WORCESTER POLYTECHNIC INSTITUTE

MECHANICAL ENGINEERING DEPARTMENT

DESIGN OF MACHINE ELEMENTS

ME-3320, B’2022

Lecture 20
December 2022

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 Shaft design
Example of rotating machinery: self-aligning ball bearings
Shaft: used for transmission of Input pulley
Locating bearing power and as a machining tool Lubrication system
(lesser load)
Sealed
bearings Clamp

Floating bearing Keyway

(heavier load)

Cutter shaft of a planer: shaft diameter (at

bearings locations) is 40 mm. Input power is
12 HP at maximum speed of 4,500 rpm

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 Shaft design
Fully-reversed bending and constant torsion
Review and Master: Example 10-1 Safety factor: 2.5
Infinite life
Design shaft to support attachments
Material: SAE 1020 (good notch sensitivity)
Operating conditions: room temperature
Power: 2 HP at 1,750 rpm
SCF of 3.5 for radii in bending, 2 in torsion,
and 4 at the keyway
Assume notch radius of 0.01 in

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 Shaft design
Fully-reversed bending and constant torsion
Safety factor: 2.5
Review and Master: Example 10-1 Infinite life
Material: SAE 1020 (good notch sensitivity)
Pressure angle
Operating conditions: room temperature
Power: 2 HP at 1,750 rpm
y
SCF of 3.5 for radii in bending, 2 in torsion,
x and 4 at the keyway
Assume notch radius of 0.01 in
Fgt F1
Fg
Gear Tension & slack side
Sheave components of the net force
Fgr
z
F2

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 Shaft design: components. Examples 10-1 and 10-2
V-belt pulley

“Slack” side
V-belt pulley system in a car

http://www.dsm.org

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Shaft design: components. Examples 10-1 and 10-2
Spur Helical

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Shaft design: components. Examples 10-1 and 10-2

Contact angle: spur gears

Figure 11-4

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Shaft design: components. Examples 10-1 and 10-2

Radial ball bearings Cross-section of a radial ball-bearing

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Shaft design: components. Examples 10-1 and 10-2

Load diagram in the X-Z plane

Moments diagram, X-Z plane

Point C

Point B Point D

Point A

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Shaft design: components. Examples 10-1 and 10-2

Load diagram in the Y-Z plane

Moments diagram, Y-Z plane

Point B Point C

Point D

Point A

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Shaft design: components. Examples 10-1 and 10-2

Total moment diagram: note that the Amplitude & Mean components of
the moments (and torque) require evaluation

 2 2
M T ( z ) = M X −Z + M Y −Z 
1/ 2

Point C
Point D

Point B

Point A

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 Total moment:
Point A Point D
Point C 
M T ( z ) = M X2−Z + M Y2−Z 1/ 2
Point B
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 Shaft design
Fluctuating bending and torsion
Review and Master: Example 10-2 Mean and alternating torque are both 74 lb-in
Safety factor: 2.5
Design shaft to support attachments
Infinite life
Material: SAE 1020 (good notch sensitivity)
Operating conditions: room temperature
Power: 2 HP at 1,750 rpm
SCF of 3.5 for radii in bending, 2 in torsion,
and 4 at the keyway

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 Total moment:
Point A Point D
Point C 
M T ( z ) = M X2−Z + M Y2−Z 1/ 2
Point B
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 Shaft design
ASME method: fully-reversed bending and constant torsion
Based on failure envelope (shown before):
2
a   m 
2
  +   = 1
 Se   S ys 
Safety factor: Nf
Sy
von Mises stress in shear (strain-energy theory): S ys =
3
Amplitude stress in bending and mean torsional stresses:  a , m
(corrected for fatigue stress-concentration factors)

Shaft diameter is calculated as:

1/ 3
  2 2 1/ 2 

 32 N f M  3 T  
d =  K f a  +  K fsm m   
   Sf  4 Sy   
 

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 Shaft design
ASME method: fluctuating bending and torsion
Based on von Mises stresses (amplitude and mean):  'a , 'm

Failure envelope given as:

1  'a  'm
= +
Nf Sf Sut
Sy
von Mises stress in shear (strain-energy theory): S ys =
3
Amplitude and mean stress components in bending and shear:
(corrected for fatigue stress-concentration factors)  a ,  m , a , m

Shaft diameter is calculated as:

1/ 3
  (K f M a )
2
+ 3
(K fsTa )
2
(K fm M m )
2
+ 3
(K fsmTm )
2 
 32 N f  
d = 4
+ 4
  Sf Sut 
   


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 Shaft design
Deflection: bending
Simple shafts: refer to notes from previous lectures

Stepped shafts: calculations become more involved

M = Moment function determined using singularity functions

EI EI

It is required the  slope =  M dz + C3

integration of equations: EI
 deflection =   slope dz + zC3 + C4

Numerical integration is preferred:

see MathCad Examples EX10-03 and EX10-09

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 Shaft design
Deflection: torsion
Angular deflection (simple shaft):

Single disk =Tl

GJ
Torsional spring constant
(simple shaft):
kt = T = G J
 l

Angular deflection (stepped shaft):

 = 1 +  2 +  3 = T  l1 + l2 + l3 
G  J1 J 2 J 3 
Effective torsional spring
 constant (stepped shaft):
1 = 1 + 1 + 1
kteffective kt1 kt2 kt3

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 Shaft design
Natural frequencies of vibration: FEM model of gear-shaft
CAD model Domain discretization

FEM model solves the discrete

version of equation:

 F =m x
Also written as

m x + k x = 0

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 Shaft design
Natural frequencies of vibration: FEM model of gear-shaft
Representative results
Mode shape #1 (fundamental) ~ 1040 Hz Mode shape #2 ~ 1240 Hz

Mode shape #3 ~ 1340 Hz Mode shape #4 ~ 5320 Hz

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Shaft design: transversal modes of vibration
Estimation of fundamental transversal
first natural frequency

 mi  i
Using Rayleigh’s method: n = g i ; [rad/sec]
 mi  i
2

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Shaft design: torsional modes of vibration
Estimation of fundamental torsional
first natural frequency
Single disk
n = kt
Simple shaft:
Im
2
With: kt = GJ , and I m = m r
l 2

For stepped shafts:

J = J eff = l
 Ji
li
i

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Shaft design: torsional modes of vibration
Estimation of fundamental torsional
first natural frequency
Two disks configuration
Note that:
1) I1 , and I 2 are mass
moment of inertia
2) Effective torsional
stiffness is
1 = 1 + 1
kteffective kt1 kt2
Natural frequency: (when two  steps define
shaft geometry)

 n = kt I1 + I 2
effective
I1 I 2

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Shaft design: transversal & torsional modes of vibration
Example
Review and Master: Example 10-8 Requires use of
numerical integration to
find deflections at gear
and sheave locations

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 Reading

Chapters 10 of textbook: Sections 10.9 to 10.16

Review notes and text: ES2501, ES2502, ES2503

Homework assignment
Author’s: as indicated in website of our course
Solve: as indicated in website of our course

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