Shaft Design

ENTC 463 Mechanical Design Applications II

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ENTC 463 Mechanical Design Applications II

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ENTC 463
Lab 3 Due 4/10 Homework HW 12 Due 4/15
Chapter 12 2, 4, 25, 27

Shafts
Mott, Chapter 12 Why use shaft?
To transmit power

Shaft geometry
Cylinder, bar, beam (length and diameter)

Load acting on shaft

Torsion (shear stress) Bending (normal stress)

Shaft Design

Shaft Design

Shaft Design
Given required power to be transmitted
Calculate torque, Calculate forces, Calculate stresses (if geometry is known), Select material

Given required power to be transmitted

Calculate torque, Calculate forces, Determine shaft diameter (if the material is known)

Shaft Design Procedure

1. Develop the free body diagram; model the various machine elements mounted on the shaft in terms of forces and torques 2. Develop the shear and moment diagram; identify bending moment (leads to normal stress) and torque (leads to shear stress) 3. Identify critical locations for stress analysis; calculate stresses (known diameter) 4. Determine diameter or select material based on failure theories

Forces Acting on Shaft

Forces due to gear (spur gear)
63000hp n T Wt = D2 Wr = Wt tan T= Wx = Wt tan (helical gear)

Forces due to Gears

Forces Acting on Shaft

Forces due to chain and sprocket
Fc = T T T = A = B D 2 DA 2 DB 2 Fcx = Fc cos Fcy = Fc sin

Forces Acting on Shaft

Forces due to V-belt and sheave
FB = F1 F2 1.5T D2 For flat belt and pulley FB FB 2.0T D2

Example
A chain is transmitting 100 kW with the chain speed at 6000 rpm and V = 50 m/s. The shaft material is AISI 1040 cold drawn. Determine the shaft diameter required.

Shaft Design Considerations

Stress Concentration (fillet or key seat)
1.5 < Kt < 2.5

Combined tangential and radial load (3-D)

Two shear and moment diagrams
Wt z

M y = M xy + M yz
2

Wr x

Stress Concentration
Keyseats
Kt = 2.0 for profile keyseat Kt = 1.6 for sled keyseat

Shoulder fillets
Kt = 2.5 for sharp fillet Kt = 1.5 for well-rounded fillet

Retaining ring grooves

Kt = Kt = 3.0, or Increase diameter by 6%

Forces Acting on A Shaft

Shear and Moment Diagrams

From bottom look up Front view

Shaft Design/Analysis Example

MSST :

1 3

Sy N

x = xy =

Tc T (d 2 ) 16T = = J d 4 32 d 3

Mc M (d 2) 32 M = = d 4 64 d 3 I

Sy 16 16 M + M 2 +T 2 3 M M 2 +T 2 d 3 d N Sy 32 M 2 +T 2 d 3 N

( (

32 N d S y

M +T
2 2

1 3

16 2 1 = + x + xy = 3 M + M 2 + T 2 2 d 2
2

) )

32 N d

M S y

2 2 T + S y

1 3

16 2 1 = x + xy = 3 M M 2 + T 2 2 d 2
2

Is this correct ?

Fatigue Failure Criterion

Cyclic loading due to shaft rotation
Find mean and alternating stresses Construct Mohrs circles for mean stress and alternating stress Derive effective mean and alternating stresses (based on MSST or DET) Use Soderberg or Goodman for design and analysis

Fatigue Failure of Shaft

Mean : mx = 0
32M x = d 3 y =0

my = 0 mxy
16T = 3 d

Alternatin : g 32M ax = 3 d my = 0

mxy = 0
ANSI/ASME equation for fully reversed bending and steady torsion : a S ' n
2

xy

16T = 3 d

32T m'= 3 d 32 M a '= d 3 Soderberg : K t a ' m ' 1 + = Sn ' Sy N

m =1 + S ys

ANSI Shaft Design Equation

For repeated reversed bending and constant torque

ANSI/ASME Shaft Equation

Fully reversed bending and steady torsion : a m + S ' S =1 n ys
2 2

Consider safety factor : a S ' n

2

m =1 + S ys
2

a S ' N n

m a N m N =1 + S ' + S =1 S N n ys ys
2

ANSI / ASME Shaft Equation

Use DET (pure shear for torsion) : a N m N = 1 a N + S ' S ' S n n ys
2 2 2

2 2 m N a N + 3 m N = 1 + S ' S 1 y n Sy 3

Consider stress concentration : a N 3 m N = 1 K t a N + 3 m N = 1 S ' S S ' + S y n y n

2 2 2 2

ANSI / ASME Shaft Equation

Mc 32M = d 3 I Tc 16T m= = 3 J d a = K N 3 m N t a + S ' S n y
2 2

32M 16T N 3 3 N Kt 3 d + d = 1 =1 Sy Sn '

32 N d=

Kt M S ' n

3 T + 4 Sy

1 3

ANSI / ASME Shaft Equation

Fully reversed bending and steady torsion 32 N d Kt M S ' n 3 T + 4S y
2 2

1 3

Static 32 N d M S y 3 T + 4S y
2 2 1 3

ANSI Shaft Design Equation

Fully reversed bending and steady torsion : a S ' n
2

m =1 + S ys

Fully reversed bending and steady torsion 32 N d Kt M S ' n

2 2 3 T + 4S y 1 3

Can we use Soderberg or Goodman criterion?

Example 12-1 (p. 548)

The system transmitting 200 hp from pinion P to gear A, and from pinion C to gear Q. The shaft rotating speed is 600 rpm. Shaft material is AISI 1144 OQT 1000

Example (p. 549)

Free body diagram Shear and moment diagrams Torque at each segment Calculate diameter for locations A, B, C, and D (at both left and right)
No moment Torque = 21000 No torque, no moment, vertical shear only

No torque

Shear and Moment Diagrams

From bottom look up Front view

Design Examples

Design Example - Torque

Design Example - Forces

Design Examples Shear and Moment