Shaft Design Machine Design

F – force, N
V – velocity, m/s

Power is also given by the formula P = Tf if f is

Shaft Design given in radians per second. In the English System, the
formula generally used is
2TN
P
Shaft design consists primarily of the determina- 33,000
tion of the correct shaft diameter to ensure satisfactory P – power, hp
strength and rigidity when the shaft is transmitting power T – torque, ft-lb
under various operating and loading conditions. Shafts are N – revolutions per minute
usually circular in cross section, and may be either solid or
hollow.
Torque
Definition of Terms Torque or moment of a force is a measure of the
tendency of the force to rotate the body upon which it acts
shaft – A rotating member supported by bearings and about an axis. The magnitude of the torque is obtained by
transmitting power. It may be subjected to torsional, multiplying the force by the perpendicular distance from
bending or axial load. the axis to the line of action of the force. The SI unit is the
axle – A stationary member carrying rotating wheels, newton-meter (N-m).
gears or pulleys. It is subjected to bending loads but
not to torsion. T = Fr
spindle – A short shaft or axle on a machine.
machine shaft – Shaft which is an integral part of the T – torque, N-m
machine. F – tangential force, N
transmission shaft – Shaft which is used to transmit r – moment arm, m
power between the source and the machine absorbing
power. The allowable twisting moment for a shaft of any
line shaft or main shaft – Transmission shaft driven by cross section such as circular, square, etc is:
primary power.
countershaft, jackshaft, headshaft, short shaft –
T = Ss Z
Transmission shaft intermediate between the line shaft
and the driven machine
T – torque, N-m
Ss – allowable shear stress, Pa
Use brittle materials for shafts instead of ductile
Z – polar section modulus of the shape, m4
materials. Brittle materials have strength in shear, ductile
see elements of sections below
materials have strength in normal stress. Design torsion on
shaft using brittle materials and a design stress of 0.75 Su
(ultimate strength) if Su is given instead of 0.6 Sy for
shear. Polar Moment of Inertia
 d4
a. Solid Shaft J
32
Method of Design
 (D 4  d4 )
b. Hollow Shaft J
Design based on strength – The design of 32
shafts for lateral rigidity is based on the permissible
J – polar moment of inertia, m4
lateral deflection for proper bearing operation, accurate
D,d – outer, inner diameters, m
machine tool performance, satisfactory gear tooth action,
shaft alignment and other similar requirements. In this
method, the shear strength of the material limits the
design. Angular (Torsional) Deflection

The allowable stresses that are generally used in Shafting must be proportioned to prevent torsio-
practice are: nal deflection (twisting) through a greater angle than has
been found satisfactory for a given type of service.
main power-transmitting shafts 4000 psi
TL
lineshafts with pulleys 6000 psi  180  rad    deg
small, short shafts, countershafts 8500 psi JG
Design based on rigidity – The design of shaft This formula is then revised using the equation for
for torsional rigidity is based on the permissible angle of the polar moment of inertia (J, above) as follows.
twist. The amount of twist permissible depends on the
particular application, and varies from about 0.28° per 32 TL
meter for machine tool shafts to about 3.28° per meter for a. Solid Shaft  
line shafting.  d4 G
32 TL
b. Hollow Shaft 
 (D 4  d4 )G
Power Transmission
θ – angle of twist, radians
T – torque, N-m (in-lb)
Power is the product of force times distance
L – length of shaft, m
divided by time. It is the rate of doing work and is
D – diameter, m (in)
expressed in watts, which is one joule of work per second.
S – shear stress, Pa (psi)
G – modulus of rigidity
P = 2πTf P = FV = 80 GPa, 11.5 Mpsi unless given

P – power, W According to some authorities, the allowable twist

T – torque, N-m in steel transmission shafting should not exceed 0.08
f – frequency of rotation, r/s degree per foot of length (3.81 m per degree of twist).

1 Patrick D. Sta. Maria / January 28, 2018

 Shaft Design Machine Design

Another rule that has been generally used in mill practice Shafts Subjected to Both
limits the deflection to 1 degree in a length equal to 20
Torsion and Bending
times the shaft diameter.
In computing the diameter when the shaft is
subjected to a combination of torsional and bending
Shafts Subjected to Pure Torsion : stresses, the equivalent bending moment and the equiva-
Torsional Stress lent twisting moment for the shaft are computed. The
corresponding diameter of the shaft is then obtained from
The torsional stress is the shearing stress expe- the two values and the larger number is taken as the
rienced by the shaft which is produced by twisting its ends correct diameter.
in opposite directions
F1 – tight side
Ss = Tc / J
Ss – shear stress, Pa Dp
T – torque, N-m
c – distance from the neutral axis to the F2 – loose side
outermost fiber, d/2 or r on round shafts
Turning Force
a. Solid Shaft F = F1 – F2
Td  32  16 T Torsion
Ss  Ss 
2   d4   d3 T = (F1 – F2)(1/2) Dp
b. Hollow Shaft
Bending
TD  32  M = (F1 + F2)(1/2) L
Ss   4 
2   (D  d ) 
4
F1 – tight side, N
16 TD F2 – loose side, N
Ss  Dp – diameter of the pulley, m
 (D 4  d4 ) L – distance between supports, m

Effects of Keyways on Shaft Strength – This formula assumes that the weight is exactly in
Keyways cut into a shaft reduce its load carrying ability, the middle of the supports of the shaft.
particularly when impact loads or stress reversals are
involved. To ensure an adequate factor of safety in the Equivalent Twisting Moment
design of a shaft with standard keyway (width, one
quarter and depth, one eight of shaft diameter), the
TE  M2  T 2
former Code for Transmission Shafting tentatively recom-
mended that shafts with keyways be designed on the basis Equivalent Bending Moment
of a solid circular shaft using not more than 75 per cent of ME  M  TE
the working stress recommended for the solid shaft.
Solid Shaft

Shafts Subjected to Bending : 16 ME Sf ME

Sf  
Flexural Stress  d3 Ss TE
16 TE Sf M
Sf = Mc / I Ss  1
 d3 Ss TE
Sf – flexural stress, Pa
M – maximum moment, N-m Hollow Shaft
I – centroidal moment of inertia, m4 16 D ME 16 D TE
Sf  Ss 
a. Solid Shaft  (D 4  d 4 )  (D 4  d4 )
 d4  Md   64 
I Sf     4 
64  2  d  Horsepower Transmitted by Shafting
32M PSME Code
Sf 
 d3 Using the allowable stresses that are generally
used in practice (see Design based on strength on p. 1
b. Hollow Shaft above) the following formulas are given by the 28th
 (D 4  d4 ) Edition of Machinery's Handbook:
I
64 For main power-transmitting shafts: P = D3 N / 80
 Md   64 
Sf     4  For lineshafts carrying pulleys: P = D3 N / 53.5
 2    (D  d ) 
4

32 MD For small short shafts: P = D3 N / 38

Sf 
 (D 4  d4 ) P – power, hp
D – shaft diameter, in
d – inner diameter, m N – angular velocity, rpm
D – outer diameter, m
M – bending moment, N-m
Sf – flexural/bending moment, Pa
Ss – shear stress, Pa Solid shafts subjected to combined torsion
T – torque, N-m and bending with shock and fatigue factors

2 Patrick D. Sta. Maria / January 28, 2018

 Shaft Design Machine Design

of 550 rpm. Calculate the torsional stress induced on

16 the 40-mm diameter motor shaft.
Ss  (K mM)2  (K s T)2
 D3
P = (3600 kg/min)(9.81 N/kg)(8 m)
16 K M  (K M)2  (K T)2  (60 s/min)(0.65) P = 7244.31 W
Sf 
 D3  m m s  T = (7244.31 W)(60 s/min)
(2pi)(550 rpm) T = 125.78 N-m
km – combined shock and fatigue factor for Ss = 16T = (16)(125.78 N-m)
moment pi d3 (pi)(40 mm)3 Ss = 10.01 MPa
ks – combined shock and fatigue factor for shear
Ss – maximum shear stress
Sf – maximum flexural stress 5. A hollow shaft has an inner diameter of 35 mm and
an outer diameter of 60 mm. Compute the torque in
The formulas recommended differ from those N-m that the shaft can handle for a maximum shear
formulas in general use in that they introduce factors km stress of 120 MPa.
and ks for shock and fatigue. These factors vary with the
nature of the load. Ss = 16TD
pi (D4 – d4)
T = (pi)[(60 mm)4 – (35 mm)4](120 MPa)
Shock and Fatigue Factors for Shafts (16)(60 mm)
T = 4500.09 N-m
Nature of loading ks km

Stationary Shafts 6. A 10-hp motor is to drive an industrial fan at 120

gradually applied load 1.0 1.0 rad/s. Calculate the diameter of the fan shaft using
suddenly applied load 1.5–2.0 1.5–2.0 AISI C1045 steel (Sy = 400 MPa) and a design factor
Rotating Shafts of 4.
gradually applied 1.5 1.0
suddenly applied/steady Sds = 0.6 Sy / N = (0.6)(400 MPa)/4
shock only 1.5–2.0 1.5–2.0 Sds = 60 MPa
heavy shocks 2.0–3.0 1.5–3.0 T= P T = (10 hp)(745.7 W)
2pi f 120 rad/s T = 62.14 N-m
Ss = 16T d3 = (16)(62.14 N-m)
pi d3 (pi)(60 MPa) d = 17.41 mm
Conversion Factors
lb = 4.448 221 615 N
Angular Deformation
psi = 6 894.757 293 Pa
hp = 745.6997 W
7. A solid shaft in a rolling mill transmits 40 kW at 25
550 ft-lb/s or 33,000 ft-lb/min
rad/s. Determine the diameter of the shaft if the
in-lb = 0.112 984 829 N-m
angle of twist is limited to one degree for every 150
ft-lb = 1.355 817 948 N-m
diameters.
rev = 2π rad
rev/min = (rad/s)(60/2pi)
T = 40,000 W / 25 rad/s T = 1600 N-m
rad/sec = (rev/min)(2pi/60)
θ = 32 TL x 180 θ = (32T)(150 d)(180)
(pi) d4G pi (pi)2 d4 G
d3 = (32)(1600 N-m)(150)(180)
(pi)2 (1°)(80 GPa) d = 120.53 mm
Problems
In all problems, let hp = 745.7 W
8. A hollow shaft with D = 2d and 5 m long is stressed
Torque to 60 MPa when twisted through 4°. Using G = 80
GPa, compute the diameters of the shaft. What
1. Compute the twisting moment developed when a torque can be transmitted by the shaft?
shaft delivers 20 hp at 1200 rpm.
Ss = 16 TD θ= 32 TL
T = (20 hp)(745.7 W/hp)(60 s/min) pi (D4 – d4) pi (D4 – d4)G
(2 pi)(1200 rpm) pi (D4 – d4) = 16D = 32L
T = 118.68 N-m T Ss θG
D = 2L x 180 (converting to degrees)
Ss θG pi
2. Find the torsional moment developed when a shaft D = (2)(5m)(180)(60 MPa) D = 107.43 mm
delivers 80 kW at 125 rad/s. (pi)(4°)(80 GPa) d = 53.715 mm
T = (pi)(D4 – d4) Ss
T = 8000 W / 125 rad/s T = 640 N-m 16 D
T = (pi)[(107.43 mm) 4 – (53.715 mm) 4](60 MPa)
(16)(107.43 mm)
Polar Moment of Inertia T = 13,693.96 N-m
Also, T = (15)(pi)(d3)(Ss)/32
3. A hollow shaft has an inner diameter of 35 mm and T = (15)(pi)(53.715 mm)3 (60 MPa)/32
an outer diameter of 65 mm. Determine the polar T = 13,693.96 N-m
moment of inertia of the hollow shaft in m4.

J = (pi/32)[ (65 mm)4 – (35 mm)4 ] 9. A steel wire 4 m long has a diameter of 3 mm. What
J = 1.605 x 10–6 m4 stress would result if this wire is given two full turns?

2L Ss = dG θ for two full turns,

Shear Stress Ss = dG θ / 2L θ = 4pi
Ss = (3 mm)(80 GPa)(4 pi)
4. A centrifugal pump is directly coupled to a motor. The 2 (4 m) Ss = 376.99 MPa
pump rating is 3600 L/min against a total head of 8
m of water. Pump efficiency is 65% at a shaft speed

3 Patrick D. Sta. Maria / January 28, 2018

 Shaft Design Machine Design

dS3 = (15/2)(dH3)
10. Determine the maximum torque that can be applied dS = (86.33 mm)(7.51/3) dS = 168.98 mm
to a hollow shaft of 100 mm OD and 70 mm ID with- – check
out exceeding a shearing stress of 60 MPa or a twist dS3 = (16)(39.79 kN-m)
of 0.7° per meter. Let G = 83 GPa. (pi)(42 MPa) dS = 168.98 mm
– equal angular deformation
– for a torsional deflection of 0.7° θH = θS: 32TL = 32TL
θ= 32 TL θr = (0.7°)(pi)/180 (pi)(D4 – d4) G (pi) d4 G
pi (D4 – d4)G θr = 0.01222 radians DH4 – dH4 = dS4 DH = 2dH
T = (pi)(0.01222)[(100 mm 4 – 70 mm 4)](83 GPa) (15)(dH)4 = (dS4
(32)(1 m) dS = (150.25)(86.33 mm) dS = 169.90 mm
T = 7566.68 N-m
– for a shear stress of 60 MPa
Ss = 16 TD T = pi (D4 – d4) Ss Combined Stresses
4 4
pi (D – d ) 16 D
T = (pi)(100 mm 4 – 70 mm 4)(60 MPa) 14. Calculate the diameter of a solid shaft when subjec-
(16)(100 mm) ted to a torque equal to 40 kN-m and a bending
T = 8952.36 N-m stress equal to 120 kN-m. Let the material have an
allowable design strength of 80 MPa.

11. If the angular deformation of a solid shaft should not TE^2 = 120^2 + 40^2 TE = 126.49 kN-m
exceed 1° in a length of 1.80 m, and the allowable ME = 120 + 126.49 ME = 246.49 kN-m
shearing stress is 85 MPa, what should be the dia- Ssd = (0.6)(80 MPa) Ssd = 48 MPa
meter of the shaft letting G = 77 GPa? – bending diameter
df^3 = 16ME = (16)(246.49 N-m)
T= pi d3 Ss θ = 32 TL pi Sd (pi)(80 MPa)
16 pi d4 G df = 250.36 mm
T = pi d3 Ss = pi d4 Gθ Ss = d Gθ/2L – shearing diameter
16 32 L ds^3 = 16TE = (16)(126.49 N-m)
d = (2)(1.80 m)(85 MPa) x 180 pi Ss (pi)(48 MPa)
(77 GPa)(1°) x pi d = 227.695 mm ds = 237.64 mm

Shaft Replacement 15. A hollow shaft is subjected to a moment of 1200 N-m

and a torque of 1000 N-m. Calculate the correct out-
12. A solid shaft with a diameter of 100 mm is to be side diameter of the shaft for a bending stress of 75
replaced by a hollow shaft with D/d = 1.2. Calculate MPa and a diameter ratio of D/d = 1.2.
the diameters of the hollow shaft if it is to have the
same (a) torsional strength (b) rigidity as the solid T = 1000 N-m TE = 1562.05 N-m
shaft. M = 1200 N-m ME = 2762.05 N-m
Ssd = (0.6)(75 MPa) Ssd = 45 MPa
– same torsional strength : SsH = SSs – bending diameter
DH = 1.2dH DH4 = 2.0736 dH4 Sf = 16DME D = 1.2d
SsH = SSs: 16TDH = 16T (pi)(D4 – d4) D4 = 2.0736d4
(pi)(DH4 – dH4) (pi) dS3 Sf = (16)(1.2d)(ME) Sf = 19.2 ME
2.0736 dH4 – dH4 = (100 mm)3 (pi)(2.0736 d4 – d4) (1.0736)(pi) d3
1.2 dH d 3 = (19.2)(2762.05 N-m) df = 59.41 mm
1.0736 dH3 = (100 mm)3 (1.0736)(pi)(75 MPa) Df = 71.29 mm
1.2 – shearing diameter
dH = (100 mm) 3(1.2/1.0736) d 3 = (19.2)(1562.05 N-m) ds = 58.25 mm
dH = 103.78 mm, DH = 124.54 mm (1.0736)(pi)(45 MPa) Ds = 69.90 mm
– same rigidity : θS = θH
θH = θs: 32 TL = 32 TL
(pi)(DH4 – dH4) G (pi) dS3 G 16. A steam engine that has a stroke of 300 mm has an
1.0736 dH4 = (100 mm)4 overhang crank of 280 mm. The maximum tangential
dH = 98.24 mm, DH = 117.89 mm force on the crank may be assumed to be 350 kN.
Which shaft can transmit a larger power without Assuming an allowable 350 kN
exceeding the specifications? shear stress of 30 MPa,
determine the crank- 0.15 m
shaft diameter. What is
13. A hollow shaft with D = 2d is to transmit 2500 kW of the corresponding flex-
power at 600 rpm. The shaft is to be made using a ural stress? 0.28 m
material with Sy = 350 MPa and a factor of safety of
5. (a) What are the diameters of hollow shaft? If the T = Fr = (350 kN)(150 mm) T = 52.50 kN-m
shaft is to be replaced by a solid shaft, what should M = (350 kN)(280 mm) M = 98 kN-m
be the latter's diameter if it is to have the same (b) TE^2 = 52.5^2 + 98^2 TE = 111.18 kN-m
torsional stress, (c) rigidity as the hollow shaft? – shearing diameter
ds^3 = 16TE = (16)(111.18 kN-m)
– diameters of the shaft pi Ss (pi)(30 MPa)
Sds = (0.6)(350 MPa)/5 Sds = 42 MPa ds = 266.25 mm
T = (2500 kW)(60) ME = 98 + 111.18 ME = 209.18 kN-m
(2pi)(600 rpm) T = 39,788.74 N-m Ssd = (0.6)(80 MPa) Ssd = 48 MPa
Ss = 16 TD D = 2d – bending stress
pi (D4 – d4) D4 – d4 = 15d4 Sf = 16ME = (16)(209.18 kN-m)
Ss = (16 T)(2d) = 32T pi d^3 (pi)(266.25 mm)^3
(15pi)(d4) (15pi)(d3) Sf = 56.44 MPa
d3 = (32)(39.79 kN-m) d = 86.33 mm
(15pi)(42 MPa) D = 172.66 mm
– equal torsional stress (dS = diameter for solid) 17. The shaft of a machine supported on bearings 1.8 m
Ss = 16T = 32T apart is to transmit 250 hp at 200 rpm while subjec-
pi dS3 (15pi) dH4 ted to a bending load of 4500 N located 0.6 m from

4 Patrick D. Sta. Maria / January 28, 2018

 Shaft Design Machine Design

one bearing. Allow a shearing stress of 40 MPa and a – forces on the x-plane
bending stress of 82 MPa. Assume a shock and
fatigue factor of 1.5 to be applied to the bending 2620 N 7000 N
moment, the same for shear. Determine the shaft
diameter a. for steady loading and b. shock loading.

4.5 kN 3943.6 N 5676.4 N

0.6 m 1.2 m  3943.6
 1323.6
L R
0.24 m 0.40 m 0.25 m
– solving for maximum moment
(1.8 m)(L) = (4.5 kN)(1.2 m) L = 3 kN  5676.4 
M = (3 kN)(0.6 m) M = 1.8 kN-m
 1475.90
T = (250 hp)(745.7 W)
(2pi)(200/60 r/s) T = 8901.14 N-m 946.46 
– steady loading:
ks = 1.5 and km = 1.0 for gradually applied
Ss = 16TE TE2 = (kmM)2 +(ksT)2
3
pi D gear pulley
TE^2 = [(1.0)(1800)]^2 + [(1.5)(8901.14)]^2
TE = 13,472.50 N-m
ds^3 = 16TE = (16)(13472.50 N-m) – forces on the y-plane
pi Ss (pi)(40 MPa)
ds = 119.71 mm – shearing 4846.7 N 1500 N 853.3 N
ME = kmM + TE
0.24 m 0.40 m
ME = (1.0)(1800 N-m) + 13472.50 N-m
ME = 15,472.50 N-m 0.26 m
df^3 = 16ME = (16)(15,472.50 N-m) 7200 N
pi Sd (pi)(82 MPa) 2353.3 
853.3 
df = 98.68 mm – bending
– shock loading:
ks = 1.5 and km = 1.5 for shock loads
TE^2 = [(1.5)(1800)]^2 + [(1.5)(8901.14)]^2   4846.7
TE = 13,621.97 N-m pulley
gear
ds^3 = 16TE = (16)(13621.97 N-m)
pi Ss (pi)(40 MPa) 221.89 
ds = 120.15 mm – shearing, +0.37%
ME = (1.5)(1800 N-m) + 13,621.97 N-m
ME = 16,327.97 N-m
 1163.21
df^3 = 16ME = (16)(16,327.97 N-m)
pi Sd (pi)(82 MPa)
df = 100.45 mm – bending, +2.24% – resultant moments
G^2 = (946.46^2 + 1163.21^2) G = 1499.61 N-m
P^2 = (1475.9^2 + 221.89^2) P = 1492.49 N-m
18. A 600-mm diameter pulley driven by a horizontal belt – Use: M = 1500 N-m TE = 1749.29 N-m
transmits power through a hollow shaft (D = 2d) to a T = 900 N-m ME = 3249.29 N-m
250-mm diameter pinion which drives a mating gear. ds^3 = 16TE = (16)(1749.29 N-m)
The pulley weighs 1500 N to provide some flywheel pi Ss (pi)(24 MPa)
effect. The arrangement of elements, the belt ten- ds = 71.87 mm – shearing
sions and the components of the gear reacting on the df^3 = 16ME = (16)(3249.29 N-m)
pinion is shown below. Calculate the diameters of the pi Sd (pi)(40 MPa)
hollow shaft using Sy = 120 MPa and N = 3. df = 74.51 mm – bending

– design stresses
Sd = 120 MPa/3 Sd = 40 MPa
Sds = (0.6)(40 MPa) Sds = 24 MPa
– torque
T = (7200 N)(0.25 m)(0.5) T = 900 N-m

400 mm 260 mm
240mm

2 kN
2.62 kN

7.2 kN

D  250 mm
D  600 mm

5 kN

5 Patrick D. Sta. Maria / January 28, 2018