Lecture.

8
By: Yaser A. Al-Shutaif
Design of Shafts
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
 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, and sprockets are
mounted on the shaft and are used to transmit
power from the driving device (motor or engine)
through a machine.
• The shaft rotates on rolling contact bearings or
bush bearings.
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
Material Used
for Shafts
 Material Used for Shafts
The material used for shafts should have the following properties :

• It should have high strength.

• It should have good machinability.

• It should have low notch sensitivity factor.

• It should have good heat treatment properties.

• It should have high wear resistant properties.

 Mechanical properties of steels used for shafts.
The material used for ordinary shafts is carbon steel of grades 40 C 8, 45
C 8, 50 C 4 and 50 C 12. The mechanical properties of these grades of
carbon steel are given in the following table.
Standard Sizes of Transmission Shafts

• 25 mm to 60 mm with 5 mm steps.
• 60 mm to 110 mm with 10 mm steps.
• 110 mm to 140 mm with 15 mm steps.
• 140 mm to 500 mm with 20 mm steps.
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
 Types of Shafts
Transmission
Shafts Machine Shafts

These shafts transmit power between the source

and the machines absorbing power. These shafts form an integral part of
• The counter shafts, the machine itself. The crank shaft
• line shafts, is an example of machine shaft.
• over head shafts and
• all factory shafts
They are subjected to bending in addition to
twisting.
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
 St
ressesi
nShaf
ts
1. Shear stresses due to the transmission of torque (i.e.
due to torsional load).

2. Bending stresses (tensile or compressive) due to the

forces acting upon machine elements like gears, pulleys
etc. as well as due to the weight of the shaft itself.

3. Stresses due to combined torsional and bending

loads.
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
 Lecture Contents
01 Types of Shafts

02 Shaft Materials

03 Types of Load on Shafts

04 Stress in Shafts

Design of shafts under

05 various loads
Design of shafts under various loads
Shafts subjected to
twisting moment or
torque only,

Shafts subjected to
Shafts subjected to
combined twisting
bending moment
and bending
only
moments

Shafts
subjected to
axial loads
 Design of shafts under various loads

The shafts may be designed on the basis of

1. Strength, and 2. Rigidity and stiffness.
In designing shafts on the basis of strength, the following cases may be considered :
(a) Shafts subjected to twisting moment or torque only,
(b) Shafts subjected to bending moment only,
(c) Shafts subjected to combined twisting and bending moments, and
(d) Shafts subjected to axial loads in addition to combined torsional and bending
loads.
Shafts Subjected to Twisting Moment Only

T = Twisting moment (or torque) acting upon the shaft,

J = Polar moment of inertia of the shaft about the axis of rotation,
𝜏= Torsional shear stress
r = Distance from neutral axis to the outer most fibre
= d / 2; where d is the diameter of the shaft.
Hollow Shafts Subjected to Twisting Moment Only

do and di = Outside and inside diameter of the shaft, and r = do / 2.

k = Ratio of inside diameter and outside diameter of the shaft

= di / do
 Hollow Shafts Subjected to Twisting Moment Only
The hollow shafts are usually used in marine work. These shafts are stronger per
kg of material
 Shafts Subjected to Twisting Moment Only
The twisting moment (T) may be obtained by using the following relation:
Power transmitted (in watts) by the shaft:

In case of belt drives, the twisting moment ( T ) is given by:

T = (T – T ) R
1 2

T and T = Tensions in the tight side and slack side of the belt respectively,
1 2

R = Radius of the pulley.

Example 14.1. A line shaft rotating at 200 r.p.m. is to transmit 20 kW. The shaft may be assumed
to be made of mild steel with an allowable shear stress of 42 MPa. Determine the diameter of the
shaft, neglecting the bending moment on the shaft.

Solution. Given : N = 200 r.p.m. ; P = 20 kW = 20 × 103 W; 𝜏 = 42 MPa = 42 N/mm2 Let d = Diameter of the shaft.
We know that torque transmitted by the shaft,

𝑃 ∗60 20 ∗103 ∗ 60
T= = = 955 ∗ 103 N.mm
2𝜋𝑁 2𝜋∗ 200

We also know that torque transmitted by the shaft ( T ),

𝜋
3
955 ∗ 10 = ∗ 42 ∗ 𝑑 3
16

d = 48.7 say 50 mm Ans.

Example 14.2. A solid shaft is transmitting 1 MW at 240 r.p.m. Determine the diameter of the
shaft if the maximum torque transmitted exceeds the mean torque by 20%. Take the maximum
allowable shear stress as 60 MPa.

Solution. Given : P = 1 MW = 1 × 106W ; N = 240 r.p.m. ; Tmax = 1.2 Tmean ; 𝜏 = 60 MPa = 60 N/mm2
Let d = Diameter of the shaft.
We know that mean torque transmitted by the shaft,
Example 14.3. Find the diameter of a solid steel shaft to transmit 20 kW at 200 r.p.m. The
ultimate shear stress for the steel may be taken as 360 MPa and a factor of safety as 8. If a hollow
shaft is to be used in place of the solid shaft, find the inside and outside diameter when the ratio of
inside to outside diameters is 0.5.
Solution. Given : P = 20 kW = 20 × 10 W ; N = 200 r.p.m. ; 𝜏u = 360 MPa = 360 N/mm ;
3 2

F.S. = 8 ; k = di / do = 0.5
We know that the allowable shear stress,
Example 14.3. Find the diameter of a solid steel shaft to transmit 20 kW at 200 r.p.m. The
ultimate shear stress for the steel may be taken as 360 MPa and a factor of safety as 8. If a hollow
shaft is to be used in place of the solid shaft, find the inside and outside diameter when the ratio of
inside to outside diameters is 0.5.
Solution. Given : P = 20 kW = 20 × 10 W ; N = 200 r.p.m. ; 𝜏u = 360 MPa = 360 N/mm ;
3 2

F.S. = 8 ; k = di / do = 0.5
We know that the allowable shear stress,

di = Inside diameter, and

do = Outside diameter.t
T
Design of shafts under various loads
Shafts subjected to
twisting moment or
torque only,

Shafts subjected to
Shafts subjected to
combined twisting
bending moment
and bending
only
moments

Shafts
subjected to
axial loads
 Shafts Subjected to Bending Moment Only

M = Bending moment,
I = Moment of inertia of cross-sectional area of the shaft about the axis of rotation.
σb = Bending stress, and
y = Distance from neutral axis to the outer-most fibre.
 Shafts Subjected to Bending Moment Only
For a hollow shaft, moment of inertia:

where k = d / d
i o
Example 14.4. A pair of wheels of a railway wagon carries a load of 50 kN on each axle box,
acting at a distance of 100 mm outside the wheel base. The gauge of the rails is 1.4 m. Find the
diameter of the axle between the wheels, if the stress is not to exceed 100 MPa.
Solution. Given : W = 50 kN = 50 × 103 N ; L = 100 mm ; x = 1.4 m ; 𝜏b = 100 MPa = 100 N/mm 2
A little consideration will show that the
maximum bending moment acts on the
wheels at C and D. Therefore maximum
bending moment.
The maximum B.M. may be obtained as follows :
R = R = 50 kN = 50 × 103 N
C D

B.M. at A, M = 0
A

B.M. at C, M = 50 × 103 × 100 = 5 × 106 N-m

C

B.M. at D, M = 50 × 103 × 1500 – 50 × 103 × 1400 = 5 × 106 N-mm

D

B.M. at B, M = 0
B
Design of shafts under various loads
Shafts subjected to
twisting moment or
torque only,

Shafts subjected to
Shafts subjected to
combined twisting
bending moment
and bending
only
moments

Shafts
subjected to
axial loads
 Shafts Subjected to Combined Twisting
Moment and Bending Moment

Various theories have been

suggested to account for the
Maximum shear stress elastic failure of the materials Maximum normal stress
when they are subjected to theory or Rankine’s
theory or Guest's theory.
various types of combined
It is used for ductile stresses:
theory. It is used for
materials such as mild brittle materials such as
steel. cast iron.
 Shafts Subjected to Combined Twisting Moment
and Bending Moment
According to maximum shear stress theory, the maximum shear stress in the shaft:

𝜏 = Shear stress induced due to twisting moment.

σb = Bending stress (tensile or compressive) induced due to bending moment.
 Shafts Subjected to Combined Twisting Moment
and Bending Moment
According to maximum shear stress theory, the maximum shear stress in the shaft:

Te
Te= important

is known as equivalent twisting moment and is denoted by Te. The

equivalent twisting moment may be defined as that twisting moment
 Shafts Subjected to Combined Twisting
Moment and Bending Moment

Various theories have been

suggested to account for the
Maximum shear stress elastic failure of the materials Maximum normal stress
when they are subjected to theory or Rankine’s
theory or Guest's theory.
various types of combined
It is used for ductile stresses:
theory. It is used for
materials such as mild brittle materials such as
steel. cast iron.
 Shafts Subjected to Combined Twisting Moment
and Bending Moment
According to maximum normal stress theory, the maximum normal stress in the shaft:

Equivalent Bending Moment

 Shafts Subjected to Combined Twisting Moment
and Bending Moment
From this expression, diameter of the shaft ( d ) may be evaluated

Notes: 1. In case of a hollow shaft, the Previous equations may be written as:
Example 14.5. A solid circular shaft is subjected to a bending moment of 3000 N-m and a torque of 10000 N-m. The
shaft is made of 45 C 8 steel having ultimate tensile stress of 700 MPa and a ultimate shear stress of 500 MPa.
Assuming a factor of safety as 6, determine the diameter of the shaft.
Solution. Given : M = 3000 N-m = 3 × 106 N-mm ; T = 10000 N-m = 10 × 106 N-mm; σtu = 700 MPa = 700 N/mm2 ; τu =
500 MPa = 500 N/mm2
𝜎𝑡𝑢 700
Allowable tensile stress, 𝜎𝑎𝑙𝑙 𝑜𝑟 𝜎𝑏 = = = 116.7 𝑁/𝑚𝑚2
𝐹. 𝑆 6
𝜏𝑡𝑢 500
Allowable shear stress, 𝜏= = = 83.3 𝑁/𝑚𝑚2
𝐹. 𝑆 6
Due to maximum shear stress theory “Guest's theory”
Equivalent Twisting
Moment (Te)
Example 14.5. A solid circular shaft is subjected to a bending moment of 3000 N-m and a torque of 10000 N-m. The
shaft is made of 45 C 8 steel having ultimate tensile stress of 700 MPa and a ultimate shear stress of 500 MPa.
Assuming a factor of safety as 6, determine the diameter of the shaft.
Solution. Given : M = 3000 N-m = 3 × 106 N-mm ; T = 10 000 N-m = 10 × 106 N-mm; σtu = 700 MPa = 700 N/mm2 ; τu
= 500 MPa = 500 N/mm2
𝜎𝑡𝑢 700
Allowable tensile stress, 𝜎𝑎𝑙𝑙 𝑜𝑟 𝜎𝑏 = = = 116.7 𝑁/𝑚𝑚2
𝐹. 𝑆 6
𝜏𝑡𝑢 500
Allowable shear stress, 𝜏= = = 83.3 𝑁/𝑚𝑚2
𝐹. 𝑆 6
Due to maximum normal stress theory “Rankine’s theory”
equivalent Bending
moment (Me),

Me

Taking the larger of the two values, we have d = 86 say 90 mm Ans.

Example 14.6. A shaft supported at the ends in ball bearings carries a straight tooth spur gear at its mid span and is to transmit 7.5
kW at 300 r.p.m. The pitch circle diameter of the gear is 150 mm. The distances between the centre line of bearings and gear are
100 mm each. If the shaft is made of steel and the allowable shear stress is 45 MPa, determine the diameter of the shaft. Show in a
sketch how the gear will be mounted on the shaft; also indicate the ends where the bearings will be mounted? The pressure angle
of the gear may be taken as 20°.
Solution. Given : P = 7.5 kW = 7500 W; N = 300 r.p.m. ; D = 150 mm = 0.15 m ; L = 200 mm = 0.2 m ;  = 45 MPa = 45 N/mm2 ;
α = 20°
Example 14.6. A shaft supported at the ends in ball bearings carries a straight tooth spur gear at its mid span and is to transmit 7.5
kW at 300 r.p.m. The pitch circle diameter of the gear is 150 mm. The distances between the centre line of bearings and gear are
100 mm each. If the shaft is made of steel and the allowable shear stress is 45 MPa, determine the diameter of the shaft. Show in a
sketch how the gear will be mounted on the shaft; also indicate the ends where the bearings will be mounted? The pressure angle
of the gear may be taken as 20°.
Solution. Given : P = 7.5 kW = 7500 W; N = 300 r.p.m. ; D = 150 mm = 0.15 m ; L = 200 mm = 0.2 m ;  = 45 MPa = 45 N/mm2 ;
α = 20°

Normal Load Acting On

The Tooth Of The Gear

the gear is mounted at the middle of

the shaft, therefore maximum bending
moment at the centre of the gear
We know that equivalent twisting moment:
Example 14.7. A shaft made of mild steel is required to transmit 100 kW at 300 r.p.m. The supported length of the
shaft is 3 metres. It carries two pulleys each weighing 1500 N supported at a distance of 1 metre from the ends
respectively. Assuming the safe value of stress, determine the diameter of the shaft.
Solution. Given : P = 100 kW = 100 × 103 W ; N = 300 r.p.m. ; L = 3 m ; W = 1500 N, We know that the torque
transmitted by the shaft,

maximum bending moment lies at each pulley i.e. at C and D. due

to moment diagram.
M = 1500 × 1 = 1500 N-m
R = R = 1500 N
A B
We know that equivalent twisting moment,

Equivalent twisting
moment (Te),
Example 14.8. A line shaft is driven by means of a motor placed vertically below it. The pulley on the line shaft is 1.5
meter in diameter and has belt tensions 5.4 kN and 1.8 kN on the tight side and slack side of the belt respectively.
Both these tensions may be assumed to be vertical. If the pulley be overhang from the shaft, the distance of the centre
line of the pulley from the centre line of the bearing being 400 mm, find the diameter of the shaft. Assuming
maximum allowable shear stress of 42 MPa.
Solution . Given : D = 1.5 m or R = 0.75 m; T1 = 5.4 kN = 5400 N ; T2 = 1.8 kN = 1800 N ; L = 400 mm ; 𝜏 = 42 MPa = 42 N/mm2

We know that torque transmitted by the shaft,

T = (T1 – T2) R = (5400 – 1800) 0.75 = 2700 N-m

= 2700 × 103 N-mm
Neglecting the weight of shaft, total vertical load acting on the pulley,
W = T1 + T2 = 5400 + 1800 = 7200 N
Bending moment,
M = W × L = 7200 × 400 = 2880 × 103 N-mm
Let d = Diameter of the shaft in mm.
We know that the equivalent twisting moment (Te),

We also know that equivalent twisting moment (Te),

𝜋 𝜋
3950 ∗ 103 = ∗ 𝜏 ∗ 𝑑3 = ∗ 42 ∗ 𝑑3 = 8.25𝑑3
16 16

or d = 78 say 80 mm Ans.
Example 14.9. A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter pulley is mounted at a
distance of 300 mm to the right of left hand bearing and this drives a pulley directly below it with the help of belt
having maximum tension of 2.25 kN. Another pulley 400 mm diameter is placed 200 mm to the left of right hand
bearing and is driven with the help of electric motor and belt, which is placed horizontally to the right. The angle of
contact for both the pulleys is 180° and 𝝁 = 0.24. Determine the suitable diameter for a solid shaft, allowing working
stress of 63 MPa in tension and 42 MPa in shear for the material of shaft. Assume that the torque on one pulley is
equal to that on the other pulley.
Solution. Given : AB = 1 m ; DC = 600 mm or RC = 300 mm = 0.3 m ; AC = 300 mm = 0.3 m ; T1= 2.25 kN = 2250 N ; DD= 400
mm or RD = 200 mm = 0.2 m ; BD = 200 mm = 0.2 m ; 𝝷 = 180° =  rad ;  = 0.24 ; σb = 63 MPa = 63 N/mm2 ; 𝜏 = 42 MPa = 42
N/mm2
 T3
T4
400

200

250

250

300

T2
60
600
0

T1
Solution. Given : AB = 1 m ; DC = 600 mm or RC = 300 mm = 0.3 m ; AC = 300 mm = 0.3 m ; T1= 2.25 kN = 2250 N ; DD= 400
mm or RD = 200 mm = 0.2 m ; BD = 200 mm = 0.2 m ; 𝝷 = 180° =  rad ;  = 0.24 ; σb = 63 MPa = 63 N/mm2 ; 𝜏 = 42 MPa = 42
N/mm2

T1 = Tension in the tight side of the belt on pulley C = 2250 N

T2 = Tension in the slack side of the belt on pulley C.

Vertical load acting on the shaft at C,

WC = T1 + T2 = 2250 + 1058 = 3308 N
Vertical load on the shaft at D = 0
We know that torque acting on the pulley C,

T = (T1 – T2) RC = (2250 – 1058) 0.3 = 357.6 N-m

Solution. Given : AB = 1 m ; DC = 600 mm or RC = 300 mm = 0.3 m ; AC = 300 mm = 0.3 m ; T1= 2.25 kN = 2250 N ; DD= 400
mm or RD = 200 mm = 0.2 m ; BD = 200 mm = 0.2 m ; 𝝷 = 180° =  rad ;  = 0.24 ; σb = 63 MPa = 63 N/mm2 ; 𝜏 = 42 MPa = 42
N/mm2
T3 = Tension in the tight side of the belt on pulley D,
T4 = Tension in the slack side of the belt on pulley D.
Since the torque on both the pulleys (i.e. C and D) is same (from the Assumption in the problem), therefore

T = 3376 N, and T = 1588 N

3 4

Horizontal load acting on the shaft at D, W = T + T = 3376 + 1588 = 4964 N

D 3 4

Horizontal load on the shaft at C = 0

Now let us find the maximum bending moment for vertical and horizontal loading

Space Diagram Horizontal Load

Diagram

Vertical B.M
Diagram

Torque Diagram
Horizontal B.M.
Diagram

Vertical Load
Resultant B.M.
Diagram
Diagram
 Resultant B.M.
at C (MC) and D (MD),

Maximum bending moment,

M = M = 819.2 N-m
D
Pick the Maximum Moment
Let d = Diameter of the shaft.
 Equivalent twisting moment (Te)

Equivalent twisting moment (Te)

Equivalent bending moment (Me),

Equivalent bending moment (Me),

Taking larger of the two values, we have

d = 51.7 say 55 mm Ans.
Thank You