SHAFT AND ITS DESIGN

FOR STRENGTH
 SHAFT
• is a common and important machine element.
• It is a rotating member
• Has a circular cross-section and is used to transmit power. The
shaft may be hollow or solid.
• The shaft is supported on bearings and it rotates a set of gears
or pulleys for the purpose of power transmission.
• The shaft is generally acted upon by bending moment, torsion
and axial force. Design of shaft primarily involves in
determining stresses at critical point in the shaft
• Other two similar forms of a shaft are axle and spindle.
TYPES OF SHAFTS:

1. Axle – stationary member carrying rotating wheels, pulleys etc.

2. Line shaft – or main shaft, the one driven by primemover.
3. Countershaft, jackshaft, shortshaft or headshaft – shafts
intermediate between a line shaft and a driven machine.
4. Spindles – short shaft
TYPES OF SHAFT

5. Machine shaft – a shaft which is an integral part of the machine.

6. Transmission shaft – shaft which is used to transmit power
between the source and the machine absorbing the power.
 MATERIAL FOR SHAFTS

• 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:

- Hot-rolled plain carbon steel

- Cold-drawn plain carbon/alloy composition
- Alloy steels
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.
• Better yield strength is also obtained.
• This is widely used for general purpose transmission shaft.
ALLOY STEELS

• Alloy steel is a mixture of various elements with the parent

steel to improve certain physical properties.
• Nickel, chromium and vanadium are some of the common
alloying materials. However, alloy steel is expensive.
• 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
 FORCES EXERTED ON SHAFTS BY
MACHINE ELEMENTS
SPUR GEARS – the force exerted on a gear tooth during power transmitting acts normal
(perpendicular) to the involute-tooth profile. The analysis of shafts to consider the
rectangular components of this force acting in the radial and tangential directions.
Torque = 63,000 (P) / n
Tangential Force, Wt = T / (D/2)
where:
P = power transmitted in hp
n = rotational speed in rpm
T = torque on the gear in lb-in Wt
D = pitch diameter of the gear
in inches
 FORCES EXERTED ON SHAFTS BY
MACHINE ELEMENTS
The angle between the total force and the tangential component is equal to the
pressure angle of the tooth form. For gears, the pressure angle is typically 14
½o, 20o, or 25o.

Radial force, Wr Wr
= Wt x tan F

Wt
 FORCES EXERTED ON SHAFTS BY
MACHINE ELEMENTS
HELICAL GEARS – in addition to the tangential and radial forces
encountered in spur gear, the helical gears produce an axial force.

Radial Force, Wr = Wt x tan Fn / cos y

Axial load, Wa = Wt x tany

Where = Fn – normal pressure angle

y - helical angle
 FORCES EXERTED ON SHAFTS BY
MACHINE ELEMENTS
CHAIN AND SPROCKET – the upper part of the chain is in tension and
produces torque on either sprockets. The lower part of the chain, referred to
as the slack side, exerts no force on either sprocket. Therefore, the total
bending force on the shaft carrying the sprocket is equal to the tension in the
tight side of the chain.

Force on chain, Fc = T / (D/2)

Where D = pitch diameter of
the sprocket
 FORCES EXERTED ON SHAFTS BY
MACHINE ELEMENTS
V-Belt Sheaves – it looks similar with the chain drive system. But in the V-belt
system, both sides are in tension. The tight side tension, F1 is greater than the
“slack side” tension, F2 and there is a net driving force on the sheaves. The
bending force is calculated by taking constant, C multiplied by the net driving
force.
Fb = C Fn Thus, Fb = 1.5 Fn = 1.5 T / (D/2)
Fb = F1 + F2
where
Fn = F1 – F2
Fn = T / (D/2)
 FORCES EXERTED ON SHAFTS BY
MACHINE ELEMENTS
Flat Belt Pulleys – it is identical to the V-belt sheaves except the ratio of the
tight side to the slack side tension taken to be 3 instead of 5.
So, we compute as:

Fb = 2.0 Fn = 2.0 T / (D/2)

 FACTOR OF SAFETY (DESIGN FACTOR)

Under typical industrial

conditions, the design factor
of N = 3 is recommended. If
the application is very
smooth, a value as low as N
= 2 may be justified. Under
conditions of shock or
impact, N = 4 or higher
should be used, and careful
testing is advised.
RECOMMENDED BASIC SIZES FOR
SHAFTS
When mounting a commercially available element, follow the
manufacturers recommendations for the basic size of the
shaft and the tolerance.
 STANDARD SIZES OF SHAFTS

• Typical sizes of solid shaft that are available in the market are,

Up to 25 mm 0.5 mm increments
25 to 50 mm 1.0 mm increments
50 to 100 mm 2.0 mm increments
100 to 200 mm 5.0 mm increments
 OTHER FORMULA FOR SHAFTING
1. TORSION OF CIRCULAR SHAFT

• Maximum value of the shearing stress occurs in the outer surface.

• Polar Moment of Inertia

Solid circular cross-section

Hollow shaft
 OTHER FORMULA FOR SHAFTING

• Angle of twist, f in radian measure:

• Axial deformation

DME by Spotts page 69

 OTHER FORMULA FOR SHAFTING
• Stress concentration factor, K – used when failure of a machine
part occur because of a sudden application of a single heavy load
or by a sudden change in form.

K = σmax/σnom
Nominal stress (σnom) is the stress without
the stress concentrators such as grooves,
while the maximum stress (σmax) is the
maximum stress with the stress raiser
feature.
OTHER FORMULA FOR SHAFTING
 EXAMPLE:

1. A hollow shaft must carry a torque of 30,000 in-lb at a shearing stress of

8,000 psi. The inside diameter is to be 0.65 of the outside diameter. Find the
value of the outside diameter.
 EXAMPLE:

1. A hollow shaft must carry a torque of 30,000 in-lb at a shearing stress of

8,000 psi. The inside diameter is to be 0.65 of the outside diameter. Find the
value of the outside diameter.
 EXAMPLE:

2. Suppose it is specified that the angular deformation in a shaft should not

exceed 1o in a length of 6 ft. The permissible shearing stress is 12,000 psi.
Find the diameter of the shaft. The material is steel.
 EXAMPLE:

2. Suppose it is specified that the angular deformation in a shaft should not

exceed 1o in a length of 6 ft. The permissible shearing stress is 12,000 psi.
Find the diameter of the shaft. The material is steel.
DME by Spotts page 69
 OTHER FORMULA FOR SHAFTING
2. HORSEPOWER

Power is defined as the rate at which work is performed.

F – force, pounds
V – velocity, feet per minute

If force F is acting on radius r, the angular velocity is:

n – rev per minute
 OTHER FORMULA FOR SHAFTING
3. MAXIMUM STATIC SHEARING STRESS

Many shaft carry combined loads of bending and torque. The bending
moment M causes stress in the axial direction of the shaft and the
torque produces the shearing stress, Ss.
 ASME DESIGN CODE
• The shafts are normally acted upon by gradual and sudden loads. Hence, the
equation is modified in ASME code by suitable load factors,

16
Smax = 𝐶𝑚 𝑀 2 + 𝐶𝑡𝑇 2 where: Smax = Sy/FS
𝜋𝑑3

note that: Sys = 0.5-0.6Sy

Sys = 0.5Sy (Spotts)
M = bending moment
T = Twisting moment Sys = 0.6Sy (Faires)
 OTHER FORMULA FOR SHAFTING
4. MAXIMUM SHEAR STRESS THEORY WHEN THE LOAD IS
FLUCTUATING

This can be applied when the normal and shear stress in a shaft are fluctuating.
Stresses normal to the shaft axis are zero. Also, it is assumed that the normal
and shear stress reach their maximum and minimum values simultaneously.
1. More conservation and predicts a narrower elastic region where a material
will maintain its shape.
2. Assumes the material will yield when the maximum shear stress reaches
the yield strength.
 OTHER FORMULA FOR SHAFTING
Examples:
1. Find the diameter by the ASME Code for a rotating shaft (commercial
shafting = 8,000 psi) subjected to a maximum steady torque of 16,200
in-lb and a steady bending moment of 27, 000 in-lb. The shaft has a
keyway (75% of the value of the working stress of the solid shaft)
Cm = 1.5, Ct = 1.0
Ssmax = 0.75 x 8,000psi = 6,000 psi
 OTHER FORMULA FOR SHAFTING
Examples:
2. A 2 in diameter rotating shaft carries a torque of 12,000 in-lb which
may be applied suddenly and a bending moment of 8,000 in-lb which
also may be applied suddenly. Shaft is under heavy shocks. Material tests
Syp = 7,000 psi. Find the value of the FS by the ASME Code.
Cm = 2, Ct = 1.5
 OTHER FORMULA FOR SHAFTING
Examples:
3. Suppose the loads in a shaft have a maximum steady torque of 16,200
in-lb and steady bending moment of 27, 000 in-lb. The value of Tr =
0.1Tav. Stress concentration is caused by a keyway and is equal to 1.35
for both bending and torque. Material tests Sult = 120,000 psi; Syp =
100,000 psi. The factor of safety equals 2. Let Se = 0.5 Sult. Because of
the keyway, let the working stress be reduced to 90% of the value for a
solid shaft. For an element on a rotating shaft, the average moment is
zero. Find the value of required diameter of the shaft using maximum
shear stress theory.
 OTHER FORMULA FOR SHAFTING

3. Solution:
Mav = 0; Mr = 27,000 in-lb
Tav = 16,200 in-lb, Tr = 0.1Tav = 1,620 in-lb
Se = 0.5Sult = 0.5 x 120,000 = 60,000 in-lb
0.5 𝑥 100,000
Ssmax = 0.9 x = 22, 500 psi working stress
2

16 100 100
𝑑3 = 𝑥 [ 𝑥 1.35 𝑥 27,000]2 +[16,000 + 𝑥 1.35 𝑥 1,620]2
22,500 𝜋 60 60
16 𝑥 63,900
= = 14.466
22,500 𝜋

𝑑 = 2.437 𝑖𝑛𝑐ℎ
 OTHER FORMULA FOR SHAFTING
5. Mises-Hencky Theory for Shafting or Shear-energy theory or
Maximum distortion energy theory

This can also be applied for equivalent static working stress in tension.
1. Used for prediction of yielding: provides accuracy as compared to
maximum shear stress theory.
2. More realistic and less conservation than the maximum shear stress
theory.
**Provides a better representation of ductile yielding, while the maximum
shear stress theory errs on the side of caution.
 OTHER FORMULA FOR SHAFTING
5. Mises-Hencky Theory for Shafting or Shear-energy theory or
Maximum distortion energy theory

4. Suppose the loads in a shaft have a maximum steady torque of 16,200 in-lb
and steady bending moment of 27, 000 in-lb. The value of Tr = 0.1Tav.
Stress concentration is caused by a keyway and is equal to 1.35 for both
bending and torque. Material tests Sult = 120,000 psi; Syp = 100,000 psi.
The factor of safety equals 2. Let Se = 0.5 Sult. Because of the keyway, let
the working stress be reduced to 90% of the value for a solid shaft. For an
element on a rotating shaft, the average moment is zero. Find the value of
required diameter of the shaft using Mises-Hencky theory.
 OTHER FORMULA FOR SHAFTING
3. Solution:
Mav = 0; Mr = 27,000 in-lb
Tav = 16,200 in-lb, Tr = 0.1Tav = 1,620 in-lb
Se = 0.5Sult = 0.5 x 120,000 = 60,000 in-lb
100,000
S = 0.9 x = 45, 000 psi working stress
2
16 1.35 𝑥 100
𝑑3 = 2
[ 3 𝑥 16,200 + 4 𝑥 27,0002 + 3 𝑥 1,6202
45,000 𝜋 60
16
= (28,060 + 2.25 𝑥 54,070) = 16.945
45,000 𝜋

𝑑 = 2.569 𝑖𝑛𝑐ℎ

A slightly larger shaft is required when the design is made by the Mises-Hencky theory.
PSME CODE:
STRENGTH OF SHAFT WITH ASSUMED ALLOWABLE
STRESSES
1. Main power transmitting shafts
(assumed stress = 4,000 psi)
P = D3N / 80
where:
2. Lineshafts carrying pulleys
(assumed stress = 6,000 psi) P = hp
P = D3N / 53.5 D = inches
N = rpm
3. Small, short shafts, countershaft
(assumed stress = 8,500 psi)
P = D3N / 38
1. Compute for the twisting moment in in-lb developed when a shaft delivers 20 Hp at 1200 rpm.
a. 1166
b. 915
c. 1050
d. 945

2. Compute the maximum unit shear stress in a 3 in diameter steel shafting that transmits 24000 in-lb
torque at 89 rpm.
a. 4527
b. 4250
c. 3860
d. 4930
3. A steel shaft transmits 50 hp at 1400 rpm. If the allowable stress is 5000 psi, find the shaft diameter.
a. 1.45”
b. 2.25”
c. 2.84”
d. 1.32”
4. Find the power, in watts, transmitted by a main power transmitting
shaft with a diameter of 65mm and a speed of 200 rpm.
a. 25,370
b. 18,920
c. 19,826
d. 31,254
5. What is the diameter of a line shaft that transmits 150 KW at 15 rps?
a. 58.1 mm
b. 65.2 mm
c. 45.3 mm
d. 34.5 mm
END
PROCEDURE FOR THE DESIGN OF SHAFT

1. Determine the rotational speed of the shaft.

2. Determine the power or the torque to be transmitted by the
shaft.
3. Determine the design of the power-transmitting components or
other devices that will be mounted on the shaft.
PROCEDURE FOR THE DESIGN OF SHAFT

4. Specify the location of the bearings to support the shaft.

5. Propose the general form of the geometry for the shaft.
6. Determine the magnitude of torque that the shaft sees at all
points.
7. Determine the forces that are exerted on the shaft.
PROCEDURE FOR THE DESIGN OF SHAFT
8. Solve the reactions on all support bearings in each plane.
9. Produce the complete shearing force and bending diagrams to
determine the distribution of bending moments in the shaft (see image
next slide).
10. Select the material from which the shaft will be made, specify its
condition: cold-drawn, heat-treated, and so on..
DISTRIBUTIO
N OF
BENDING
MOMENTS
IN THE
SHAFT.
PROCEDURE FOR THE DESIGN OF SHAFT

11. Determine an appropriate designs stress, considering the

manner of loading (smooth, shock, repeated and reversed, or
other).
12. Analyze each critical point of the shaft to determine the
minimum acceptable diameter of the shaft at the point in
order to ensure safety under the loading at the point.
SAMPLE DESIGN OF SHAFT

A SAE 1010 hot-rolled steel is to be used for the transmission shafting.

The transmission shaft is directly coupled to a driven machine. The shaft
rotates and acquiring steady load or gradually applied. The motor runs at
240 rpm with power rating of 10hp. The diameter of the shaft
designed/selected was 2 inches. The power of the motor is transmitted
using 5 inches diameter pulley. The maximum bending moment is at the
midpoint of the shaft in which the pulley is installed. Determine whether,
it is safe to use a factor of safety of 2. If no, indicate the new design value
for the factor of safety. Length of shaft is 2 feet.
ASME DESIGN CODE
• The shafts are normally acted upon by gradual and sudden loads. Hence, the
equation is modified in ASME code by suitable load factors,

16
Smax = 𝐶𝑚 𝑀 2 + 𝐶𝑡𝑇 2 where: Smax = Sy/FS
𝜋𝑑3

note that: Sys = 0.5-0.6Sy

M = bending moment Sys = 0.5Sy (Spotts)

T = Twisting moment
Sys = 0.6Sy (Faires)
 SOLUTION:

1. Torque developed by the motor shaft.

P = 2𝜋TN
10 ℎ𝑝 𝑥 550 𝑓𝑡−𝑙𝑏𝑠/𝑠
T= 1𝑚𝑖𝑛
2 𝜋 ( 240 𝑟𝑝𝑚 𝑥
60 𝑠𝑒𝑐
T = 2,626 in-lbs
 SOLUTION:

2. Tangential force created by the pulley.

T = Ft x r
2626 𝑖𝑛−𝑙𝑏𝑠
Ft =
5/2
Ft = 1,050.4 lbs
 SOLUTION:
3. Bending moment on the transmission shaft due to pulley attached.

M = FtL / 4
= 1,050.4 lbs (24 lbs) / 4
M = 6,302.4 in-lbs
 SOLUTION
4. Maximum stress developed by the shafting.
16
Smax = 𝐶𝑚 𝑀 2 + 𝐶𝑡𝑇 2
𝜋𝑑3

rotating shaft, steady load

Cm = 1.5 Ct = 1.0
16
Smax = = 1.5 𝑥 6,302.4 2 + 1 𝑥 2626 2
𝜋 2 3

Smax = 6,246.22 psi

 SOLUTION

5. The yield strength of the steel to be used.

SAE 1010 hot-rolled steel

Chapter 14, Sec 4 page. 531 DME by Spotts

Yield strength = 29,000 psi
SOLUTION
6. Factor of safety
0.5𝑆𝑦 0.5 (29,000 𝑝𝑠𝑖)
FS = = = 2.3
𝑆𝑚𝑎𝑥 6,246.22 𝑝𝑠𝑖

Allowable factor of safety:

If FS = 3 (recommended)
0.5(29,000 𝑝𝑠𝑖)
Smax = = 4, 833.33 psi
3

therefore:
FS allowed is 3, but the computed and the assumed FS should be justified.
What is the justification for this???
END