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Chapter09 (Shaft)

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181 views70 pages

Chapter09 (Shaft)

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Uploaded by

Ganesh Dongre
Copyright
© © All Rights Reserved
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Chapter 9

Shafts, Keys and Couplings

:
:
PROPRIETARY MATERIAL.
MATERIAL 2007 The McGraw-Hill Companies, Inc. All rights reserved. No part of this PowerPoint slide may be displayed,
reproduced or distributed in any form or by any means, without the prior written permission of the publisher, or used beyond the limited
distribution to teachers and educators permitted by McGraw-Hill for their individual course preparation. If you are a student using this
PowerPoint slide, you are using it without permission.

Fig. 9.1 Transmission Shaft

Shaft Design based on fatigue strength


The state of stress at a selected critical point on the surface of a rotating
power transmission shaft may involve torsional shearing stress, bending
stress, or axial stress components, any or all of which may be fluctuating
about zero or non-zero mean value.
Shaft design must be based on multi-axial states of stress produced by
fluctuating loads.
Many shaft design cases involve a reasonably simple state of stress, often
characterized by a steady torsional shearing stress component
produced by a steady operating torque, and a completely reversed
bending stress component produced by steady traverse forces on a
rotating shaft.
Because the material of shaft is ductile, the appropriate selection for a
combined stress design equation would be either the maximum shear
stress theory, or the distortion energy theory.

( x ) max

( M bm + M ba ) c
= ( x ) m + ( x ) a =
I

For the case of completely reversed bending M = 0 , and for


ductile materials a fatigue stress concentration factor k fb is
applied to the alternating component of bending stresses.
bm

( x ) max =

32k fb M ba

d3

By similar reasoning,
( M tm + M ta ) a
( xy ) max = ( xy ) max + ( xy ) a =
J
where a is radius to the outer fibers of the cylinder.

For the case of steady torsion M ta = 0 , and no stress


concentration factor is needed be considered, for a cylindrical
M tm a 16 M tm
=
shaft, ( xy ) max =
J
d3

The resulting stress based on distortion energy theory may be

x2 + 3 xy2 = d
(

32k fb M ba

d3

16M tm 2
) +(
) =d
3
d
2

1/ 3

32 ( fs )
2
2
d =
( K fb M ba ) + 0.75( M tm )
Se

fs = selected design safety factor.


k = fatigue stress concentration factor for bending case.
fb

S e = endurance limit of the shaft material.

Shaft design based on maximum shear stress theory is derived as


follows:
1/ 3

32 ( fs )
2
2
( K fb M ba ) + 0.75( M tm )
d =
Se

Fig. 9.16 Key-joint

Common types of shaft keys (I)

Common types of shaft keys (II)

Common types of shaft keys (III)

Fig. 9.17

(a) Hollow Saddle Key (b) Flat Saddle Key

Fig. 9.18 (a) Square Key (b) Flat Key

Fig. 9.19 Gib-head Taper Key

Fig. 9.20 Feather Key

Fig. 9.21 Woodruff Key

9.13 design of square and flat keys

Fig. 9.22 Forces Acting on Key

Key shear of failure mode

Fig. 9.23 Failure of Key (a) Shear Failure (b) Crushing Failure

1. Failure due to shear stress


The force P is tangential to the shaft diameter.
M
2M
P=
=
( d / 2)
d
where M = tangential torque
t

(a)

d = shaft diameter
P = force on key

The shear failure will occur in plane AB. The shear


stress in the plane AB is given by,
P
P 2M
=
= =
area of plane AB bl d b l
where b = width of key
l = length of key
t

(b)

2. Failure due to compressive stresses


The failure due to compressive stresses will occur on
surfaces AC or DB.

h
AC = BD =
2
where h = height of key (mm)
The compressive stress in the key is given by

P
P
2 P 4M
=
=
=
=
area of surface AC (h / 2)l hl d h l
t

Fig. 9.27 Splines (a) Shaft (b) Hub

Fig. 9.28 Types of Spline Profiles

Fig. 9.29 Muff Coupling

Fig. 9.30 Free Body Diagram for Torques

Fig. 9.31 Split Muff Coupling

Fig. 9.33

Unprotected Type Flange Coupling

Fig. 9.34 Protected Type Rigid Coupling

Fig. 9.35 Proportions of Rigid Coupling

Fig. 9.38 Types of Misalignment

Fig. 9.39 Flexible Coupling

Fig. 9.43 Bending Moment at Section XX

Fig. 9.44 Dimensions of Bush and Pin

Fig. 9.45 Dimensions of Driving Flange

Fig. 9.46 Multiflex Coupling

STEELFLEX metallic grid coupling

Cushion-type flexible coupling

Gear coupling

Gear coupling

Gear coupling

Chain coupling

9.25 Design for lateral rigidity

Design for lateral rigidity


The maximum permissible deflection for the transmission
shaft is taken as = (0.001) L to (0.003) L , where L is the span
length between the two bearing.
The maximum permissible deflection at the gear is taken as
= 0.01m , where m is the modulus of the gear teeth.
Shaft slopes at the bearing sites must be evaluated against
allowable angular misalignments for the specific bearing
chosen. For example, deep-groove ball bearings operate well
up to about 0.25o angular misalignment

Important methods for determining the lateral deflection of


bearing are:
(i) Double integration
(ii) Area moment method
(iii) Strain energy method (Castiglianos Theorem)
(iv) graphic integration method

9.26 Castiglianos Theorem

Castiglianos Theorem

When a body is elastically deflected by any combination of


forces or moments, the deflection at any point and any
direction is equal to the partial derivative of the total
strain energy of the body with respect to force located at
that point and acting in that direction.

U
i =
Pi
where U is the total strain energy of the body.

Force type
Tension rod (P)
External torque (M t )

Bending moment ( M b )

Strain energy
P 2l
U=
2 AE
(M t )2 l
U=
2 JG
( M b ) 2 dx
U =
2 EI

Fig. 9.48

9.27 Area moment method

Area moment method

The vertical distance of any point C on the elastic curve of the


shaft from the tangent at ant other point A on the elastic curve,
is equal to the moment of the area of M/EI diagram between A
and C with respect to the ordinate through C.

Fig. 9.49 (a) Forces on Shaft (b) Elastic Curve


(c) M/EI Diagram

9.28 Graphic integration method

Fig. 9.50

Fig. 9.51 Graphical Integration Method

Example:
A shaft is to be supported on two bearings spaced 30 inches
apart. A straight spur gear with a pitch diameter of 20
inches is to be supported midway between bearings, and
straight spur gear pinion having a pitch diameter of 5
inches is to be supported 6 inches to the right of the righthand bearing. The

20

involute gears are to transmit 150

horsepower at a rotational speed of 150 rpm. The proposed


shaft material is hot-rolled AISI 1020 steel with S = 65000 psi
ut

and S e = 33000 psi.. Design the shaft using a design safety


factor fs = 2.0.

Solution:
(1) The first step is to make a first-cut sketch conceptual
sketch of shaft as shown in Fig. A.
(2) A coordinate system is established with the position of
shaft, gears, and bearings, So that the forces and moments
on the shaft may be shown (Fig. B). The cross section of
the shaft at A, B, C and D are selected as critical section.
(3) Perform the force analysis to determine the magnitudes
and directions for all forces and moments on the shaft (Fig.
C).
(4) Determine the diameter at cross section of A, B, C, D.
(5) Using the diameter just calculate at section A, B., C, and D,
and the should restrictions from the problem statements,
the first-cut sketch may be updated and modified to obtain
the second-cut sketch of Fig. D.

Fig. A First-cut conceptual sketch

Fig. B Coordinate system and force notation

Fig. C Forces on the shaft

M ( A D) = 63,025 in lb
t

M =0
bA

M = 15 ( 2982) + (1891) = 52,955 in lb


2

bB

M = 6 (25210) + (9176) = 160,968 in lb


2

bC

M =0
bD

For a steel with S = 65,000 psi , q value around 0.8.


u

k = q ( K 1) + 1 = 0.8(1.7 1) + 1 = 1.6
fb

Fig. D Second-cut sketch of shaft showing principal dimension

At critical section B
1/ 3

32 (2.0)

d =
(1.6 52,966) + 0.75(63.025)
(33,000)

= 3.96 inch
2

At critical section C
1/ 3

32 (2.0)

d =
(1.6 160,968) + 0.75(63.025)
(33,000)

= 5.46 inch
2

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