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ME364-07 Shafts and Components
ME364-07 Shafts and Components
ME364-07 Shafts and Components
ME – 364
Design of Machine
Elements – II
Instructor
Muhammad Ilyas, PhD
➢ Shaft
➢ In general, a long narrow rotating member, usually having a circular cross-
section, used to transmit power or motion.
➢ Axle
➢ A non-rotating member that carries no torque and is used to support
rotating wheels, pulleys, and such elements
➢ Spindle
➢ Refers to a short shaft or to the end of a shaft where an element such as a
hub, rotor, chuck, etc. is mounted (e.g., in machining equipment)
2
Shaft Design
➢ Material Selection
➢ Geometric Layout
➢ Stress and strength
➢ Static strength
➢ Fatigue strength
➢ Torsional deflection
3
Shaft Materials
4
Shaft Materials
➢ Cold drawn steel typical for 𝑑 < 3 in.
➢ Hot rolled steel common for larger sizes. Should be machined all over.
➢ Low production quantities
➢ Lathe machining is typical
5
General rules of thumb
➢ Mminimize both deflections and stresses, keep the shaft length as short
as possible and overhangs minimized
➢ A cantilever beam will have a larger deflection than a simply supported
(straddle mounted) one for the same length, load, and cross section, so
straddle mounting should be preferred whenever possible
➢ A hollow shaft has a better stiffness/mass ratio (specific stiffness) and
higher natural frequencies than a comparably stiff or strong solid shaft,
but will be more expensive and larger in diameter
➢ Try to locate stress-raisers away from regions of large bending moment
and minimize their effects with generous radii and reliefs
6
General rules of thumb
➢ Deflections at gears carried on the shaft should not exceed about
0.13mm (0.005) in and the relative slope between the gear axes should
be less than about 0.03°
➢ If plain (sleeve) bearings are used, the shaft deflection across the
bearing length should be less than the oil-film thickness (see Chapter
12) in the bearing
➢ If non-self-aligning rolling element bearings are used, the shaft’s slope
at the bearings should be kept to less than about 0.04°
➢ Axial thrust loads should be taken to ground through a single thrust
bearing per load direction. Do not split axial loads between thrust
bearings, thermal expansion of the shaft can overload bearings
➢ The first natural frequency of the shaft should be at least two/three
times the highest forcing frequency expected in service, and preferably
much more. (A factor of 10 × or more is preferred, but this is often
7
difficult to achieve in mechanical systems).
Shaft Layout
➢ Issues to consider for shaft
layout
➢ Axial layout of components
https://koyo.jtekt.co.jp/en/support/bearing-knowledge/5-3000.html
8
Axial Layout of Components
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Axial Layout of Components
Norton RL, Machine Design–An Integrated Approach, Prentice Hall, 5th edition, 2010
10
Supporting Axial Loads
➢ Axial loads must be supported through a bearing to the frame.
➢ Generally best for only one bearing to carry axial load to shoulder
➢ Allows greater tolerances and prevents binding
11
Providing for Torque Transmission
➢ Splines
➢ Setscrews
➢ Pins
➢ Tapered fits
12
Assembly and Disassembly
13
Assembly and Disassembly
14
Reading Assignment
➢ Shaft Materials
➢ Shaft layout
15
Shaft Design for Stress
16
Shaft Design for Stress
➢ Standard stress equations can be customized for shafts for convenience
➢ Axial loads are generally small and constant, so will be ignored in this
section
➢ Standard alternating and midrange stresses
17
Shaft Stresses
2 2 1/2
32𝐾𝑓 𝑀𝑎 16𝐾𝑓𝑠 𝑇𝑎
𝜎𝑎′ = 𝜎𝑎2 + 3𝜏𝑎2 1/2 = +3 (7–5)
𝜋𝑑 3 𝜋𝑑 3
2 2 1/2
32𝐾𝑓 𝑀𝑚 16𝐾𝑓𝑠 𝑇𝑚
′
𝜎𝑚 = 2
𝜎𝑚 + 2 1/2
3𝜏𝑚 = +3 (7–6)
𝜋𝑑 3 𝜋𝑑 3
18
Shaft Design
➢ Substitute von Mises stresses (Eq. 7–5 and 7–6) into failure criteria
equation. For example, using modified Goodman line,
1 𝜎𝑎′ 𝜎𝑚
′
= +
𝑛 𝑆𝑒 𝑆𝑢𝑡
1 16 1 2 2 1/2 1 2 2 1/2
= 4 𝐾𝑓 𝑀𝑎 + 3 𝐾𝑓𝑠 𝑇𝑎 + 4 𝐾𝑓 𝑀𝑚 + 3 𝐾𝑓𝑠 𝑇𝑚
𝑛 𝜋𝑑 3 𝑆𝑒 𝑆𝑢𝑡
(7–7)
19
Shaft Design
➢ Similar approach can be taken with any of the fatigue failure criteria
➢ Equations are referred to by referencing both the Distortion Energy
method of combining stresses and the fatigue failure locus name e.g.
DE-Goodman, DE-Gerber, etc.
➢ In analysis situation, either use these customized equations for factor of
safety, or use standard approach from Chapter 6.
➢ In design situation, customized equations for shaft diameter, 𝑑, are
much more convenient.
20
Shaft Design
➢ DE-Gerber
2 1/2
1 8𝐴 2𝐵𝑆𝑒
= 1+ 1+ (7–9)
𝑛 𝜋𝑑 3 𝑆𝑒 𝐴𝑆𝑢𝑡
1/3
2 1/2
8𝑛𝐴 2𝐵𝑆𝑒
𝑑= 1+ 1+ (7–10)
𝜋𝑆𝑒 𝐴𝑆𝑢𝑡
where
2 2
𝐴= 4 𝐾𝑓 𝑀𝑎 + 3 𝐾𝑓𝑠 𝑇𝑎
2 2
𝐵= 4 𝐾𝑓 𝑀𝑚 + 3 𝐾𝑓𝑠 𝑇𝑚
21
Shaft Design
➢ DE-ASME Elliptic
➢ DE-Soderberg
22
Stresses for Rotating Shaft
23
Checking for Yielding in Shafts
24
Check for Yielding in Shafts
′
𝜎𝑚𝑎𝑥 ≈ 𝜎𝑎′ + 𝜎𝑚
′
25
Example 7–1
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Example 7–1 (continues)
27
Example 7–1 (continues)
6-5
28
Example 7–1 (continues)
29
Example 7–1 (continues)
30
Example 7–1 (continues)
31
Estimating Stress Concentrations
32
Estimating Stress Concentrations
33
Reducing Stress Concentration at Shoulder Fillet
➢ Bearings often require relatively sharp fillet radius at shoulder
➢ If such a shoulder is the location of the critical stress, some
manufacturing techniques are available to reduce the stress
concentration
a) Large radius undercut into shoulder
34
Safety standards for rotating components
35
Example 7–2
36
Example 7–2 (continued)
68
37
Example 7–2 (continued)
= 876.6 N
= 2403 N
= 3938 N
= 10818 N
(lbf-in)
38
Example 7–2 (continued)
(lbf)
𝑡 𝑅𝐵𝑧
𝑅𝐴𝑧 𝑊23
50mm
55mm
𝑡
𝑊54
𝑟 𝑟
𝑊23 𝑊54
145mm
39
Example 7–2 (continued)
40
Example 7–2 (continued)
41
Example 7–2 (continued)
42
Example 7–2 (continued)
43
Example 7–2 (continued)
A-15-8
A-15-9
44
Example 7–2 (continued)
45
Example 7–2 (continued)
46
Example 7–2 (continued)
47
Example 7–2 (continued)
48
Setscrews
➢ Resistance to axial motion of
collar or hub relative to shaft
is called holding power
62
Keys and Pins
➢ Used to secure rotating
elements and to transmit
torque
63
Keys
➢ Factor of safety should not be excessive, so the inexpensive key is the weak link
➢ Key length should not exceed 1.5 times shaft diameter to avoid problems from
twisting
➢ Multiple keys may be used to carry greater torque, typically oriented 90º from
one another
➢ Stock key material is typically low carbon cold-rolled steel, with dimensions
slightly under the nominal dimensions to easily fit end-milled keyway
➢ A setscrew is sometimes used with a key for axial positioning, and to minimize
rotational backlash
64
Stress Concentration Factors for Keys
➢ For keyseats cut by standard end-mill cutters, with a ratio of r/d = 0.02,
Peterson’s charts give
➢ 𝐾𝑡 = 2.14 for bending
➢ Keeping the end of the keyseat at least a distance of 𝑑/10 from the
shoulder fillet will prevent the two stress concentrations from
combining.
65
Tolerances and Fits
66