Lecture (1) Shaft Design Dr.

Mohammed Altemimi

(( Shafts Design ))

Instructional Objectives:
At the end of this lesson, the students should be able to understand:
1. Definition of shaft.
2. Standard shaft materials.
3. Design considerations for shaft.
4. Design of shaft based on strength.

1. Introduction
A shaft is a rotating machine element which is used to transmit power from one
place to another. The power is delivered to the shaft by some tangential force and the
resultant torque (or twisting moment) set up within the shaft permits the power to be
transferred to various machines linked up to the shaft. 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.

2. Material for Shafts

The material used for shafts should have the following properties:

1. It should have high strength.

2. It should have good machinability.
3. It should have low notch sensitivity factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties.

1
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

Some of the common materials used for shaft are: Hot-rolled plain carbon steel, Cold-
drawn plain carbon/alloy composition, and Alloy steels.

3. Design of Shafts
In designing shafts based on the strength of material, the following cases may be
considered:

3.1. Shafts subjected to a normal force or load.

When the shaft is subjected to a tensile load acting perpendicularly on the cross
section area, then the maximum stress (tensile or compressive) is given as following:

𝑭
𝝈𝒂 =
𝑨
Where 𝜎𝑎 : Axial tensile stress in 𝑀𝑃𝑎 unit.
𝐹 : Tensile load or force in 𝑁 unit.
𝐴 : The shaft cross section area in 𝑚𝑚2 unit.

Example 1. Determine the axial stress of the cantilever shafts show in the figures below:

2
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

Answer 1.
A)
𝐹 30 × 103
𝜎𝑎 = = = 75 𝑁⁄ = 75 𝑀𝑃𝑎
𝐴 (20)2 𝑚𝑚2

B)
𝐹 𝐹 30 × 103
𝜎𝑎 = = 𝜋 = 𝜋 = 95.493 𝑁⁄ = 95.493 𝑀𝑃𝑎
𝐴 𝑑 2 (20) 2 𝑚𝑚2
4 4

C)
𝐹 𝐹 30 × 103
𝜎𝑎 = = 𝜋 =𝜋 = 218.267 𝑀𝑃𝑎
𝐴 (𝑑𝑜2 − 𝑑𝑖2 ) ((20)2 − (15)2 )
4 4

3.2. Shafts subjected to bending moment.

When the shaft is subjected to a bending moment only, then the maximum stress
(tensile or compressive) is given by the bending equation, as follow:

𝑴𝒚
𝝈𝒃 =
𝑰
Where 𝜎𝑏 : Bending stress in 𝑀𝑝𝑎 unit.
𝑀 : Bending moment in 𝑁. 𝑚 unit.
𝑦 : Distance from neutral axis to the outer-most fiber in 𝑚𝑚 unit.
𝐼 : Moment of inertia of cross-sectional area in 𝑚𝑚4 unit.

It may be noted that:

A. For the rectangular sold shaft, the moment of inertia is:

𝑏. ℎ3
𝐼=
12
Where 𝑏 : The base of the rectangular cross-sectional area in 𝑚𝑚 unit.
ℎ : The high of the rectangular cross-sectional area in 𝑚𝑚 unit.

3
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

B. For a round solid shaft, the moment of inertia is:

𝜋 𝑑
𝐼= × 𝑑4 and 𝑦 =
64 2

C. For a hollow shaft, the moment of inertia is:

𝜋 𝜋 𝑑𝑖
𝐼= × [(𝑑𝑜 )4 − (𝑑𝑖 )4 ] = × (𝑑𝑜 )3 (1 − 𝐾 4 ), Where 𝑘 =
64 64 𝑑𝑜
𝑑𝑜
and 𝑦 =
2

Example 2. Determine the bending stress at the pints a and b of the cantilever shafts
show in the figures below:

Answer 2.
B)
𝑀 = 𝐹. 𝐿 = 10 × 200 = 2000 𝐾𝑁. 𝑚𝑚

4
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

𝑀𝑦 𝑀 𝑑⁄2 32 𝑀 32 × 2000 × 103

𝜎𝑏 = = 𝜋 = = = 2546 𝑀𝑃𝑎
𝐼 × 𝑑4 𝜋 × 𝑑3 𝜋 × (20)3
64

C)
𝑑
𝑀𝑦 𝑀 𝑜⁄2 32 𝑀 𝑑𝑜 32 × (2000 × 103 ) × 20
𝜎𝑏 = = 𝜋 = =
𝐼 × (𝑑𝑜4 − 𝑑𝑖4 ) 𝜋 × (𝑑𝑜4 − 𝑑𝑖4 ) 𝜋 × (204 − 154 )
64
= 3725 𝑀𝑃𝑎

3.3. Shafts subjected to twisting moment or torque only.

When the shaft is subjected to a twisting moment (or torque) only, then the diameter
of the shaft may be obtained by using the torsion equation.

𝑻𝒓
𝝉=
𝑱

Where 𝜏 : Torsional shear stress in 𝑀𝑃𝑎 unit.

𝑇 : Twisting moment (or torque) acting upon the shaft in 𝑁. 𝑚 unit.
𝑟 : Distance from neutral axis to the outer most fiber = d / 2 in 𝑚𝑚 unit.
𝐽 : Polar moment of inertia of the shaft about the axis of rotation in
𝑚𝑚4 unit.

It may be noted that:

A. For the rectangular sold shaft, the polar moment of inertia is:

𝑏. ℎ 2
𝐽= (𝑏 + ℎ2 )
12
Where 𝑏 : The base of the rectangular cross-sectional area.
ℎ : The high of the rectangular cross-sectional area.

5
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

B. For round solid shaft, the polar moment of inertia is:

𝜋
𝐽= × 𝑑4
32

C. For hollow shaft, the polar moment of inertia is:

𝜋 𝜋 𝑑𝑖
𝐽= × [(𝑑𝑜 )4 − (𝑑𝑖 )4 ] = × (𝑑𝑜 )3 (1 − 𝐾 4 ), Where 𝑘 =
32 32 𝑑𝑜

D. The twisting moment (𝑇) may be obtained by using the following relation :
1. In case of power transmission, the power transmitted (𝑃), in watts unit, by the shaft
defines as the following:
2𝜋𝑁 × 𝑇 60 𝑃
𝑃 =𝜔×𝑇 = 𝑜𝑟 𝑇 =
60 2𝜋𝑁
Where 𝜔 : The angular velocity in 𝑟𝑎𝑑/𝑠𝑒𝑐 unit.
𝑇 : Twisting moment in 𝑁. 𝑚 unit.
𝑁 : Speed of the shaft in 𝑟. 𝑝. 𝑚 unit.

E. In case of belt drives, the twisting moment ( 𝑇 ) is given by

𝑇 = (𝑇1 − 𝑇2 ) × 𝑅 , 𝑇1 > 𝑇2

Where 𝑇1 : Tensions in the tight side of the belt in 𝑁 unit.

𝑇2 : Tensions in the slack side of the belt in 𝑁 unit.
𝑅 : Radius of the pulley in 𝑚𝑚 unit.

Example 3. Determine the torsional stress of the cantilever shafts show in the figures
below:

6
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

Answer 3.
B)
𝑇 = 𝐹. 𝐿 = 5 𝐾𝑁. 𝑚 = 5 × 106 𝑁. 𝑚𝑚
𝑇𝑟 𝑇 𝑑⁄2 16 𝑇 16 × 5 × 106
𝜏= = 𝜋 = = = 424400 𝑀𝑃𝑎
𝐽 × 𝑑4 𝜋 × 𝑑3 𝜋 × (20)3
32

C)
𝑑
𝑇𝑟 𝑇 𝑜⁄2 16 𝑇 𝑑𝑜 16 × (5 × 103 ) × 20
𝜏= = 𝜋 = =
𝐽 × (𝑑𝑜4 − 𝑑𝑖4 ) 𝜋 × (𝑑𝑜4 − 𝑑𝑖4 ) 𝜋 × (204 − 154 )
32
= 4656.4 𝑀𝑃𝑎

3.4. Shafts subjected to combined twisting and bending moments.

When the shaft is subjected to combine twisting moment and bending moment, then
the shaft must be designed based on the two moments simultaneously. Various theories
have been suggested to account for the elastic failure (Theories of failure under static

7
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

load) of the materials when they are subjected to various types of combined stresses. The
following two theories are important from the subject point of view:

1. Maximum shear stress theory or Guest's theory. It is used for ductile materials
such as mild steel.
2. Maximum normal stress theory or Rankine’s theory. It is used for brittle materials
such as cast iron.

3.4.1. According to maximum shear stress theory

The maximum shear stress in the shaft,

𝟏 𝝉𝒚 𝝉𝒖
𝝉𝒎𝒂𝒙. = √𝝈𝒃 𝟐 + 𝟒𝝉𝟐 = 𝒐𝒓 =
𝟐 𝒇. 𝒔 𝒇. 𝒔

Where 𝜏𝑚𝑎𝑥 : Maximum shear stress in 𝑀𝑃𝑎 unit.

𝜏𝑦 : Yield shear stress in 𝑀𝑃𝑎 unit.
𝜏𝑢 : Ultimate shear stress in 𝑀𝑃𝑎 unit.
𝑓. 𝑠 : A factor of safety.

For the sold circular shaft, substituting the values of 𝜎𝑏 and 𝜏, get:

1 32𝑀 2 16𝑇 2 16
𝜏𝑚𝑎𝑥. = √( 3 ) + 4 ( 3 ) = 3
√𝑀 2 + 𝑇 2
2 𝜋𝑑 𝜋𝑑 𝜋𝑑
𝜋
𝑂𝑟 × 𝜏𝑚𝑎𝑥. × 𝑑3 = √𝑀2 + 𝑇 2
16

The expression √𝑀 2 + 𝑇 2 is known as equivalent twisting moment and is denoted

by (𝑇𝑒 ). The equivalent twisting moment may be defined as that twisting moment,
which when acting alone, produces the same shear stress (𝜏) as the actual twisting
moment. However, the equation above may be written as

8
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

𝜋
𝑇𝑒 = √𝑀2 + 𝑇 2 = × 𝜏 × 𝑑3
16
3.4.2. According to maximum normal stress theory
The maximum normal stress in the shaft,
𝟏 𝟏 𝝈𝒚 𝝈𝒖
𝝈𝒃(𝒎𝒂𝒙.) = 𝝈𝒃 + √𝝈𝒃 𝟐 + 𝟒𝝉𝟐 = 𝒐𝒓 =
𝟐 𝟐 𝒇. 𝒔 𝒇. 𝒔
For the sold circular shaft, substituting the values of 𝜎𝑏 and 𝜏, get:

1 1 32𝑀 2 16𝑇 2 16 1
𝜎𝑏(𝑚𝑎𝑥.) = 𝜎𝑏 + √( 3 ) + 4 ( 3 ) = 3
[ (𝑀 + √𝑀2 + 𝑇 2 )]
2 2 𝜋𝑑 𝜋𝑑 𝜋𝑑 2

𝜋 1
𝑂𝑟 × 𝜎𝑏(𝑚𝑎𝑥.) × 𝑑3 = (𝑀 + √𝑀2 + 𝑇 2 )
32 2

1
The expression [𝑀 + √𝑀2 + 𝑇 2 ] is known as equivalent bending moment and is
2

denoted by(𝑀𝑒 ). The equivalent bending moment may be defined as that moment which
when acting alone produces the same tensile or compressive stress (𝜎𝑏 ) as the actual
bending moment. By limiting the maximum normal stress [𝜎𝑏(𝑚𝑎𝑥.) ] equal to the
allowable bending stress (𝜎𝑏 ), then the equation above may be written as

1 𝜋
𝑀𝑒 = (𝑀 + √𝑀2 + 𝑇 2 ) = × 𝜎𝑏 × 𝑑3
2 32

Notes:
1. In case of a hollow shaft, the equations (ii) and (v) may be written as

𝜋
𝑇𝑒 = √𝑀2 + 𝑇 2 = × 𝜏 × (𝑑𝑜 )3 (1 − 𝐾 4 )
16

9
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

1 𝜋
𝑀𝑒 = (𝑀 + √𝑀2 + 𝑇 2 ) = × 𝜎𝑏 × (𝑑𝑜 )3 (1 − 𝐾 4 )
2 32

2. It is suggested that diameter of the shaft may be obtained by using both the
theories and the larger of the two values is adopted.

Example 4. Determine the maximum shear stress and maximum normal stress of the
cantilever shafts show in the figures below:

Answer 4.
B)

𝑀𝑦 𝑀 𝑑⁄2 32 𝑀 32 × 2000 × 103

𝜎𝑏 = = 𝜋 = 3
= 3
= 2546 𝑀𝑃𝑎
𝐼 ×𝑑 4 𝜋 × 𝑑 𝜋 × (20)
64

𝑇𝑟 𝑇 𝑑⁄2 16 𝑇 16 × 5 × 106
𝜏= = 𝜋 = = = 424400 𝑀𝑃𝑎
𝐽 × 𝑑4 𝜋 × 𝑑3 𝜋 × (20)3
32

10
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

 Maximum shear stress

1 1
𝜏𝑚𝑎𝑥. = √𝜎𝑏 2 + 4𝜏 2 = √(2546)2 + 4(424400)2 = 424.42 × 103 𝑀𝑃𝑎
2 2

 Maximum normal stress

1 1 1 1
𝜎𝑏(𝑚𝑎𝑥.) = 𝜎𝑏 + √𝜎𝑏 2 + 4𝜏 2 = (2546) + √(2546)2 + 4(424400)2
2 2 2 2
= 425.69 × 103 𝑀𝑃𝑎
C)
𝑑
𝑀𝑦 𝑀 𝑜⁄2 32 𝑀 𝑑𝑜 32 × (2000 × 103 ) × 20
𝜎𝑏 = = 𝜋 = =
𝐼 × (𝑑𝑜4 − 𝑑𝑖4 ) 𝜋 × (𝑑𝑜4 − 𝑑𝑖4 ) 𝜋 × (204 − 154 )
64
= 3725 𝑀𝑃𝑎
𝑑
𝑇𝑟 𝑇 𝑜⁄2 16 𝑇 𝑑𝑜 16 × (5 × 103 ) × 20
𝜏= = 𝜋 = =
𝐽 × (𝑑𝑜4 − 𝑑𝑖4 ) 𝜋 × (𝑑𝑜4 − 𝑑𝑖4 ) 𝜋 × (204 − 154 )
32
= 4656.4 𝑀𝑃𝑎

 Maximum shear stress

1 1
𝜏𝑚𝑎𝑥. = √𝜎𝑏 2 + 4𝜏 2 = √(3725)2 + 4(4656.4)2 = 5015 × 103 𝑀𝑃𝑎
2 2

 Maximum normal stress

1 1 1 1
𝜎𝑏(𝑚𝑎𝑥.) = 𝜎𝑏 + √𝜎𝑏 2 + 4𝜏 2 = (3725) + √(3725)2 + 4(4656.4)2
2 2 2 2
= 6877.7 𝑀𝑃𝑎

11
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

3.5. Shafts subjected to axial loads in addition to combined torsional and

bending loads.
According to maximum shear stress theory, the maximum shear stress in the shaft,
𝝈𝒙 = 𝝈 𝒃 ± 𝝈𝒂
𝟏 𝝉𝒚
𝝉𝒎𝒂𝒙. = √𝝈𝒙 𝟐 + 𝟒𝝉𝟐 =
𝟐 𝒇. 𝒔
According to maximum normal stress theory, the maximum normal stress in the shaft,
𝝈𝒙 = 𝝈 𝒃 ± 𝝈𝒂
𝟏 𝟏 𝝈𝒚
𝝈𝒃(𝒎𝒂𝒙.) = 𝝈𝒙 + √𝝈𝒙 𝟐 + 𝟒𝝉𝟐 =
𝟐 𝟐 𝒇. 𝒔

𝜎𝑦
Hint: From the Mohr's circle conclude: 𝜏𝑦 =
2
Example 5. Determine the maximum shear stress and maximum normal stress of the
cantilever shafts show in the figures below:

12
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

Answer 5.

B)
𝐹 𝐹 30 × 103
𝜎𝑎 = = 𝜋 = 𝜋 = 95.493 𝑁⁄ = 95.493 𝑀𝑃𝑎
𝐴 𝑑 2 (20) 2 𝑚𝑚2
4 4

𝑀𝑦 𝑀 𝑑⁄2 32 𝑀 32 × 2000 × 103

𝜎𝑏 = = 𝜋 = = = 2546 𝑀𝑃𝑎
𝐼 × 𝑑4 𝜋 × 𝑑3 𝜋 × (20)3
64

𝑇𝑟 𝑇 𝑑⁄2 16 𝑇 16 × 5 × 106
𝜏= = 𝜋 = = = 424400 𝑀𝑃𝑎
𝐽 × 𝑑4 𝜋 × 𝑑3 𝜋 × (20)3
32

1. At point (a):

𝜎𝑥 = 𝜎𝑏 − 𝜎𝑎 = 2546 − 95.493 = 2450.5 𝑀𝑃𝑎

 Maximum shear stress

1 1
𝜏𝑚𝑎𝑥. = √𝜎𝑥 2 + 4𝜏 2 = √(2450.5)2 + 4(424400)2 = 424.4 × 103 𝑀𝑃𝑎
2 2

 Maximum normal stress

1 1 1 1
𝜎𝑏(𝑚𝑎𝑥.) = 𝜎𝑥 + √𝜎𝑥 2 + 4𝜏 2 = (2450.5) + √(2450.5)2 + 4(424400)2
2 2 2 2
= 425.64 × 103 𝑀𝑃𝑎

13
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

2. At point (b):

𝜎𝑥 = 𝜎𝑏 + 𝜎𝑎 = 2546 + 95.493 = 2641.5 𝑀𝑃𝑎

 Maximum shear stress

1 1
𝜏𝑚𝑎𝑥. = √𝜎𝑥 2 + 4𝜏 2 = √(2641.5 )2 + 4(424400)2 = 424.42 × 103 𝑀𝑃𝑎
2 2

 Maximum normal stress

1 1 1 1
𝜎𝑏(𝑚𝑎𝑥.) = 𝜎𝑥 + √𝜎𝑥 2 + 4𝜏 2 = (2641.5 ) + √(2641.5 )2 + 4(424400)2
2 2 2 2
= 425.74 × 103 𝑀𝑃𝑎

C)
(Homework)

4. Shafts Subjected to Fluctuating Loads

In the previous points are assumed that the shaft is subjected to constant torque and
bending moment. But in actual practice, the shafts are subjected to fluctuating torque
and bending moments. In order to design such shafts like line shafts and counter shafts,
the combined shock and fatigue factors must be taken into account for the computed
twisting moment (𝑇) and bending moment (𝑀). Thus, for a shaft subjected to combined
bending and torsion, the equivalent twisting moment and the equivalent bending
moment will be as follow:

𝑇𝑒 = √(𝐾𝑚 × 𝑀)2 + (𝐾𝑡 × 𝑇)2

14
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

1
𝑀𝑒 = ((𝐾𝑚 × 𝑀) + √(𝐾𝑚 × 𝑀)2 + (𝐾𝑡 × 𝑇)2 )
2

Where 𝐾𝑚 : Combined shock and fatigue factor for bending.

𝐾𝑡 : Combined shock and fatigue factor for torsion.

Recommended values for Km and Kt.

Example 6. A mild steel shaft transmits 20 kW at 200 r.p.m. It carries a central load of
900 N and is simply supported between the bearings 2.5 metres apart. Determine the size
of the shaft, if the allowable shear stress is 42 MPa and the maximum tensile or
compressive stress is not to exceed 56 MPa. What size of the shaft will be required, if it
is subjected to gradually applied loads?

Answer 6.

15
Lecture (1) Shaft Design Dr. Mohammed Altemimi

16
Lecture (1) Shaft Design Dr. Mohammed Altemimi

17
 Lecture (1) Shaft Design Dr. Mohammed Altemimi

Example 7. Find the diameter of a solid steel shaft to transmit 20 kW at 200 r.p.m. The
ultimate shear stress for the steel may be taken as 360 MPa and a factor of safety as (8).
If a hollow shaft is to be used in place of the solid shaft, find the inside and outside
diameter when the ratio of inside to outside diameters is 0.5.

18