Machine Design

Tutorials
Spring/Summer 2021
June 3rd - Week 5
DGD 5
Problem 1
Estimate the critical speed of rotation for the steel shaft shown below.

120 lb
80 lb

2-in.-dia. shaft

20 in. 40 in. 30 in.

Critical Speed
Shafts which operate at high
speeds are designed to avoid
operation at critical speeds

Juvinall & Marshek pg. 721

Assumptions
120 lb
80 lb
2-in.-dia. shaft

20 in. 40 in. 30 in.

1. Bearing friction is negligible

2. The bearing supporting the shafts are accurately aligned (no misalignment)
3. The shaft remains linearly elastic
4. The shaft is simply supported
5. The mass of the shaft is negligible
From Figure 17.5, we use (b)….

Adapting for our shaft and loads….

𝛿𝐴 𝛿𝐵
30 𝑔(𝑤𝐴 𝛿𝐴 + 𝑤𝐵 𝛿𝐵 )
𝑛𝑐 ≈
𝜋 𝑤𝐴 𝛿𝐴2 + 𝑤𝐵 𝛿𝐵2
A 120 lb B
80 lb
Using Appendix D-2 and method of superposition to find 𝜹𝑨 and 𝜹𝑩

Appendix D-2; Case 2: Concentrated load at any point

Slope at ends Maximum Deflection Deflection at any point x

Also required:
Modulus of elasticity for steel: Moment of inertia for circular cross section of 2” diameter
𝜋𝑑 4 𝜋24
𝐸𝑠𝑡𝑒𝑒𝑙 = 30 × 106 𝑝𝑠𝑖 𝐼= = = 0.785 𝑖𝑛4
64 64
Recall: 120 lb
80 lb
2-in.-dia.
𝐿
𝑎 𝑷
𝑏 20 40 30
𝑥
in. in. in.
𝑃𝑏 𝛿 𝑃𝑎 𝑃𝑏𝑥 2
𝐴 𝛿= 𝐿 − 𝑥 2 − 𝑏2 for 0 ≤ x ≤ a
𝐿 𝐵 𝐿 6𝐿𝐸𝐼
𝜋𝑑 4 𝜋24
𝐸𝑠𝑡𝑒𝑒𝑙 = 30 × 106 𝑝𝑠𝑖 𝐼= = = 0.785 𝑖𝑛4
64 64

Deflection at A due to 120 lb:

120 𝑙𝑏 70 𝑖𝑛 20 𝑖𝑛 2 2 2
𝛿𝐴1 = 90𝑖𝑛 − 20𝑖𝑛 − 70𝑖𝑛 = 𝟎. 𝟎𝟑𝟕𝟎 𝒊𝒏 Total deflection at A:
6 90 𝑖𝑛 30 × 106 𝑝𝑠𝑖 0.785 𝑖𝑛4
𝛿𝐴 𝑡𝑜𝑡𝑎𝑙 = 𝛿𝐴1 + 𝛿𝐴2
Deflection at A due to 80 lb:
𝜹𝑨 𝒕𝒐𝒕𝒂𝒍 = 𝟎. 𝟎𝟔𝟐𝟕 𝒊𝒏
80 𝑙𝑏 30 𝑖𝑛 20 𝑖𝑛 2 2 2
𝛿𝐴2 = 90𝑖𝑛 − 20𝑖𝑛 − 30𝑖𝑛 = 𝟎. 𝟎𝟐𝟓𝟕 𝒊𝒏
6 90 𝑖𝑛 30 × 106 𝑝𝑠𝑖 0.785 𝑖𝑛4
Recall: 120 lb
80 lb
2-in.-dia.
𝐿
𝑏 𝑷
𝑎 20 40 30
𝑥 in. in. in.
𝑃𝑏 𝛿 𝑃𝑎 𝑃𝑏𝑥
****𝛿 = 6𝐿𝐸𝐼 𝐿2 − 𝑥 2 − 𝑏2 for 𝟎 ≤ 𝐱 ≤ 𝐚
𝐿 𝐴 𝐿
𝐵
𝜋𝑑 4 𝜋24
𝐸𝑠𝑡𝑒𝑒𝑙 = 30 × 106 𝑝𝑠𝑖 𝐼= = = 0.785 𝑖𝑛4
64 64

Deflection at B due to 120 lb (using diagram above because condition doesn’t

satisfy 0<x<a):
120 𝑙𝑏 20 𝑖𝑛 30 𝑖𝑛 2 2 2
𝛿𝐵1 = 90𝑖𝑛 − 30𝑖𝑛 − 20𝑖𝑛 = 𝟎. 𝟎𝟑𝟖𝟓 𝒊𝒏 Total deflection at B:
6 90 𝑖𝑛 30 × 106 𝑝𝑠𝑖 0.785 𝑖𝑛4
𝛿𝐵 𝑡𝑜𝑡𝑎𝑙 = 𝛿𝐵1 + 𝛿𝐵2
Deflection at B due to 80 lb (using diagram on prev. slide because condition
satisfies 0<x<a):
𝜹𝑩 𝒕𝒐𝒕𝒂𝒍 = 𝟎. 𝟎𝟕𝟗𝟑 𝒊𝒏
80 𝑙𝑏 30 𝑖𝑛 60 𝑖𝑛 2 2 2
𝛿𝐵2 = 90𝑖𝑛 − 60𝑖𝑛 − 30𝑖𝑛 = 𝟎. 𝟎𝟒𝟎𝟖 𝒊𝒏
6 90 𝑖𝑛 30 × 106 𝑝𝑠𝑖 0.785 𝑖𝑛4
Finding the critical speed:

Using Eq. 17.2:

30 𝑔(𝑤𝐴 𝛿𝐴 + 𝑤𝐵 𝛿𝐵 )
𝑛𝑐 ≈
𝜋 𝑤𝐴 𝛿𝐴2 + 𝑤𝐵 𝛿𝐵2

𝑓𝑡 𝑖𝑛
30 32.2 2 12 120 𝑙𝑏 0.0627 𝑖𝑛 + (80 𝑙𝑏)(0.0793 𝑖𝑛)
𝑠 𝑓𝑡
𝑛𝑐 ≈
𝜋 120 𝑙𝑏 0.0627 𝑖𝑛 2 + 80 𝑙𝑏 0.0793 𝑖𝑛 2

𝑛𝑐 ≈ 708 𝑟𝑝𝑚
𝐴𝑁𝑆.
Problem 2
Estimate the length of a flat key required to transmit a torque equal
to the elastic torque capacity of a round shaft of diameter d.
Assume that the key and shaft are made of the same ductile material
and that the key is tightly fitted at its top and bottom.
Compare this result with the length of square key required, and
suggest a possible reason why a flat key might be preferred in some
cases.

(Section 17.3 in J&M txtbk)

Notes
• A flat key is used with a round shaft to
transmit a torque equal to the elastic
torque capacity of the shaft

• The key and shaft material are made from

the same ductile material and the key in
tightly fitted at its top and bottom

Assumptions
• Forces on the key are uniformly distributed
• Materials used are both ductile steels
• The loading on the shaft is steady (no shock or fatigue)
Elastic limit of Shaft:

Max stress (for steel)

𝜏𝑚𝑎𝑥 = 𝑆𝑠𝑦 = 0.58𝑆𝑦

Using Eq. 4.4 in J&M textbook:

16𝑇
𝜏𝑚𝑎𝑥 = 0.58𝑆𝑦 =
𝜋𝑑 3

Rearranging for torque:

𝜋𝑑3
𝑇= (0.58𝑆𝑦 ) A
16
For a standard proportioned flat key, key torque capacity is limited by either
compression or by shear

For key torque limited by COMPRESSION:

Max normal stress:

𝐹
𝜎𝑚𝑎𝑥 = 𝑆𝑦 =
𝐴

Force from torque:

𝑇
𝐹=
𝑑/2

Key Contact area in shaft:

ℎ
𝐴=𝐿∙
2
For key torque limited by compression cont.:

Plugging Eq. 2 and Eq. 3 into Eq. 1:

𝑑
𝑇/ 2 𝑑 ℎ
𝑆𝑦 = 𝑇 = 𝑆𝑦 ∙ ∙ 𝐿 ∙
ℎ 2 2
𝐿∙
2

From flat key diagram geometries: ℎ 3𝑑

=
2 32

Max torque limited by compression

(plugging Eq. 5 into Eq. 4):
𝑑 3𝑑𝐿
𝑇𝑚𝑎𝑥 = 𝑆𝑦 = 0.047𝑆𝑦 𝐿𝑑 2
2 32
**Tmax=(Limiting stress)(radius)(contact area)
For key torque limited by SHEAR:
Max stress (for steel)
𝜏𝑚𝑎𝑥 = 𝑆𝑠𝑦 = 0.58𝑆𝑦

Key Contact area in shaft:

𝐴 = 𝐿𝑤

Max torque limited by shear, plugging Eq. 8 and 9 into:

𝑇𝑚𝑎𝑥 = (𝐿𝑖𝑚𝑖𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠)(𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑎𝑟𝑒𝑎)(𝑟𝑎𝑑𝑖𝑢𝑠)

𝑑 𝑑
𝑇𝑚𝑎𝑥 = (0.58𝑆𝑦 )(𝐿𝑤) 𝑤=
2 4

𝑑2
𝑇𝑚𝑎𝑥 = 0.58𝑆𝑦 𝐿
8
Equate Eq. A and Eq. 6:

𝐿 = 2.4𝑑 Fail via compression of key

Equate Eq. A and Eq. 10:

𝐿 = 1.57𝑑 Fail via shear of key

Torque capacity limited by lowest ‘L’.

So, limited by shear because 2.4d > 1.57d

Problem 3
A bevel pinion and shaft are shown in the figure below. Bearing A takes thrust. The
left end of the shaft is coupled to an electric motor, and the right end is free. Load
components applied by the mating bevel gear are shown.
y 𝐹𝑟 = 2.4 𝑘𝑁
(a) Draw load, shear force and bending moment diagrams
for the shaft in both horizontal (x-z) and vertical (x-y) 𝑥 𝐹𝑡 = 4.0 𝑘𝑁
planes, plus torsional-load and axial-load diagrams. z
(b) Determine the radial and thrust loads applied to the
two bearings.
(c) Identify the critically loaded shaft cross section and
estimate the safety factor with respect to fatigue using 𝐹𝑎 = 1.5 𝑘𝑁
the following data:
Shaft diameter = 33 mm Material: steel
(critical surfaces have a ground finish)
Note: Gear
125 𝑚𝑚
𝐾𝑓 = 1.3 bending 𝑆𝑢 = 900 𝑀𝑃𝑎 forces act at a
𝐾𝑓 = 1.2 (torsion) 75-mm radius
𝑆𝑦 = 700 𝑀𝑃𝑎
𝐾𝑓 = 1.3 (axial) 50 𝑚𝑚 from shaft axis.
Assumptions:
1. The bearing widths are small relative to the length of the shaft so that they
can be idealized as point supports.
2. Bearing friction is negligible.
3. Shaft deflection is small so that locations and directions of loads are constant
with respect to the shaft.
4. The gear is rigidly connected to the shaft.
5. The weights of the shaft and gear can be neglected.
(a) Draw load, shear force and bending moment diagrams for the shaft in both
horizontal and vertical planes, plus torsional-load and axial-load diagrams.
Load Diagrams:
VERTICAL
𝑦 ෍ 𝐹𝑥 = 0 = −1.5 + 𝐹𝑥𝐴
2.4 kN

𝐹𝑥𝐴 = 1.5 𝑘𝑁
𝑥 1.5 kN

+ ෍ 𝑀𝐴 = 0 = 2.4 125 − 1.5 75 − 𝐹𝑦𝐵 (125 + 50)

75 𝑚𝑚

A 125 𝑚𝑚 50 𝑚𝑚 B 𝐹𝑦𝐵 = 1.07 𝑘𝑁

𝐹𝑥𝐴

෍ 𝐹𝑦 = 0 = −2.4 + 𝐹𝑦𝐴 + 𝐹𝑦𝐵

𝐹𝑦𝐴 𝐹𝑦𝐵
𝐹𝑦𝐴 = 1.33 𝑘𝑁
(a) Draw load, shear force and bending moment diagrams for the shaft in both
horizontal and vertical planes, plus torsional-load and axial-load diagrams.

Load Diagrams:

HORIZONTAL
𝑥 ෍ 𝑀𝐴 = 0 = 4.0 125 − 𝐹𝑧𝐵 (125 + 50)
+
4.0 kN

𝑧 𝐹𝑧𝐵 = 2.86 𝑘𝑁

෍ 𝐹𝑧 = 0 = 4.0 − 𝐹𝑧𝐴 − 𝐹𝑧𝐵

A 125 𝑚𝑚 50 𝑚𝑚 B
𝐹𝑥𝐴
1.5 kN
𝐹𝑧𝐴 = 1.14 𝑘𝑁

𝐹𝑧𝐴
𝐹𝑧𝐵
(a) Draw load, shear force and bending moment diagrams for the shaft in both
horizontal and vertical planes, plus torsional-load and axial-load diagrams.
Load Diagrams:

VERTICAL HORIZONTAL
𝑦 𝑥
2.4 kN
4.0 kN
𝑥 𝑧
1.5 kN

A B 1.5 kN A 1.5 kN B
1.5 kN

1.07 kN
1.33 kN 1.14 kN
2.86 kN
(a) Draw load, shear force and bending moment diagrams for the shaft in both
horizontal and vertical planes, plus torsional-load and axial-load diagrams.
Shear Force Diagrams:
VERTICAL HORIZONTAL

1.33 kN 1.14 kN

-1.07 kN

-2.86 kN

Bending Moment Diagrams:

1.33(125) = 166.3 Nm
1.14(125) = 142.5 Nm

166.3-(1.5)(75) = 53.8 Nm
(a) Draw load, shear force and bending moment diagrams for the shaft in both
horizontal and vertical planes, plus torsional-load and axial-load diagrams.

Torsional Load Diagram

𝐹𝑟 = 2.4 𝑘𝑁
4.0(75) = 300 Nm
𝐹𝑡 = 4.0 𝑘𝑁

Opposed by
𝐹𝑎 = 1.5 𝑘𝑁
thrust bearing
at A
Axial Load Diagram
Note: Gear forces
125 𝑚𝑚
act at a 75-mm
radius from shaft
50 𝑚𝑚 axis.

-1.5 kN
(b) Determine the radial and thrust loads y 𝐹𝑟 = 2.4 𝑘𝑁

applied to the two bearings. z 𝑥 𝐹𝑡 = 4.0 𝑘𝑁

1.5 kN

𝑦
Radial Loads 1.14 kN
𝑧 𝐹𝑎 = 1.5 𝑘𝑁
1.33 kN

Bearing A
125 𝑚𝑚 2.86 kN
1.07 kN

𝐴𝑟 = 𝐹𝑦𝐴 2 + 𝐹𝑧𝐴 2
50 𝑚𝑚

𝐴𝑟 = 1.332 + 1.142 = 1.75 𝑘𝑁

Thrust Loads 𝑥
Bearing B
Bearing A Bearing B
𝐵𝑟 = 𝐹𝑦𝐵 2 + 𝐹𝑧𝐵 2
𝐴𝑡 = 𝐹𝑥𝐴 𝐵𝑡 = 𝐹𝑥𝐵
𝐵𝑟 = 1.072 + 2.862 = 3.05 𝑘𝑁
𝐴𝑡 = 1.5 𝑘𝑁 𝐵𝑡 = 0 𝑘𝑁
(c) Identify the critically loaded shaft cross section and estimate the safety factor
with respect to fatigue
The most critical section is just to the left of the gear.

We know:
𝑇 = 4.0𝑘𝑁 75𝑚𝑚 = 300 𝑁𝑚 Mean shear stress
𝑑 = 33 𝑚𝑚 (𝑠ℎ𝑎𝑓𝑡 𝑑𝑖𝑎𝑚. ) 16𝑇 16 300
𝐾𝑓 = 1.3 bending 𝜏𝑚 = 𝐾 = 1.2 = 0.0510 𝐺𝑃𝑎
𝜋𝑑 3 𝑓 𝑡𝑜𝑟𝑠𝑖𝑜𝑛 𝜋 33 3
𝐾𝑓 = 1.2 (torsion)
𝐾𝑓 = 1.3 (axial) 𝜏𝑚 = 51.0 𝑀𝑃𝑎

Axial mean stress

𝑃 −1.5 4
𝜎𝑎,𝑚 = 𝐾 = 1.3 = −0.00228 𝐺𝑃𝑎 → 𝜎𝑎,𝑚 = −2.28 𝑀𝑃𝑎
𝜋𝑑 3 𝑓 𝑎𝑥𝑖𝑎𝑙 𝜋 33 3

Bending alternating stress

32𝑀 32 166.22 + 142.52
𝜎𝑏,𝑎 = 𝐾 = 1.3 = 0.0807 𝐺𝑃𝑎 → 𝜎𝑏,𝑎 = 80.7 𝑀𝑃𝑎
𝜋𝑑 3 𝑓 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝜋 33 3
(c) Identify the critically loaded shaft cross section and estimate the safety factor
with respect to fatigue
Review from last week!
(pg 327 J&M txtbk)

Equivalent Alternating (𝜎𝑒𝑎 ) and Equivalent Mean Stresses (𝜎𝑒𝑚 )

Used in cases where both normal and shear stresses are experienced in a part due to combined
external loading

Equivalent Alternating Stress Equivalent Mean Stress:

𝜎𝑚 𝜎𝑚 2
𝜎𝑒𝑎 = 𝜎𝑎2 + 3𝜏𝑎2 𝜎𝑒𝑚 = 2
+ 𝜏𝑚 +
2 2
(c) Identify the critically loaded shaft cross section and estimate the safety factor
with respect to fatigue

Equivalent Alternating Stress Known:

𝜎𝑎 = 𝜎𝑏,𝑎 = 80.7 𝑀𝑃𝑎
𝜎𝑒𝑎 = 𝜎𝑎2 + 3𝜏𝑎2
𝜎𝑚 = 𝜎𝑎,𝑚 = −2.28 𝑀𝑃𝑎
𝜎𝑒𝑎 = 80.72 + 3 0 2 → 𝜎𝑒𝑎 = 80.7𝑀𝑃𝑎
𝜏𝑎 = 0 𝑀𝑃𝑎

𝜏𝑚 = 51.0 𝑀𝑃𝑎
Equivalent Mean Stress

𝜎𝑚 𝜎𝑚 2
2
𝜎𝑒𝑚 = + 𝜏𝑚 +
2 2

2
−2.28 −2.28
𝜎𝑒𝑚 = 2
+ 51.0 + → 𝜎𝑒𝑚 = 49.9 MPa
2 2
(c) Identify the critically loaded shaft cross section and estimate the safety factor
with respect to fatigue
𝜎𝑒𝑎 = 80.7𝑀𝑃𝑎 𝜎𝑒𝑚 = 49.9 MPa

𝜎𝑒𝑎
Material Properties:
𝑆𝑦 = 700 𝑀𝑃𝑎 (given)

𝑆𝑢 = 900 𝑀𝑃𝑎 (given)

700
𝑆𝑛′ = 0.5𝑆𝑢 = 450 𝑀𝑃𝑎 Yield Line

𝑆𝑛 = 𝑆𝑛′ 𝐶𝐿 𝐶𝐺 𝐶𝑠 = 450 (1)(0.9)(0.9)

Slope = 80.7/49.9
= 364.5 𝑀𝑃𝑎
364.5
290
Fatigue Safety Factor
(49.9 , 80.7)
290 Goodman Line
𝑛≈ = 3.59 → 𝑛 = 3.6 𝐴𝑁𝑆.
80.7 𝜎𝑒𝑚
700 900
Problem 3 - Comments
1. In this problem, the mean axial stresses are small compared to the mean
torsional stresses but are still included in the analysis. 𝜎𝑒𝑚 changes by
about 2% when axial stresses are considered.

2. It is important to estimate the stress concentration factors accurately since

they inversely affect the safety factor.

3. The maximum bending moment can be reduced by decreasing the length of

the shaft and/or placing the gear closer to one of the support bearings.
Placing the gear closer to a bearing, however, has the undesirable side-
effect of producing higher loads on the bearing.
See you next
week!