Design of Machine Elements

Machine Design

Design of Shafts
 Design of Shafts

 The shafts are usually cylindrical, but may be square or cross-shaped in section. They are
solid in cross-section but sometimes hollow shafts are also used.
 An axle, though similar in shape to the shaft, is a stationary machine element and is used
for the transmission of bending moment only. It simply acts as a support for some rotating
body such as hoisting drum, a car wheel or a rope sheave.
 A spindle is a short shaft that imparts motion either to a cutting tool (e.g. drill press
spindles) or to a work piece (e.g. lathe spindles).
 Transmission shafts. These shafts transmit power between the source and the machines
absorbing power. The counter shafts, line shafts, over head shafts and all factory shafts
are transmission shafts. Since these shafts carry machine parts such as pulleys, gears
etc., therefore they are subjected to bending in addition to twisting.
 Machine shafts. These shafts form an integral part of the machine itself. The crank shaft
is an example of machine shaft.
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 Design of Shafts

Shaft should have high strength, good machinability, low notch sensitivity
factor, good heat treatment properties, high wear resistant properties, etc.

When a shaft of high strength is required, then an alloy steel such as nickel, nickel-chromium
or chrome-vanadium steel is used.
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 Design of Shafts

The standard sizes of transmission shafts are :

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.

The standard length of the shafts are 5 m, 6 m and 7 m.

The maximum permissible tensile stress may be taken as: or

The maximum permissible shear stress may be taken as: or

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 Design of Shafts

The shafts may be designed on the basis of

1. Strength
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.

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 Design of Shafts
Shafts Subjected to Twisting Moment Only

Solid Shaft Hollow Shaft Power transmitted (in watts)

In case of belt drives

? ?

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 Design of Shafts

Shafts Subjected to
Twisting Moment Only

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.

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 Design of Shafts
Shafts Subjected to Bending Moment Only

Solid Shaft Hollow Shaft Rotating Shaft

? ? when,

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 Design of Shafts
Combined Twisting Moment and Bending Moment
Maximum shear stress theory Maximum normal stress theory

Hollow Shaft

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 Design of Shafts
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

Maximum shear stress theory

(Assumed)

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 Design of Shafts
Shafts Subjected to Fluctuating Loads (ASME code)
The combined shock and fatigue factors must be taken into account for the computed
twisting moment (T ) and bending moment (M )

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 Design of Shafts
Shafts Subjected to Variable Load

Goodman line for design:

Check for the first-cycle localized yielding,

For a rotating shaft with constant bending and torsion, the bending stress is completely
reversed and the torsion is steady. Therefore,
and
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 Design of Shafts

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 ultimate tensile strength is 180 MPa,
determine the diameter of the shaft with a factor of safety 2. The pressure angle of the gear may be taken as 20°.
Correction factor for machined surface = 0.8, for size = 0.85 and for reliability = 0.9.

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 Design of Shafts

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 with ultimate
tensile strength 260 Mpa and factor of safety 2. Assume that the torque on one pulley is equal to that on the
other pulley. Correction factor for machined surface = 0.8, for size = 0.85 and for reliability = 0.9.

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 Design of Shafts

A transmission shaft supporting a spur gears B and the pulley D. The shaft is mounted on two bearings A and C.
The diameter of the pulley and the pitch circle diameter of the gear are 450 mm and 300 mm respectively. The
pulley transmits 20 kW power at 500 rpm to the gear. P1 and P2 are belt tensions in the tight and loose sides.
Assume, P1 = 3P2 and gear pressure angle is 200. The gear and pulley are keyed to the shaft. The material of the
shaft is steel 50C4 (Sut = 700 and Syt = 460 N/mm2). Determine the suitable diameter for a solid shaft with factor of
safety 4. Correction factor for machined surface = 0.8, for size = 0.85 and for reliability = 0.9.

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 Design of Shafts (based on Rigidity)

Torsional Rigidity

Lateral Rigidity

Slope

Deflection

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 Critical Speed (Shaft Design)
The critical speed of the shaft is the speed at which the rotating shaft becomes
dynamically unstable and starts to vibrate violently in a transverse direction.
Critical (whirling) speed is dependent on: shaft dimensions, shaft material and loads on shaft
Force balance (centrifugal force and restoring force):

Critical speed of the point mass (rad/sec):

Critical speed of the point mass (rev/sec):

Critical speed for a horizontal shaft: or

is the static deflection for the point mass

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 Critical Speed (Shaft Design)
For an ensemble of attachments, Rayleigh’s method for lumped masses gives

where, is the weight of the th location and

is the deflection at the th body location

where, is the
A shaft of uniform diameter and simply supported: mass per unit length

It is possible to use Rayleigh’s method for the case above by partitioning the shaft into
segments and placing its weight force at the segment centroid.
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 Critical Speed (Shaft Design)

Cantilevered Shaft
Cantilevered Shaft
With disc at the free end

where, is the
mass per unit length
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 Critical Speed (Shaft Design)

Shaft between short bearings

Shaft between long bearings

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where, is the mass per unit length
 Critical Speed (Shaft Design)

Central disc with short bearings

Central disc with long bearings

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 Critical Speed (Shaft Design)

Non-central disc with short bearings

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 Critical Speed (Shaft Design)
Dunkerley’s Method

Based on the theory of superposition

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 Keys

A key can be defined as a machine element

which is used to connect the transmission
shaft to rotating machine elements like
pulleys, gears, sprockets or flywheels.

According to Indian standards, steel

of tensile strength not less than
600 MPa shall be used as the
material for the key.

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 Sunk Keys
Square Key Rectangular Key

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 Design of Keys

Shear Failure Crushing Failure

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 Couplings
A coupling can be defined as a mechanical device that joins two rotating shafts

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 Couplings

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 Couplings

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 Couplings

Sleeve or Muff Coupling Split Muff Coupling

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 Couplings

Flange Coupling Tyre Coupling

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 Couplings

Jaw Coupling Oldham‘s Coupling

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 Couplings

Helical Coupling Universal Coupling

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 Design of Rigid Flange Coupling

Number of bolts

for 40
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 Couplings

Shaft
Keys
Shearing
Hub

Flange
(at the Crushing
junction of hub)

Shearing
Bolt
Refer the previous section for
Crushing Design of Keys
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