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Abstract
A shaft is a rotating machine element which is used to transmit power from one place to another.
Shaft is subjected to torque due to power transmission and bending moment due to reactions on
the components that are supported by the shaft. Discontinuity added on the shaft for essential
functional requirements. There are different types of loading conditions carried (torsion,
bending, axial and combination of them) by shaft during working. Here, a case study is taken on
ball mill shaft keyway for investigation of stress concentration factor. In this paper, stresses are
calculated for ball mill shaft with keyway as discontinuity at various critical locations under
torsion, bending, axial and combined loadings. Also, stress concentration factor for keyway on
shaft is investigated by Xiaobin equations for all three loadings, i.e. torsion, bending and axial
and by Peterson equations for torsion and bending for range of shaft diameters from 10 mm to
500 mm as per standard sizes available for shaft. Comparisons are made with the results obtained
from Xiaobin equations and Peterson equations for Stress Concentration Factor (SCF) and it is
concluded that the SCF is reduced, if fillet radius of keyway is increased. FEA analysis is also
carried out and result shows the conformal agreement with theoretical calculations. At the end,
the optimal fillet radius is determined which reduces the stress developed in the shaft.
Keywords: Shaft; Keyway; Discontinuity; Stress analysis; Finite element analysis
Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000
Nomenclature
Tensile stress
Bending stress
Shear stress
Axial stress
Maximum stress
Axial force
Bending moment
Width of keyway
Radius of keyway
( )
( )
()
N
SCF
Factor of safety
Stress concentration factor
1. Introduction
In industrial world many unexpected failures of equipment and various machine components
have occurred. A number of these failures have been due to poor design of equipment and
machines. However, it has been found that many failures have been caused by pre-existing
geometrical irregularities such as notches (circumferential), groove (V, U, Square), shoulders,
fillets, keyway, holes, threads etc. or flaws in materials that initiate cracks that grow and lead to
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Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000
(a)
(b)
Figure 1. Peeling-type cracks in shafts originate at the keyway (Bonnett et. al., 1998)
Keys and keyways are one of the most common shafthub connections. The design is often
regulated by the standards that are almost half a century old, and most of the results reported in
the literature are based on experimental photo elastic analysis (Pedersen, 2009). However, the
keyway on the take-off end or driven end of the shaft is one of the most concern because it is
located in the area where the highest shaft loading occurs. When this loading has a high torsional
component, fatigue cracks usually emanate in the fillets or roots of the keyway. Keyways that
end with a sharp step have a higher level of stress concentration than those that use a sledrunner type of keyway. In the case of heavy shaft loading, cracks frequently emanate at this
sharp step. Figure 1(a) and (b) illustrate this type of failure. It is important to have an adequate
radius on the edges of the keyway (Bonnett et. al., 1998).
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Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000
It is remarkable that very little effort has been done to improve the design with respect to
minimizing the stress concentrations. In this paper, stress concentration factor for profile keyway
present in the ball mill shaft is calculated by using Xiobian equations for a given range of shaft
diameters (smaller to larger) in the PSG design data book (Kalaikathir, 2007) for/in different
loading conditions. A set of stress concentration factor curves/tables for keyway on shafts are
presented in this paper. The preliminary stress concentration factors for profile keyway under
bending, torsion, axial loading and combined loading for shaft design are also provided.
The specifications of ball mill are given in the Table 1 and properties of shaft material are
presented in Table 2.
Table 1. Specifications of ball mill
Grinding capacity
: 20-25
Kg
: 193
Motor
: 1.5
Gearbox
: 40:1
: 35
mm
: 10
mm
:5
: 0.40
Kg
HP, 1480 rpm
worm reduction gear box
mm
mm
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Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000
Material of shaft
: C40
Carbon steel
: 290
MPa
: 1.5
So, based on the factor of safety, the allowable stress is calculated (193.33 MPa). From the given
data and dimensions torque (T = 284 103 Nmm), bending moment (M = 89933 Nmm) and
axial force (F = 469.5 N) is calculated (Norton et. at., 2006).
( ) = 3
... (6)
= 3
... (7)
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Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000
4
( ) = 2
...(8)
32
3
( )2 + ( )2
... (9)
= 168.28MPa
= 3 ( +
2
8
) + 4 ( )2
... (10)
r 2
r 2
(11)
(12)
r 2
(13)
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Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000
Where, the ratio of keyway radius (r) to keyway width (b) varies from 0.02 to 0.0832. i.e. 0.02
r
b 0.0832
Table 3. Calculation of SCF value from Indian standard data (Xiaobin et. al., 2013)
Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shaft
dia.
(mm)
10
12
17
22
30
38
44
50
58
65
75
85
95
110
130
150
170
200
230
260
290
330
380
440
Up to
Width
(mm)
Height
(mm)
Radius
(mm)
r/b
12
17
22
30
38
44
50
58
65
75
85
95
110
130
150
170
200
230
260
290
330
380
440
500
4
5
6
8
10
12
14
16
18
20
22
25
28
32
36
40
45
50
56
63
70
80
90
100
4
5
6
7
8
8
9
10
11
12
14
14
16
18
20
22
25
28
32
32
36
40
45
50
0.16
0.25
0.25
0.25
0.4
0.4
0.4
0.4
0.4
0.6
0.6
0.6
0.6
0.6
1
1
1
1
1.6
1.6
1.6
2.5
2.5
2.5
0.04
0.05
0.04167
0.03125
0.04
0.0333
0.02857
0.025
0.0222
0.03
0.02727
0.024
0.02142
0.01875
0.02777
0.025
0.0222
0.02
0.02857
0.02539
0.02285
0.03125
0.02777
0.025
2.7757
2.5533
2.7342
3.022
2.7757
2.9592
3.1076
3.2283
3.3278
3.0616
3.1505
3.2635
3.3571
3.459
3.1337
3.2283
3.3278
3.4109
3.1076
3.2145
3.3046
3.0224
3.1337
3.2283
2.689
2.5106
2.6557
2.8867
2.689
2.8361
2.955
3.0517
3.1314
2.9181
2.9894
3.08
3.1549
3.2366
2.976
3.051
3.1314
3.198
2.955
3.0407
3.1129
2.8867
2.976
3.051
3.5423
3.2659
3.4908
3.8483
3.5423
3.77
3.954
4.1036
4.2268
3.8969
4.007
4.1472
4.2631
4.3893
3.9863
4.1036
4.2268
4.3297
3.954
4.0864
4.1981
3.8483
3.9863
4.1036
By using Petersons equations (Pilkey, 1997) stress concentration factor for profile keyway
present in the shaft is calculated for a given range of shaft diameters (smaller to larger) as per the
PSG design data book (Kalaikathir, 2007) under bending and torsion loading conditions for
different r/d ratio which is given in Table 4.
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0.1 2
0.1
0.1 2
...(14)
(15)
Table 4. Calculation of SCF value from Indian standard data (Peterson equation) (Pilkey, 1997)
Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shaft
diameter
(d) (mm)
10
12
17
22
30
38
44
50
58
65
75
85
95
110
130
150
170
200
230
260
290
330
380
440
Up
To
12
17
22
30
38
44
50
58
65
75
85
95
110
130
150
170
200
230
260
290
330
380
440
500
Width Height
(mm) (mm)
4
5
6
8
10
12
14
16
18
20
22
25
28
32
36
40
45
50
56
63
70
80
90
100
4
5
6
7
8
8
9
10
11
12
14
14
16
18
20
22
25
28
32
32
36
40
45
50
Radius
(r)
(mm)
0.16
0.25
0.25
0.25
0.4
0.4
0.4
0.4
0.4
0.6
0.6
0.6
0.6
0.6
1
1
1
1
1.6
1.6
1.6
2.5
2.5
2.5
r/d
Kb
Kt
0.01600
0.02083
0.01470
0.01136
0.01333
0.01052
0.00909
0.00800
0.00689
0.00923
0.00800
0.00705
0.00631
0.00545
0.00769
0.00666
0.00588
0.00500
0.006956
0.006153
0.005517
0.007575
0.006578
0.005681
2.3786
2.1708
2.4553
2.7247
2.5513
2.8153
3.0034
3.1828
3.4088
2.9829
3.1828
3.3722
3.551
3.7995
3.2408
3.463
3.67
3.952
3.3951
3.5941
3.7797
3.2637
3.4843
3.7291
2.7672
2.5929
2.831
3.0522
2.9103
3.1257
3.2763
3.4173
3.5907
3.26
3.4173
3.563
3.697
3.8761
3.4623
3.6315
3.7839
3.981
3.5804
3.7287
3.8622
3.4799
3.6474
3.8263
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In the next section, the comparisons of results obtained from Xiobian equations and Peterson
equations are given with the help of charts for bending and torsion load.
3
2
1
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Figure 4. Stress concentration factor for bending (Kb) vs. Filler radius (r)
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
kt peterson
kt xiobian
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Figure 5. Stress concentration factor for bending and torsion (Kt) vs. Filler radius (r)
From this Figure 4 and Figure 5 it is concluded that fillet radius increases then SCF for bending
and torsion decreases. Xiobian equation of SCF is calculated based on r/b ratio where Peterson
equation of SCF is calculated based on r/d ratio. In Xiobian equation, SCF value is accurate at
critical location. There is no such guideline provided by Peterson to calculate the stress
concentration factor for axial loading (Ka) whereas by using Xiobian equation, Ka is calculated
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easily.
5. Finite element analysis (FEA)
Figure 6 shows that the fixed support is applied on opposite side of keyway on the shaft. Now,
different kinds of loads are applied on this shaft and observed the FEA results.
Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000
Analytical
analysis
(MPa)
FEA
Analysis
1.72
1.60
6.9
90.76
94
3.6
90.76
92
2.2
60
61
1.6
168.28
165.61
1.5
168.90
165.89
1.7
Sr.
No.
(MPa)
(%)
Error
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Sr.
Different
Max. stress
No.
Stress (MPa)
0.4
0.5
0.6
0.7
0.8
0.832
0.850
reduction in %
Axial stress
1.72
1.59
1.49
1.43
1.41
1.41
1.42
18 %
Bending stress
60
59
54
51
49
48
48.5
20 %
Torsional stress
90
84
80
77
76
76.5
76.9
15 %
From the above Table 6 it is concluded that when fillet radius of keyway increases up to some
level, stress value decreases. If further keyway radius is increased (after 0.850 mm), the stress
value increases. As a result, from that it is possible to find the optimal value of fillet radius which
gives minimum stress value.
8. Conclusion
By theoretical calculations, stresses are calculated for ball mill shaft with keyway as
discontinuity at various critical locations. In this paper, stress concentration factor for keyway as
discontinuity on shaft is investigated by using Xiaobin equations for all three loading torsion,
bending and axial and by using Peterson equations for torsion and bending for total range of shaft
diameters from smaller to larger (10 mm to 500 mm) given in the PSG design data book.
Comparisons are made for results obtained from Xiaobin equations and Peterson equations and it
is conclude that the SFC is reduced if radius of rotation is increased. FEA analysis is also carried
out and a result shows the conformed agreement with theoretical calculations. At the end, the
optimal fillet radius is found out which will reduce the stress developed in the shaft with keyway.
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Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000
Reference
Bonnett A. H., (1998). Cause, analysis and prevention of motor shaft failures. U.S. Electrical
motors, Division of Emerson Electric, ST. Louis, Missouri, IEEE. 166-180.
Norton, R. L., (2006). Machine design: an integrated Approach. Third edition, Pearson
Education, Upper Saddle River, NJ.
Pedersen, N. L., (2009). Stress concentrations in keyways and optimization of keyway design.
Journal of Strain Analysis, 45, 593-604.
Pilkey, W. D. (1997). Petersons stress concentration factors. Third edition, John-Wiley and
Sons, New York.
Xiaobin Le P.E.; Mr. Zelong Le (2013). Stress concentration factors due to typical geometric
discontinuities for shaft design by numerical simulation. American Society for Engineering
Education, 120th ASEE Annual Conference & Exposition.
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