Design of Shafts

Instructor-Dharmendra Kumar Shukla

Email id- [email protected]
Contact No. 9452695306
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Introduction
Shaft: A shaft is a rotating member, usually of
circular cross section, used to transmit power or
motion
 It provides the axis of rotation, or oscillation, of
elements such as gears, pulleys, flywheels,
cranks, sprockets, and the like and controls the
geometry of their motion.
Axle: An axle is a non-rotating member that carries
no torque and is used to support rotating wheels,
pulleys, and the like.
 The automotive axle is not a true axle.
 A non-rotating axle can readily be designed and
analyzed as a static beam. 2
Spindle: A spindle is a short shaft.
Line shaft: Power driven rotating shaft for power
transmission that was used extensively from the
industrial revolution till the early 20 th century.
Head Shaft: The shaft driven by a chain and mounted at
the delivery end of a chain conveyor.
 It serves as the mount for a sprocket which drives the
drag chain.
Stub Shaft: A shaft which is integral with an engine,
motor or prime mover.
 It is of suitable size, shape and projection to allow its
easy connection to other shaft.
Transmission shaft: Same as line shaft.
Counter shaft: an intermediate horizontal shaft in a grist
mill driven through gearing by the water wheel and
driving the mill stones through bevel gear.
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Flexible Shaft: permits the transmission of power
between two shafts e.g. motor shaft and machine
shafts whose rotational axes are at an angle or where
the angle between the shafts may change.
Design of Shaft:
 Material selection (40C,45C, 50C1,55C, 55C75
 Geometric layout
 Stress and strength
 Static strength
 Fatigue strength
 Deflection and rigidity
 Bending deflection
 Torsional deflection
 Slope at bearings and shaft-supported elements
 Shear deflection due to transverse loading of short shafts
 Vibration due to natural frequency
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Shaft Materials
 Many shafts are made from low carbon, cold-drawn
or hot-rolled steel, such as AISI 1020-1050 steels.
 If strength considerations turn out to dominate
over deflection, then a higher strength material
should be tried, allowing the shaft sizes to be
reduced until excess deflection becomes an issue.
 When warranted, typical alloy steels for heat
treatment include AISI 1340-50, 3140-50, 4140,
4340, 5140, and 8650.
 Cold drawn steel is usually used for diameters
under about 3 inches.
 Stainless steel may be appropriate for some
environments.

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Shaft Layout
Common torque transfer elements are
1) Keys
2) Splines:
 gear teeth cut or forged into the shaft surface
 Can transmit large amount of torque
3) Set screws
4) Pin
5) Press or shrink fits
6) Tapered fits

1, 3, 4: high stress concentration

2: moderate
5, 6: quite small stress concentration
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Locational Devices
 Cotter and washer
 Nut and washer
 Sleeve
 Shaft shoulder
 Ring and groove
 Setscrews
 Split hub and tapered two piece hub
 Collar and screw
 Pins

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(a) Choose a shaft configuration to support and locate the two gears and
two bearings. (b) Solution uses an integral pinion, three shaft
shoulders, key and keyway, and sleeve. The housing locates the
bearings on their outer rings and receives the thrust loads.
(c) Choose fan-shaft configuration. (d) Solution uses sleeve bearings,
a straight through shaft, locating collars, and setscrews for collars,
fan pulley, and fan itself. The fan housing supports the sleeve 8

bearings.
Tapered roller bearings used in a mowing machine spindle. This design
represents good practice for the situation in which one or more torque
transfer elements must be mounted outboard.

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A bevel-gear drive in which both pinion and gear are straddle-mounted.
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Shaft Design for Stress
Critical Locations
 It is not necessary to evaluate the stresses in a
shaft at every point; a few potentially critical
locations will suffice.
 Critical locations will usually be on the outer
surface, at axial locations where the bending
moment is large, where the torque is present,
and where stress concentrations exist.
 Most shafts will transmit torque through a portion
of the shaft. Typically the torque comes into the
shaft at one gear and leaves the shaft at another
gear.

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Shaft Stresses
 Bending, torsion, and axial stresses may be
present in both midrange and alternating
components.
 Axial loads are usually comparatively very small
at critical locations where bending and torsion
dominate, so they will be left out of the following
equations.
 The fluctuating stresses due to bending and
torsion are given by

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 Assuming a solid shaft with round cross section,
appropriate geometry terms can be introduced
for c, I, r, and J resulting in

 Using the distortion energy failure theory, the von

Mises stress is given by

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 Using the modified Goodman line

 Substituting of σ’a and σ’m

 Diameter

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Estimating Stress
Concentration Factor
 Stress concentrations for shoulders and keyways are
dependent on size specifications that are not known
the first time through the process.
 These elements are usually of standard proportions,
it is possible to estimate the stress-concentration
factors for initial design of the shaft.
 Shoulders for bearing and gear support calls for the
ratio of D/d to be between 1.2 and 1.5.
 For a first approximation, the worst case of 1.5 can
be assumed.
 The fillet radius (r) at the shoulder r/d typically
ranging from around 0.02 to 0.06.
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Techniques for reducing stress concentration at a
shoulder supporting a bearing with a sharp radius.

(a) Large radius undercut into the shoulder.

(b) Large radius relief groove into the back of the
shoulder.
(c) Large radius relief groove into the small
diameter

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Deflection Considerations
 Typical Maximum Ranges for Slopes and
Transverse Deflections

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Critical Speeds for Shafts
 Critical speeds: at certain speeds the shaft is
unstable, with deflections increasing without upper
bound.
 Designers seek first critical speeds at least twice
the operating speed.
 The shaft, because of its own mass, has a critical
speed.
 The ensemble of attachments to a shaft likewise
has a critical speed that is much lower than the
shaft’s intrinsic critical speed.
 Estimating these critical speeds (and harmonics) is
a task of the designer.
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 When geometry is simple, as in a shaft of uniform
diameter, simply supported, the task is easy. It can
be expressed as

 where m is the mass per unit length, A the cross-

sectional area, and γ the specific weight.
 For an ensemble of attachments, Rayleigh’s method
for lumped masses gives

 where wi is the weight of the ith location and y i is

the deflection at the ith body location
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Example: A shaft with the relative proportions in
figure given below is to carry a load that consists
of a reversed bending moment of 340 N-m and a
steady torque of 450 N-m. What dimensions do
you recommend if the factor of safety is to be 2.5
and the shaft is to be machined from C20 steel?

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Ma=340 Nm; Tm=450 Nm
For C20; Sut=432 MPa; Sy=245 MPa
S’e=0.5×432=216 MPa
D/d=3/2=1.5; r/d=0.5/2=0.25
Assume a diameter, lets say d=10 mm
Calculate Ka, Kb, Kc. Then Se.
Find out Kt, q, kts and qs from data sheet.
Calculate kf and kfs .
Find out FOS using modified Goodman failure locus.
If FOS is less than 2.5, increase the diameter and do
the calculations again till FOS becomes more or
equal to 2.5.

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Example: The figure shows a shaft mounted in
bearings at A and D and having pulleys at B and
C. The forces shown acting on the pulley surfaces
represent the belt tensions. The shaft is to be
made of AISI 1035 CD steel(Sut=550 MPa, Syt=440
MPa). Using distortion energy theory with a
design factor of 2, determine the minimum shaft
diameter to avoid yielding.

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Reference Books
 Mechanical Engineering Design by J. E.
Shigley, McGraw-Hill

 Design of Machine Element by V. B. Bhandari, Tata

McGraw-Hill

 Machine Design An Integrated Approach by R. L.

Norton, Pearson Prentice Hall

 Design Data – PSG College of Technology

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Questions ??

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Thank You.

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