2022.10.24 Chapter 09 Shaft

Chapter 9 Shaft
445 Handbook of Mechanical Engineering

Content
9.1 Introduction
9.2 Classification of shafts
9.3 Failures and criteria of calculation, Materials
9.4 Forces acting on shaft
9.5 Basic design layout
9.6 Strength Calculations
9.7 Calculation of the shaft for fatigue strength
9.8 Rigidity calculations
9.9 Calculation of the shaft for oscillations
https://uni.edu/~rao/Md-17%20Shaft%20Design.pdf
Assoc. Prof. Nguyen Huu Loc

Learning Outcomes
- Select the materials for shaft (LO3.4)

- Understand the types of shafts (LO7.4)
- Analyze and calculate the forces acting in the
shafts (L01.6)
- Design and analyze the shafts on the basis of
strength and rigidity (L01.7)
- Use the CAD softwares to design and analyze
the shafts (L05.5)

9.1 Introduction
Links intended to carry rotating

elements (pulleys, sprockets,
pinions, gears, half-couplings,
etc.) are called as axles or
shafts.

9.1 Introduction
A shaft is a rotating member usually of circular cross-section (solid or

hollow), which transmits power and rotational motion.
Machine elements such as gears, pulleys (sheaves), flywheels,
clutches, sprockets… are mounted on the shaft and are used to
transmit power from the driving device (motor or engine) through a
machine.
Press fit, keys, dowel, pins and splines are used to attach these
machine elements on the shaft.
The shaft rotates on rolling contact bearings or bush bearings.
Various types of retaining rings, thrust bearings, grooves and steps in
the shaft are used to take up axial loads and locate the rotating
elements.
Couplings are used to transmit power from drive shaft (e.g., motor) to
the driven shaft (e.g. gearbox, wheels).


Axles are intended to support rotating parts that do not

transmit torques and are subjected to bending only.
immovable axle
movable axle

Shafts are designed to carry links which transmit torques and

experience both bending and torsion.

1. According to purpose
• Shafts of various drives (gear drives, belt drives, chain

drives and so on);
• Main shafts of mechanisms and machines whose

function is to carry not only drive elements but other
elements that do not transmit torques such as rotors,
fly-wheels, turbine disks, etc.

2. According to the shape

• Straight shafts;
• Stepped shafts
• Cranked shafts;
• Flexible shafts.

3. According to the construction
a) Shafts of constant cross section (without steps);
b) Shafts of variable cross section (of stepped configuration);
c) Shafts made solid with gears or worms.

4. According to the shape of the cross section

a) Shafts with solid circular cross section;
b) Shafts with hollow circular cross section;
c) Shafts with keyways;
d) Shafts with splines;
e) Shafts with rectangular cross section.

9.2 Types of shafts and axles
Portion of the shaft which is in contact with a bearing is called journal.
We will distinguish between end journal, neck journal and thrust journal.
Standard shaft diameter range (Seating Surface): R40: 10; 10,5; 11; 12; 13; 14; 15;
16; 17; 18; 19; 20; 21; 22; 24; 25; 26; 28; 30; 32; 34; 36; 38; 40; 42; 45; 50; 52; 55; 60;
63; 70; 75; 80; 85; 90; 95; 100; 105; 110; 120; 125; 130; 140; 150; 160....


• Deflection primarily controlled by geometry, not material
• Strain controlled by geometry but material has a role in stress
• Strength, Yield or UTS (Ultimate tensile strength) is a
material property. Cold drawn steel typical for d < 80mm.
• HR steel (Hot rolled steel) common for larger sizes. Should
be machined all over.
• Low production quantities: Machining
• High production quantities: Forming
The ferrous, non-ferrous materials and non metals are used as shaft
material depending on the application. Some of the common ferrous
materials used for shaft are discussed below.
Hot-rolled plain carbon steel
These materials are least expensive. Since it is hot rolled, scaling is
always present on the surface and machining is required to make the
surface smooth.

Cold-drawn plain carbon/alloy composition
Since it is cold drawn it has got its inherent characteristics of smooth
bright finish. Amount of machining therefore is minimal. Better yield strength
is also obtained. This is widely used for general purpose transmission shaft.
Alloy steels
Alloy steel as one can understand is a mixture of various elements
with the parent steel to improve certain physical properties. To retain the
total advantage of alloying materials one requires heat treatment of the
machine components after it has been manufactured. Nickel, chromium and
vanadium are some of the common alloying materials. However, alloy steel
is expensive. These materials are used for relatively severe service
conditions. When the situation demands great strength then alloy steels are
used. They have fewer tendencies to crack, warp or distort in heat
treatment. Residual stresses are also less compared to CS(Carbon Steel).
In certain cases the shaft needs to be wear resistant, and then more
attention has to be paid to make the surface of the shaft to be wear
resistant. The common types of surface hardening methods are,
Hardening of surface
Case hardening and carburizing Cyaniding and nitriding


Failures
The main types of shaft failure include:
broken shaft (overload or fatigue), shaft
wear, insufficient stiffness (too large shaft
a) b) deflection),...
c)
1 2
Figure 10.9 Fatigue fractured shaft: a) The truck transmission shaft is broken
due to fatigue; b) Shaft broken due to torsion; c) Shaft fatigue fracture at the
transition surface
9.3 Failures and Criteria of calculation, Materials
Criteria of calculation
- For a shaft that does not rotate and the resulting stress is constant,
we calculate the static strength.
- The main failure mode of the fast rotating shaft is fatigue failure
(about 40- 50% of all shaft failures), then we calculate the shaft
according to the fatigue strength.
- For slow-rotating shafts, we must calculate not only the fatigue
strength but also the static strength to avoid overload.
- When there is no dimension according to the shaft length, first we
calculate the shaft design to determine the preliminary diameter and
structure of the shaft according to the allowable torsional stress, then
calculate the test of the shaft according to the safety factor.
- In addition, in order for the parts to work with the shaft normally, we
must calculate the shaft according to the stiffness.
- For fast rotating shaft, we also have to calculate the oscillation of the
shaft.







Design layout of shafts for strength is divided into 3 stages:
1. Determination of the minimum diameter of the shaft
(torsion stress);
2. Designing the shaft construction (design layout);
3. Strength analysis of the shaft.
Minimum diameter of the shaft is determined taking into
account torsion stresses only. In order to compensate
neglect of bending stresses the allowable torsion stress is
assumed as down rated.
T πd 3
τ ; Wp =
Wp 16
T
d min = 10 3
0.2  [τ]

X = 8…10mm

X = 8…10mm
Input shaft
Half coupling
Bearing Bearing
Seal Pinion
d3 d4 d4 d3
d1 d2
t1
t2 t1
d 1 = d min ;
d, mm 20…50 55…120
d 2 = d 1 + 2t1 ;
t1, mm 2; 2.5 5
d 3 = d 2 + 2t 2 ;
t2 , mm 1; 1.5 2.5
d 4 = d 3 + 2t1 .
Seals are divided into: Rubbing element

Steel ring of L-shaped
• Commercial seals; cross-section
Coil spring
• Labyrinth seals;
• Groove seals;
• Combined seals.

Input bevel pinion shaft

Half coupling
Bearing
Slotted nut
Seal Bevel pinion
d2 d2 ’ d3 d4
d1
Input worm shaft

Half coupling Bearing
Bearing
Slotted nut
Worm
Seal
d1 d2 d2’ d3 d4 d3

Intermediate shaft
Bearing Bearing
Gear
Pinion
d1 d2 d3 d2 d1

Output shaft
Gear
Half coupling
Bearing Bearing
Seal
d2 d3 d4 d5 d3
d1




Double stage spur gear speed reducer (Sketch layout)
20
3…4 I
lhalf coupl 20
I m 1.25m
aw ssg 10
10 10 1.25m m
0.5B 10 0.5B
awhsg 10 3…4
20 lhub
10 10
20

Double stage coaxial spur gear speed reducer (Sketch layout)
20
0.5B
10
10 10
10 10
aw
10 10 0.5B
10
10 10 3…4
3…4
10
lhalf coupl 20
20
lhub
20
Bevel gears (Sketch layout)
deg
me
bg
1.2me d
dep
lhub C
10 dhub

Double stage bevel and spur gear speed reducer (Sketch layout)
awhsg
lhub
3…4 20
10
0.5B
10
(1.5…2.3)f 10
f
20
10
10
10
10
10

Sketch layout and calculation scheme

Calculation sequence:
1- According to the kinematic
sheme, we make a calculation
scheme (analyze the forces).
Select material for shaft.
2- Determine the value of the
forces acting on the shaft.
3- Determine the reaction at the
supports.
4- Plot the bending moment
diagram in two perpendicular
planes. Build a torque diagram.
5- According to the moment
diagram, we choose the
dangerous section to calculate the
equivalent moment.
6- Determine the shaft diameter.
For Steps 3 and 4 Determine the reaction at the supports and Plot the
bending moment diagram in two perpendicular planes. Build a torque
diagram.
1. Determine vertical support reactions RyA and RyC. For this purpose
we set up equations of moments relative to points A and C. For
checking we will write equation of forces that are parallel to Y axis;
2. Plot the bending moment diagram in the vertical plane;
3. Draw the analytical model in the horizontal plane and transfer all
forces to the shaft;
4. Determine horizontal support reactions RxA and RxC. For that we set
up equations of moments relative to points A and C. For checking we
write equation of forces that are parallel to X axis;
5. Plot the bending moment diagram in the horizontal plane;
6. Plot the total bending moment diagram ( M  = M x2 + M y2 );
7. Plot the torsion moment diagram;
8. Plot the reduced moment diagram ( M red = M t2 + 0.75  T 2 ).




For single stage

speed reducers
Fc = 125 T ;
For double stage
speed reducers
Fc = 250 T .
Y Fa
Z RyA RyC
X A d/2 Ft B Fr C D
RxA RzA RxC T
Fc

d
1. M a = Fa  .
2
2.  M A = 0 : -Fr  a - M a + R yС  (a + b) = 0;
F  a + Ma
R yC = r ;
a+b
 M c = 0 : -RyA  (a + b)+ Fr  b - M a = 0;
F  b - Ma
R yA = r ;
a+b
Checking: Fyi = 0 : R yA - Fr + R yC = 0.
3. 0  x  a; M y = R yA  x;
M y (0) = 0; M y (a) = R yA  a;
a  x  a + b;
M y = R yA  x + M a - Fr  (x - a);
d M y (a) = R yA  a + M a ; M y (a + b) = 0.
4. T = Ft  .
2
 Ft  a + Fc  (a + b + c)
5.  M A = 0 : Ft  a + RxС  (a + b)  Fc  (a + b + c) = 0; RxC = ;
a+b
-F  b - Fc  c
 Mc = 0 : -RxA  (a + b) - Ft  b - Fc  c = 0; RxA = t ;
a+b
Checking:  Fxi = 0 : RxA + Ft + RxC - Fc = 0.
6. 0  x  a; M x = RxA  x; M x (0) = 0; M x (a) = RxA  a;
0  x  c; M x = Fc  x; M x (0) = 0; M x (c) = Fc  c .
7. M  = M x2 + M y2 ;
8. T
9. M red = M t2 + 0.75  T 2 ;
Calculation for static strength

M
σb =  [σ b ];
W
πd3
M = M red max ; W= ;
32
M red max
σb =  [σ b ] , where
0.1  d 3
Mred max is the reduced

moment at the critical
section;
d is diameter of the shaft at
the critical section;
[sb]  100…120 MPa.
1. (1) According to the kinematic diagram, we make a calculation diagram

(analyze the force acting)
2. (2) Determine the value of the forces acting on the shaft.
3. Preliminary calculation of diameter d according to torsional stress
4. Select shaft length and diameter sizes
5. (3) Determine the reaction at the supports
6. (4) Plot the bending moment diagram in two perpendicular planes. Plot a
torque diagram.
7. Corresponding to the shaft shape and according to the moment diagram, we
choose the dangerous cross section to test according to the safety factor. For
each dangerous position, we determine ss, s according to the following
formula:
 1 s 1
s  ss 
K a K ssa
  m  ssm
   s
s ss 
s
s s2  s 2
8. Compare with the allowable factor of safety [s]. The condition s  [s]
must be satisfied. If not reselect diameter or material and recalculate (Or
define shaft diameter).
9. If in the process of working the shaft is subjected to sudden overload,
then at the largest load-bearing cross section we check the overload
strength according to (10.28).
Changing of bending stresses Safety factor
SσSτ
S=  [S] = 1.5...2.5.
2 2
S +S
σ τ
Safety factor for bending
σ lim
Sσ = ;
Kσ
σ peak + ψ σ σ mean
Changing of torsion stresses KdKF
Safety factor for torsion
τ lim
Sτ =
Kτ
τ peak + ψ τ τ mean
Assoc. Prof. Nguyen Huu Loc KdKF
Calculation of the shaft for fatigue strength
σ lim τ lim
Sσ = ; Sτ =
Kσ Kτ
σ peak + ψ σ σ mean τ peak + ψ τ τ mean
KdKF K K d F
slim, lim – limit of endurance in bending and in torsion

σ lim = 0.43  σ ult - for carbon steels;
σ lim = 0.35  σ ult +120 - for alloy steels;
τlim = (0.2...0.3)  σ ult

speak, peak – variable (peak) components of bending and torsion stresses
σ max - σ min M M
σ peak = = σ max = = ;
2 W 0.1  d 3
τ max + τ min τ max T T

τ peak = = = 0.5  = 0.5  .
Assoc. Prof. Nguyen Huu Loc 2 2 Wp 0.2  d 3
Calculation of the shaft for fatigue strength
σ lim τ lim
Sσ = ; Sτ =
Kσ Kτ
σ peak + ψ σ σ mean τ peak + ψ τ τ mean
KdKF K K d F
smean, mean– constant (mean) components of bending and torsion stresses
σ max + σ min
σ mean = = 0;
2
τ max + τ min τ max T T
τ mean = = = 0.5  = 0.5  .
2 2 Wp 0.2  d 3
 s, – factors of constant components of bending and torsion stresses

s = 0.1;  = 0.05 - for carbon steels;
s = 0.15;  = 0.1 - for alloy steels.
K s, K– effective stress concentration factors;
K d – scale factor;
K F - surface roughness factor.
The most typical stress concentrations of the shaft
• Filleted transition regions;
• Grooves;
• Radial holes;
• Keyed and splined portions;
• Threaded portions;
• Interference fits.
m
pa pb a b
sF
ptb
sF
a b
sF
Assoc. Prof. Nguyen Huu

a) Loc b) c)
Flexural rigidity
Basic criteria of flexural rigidity are:
• Maximum deflection (sag) y of the shaft;
•Angle of rotation q of support sections.
Flexural rigidity conditions
y  [ y ]; θ  [θ ] ,
where:
[y] is the maximum safe sag; [q] is the maximum safe angle of rotation.
[y]= 0.01m – for shafts of spur gears and worm gear drives;
[y]= 0.005m – for shafts of bevel gear, hypoid gear and hourglass
worm gear drives;
[y]= (0.0002…0.0003)l – for general purpose shafts used in machine
tools;
[q]= 0.001 rad – for shafts mounted in sliding contact bearings;
[q]= 0.005 rad – for shafts mounted in radial ball bearings.
Flexural rigidity
F  a  b  (l + b)
θA  ;
6 E J l
F  a  b  (l + a)
θB  ;
6 E J l
F  a  b  c  (l + a)
θC = θB ; yC = ;
6 E J l
F  b  (l 2 - b 2 - 3d 2 ) F  b  d  (l 2 - b 2 - d 2 )
θD  ; yD = ;
6 E J l 6 E J l
F  a  (l 2 - a 2 - 3e 2 ) F  a  e  (l 2 - a 2 - e 2 )
θE = ; yE = ;
6 E J l 6 E J l
F  a  b  (b - a ) F  a 2  b2
θH = . yH = .
3 E J l 3 E J l
E is modulus of elasticity of the shaft material; J is centroidal moment of inertia.

Flexural rigidity
F1  c  l
θA = ;
6EJ
F1  c  l
θB = ;
3 E J
F  c  (2  l + 3  c) F1  c 2  (l + c)
θC = 1 ; yC = ;
6EJ 3 E J
F1  c  (3  d 2 + l 2 ) F1  c  d  (l 2 + d 2 )
θD = ; yD = .
6 E J l 6 E J l

Torsional rigidity
Basic criterion of torsional rigidity is the angle of twist.
Torsional rigidity condition
  [ ] ,
where [] is the maximum safe angle of twist.
T l
 ,
G  Jp
where T is torque; l is length of the shaft; G is shear modulus;
Jp= pd4/32 is polar moment of inertia.

G - static deflection;
st 
c
Fc = m  ω2  (y + e);
Fel  c  y;
Fc  Fel ;
m   2  ( y  e )  c  y;
m  2  e e
y   dynamic
c  m  2
c
1 deflection
m  2
m   2  c - condition of resonance.
c
 cr  - critical angular velocity.
m
p n 30
c 30 cg
30 30 g
  ncr    cr       ;
30 p p m p mg p st
30 g
ncr   - critical rotational speed,
p st
where g  9.81 m / s 2 - free fall acceleration;

G
st  - static deflection;
c
48  E  J
c 3 - rigidity of the shaft;
L
E - modulus of elasticity of the shaft material;
L - distance between shaft supports;
p d4
J - shaft moment of inertia.
Assoc. Prof. Nguyen 64
Huu Loc
if n  0.7  ncr - rigid shafts;
if n  1.2  ncr - flexible shafts.
e
y .
c
1
m  2
if    ,
y  e.
In this case we deal with shaft self-centering.

Bearing mounting considerations
and stress concentration

Conventional retaining (or snap) rings fit
in grooves and take axial load, but groves
cause stress concentration in shaft
Retaining rings are

standardized items,
available in various
standard sizes with
various axial load
capacities.

Push type retaining rings – no grooves
required, less stress concentration, but
less axial support

Various types of keys for transmitting
torque

Other common types of keys

Various types of collar pins

Integrated splines in hubs and shafts
allow axial motion and transmits torque
All keys, pins and splines give rise to stress

concentration in the hub and shaft


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Chapter 9 Shaft

445 Handbook of Mechanical Engineering

Assoc. Prof. Nguyen Huu Loc

- Select the materials for shaft (LO3.4)

Assoc. Prof. Nguyen Huu Loc

Links intended to carry rotating

Assoc. Prof. Nguyen Huu Loc

A shaft is a rotating member usually of circular cross-section (solid or

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Axles are intended to support rotating parts that do not

Assoc. Prof. Nguyen Huu Loc

Shafts are designed to carry links which transmit torques and

Assoc. Prof. Nguyen Huu Loc

• Shafts of various drives (gear drives, belt drives, chain

• Main shafts of mechanisms and machines whose

Assoc. Prof. Nguyen Huu Loc

2. According to the shape

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

4. According to the shape of the cross section

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Seals are divided into: Rubbing element

Assoc. Prof. Nguyen Huu Loc

Input bevel pinion shaft

Input worm shaft

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Sketch layout and calculation scheme

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

Assoc. Prof. Nguyen Huu Loc

For single stage

Assoc. Prof. Nguyen Huu Loc

Calculation for static strength

Mred max is the reduced