Design Computations

Summary of the given conditions for the Design options

Power The The
The material used delivered rotational The material used material
Design
for the shaft and by the speed of for the sprocket used for the
Options
key motor the motor gears belt and
(HP) (rpm) pulleys
Stainless steel 430 Cast Iron
1
(annealed bar) ASTM 30
Commercial bronze for the
5 400 AISI C1020
2 ASTM B134-2 pulley and
(Spring H(g)) Polyurethane
3 Nickel Silver B for the belt

Since the power and the rotational speed of the shaft is constant all throughout the design
options we can compute the torque, load, and bending moment for all the design options:
Given:
n = 400rpm
HP = 5 HP
Required: Torque (T), Weight on one shaft (W), Bending Moment (M)
Solution:
Solving for the torque T using the formula:
P
T=
2x π x n
lb∙ ft
33,000
min 12∈.
5 HP x x
1 HP 1 ft .
T=
2 x π x 400 rev /min

T =787.8169683 lb ∙∈.

Solving now for the weight of the load that the shaft will support:
 W =mg
Using SolidWorks, the mass of the load is obtained through mass properties feature:
m=12 .913 kg

W =(12 .913 kg) 9.81

( m
s )
2 W =67.81653 N

Converting N to lbm ft/s2

(
W = 67.81653
kg ∙ m
s2 () 2.2lb
1 kg )( 3.281 ft
1m ) W =489.5132768 lb∙
ft
s
2

Since the whole load is supported by two shafts, therefore, the load on one shaft is half of the
whole load.
W
W on one shaft=
2
ft
489.5132768 lb∙ lb∙ ft
s 2 W on one shaft =244.7566384 2
W on one shaft= s
2

Then solving for the moment M using the formula:

F xl
M=
4

( 244.7566384 lbms ft ) x ( 32.2lbm

2
1 lbf
ft
) x (34.6457∈.)

s2
M=
4

M =65.83668531 lb∈.

Design option 1
Given:
P = 5 HP
n = 400 rpm
l = 34.6457 in.
T = 787.8169683 lb ∙ in.
M = 65.83668531 lb in
Material specification: Stainless steel AISI no. 430 (annealed bar) for the shaft
Required: Diameter of the Shaft (Dshaft)
Solution:
Solving for the maximum shear stress:
0.6 x Sy x SRF
Ssmax=
N
From table AT 4: Typical Properties of some Stainless Steel, the S y for AISI no. 430 (annealed
bar) is 45 ksi. From table 1.1 Factor of Safety (Design Factors), considering that the load is a
dead load, N = 1.5. The SRF is the strength reduction factor where in it is used to reduce the
actual strength of a member in design. The typical factor used in a shear member is 0.75
Substituting the obtained values:

Ssmax =
(
0.6 x 45 ksi x
1000 psi
1 ksi )
x 0.75

1.5
lb
Ssmax =13500 2
¿
Solving for the diameter using the formula:

D=
√
3 16
π S smax
√ (K s T )2 +( K m M )2

From table 9.1, the values of Km and Ks for rotating shafts where the load is suddenly applied
with heavy shock is Km = 2.0 and Ks = 1.5

Substituting the obtained values:

√
16
D= 3
lb
√(( 1.5)(787.8169683 lb ∙∈.))2 +((2.0)(65.8366853 lb∙∈.))2
π (13500 2 )
¿

D = 0.7654980785 in.

From 9.5 Shaft Sizes and Materials, the standard size is 13/16 in. Thus,
D = 13/16 in.

Solving for the Design of the key

Given:

Dshaft = 13/16 in.

N = 1.5

Material Specification: Stainless steel AISI no. 430 (annealed bar) for the shaft and key

AISI C1020 for the sprocket gears

Required: Length of the key

Solution:

In order to make the calculations of the key, the weakest among the members must be obtain by
comparing their yield strength. From table AT 4: Typical Properties of some Stainless Steel, the
yield strength, Sy, for AISI no. 430 (annealed bar) is 45 ksi. On the other hand, from table AT 7,
the yield strength, Sy, for AISI C1020 (annealed) is 42 ksi. Since the gear has the lowest yield
strength, therefore it will be used in the computation of design stress.

Solving for the design stress for shearing of the key,

1
σ
τy 2 y
τ d= =
N N

1
( )(42 ksi)
2
τ d=
1.5

τ d=14 ksi

Solving for the design stress for compression of the key,

σy
σ d=
N
 42ksi
σ d=
1.5

σ d=28 ksi

From the computation of torque:

T =787.8169683 lb ∙∈.T =0.7878169683∈∙ kips

Solving for the tangential force at the shaft:

2T
F=
D

2(0.7878169683∈. kips)
F=
13
∈.
16

F=1.939241768 kips

Solving for Design of Key Based on Shearing:

Since

F
τ=
bL

Manipulating the equation:

F
L=
τb

From table AT19, for the standard size of 13/16 inch: b = 3/16 in.

1.939241768 kips
L=
3
14 ksi x ∈.
16

L=0.170482793∈.

Solving for Design of Key Based on Compression:

Since

F
σ d=
()
1
2
tL

Manipulating the equation:

F
L=
( 12 ) t σ d

From table AT19, for the standard size of 13/16 inch: t = 1/8 in.

1.939241768 kips
L=
1 1
( )( ∈.)(28 ksi .)
2 8

L=1.108138153∈.

The length required is centered on the computation of the design based on compression and
shearing stress. The longer length will be used, therefore, the length of the design based on
compression will be used. L ≈ 1.1 in. with 3/16 in. x 1/8 in. cross section.

Design option 2:
Given:
P = 5 HP
n = 400 rpm
l = 34.6457 in.
T = 787.8169683 lb ∙ in.
M = 65.83668531 lb in
Material specification: Commercial bronze ASTM B134-2 (Spring H(g)) for shaft
Required: Diameter of the Shaft (Dshaft)
Solution:
Solving for the maximum shear stress:
0.6 x Sy x SRF
Ssmax=
N
From the module 1_Tables and Figures, the yield strength, S y, for Commercial bronze ASTM
B134-2 (Spring H(g)) is 62 ksi. From table 1.1 Factor of Safety (Design Factors), considering
that the load is a dead load, N = 1.5. The SRF is the strength reduction factor where in it is used
to reduce the actual strength of a member in design. The typical factor used in a shear member is
0.75
Substituting the obtained values:

Ssmax =
(
0.6 x 62 ksi x
1000 psi
1 ksi)x 0.75

1.5
lb
Ssmax =18600
¿2
Solving for the diameter using the formula:

D=
√
3 16
π S smax
√ ( K s T )2 +( K m M )2

From table 9.1, the values of Km and Ks for rotating shafts where the load is suddenly applied
with heavy shock is Km = 2.0 and Ks = 1.5

Substituting the obtained values:

√
16
D= 3
lb
√(( 1.5)(787.8169683 lb∙∈.))2 +((2.0)(65.8366853 lb∙∈.))2
π (13500 2
)
¿

D = 0.687940767 in.

From 9.5 Shaft Sizes and Materials, the standard size is 3/4 in. Thus,

D = 3/4 in.
Solving for the Length of the key

Given:

Dshaft = 3/4 in.

N = 1.5

Material Specification: Commercial bronze ASTM B134-2 (Spring H(g)) for the shaft and key,

AISI C1020 (annealed) for the sprocket gears

Required: Length of the key

Solution:

In order to make the calculations of the key, the weakest among the members must be obtain by
comparing their yield strength. From the module 1_Tables and Figures, the yield strength, S y, for
Commercial bronze ASTM B134-2 (Spring H(g)) is 62 ksi. On the other hand, from table AT 7,
the yield strength, Sy, for AISI C1020 (annealed) is 42 ksi. Since the gear has the lowest yield
strength, therefore it will be used in the computation of design stress.

Solving for the design stress for shearing of the key,

1
σ
τy 2 y
τ d= =
N N

1
( )(42 ksi)
2
τ d=
1.5

τ d=14 ksi

Solving for the design stress for compression of the key,

σy
σ d=
N

42ksi
σ d=
1.5

σ d=28 ksi
From the computation of torque:

T =787.8169683 lb ∙∈.T =0.7878169683∈∙ kips

Solving for the tangential force at the shaft:

2T
F=
D

2(0.7878169683∈. kips)
F=
3
∈.
4

F=2.100845249 kips

Solving for Design of Key Based on Shearing:

Since

F
τ=
bL

Manipulating the equation:

F
L=
τb

From table AT19, for the standard size of 3/4 inch: b = 3/16 in.

2.100845249 kips
L=
3
14 ksi x ∈.
16

L=0.800322∈.

Solving for Design of Key Based on Compression:

Since
 F
σ d=
()
1
2
tL

Manipulating the equation:

F
L=
( 12 ) t σ d

From table AT19, for the standard size of ¾ inch: t = 1/8 in.

2.100845249 kips
L=
1 1
( )( ∈.)(28 ksi .)
2 8

L=1.200482999∈.

The length required is centered on the computation of the design based on compression and
shearing stress. The longer length will be used, therefore, the length of the design based on
compression will be used. L ≈ 1.2 in. with 3/16 in. x 1/8 in. cross section.
Design option 3:
Given:
P = 5 HP
n = 400 rpm
l = 34.6457 in.
T = 787.8169683 lb ∙ in.
M = 65.83668531 lb ∙ in
Material specification: Nickel Silver B
Required: Diameter of the Shaft (Dshaft)
Solution:
Solving for the maximum shear stress:
0.6 x Sy x SRF
Ssmax=
N
From the module 1_Tables and Figures, the yield strength, Sy, for Nickel Silver B is 85 ksi.
From table 1.1 Factor of Safety (Design Factors), considering that the load is a dead load, N =
1.5. The SRF is the strength reduction factor where in it is used to reduce the actual strength of a
member in design. The typical factor used in a shear member is 0.75.
Substituting the obtained values:

Ssmax =
(
0.6 x 85 ksi x
1000 psi
1 ksi )
x 0.75

1.5
lb
Ssmax =25500 2
¿
Solving for the diameter using the formula:

D=
√
3 16
π S smax
√(K s T )2 +( K m M )2

From table 9.1, the values of Km and Ks for rotating shafts where the load is suddenly applied
with heavy shock is Km = 2.0 and Ks = 1.5

Substituting the obtained values:

 √
16
D= 3
lb
√((1.5)(787.8169683 lb∙∈.))2 +((2.0)(65.8366853 lb∙∈.))2
π (25500 )
¿2

D = 0.61926324 in.

From 9.5 Shaft Sizes and Materials, the standard size is 5/8 in. Thus,

D = 5/8 in.

Solving for the Length of the key

Given:

Dshaft = 5/8 in.

N = 1.5

Material Specification: Silver Nickel B for the shaft and key, AISI C1020 (annealed) for the
sprocket gears

Required: Length of the key

Solution:

In order to make the calculations of the key, the weakest among the members must be obtain by
comparing their yield strength. From the module 1_Tables and Figures, the yield strength, S y, for
Nickel Silver B is 85 ksi. On the other hand, from table AT 7, the yield strength, Sy, for AISI
C1020 (annealed) is 42 ksi. Since the gear has the lowest yield strength, therefore it will be used
in the computation of design stress.

Solving for the design stress for shearing of the key,

1
σ
τy 2 y
τ d= =
N N

1
( )(42 ksi)
2
τ d=
1.5
 τ d=14 ksi

Solving for the design stress for compression of the key,

σy
σ d=
N

42ksi
σ d=
1.5

σ d=28 ksi

From the computation of torque:

T =787.8169683 lb ∙∈.T =0.7878169683∈∙ kips

Solving for the tangential force at the shaft:

2T
F=
D

2(0.7878169683∈. kips)
F=
5
∈.
8

F=2.521014299 kips

Solving for Design of Key Based on Shearing:

Since

F
τ=
bL

Manipulating the equation:

F
L=
τb

From table AT19, for the standard size of 5/8 inch: b = 3/16 in.
 2.521014299 kips
L=
3
14 ksi x ∈.
16

L=0.960386399∈.

Solving for Design of Key Based on Compression:

Since

F
σ d=
()
1
2
tL

Manipulating the equation:

F
L=
( 12 ) t σ d

From table AT19, for the standard size of 5/8 inch: t = 1/8 in.

2.521014299 kips
L=
1 1
( )( ∈.)(28 ksi .)
2 8

L=1.440579599∈.

The length required is centered on the computation of the design based on compression and
shearing stress. The longer length will be used, therefore, the length of the design based on
compression will be used. L ≈ 1.4 in. with 3/16 in. x 1/8 in. cross section.
Design Calculation for Belt and Pulley

Motor specification based on Alibaba.com

Power 5.5 HP
Rotations per Minute 1500 rpm

Given:

Nmotor = 1500 rpm

Nshaft = 400 rpm

Assuming the Diameter of pulley of the motor = 3.5 in

Material Specification: Cast Iron ASTM 30 for the pulley and Polyurethane for the belt

Required: Diameter of the pulley of the shaft ( D shaft ¿ , Length of the Belt (Lbelt)

Solution:

Solving for the diameter of the pulley of the shaft

N motor Dshaft 1500rpm Dshaft

= =
N shaft Dmotor 400 rpm 3.5∈.

Dshaft =13.125∈¿
Solving for the length of the Belt
 2
π ∙( Dshaft + Dmotor ) (D shaft−D motor )
Lbelt =2C + +
2 4C
Using SolidWorks, the center distance between the two pulleys (C) is obtained through
measuring the distance from the center of the shaft to the center of the motor.
C = 19.87 in.
Lbelt =2(19.87∈.)+ π ∙¿ ¿
Lbelt =67.02∈.
 Summary of the Calculations for the Design options

The material used Computed Standard Cross

Design Computed Length
for the shaft and Diameter of Diameter Section of
Options of key (in.)
key the shaft (in.) Size (in.) the key

Stainless steel 430 0.765498078

1 13/16 1.440579599
(annealed bar) 5

Commercial 3/16 in. x

bronze ASTM 1/8 in.
2 3/4 1.200482999
B134-2 (Spring 0.687940767
H(g))
3 Nickel Silver B 0.61926324 5/8 1.108138153

Summary of the Calculations for the belt and pulley

Parameters Pulley of the Motor Pulley of the Shaft

Diameter 3.5 13.125

RPM 1500 400