074 6066






March 2013
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Table of Contents
1.0 Introduction ...................................................................................................................................... 2
2.0 Specifications .................................................................................................................................... 3
2.1 Simplifications and Assumptions 2.1.1 Assumptions ............................................................... 4
2.1.2 Simplifications ........................................................................................................................ 4
3.0 Calculations ....................................................................................................................................... 4
3.1 Gear Ratio ..................................................................................................................................... 4
3.2 Central Line Distance .................................................................................................................... 5
3.3 Bending moment and shear force analysis ................................................................................... 6
3.4 Shear stress analysis ..................................................................................................................... 6
3.5 Power and torque ......................................................................................................................... 6
3.6 Von Mises stress analysis .............................................................................................................. 6
3.6.1 Minimum shaft diameter ....................................................................................................... 7
3.7 Deflection ...................................................................................................................................... 7
4.0 Material Selection ............................................................................................................................. 7
5.0 Bearings ............................................................................................................................................. 8
6.0 Program subroutine .......................................................................................................................... 9
7.0 Technical Drawing ........................................................................................................................... 13
8.0 Responsibilities ............................................................................................................................... 13
9.0 References ...................................................................................................................................... 14











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1.0 Introduction
A certain company produces gear trains for different applications with different power input
and rotational speeds. Consequently, the dimensions of shaft II will vary to adjust to these
varying requirements. Our focus for this project is to design shaft II of the gear train. Shaft II
is supported horizontally by two bearings and carries two gears (as shown). We are asked
to develop a procedure program that determines the minimum shaft diameter when the
user inputs their desired design parameters of a specific range. The program also is required
to plot the distribution of the bending moment, torque, force and deflection along the shaft,
and also a distribution of von Mises stresses along the shaft. We are also asked to select
rolling-element bearings for shaft II and include general technical drawing of the shaft
containing all key information for manufacturing.







Figure 1
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Figure 2


2.0 Specifications

Power 1000 W 1500W
Rotational Speed 1000 rpm 2000rpm
Gear teeth (small) 15 teeth
Gear teeth (large) 45 teeth
Shaft II length 160 mm
Bearing distance from gears 30 mm
Pressure angle 25 degrees
Module 5 mm



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2.1 Simplifications and Assumptions

2.1.1 Assumptions
- Assume 100% efficiency of the gear train (i.e. no energy losses)
- Disregard inertia effects
- Disregard fatigue failure mechanism, and use failure by yielding (von Mises Failure
Theory)
- 15 000 life hours for bearings
- 98% reliability for bearings
2.1.2 Simplifications

For this project we have selected a safety factor of 2. This is due to any safety factor higher
than this value is deemed a waste of material and cost ineffective as the safety factor
influences our minimum diameter of the shaft and therefore causing wastage of excess
material needed for our situation.

3.0 Calculations

3.1 Gear Ratio

Gear ratio e is bound by the equation,






Therefore,

Thus we get a gear ratio of

. This is the same for the other pair of gears as we are told they
are identical pairs of gears with the same number of teeth in both pairs.

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Figure 3
3.2 Central Line Distance

In order to work out the central line distance between the two co-linear shafts I & III and the
shaft II, we need to determine the diameter of the gears.
By using the gear modulus equation,





We get,





Given that the modulus is the same for all gears,



If we picture this in a diagram,

We result in a central line of 150mm.

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Figure 4
3.3 Bending moment and shear force analysis

As illustrated in the Mathematical model of shaft design-section III, bending moment
analysis takes place in two different planes (i.e. X-Z plane and X-Y plane).This assumption is
based on the present of the applied force by the motor when it rotates and produces torque
along the shaft. The reason for us to consider in two planes is due to the pressure angle of

that causes the applied force to split into 2 components in X-Y and X-Z planes. The shear
force can be found by differentiating the bending moment equations. Further calculation is
clearly shown in Mathematical model of shaft design-section III.

3.4 Shear stress analysis

Due to the torsion caused by the rotational motor, there exists shear stress distribution that
extends radially outwards from the centre of the shaft crossed section area and this shear
stress reaches it maximum at the outer most layer of the shaft as shown in Figure 4. Further
calculation of this maximum shear stress is shown in Mathematical model of shaft design-
section IV.




3.5 Power and torque

Based on the assumption that the motor is 100% efficient, the power is theoretically
transferred successfully along the shaft. That is power input will be equal to power output.
Since the power is the same along shaft II, the rotational effect produces constant torques
along shaft II with the two ends of the shaft II under opposite but equal torques.
Calculation of this value of Torque is shown in Mathematical model of shaft design-section
I.

3.6 Von Mises stress analysis

Disregarding the failure of shaft due to fatigue as assumption shown above, yield strength is
used to determine failure criteria. Applying distortion strain energy theory, Von Mises stress
is then calculated and this stress value must always be less than the yield strength. In other
words, the shaft will fail when Von Mises exceeds the yield strength of the material. A
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clearer analysis of Von Mises failure criteria are in Mathematical model of shaft design-
section V.

3.6.1 Minimum shaft diameter
From the Von Mises failure criteria, with some algebraic operations on the inequality
between the Von Mises stress and yield stress, we can derive the formula for the minimum
allowable shaft diameter before failure occurs. For safety purpose when design rotational
shaft, safety factor can be added into the equation to obtain a more safe version of
diameter. Full calculation is shown in Mathematical model of shaft design-section IV.

3.7 Deflection

Under loads, the shaft will deflect. The amount of deflection is complicated to analyse, so in
order to obtain the deflection behaviour of shaft under loads, we have to derive it
mathematically by applying simple beam theory to simplify all other complex cases.
According to the theory, deflection can be expressed in term of pure bending moment along
the shaft as shown,

E and I are the modulus of elasticity and second moment of inertia. M(x) is the bending
moment of shaft and y is the deflection distance from it neutral position. Full derivation is
shown in Mathematical model of shaft design-section VI.

4.0 Material Selection

We are specifically asked to use mild steel as the material for the shaft. Due to mild steel
having a small amount of carbon, it is softer and more easily shaped than higher carbon
steels. This also means that it is ductile and not brittle therefore able to handle bending. It is
also a lot cheaper than using steel and also better than using iron. It is cheap and also
versatile making it an optimum choice.
We selected the 1030 grade mild steel due to its mechanic properties and slightly higher
yield strength over the 1020 grade.
Mechanical Properties
Tensile Strength (MPa) Yield Strength (MPa) Elongation (%)
500 250 20

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We also got a quote on the prices for our shaft on both grades of mild steel. Both grades are
exactly the same costing an approximate $20 for the dimensions of our shaft.
5.0 Bearings

There are two bearings located on shaft two on the gear train. We assume it have a life of
15 000 hours and a 98% reliabililty and with the given inputs,
Inputs Values Outputs Value
Input power 1KW Diameter of shaft 13.4 mm
Rotational speed 12000 rpm Max shear stress 50.54 MPa
Safety factor 2 Max normal stress 89.22 MPa
Yield strength 250 MPa Max BM in x-z plane 19.1 Nm
Max BM in x-y plane 8.91 Nm
Torque 23.87 Nm

Our selection of bearings depended on the load on the shaft and the type of forces involved.
This led to a final decision of using ball bearings are they are suitable for both axial and
radial forces. Since we know there are two bearings, the overall reliablility of the bearings
will be,

In order to select our bearings, we need to determine its basic dynamic load rating.
From the equation,

And from the equation,

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Substituing it in we get,

) (

To get P,

Then rearranging for C
r
,

Looking at the catalogue provided by NSK we selected the 6802 bearings.

6.0 Program subroutine

Our subroutine can only be run using MATLAB. It is not compatible with other software such
as MATHEMATICA and EXCEL. The followings are step by step guide on how to use this
subroutine.
1. Run MATLAB software and then open our m.file named shaft_1. Doing this will pop
up an editor box.
2. On the top row of menu, click run shaft_1 or simply press F5 on your keyboard.
A GUI that looks like figure () will shows up afterward. If a message box with several
options appears, click Add to Path.
Figure () The layout of our GUI
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3. Insert the input parameter in the empty boxes in input panel and after that press
Compute push button. Doing this will give you the bending moment, shear force
and deflection diagram as well as other useful information.

4. Click the Click here for other graphs for viewing Von Mises stress and torque
diagrams.

5. A sub-GUI will shows up and insert again the same input parameters to obtain the
graphs. The sub-GUI will look like this.
Figure () The input panel on the top
left side of our GUI.
Figure () This push button is located
between input and output panels.
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Testing the subroutine:
Testing of the error dialog box
To prevent users from inserting out-of-range values for the inputs, a useful mechanism like
error dialog box has been implemented to our subroutine. It warns users if users
accidentally key in the wrong inputs. Various input values have been tested to verify its
functionality and the table () is our test result. Status Yes means error dialog box appears
and No means error dialog box does not appear.
Inputs: Status: Inputs: Status:
Input Power = 900 W Yes Rotational speed = 500 rpm Yes
Input Power = 1250 W No Rotational speed = 1500 rpm No
Input Power = 1600 W Yes Rotational speed = 2001 rpm Yes
Safety factor = 0.5 Yes Safety factor = 2 No
Safety factor = 5 Yes


Testing of the graphs and output data
Our subroutine is tested with input data of following table and the tested result is shown in
figure () and figure (). Table () also shows the output data for a given inputs.
Inputs Values Outputs Value
Input power 1.2 KW Diameter of shaft 15.13 mm
Rotational speed 1000 rpm Max shear stress 50.54 MPa
Safety factor 2 Max normal stress 89.22 MPa
Yield strength 250 MPa Max BM in x-z plane 27.5 Nm
Max BM in x-y plane 12.8 Nm
Torque 34.38 Nm

Figure () The layout of our sub-GUI
Table () The tested result of the error dialog box
Table () Table above shows the tested outputs with certain inputs.
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7.0 Technical Drawing

See end page.
8.0 Responsibilities
Name Main Responsibility
Robin Kwan -Programming
-Debugging
-Research
Cong Thanh Le -Calculations
-Bending , Shear, Power, Torque, von Mises,
Deflection
-Research
Mu-Hua Sun -Gear ratio, Central line distance
-Material, Bearing selection
-Technical Drawing
-Report
Figure () The graphs and outputs result.in GUI
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9.0 References

References:
Stephen J. Chapman, 2004, MATLAB Programming for Engineers, 3
rd
edition, Nelson, Thomson
Canada Limited.
Desmond J. Higham & Nicholas J. Higham, 2000, MATLAB guide, Society for Industrial and Applied
Mathematics Philadelphia.
Budynas, R. G. and Nisbett, J. K. Shigleys 2008 Mechanical Engineering Design, 9th
Edn, McGraw-Hill
Bhler Uddeholm (Australia) Pty Ltd 2005, Bright Steels, viewed 24 March 2013,
<http://www.buau.com.au/english/files/BMS.pdf>
Cixing Group Co. Ltd 2008, Basic Rating Life, viewed 25 March 2013,
<http://www.cwbearing.com/basic_ratinglife.html>
The Timkem Company 2013, Bearing Life Calculations/Selection, viewed 25 March 2013,
<http://www.timken.com/sites/newproducts/en-us/typee/Documents/Bearing_Life_Calculations.pdf>
NSK Ltd. Copyright , E1102k Rolling Bearings Catalogue, viewed 26 March 2013
<http://www.jp.nsk.com/app01/en/ctrg/index.cgi?rm=pdfView&pno=e1102k>
Mott Souders, Ovid Wallace Eshbach, 2001, Hand book of Engineering Fundamentals, 3
rd
edition,
Wiley Engineering handbook series.










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Table of symbols used and their standard units
For calculation pages reference only

Meaning Symbol Unit
Power input P W (Watt)
Angular velocity Rad per sec
Torque T Nm
Applied Force F N
Bending moment M Nm
Shear force V N
Shear stress Pa
Normal stress Pa
Von Mises stress

Pa
Polar moment of inertia

Second moment of
inertia
I

Shaft diameter d m
Youngs modulus E GPa
10^9 Pa