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    CHP 4 PDF

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    Chapter 4 : Design of Shafts and Keys Section 4.8: Example 4.5: A hoisting drum of 0.5 m diameter is keyed to a shaft which is supported in two bearings and driven through a reduction gear pair having a reduction ratio of 12: 1. The gear, having pitch circle diameter of 450 mm, is mounted at the end of the shaft such that it overhangs the nearest bearing by 150 mm. TI load to be hoisted is 8 KN at the speed of 50 m/min. The efficiency of drive is 80%, The shaft is made of steel, for which the working stresses are 115 MPa in tension and 50 MPa in shear. If the combined shock and fatigue factors for bending and torsion are 2 and 1.5 respectively, determine (the power and speed of electric motor : and Gi) the diameter of shaft Solution Given: D = 500mm; G= 1 d= 450mm L = 150mm . 50 We 8xlN ; Vv = Syms: = 08 5 6, = 115 Nimm? = SON/mm™ K, = 20; K, = 1s. © Torque on drum: WD _ 8x10" «500 2 z or T = 2000 Nam it 2000 10° N-mm ‘© Drum speed and motor speed : Let N = drum speed, r:p.m n= motor speed, rpm. DN @ x 1000 xx 500xN 60 x 1000 31.83 rp.m, n= GN=12%3183 or n= 381.98 rpm, Design of Machine Elements (CBE / Tr) 42 Design of Shafts & Keys Gee o ' — ° = b ear}, | : usw HL} | w w Fig 451 ¢Blectre moter power: pe —_2aNT 21.83 «2000 BW 100 =H,” 60100008 or P= 833kW Ans. + Equivalent torque and bending moment on shat: Assume pressure angle of gear, = ‘Tangential force on gear, FR Radial force on gear, F, fan 20 = 3235.29 N Resultant force on gear, B= fF + =-V(8888.88)" + (3235.29) or F = 9459,35N ‘Maximum bending moment on shafl, M L=9459,35 « 150 or M = 1418.9 10° Namm = VRMFKTY = VDRO TYE FS «2000 x 10 or T, = 4129.54 x 10° Nanm Equivalent bending moment on shafi, we = SKM HRM RTY I $ [2x 14189 10° +Y(2x 89 10 CTS x 200% 10)" ] or M, = 3483.67 x 10° Namm Equivalent torque on shaft Design of Machine Elements (CBE / Tr) 43 Design of Shafts & Keys © Diameter of shaft by maximum shear stress theory : According to maximum shear stress theory 16T, Tam = gh 16 « 4129.54 x 10° 50 = ad d= 74.92 mmor 75 mm « © Diameter of shaft by maximum principal stress theory According to maximum principle stress theory 32. 3483.67 x 10" ad d= 67.57 mm or 68 mm (b) 1s © Diameter of shaft : ‘Taking larger of the two values given by Equations (a) and (b) we get, q 75mm Ams, Example 4. A sicel shaft made of 40C8 is used to drive a machine. The pulleys X, Y and bearings A, B are located as shown in Fig. 4.7.1. Belt tensions are also shown in Fig. 4.7.1. Determine the diameter of the shaft using ASME. code, Yield strength of shaft material is 330 Némm° and ultimate tensile strength is 600 Nimmn”, Take K, = 1.$ and K,= 1.2. Ifthe rectangular key is made of the same material, design the key 250N 165N 195 —————— = Mas|~> fe : | F Fig. 4.7.1 Solution = 600 Nimm: 2 300 N/mm’ Ky=15 K According to A.S.M.E, code, allowable shear stress for shaft and key material is, Ty = 0.18$,,=0.18 x 600 = 108 Nimm* or Ty = 035, = 03 x 330 = 99 Nimm* 99 Némm? Design of Machine Elements (CBE/ 1) a4 Design of Shafts & Keys Considering the keyway effect, the allowable shear stress for shaft is, 4 = OTS x ty, = 0.75 x 99= 74.25 Nim? © Torque on shaft: ‘Torque on pulley X, Ty= (Fy) Fre) ty 300 350 ~ 138) 99 T= y= 32.285 10" Names Now, clockwise torque on pulley X= anticlockwise tome on pulley Y 32.25 «10° Fur = 48TSN © Bending moment on shaft : At pulley X. the belt tensions are vertical. Vertical force at pulley X, Fay = Fy + Ry = 3504 135 At pulley Y. the belt tensions are inclined at 45° Vertical force at pulley Y, Fy = (Fy + Fy) cos 45 or Fyy = 87S +165) cos 45 = 461.4N Horizontal force at pulley Y, Fy = Fy + Fy) sin ds or Fyy = 4875 + 165) sin 45= 461.4 N Fig. 4.7.2(a) shows the vertical loading diagram. ‘Taking moment about point A, 485 « 200 —Ryy » $00 + 461.40 x 700 = 0 s+ Ray = 839.95 Now, LF, = 0; —Ryy 839.95 448544614 = 0 & Ry = 106.45N ‘Vertical bending moments at point X and B are : Muy = Ray x 200 Mgy = Fy x 200 Fig, 4.7.2(c) shows the horizontal loading diagram, ‘Taking moment about point A Ruy: «500-4614 x 700 = 0 2 Rey = O1ON Now, = Fy = 0: Ry + H6L4—646 = 0 Ry, = 1846N Horizontal bending moments at points X and B are Myyy = Ray % 200 = 184.6 x 200 = 36,92 x 10" N-mm Design of Machine Elements (CBE / Tr) 45 Design of Shafts & Keys Moy = 461.4 x 200 = 92,28 x 10" Nem Resultant bending moments at points X and B are Mg = VOM) * Mad) = VQ129« 109"+ 692 x 1077 Ry 200 or My = 42618 10°N-mm My = Vivo OMgp? = VO228s 10 228s 1 or Mz = 130.303 x 10°N-mm. axioms bending moment an shat M 130.503 x 10° Nemm_ 200 500 —re— 200 4 Ray 108405 gy 890.6 [FF 4 (@) Vertical loading diagram Fy HAN eran A x |. D 24.29% 10°Namm foam » Y x 8 (© Horizontal loading diagram y= 18408 sora 6228 10°tsnm 36.92 x 10°N-mm, (d) Horizontal bending moment diagram aN “e * 8 130,503 x 10° humm 42018x10" nam (©) Resulitant bending moment diagram a Y Fig. 4.7.2 Design of Machine Elements (CBE / Tr) 46 Design of Shafts & Keys © Diameter of shaft : Equivalent torque, = VK KI = 130,503 x 10° + (12 = 32.25 » 10 or 199.544 x 10° Nam, Now a ad 16 «199, ad d= 23.92 mmor 24mm 24mm oo AS, © Design of key : tq = 99 Nine Let us take, a, = 244.2% 99% 198Nénm? For rectangular key, Width of ke Height of key Considering crushing of key ho, ah oleae og = 4232.25 x10" 198 = dT 1 = 6.79 mm or7 mm (@ Considering shearing of key 27 wl dwi 232.25 «10° 99 = UK OxT J = 452mm or$ mm o) Selecting larger of two values given by Equations (a) and (b) = 7mm Key dimensions: w = 6mm h = 4mm 1 = 7mm eo AS, Design of Machine Elements (CBE / Tr) 47 Design of Shafts & Keys Example 4.11 : Fig. 4.11.1 shows the transmission shaft supporting the helical gears. Helical gear G of pitch circle diameter 400 mm receives the power from an electric motor and helical pinion P of pitch circle diameter 100 mm drives the machine. The ultimate and yield strengths of shaft material are 630 and 380 Némm: respectively, If K, = 2.0 and K, = 1.5, design the shaft using the A.S.M.E, code. Find also the torsional deflection of the shaft Solution Given: Sy = 630 Nim’ S, = 380.N) = 20 K, = 18 400 mm d= 100mm, 4000.N Frp = 1500: = 1000. d, = 100mm, For helical gear G Fy = 1000N Frg = 350N; Fag = 400 d, = 400mm, According io A.S ME, code, the allowable shear stress for shaft with keyway effet is 4, = 0.75 (0.18 8,) = 0.75 « 0.18 x 630 = 85.08 Nim? 1 aller of ort, = 0.75(03S,)=0.75 « 0.3 x 380= 85.5 Nim’ two values: Torque on pinion P, 100 . Tp = Fy d,/2= 4000 <3 °= 200 10° Nemm Torque on gear G, 400 : = Fy = 1000222 200 x 10" Nemm 200 x 10° Nem Design of Machine Elements (CBE / Tr) 48 Design of Shafts & Keys © Bending moment on shaft : Fig 4.11.2(a) shows the vertical loading diagram, fe 500 ee 500 +} — 500 y= 20850 Raya 1855N—S5ON P oe ; 4 @) Moy =89% 10° (a) Vertical loading 4000N 80x70" A p 8 1 6 $x 10°wmm | — (b) Vertical bending moment diagram Rag 10008 P 8 A G L (©) Horizontal loading diagram *500N a P 2 6 $00 10°N-mm (4) Horizontal bending moment diagram 600 10°Nemm 850 10°Nmm 412 Moment at point G in vertical plane due to force F,, My, = Fux 200 or Myy = 400 x 200= 80 « 10° Nemm Taking moment about point A, 4000 x $00 ~ Ryy x 1000 ~ 350 x 1500 +80 x 10"=0. Ryy = 158 V ‘Taking moment about point B, Ray * 1000 ~ 4000 x 500 ~ 350 x $00+ 80 x 10° Ryy = 2095 Vertical bending moments at points P, B, and Gare Mpy = 2095 x $00= 1047.5 « 10° N-mm Design of Machine Elements (CBE / Tr) 49 Design of Shafts & Keys Mgy = 350 x 500-80 x 10°=95 « 10° Nem Mjy = 8010" Fig, 4.11.2(¢) shows the horizontal loading diagram. Moment at point P due to force F,, Mpy = 1000 x 50 Taking moment about point A, 1000 = 1500 Rey,» 1000~ 1500 $00 + 50 x 10° Ray = 800N ‘Taking moment about point B, Ray x 1000 + 1500 x 500 + 50 x 10° + 1000 « 500 = 0 Ruy = 1300N Horizontal bending moments at points P and B are Myy = 1300 « $00= 650 x 10° N-mu Mgy, = 1000 x $00 = $00 x 10° Nem. Resultant bending moments at points P and B are M, = Va) May or Mp = V(lOITS x 10) + (680% 10°F = 1232.78 x 10° Nem Me (Moy) + (Mou) or | Mp, (95 = 10° + (300 « 10°)" = $08.89 x 10° N-mm Maximum bending moment is, M = M,= 1232.78 « 10°N-mm. © Diameter of shaft : Equivalent torque, T= ViKM HKD = VQ.05 1232.78 x 10 + (1.5 x 200 10" 2483.75 « 10° Nem 161, 85,05 16 « 2483. 75x10" a d = 52.98 mmor53 mm a= 33mm aA Go Design of Machine Elements (CBE / Tr) 4-10 Design of Shafts & Keys aye sTi Gad Now, portion of shaft between two gears is subjected to torque Hence, L = 100mm 32 x 200% 10" « 1000 80x 10° xx (53) 3 180, 3.227 « 10" tad = 3.227 x 10x degree or 8 = 0.185" eo AMS, Example 4.13 : A shaft is supported by two bearings which are 1100 mm apart. The shaft carries two belt pulleys A and B, The pulley A, of diameter 620 mm, is keyed at 400 mm to the right of left bearing and drives a pulley directly below it with the maximum belt tension of 2.75 KN. The pulley B, of diameter 400 mm, is Keyed at 200 mm to the left of right bearing and is driven by an electric motor placed horizontally to the right. The angle of lap for both the pulleys is 180° and the coefficient of friction between the belt and pulley is 0.3. The shaft is made of steel with an ultimate tensile strength of 300 N/mm” and a tensile yield strength of 190 N/mm’, If K,, and K, are 3.0 and 2.5 respectively. design the shaft using A.S MLE. code. Ifa solid shaft is to be replaced by the hollow shaft of outer diameter 80 mm, determine (i) the inner diameter of hollow shaft : and Gi) the ratio of weights of solid shaft to hollow shatt Solution Given : dy = 620mm Fy = 2750N dy = 400mm H= 03 Sy = 190 Nénm® Ks According io A.S.MLE. code, the allowable shear srs for shaft with Keyway fet = 0.750.188, 75 x 0.18 x 300 = 40.5 Nimm* smaller of = 405mm! or ‘ovo values +100 400 1 =200 Fig, 4.13.41 Design of Machine Elements (CBE /) ant Design of Shafts & Keys + Vertical force on pulley A: Fu z= e gue Fay FL = 2566 2750 Te 2566 Fy = 10717 Vertical force on pulley A Fy, + Fay = 2780+ 1071.87 = 3821.57 Torque on shat, dy T= Fy-Fd or T © Horizontal force on pulley B Fa Fs Fu Fu or Fy Now, T 520.31 « 10° and Fy, Horizontal force on pulley B, © Bending moment on shaft : 5) £20 (2750 1071.51) 5 520.31 x 10 Nem 2.366 2.566 Fs (Fp, ~ Fos) * qi 2.566 Fs = Fy) x 2601.55 1661.27 N 2.566 Fys = 2,566 « 1661.27 = 4262.82 N = 4262.82 + 1661.27 = 15924.1N Fig. 4.13.2(a) shows the vertical loading diagram. ‘Taking moment about point C AF, 400+ Ryy x 1100 = = 3821.57 400 + Ryy x 1100 Rov Now. DF, Roy + Roy ~ 3821.57 + 1389.66 ~ 3821.57 Roy 0 o 1389.66 N ° ° ° 2431,91N Design of Machine Elements (CBE / Tr) 4-12 Design of Shafts & Keys Vertical bending moments at points A and B are Mgy = Rey « 400 = 2431.91 « 400 = 972.764 x 10° Nem, Moy = Row ¥ 200 = 1389.66 x 200 = 277.932 « 10° Nemm. 982187 (a) Vertical loading diagram Roy= 2498 91 N Rpy= 198966 N 072.764 x 10°Nmm (b) Vertical bending moment diagram eee rr 024.1 N (©) Horizontal loading diagram 969.4 10 490 84x 10°W-mey, c ny to 1063.9 10° mm 4008.46 x 10°N-mm (©) Resultant bending moment diagram ig, 4.13.2 Fig, 4.13.2(¢) shows the horizontal loading diagram, Taking moment about point C. =F yx 900+ Ry, x 1100 = 0 924.1 x 900-+ Rix, 1100 = 0 Ruy = 4847N Now, Lk, = 0 Design of Machine Elements (CBE / Tr) 4-13 Design of Shafts & Keys Roy + Roy 59241 = 0 Rey + 4847 $924.1 = 0 Rox = 1077.1 Horizontal bending moments at points A and B are May = Rey 400= 1077.1 x 400 430.84 x 10" N-mm My = Roy: 200 = 4847 200 = 969.4% 10° N.mm Resultant bending moments at points A and B are My = Vt) * May: V7. 76 10F 1063.9 x 10° Nem, VM) + (Men) = 1008.45 « 10° N-mm Maximum bending moment is, M_— = Mj = 1063.9 « 10° N-mm (430.84 x 10°) 77.932 « 10°) + (969.4 x 10°) Ms: © Torque on shaft : ae co, 620 T= @y-Fadx f= 2750-10715) Wx xed 4 = 30.29 mm of 30.5 mm d= 305mm Ans. Design of Machine Elements (CBE / Tr) 4-18 Design of Shafts & Keys Example 4.15 A transmission shafl supports two pulleys A and B, as shown in Fig. 4.15.1. The pulleys are keyed to the ide of plain carbon steel 45C8 (Sq = 600 Ninm’, S,, = 380 Némm? and ‘The combined shock and fatigue factors in bending and torsion are 1.5 and 1.0 respectively. The permissible angle of twist for shaft is 0.5°, Determine diameter of shaft co) using AS.M.E, code ; and (i) based on torsional rigidity Fa 800 N 20, A ss00n 2200 Jy 2300 & 4 ke ray22000N | Fi = 500N 100 “+ 200 +L — 150 +} AAS Sa. = 600 Nim? fl Sy = 380Némn G = 79300Nimm? ; K,= 13; K,= 10 5 6 = 05 degree. © Bending moment diagram : Vertical force on pulley A. Fy = Faq, +Fy:= 2000+ 500= 2500. ‘Vertical force on pulley B, Fay = (Fu + Fy) 608 30 = (1500 + 500) cos 30 = 1732.N Horizont al force on pulley B. Fy: = (Fa: + Fpa) sin 30 = (1500 + $00) sin 30 = 1000 N Fig. 4.15.2(a) shows the veical loading diagram, Taking moment about point C F, x 100-4 Fy x 300 ~Ryy x 450 2500 x 100+ 1732 x 300 Ry» 450 Ryy = 399.11 Now, EF, = 0 Roy + Foy-Fy-Rov = 0 Roy + 1732-2500 - 599.11 = 0 Re 1367.11 N 49 Elements (CBE /T1) Vertical bending moments at points A and B are : Myy = Roy x 100= 1367.11 x 100 Myy = Rey «300-F, «200 1367.11 x 300-2500 « 200 Design of Shafts & Keys 136.71 x 10° Nem, orgy =~ 89.87 x 10" N-mm F,22600N Rpy= 800.11 : - (@) Vertical loading diagram 4367.1 136.71 x 104mm D 189.87 x 10°Nmm 1000 N > 400% 10°Nmm 14074 «107m 13445 x 10°N-evm I D (b) Vertical bending moment diagram (€) Horizontal loading diagram (@) Horizontal bending moment diagram (©) Resultant bending moment diageam Fig. 415.2 Design of Machine Elements (CBE/ 1) 4.20 Design of Shafts & Keys Fig. 4.15.2(6) shows the horizontal loading diagram, ‘Taking moment about point C, Fg % 300+ Rye 450 ° = 1000 « 300+ Ry, 450 = 0 Roxy = 666.67 N Now EFy = 05 Rew * Roa Fan = Roy + 666.67 - 1000 = 0 + Roy = 333.33N Horizontal bending moments at points A and B are Mar = Reye 100 = 333,33 « 100= 33,33 10° Nem Myyy = Roy x 150 = 666.67 x 150= 100 x 10° Nem Resultant bending moments at points A and B are My = [Mg +My,

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