UNIT - II

Design of Shafts and Couplings

Design of Shafts
1
 Shafts
1. Rotating machine element

2. Tangential force and the resultant torque (or twisting moment)

3. Pulleys, gears etc.,

4. keys or splines.
Types:

1.Cylindrical, but may be square or cross-shaped in section.

2. An axle, though similar in shape to the shaft, is a stationary machine element and

is used for the hoisting drum, a car wheel or a rope sheave.

3. A spindle is a short shaft that imparts motion either to a cutting tool (e.g. drill press

spindles) or to a work piece (e.g. lathe spindles).

2
Material Used 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.
 Manufacturing of Shafts
1.Shafts are generally manufactured by hot rolling and finished to size by cold

drawing or turning and grinding. The cold rolled shafts are stronger than hot rolled

shafts but with higher residual stresses.

2. The residual stresses may cause distortion of the shaft when it is machined,

especially when slots or keyways are cut.

3.Shafts of larger diameter are usually forged and turned to size in a lathe.

4
 Types of Shafts
1. Transmission shafts.
Pulleys, gears etc., therefore they are subjected to
bending in addition to twisting.
2. Machine shafts.
These shafts form an integral part of the machine
itself. The crank shaft is an example of machine shaft.

5
6
 Stresses in Shafts
The following stresses are induced in the shafts :

1. Shear stresses due to the transmission of torque (i.e.

due to torsional load).

2. Bending stresses (tensile or compressive) due to the

forces acting upon machine elements like gears,
pulleys etc. as well as due to the weight of the shaft
itself.

3. Stresses due to combined torsional and bending

7
 Maximum Permissible Working Stresses for
Transmission Shafts
ASME - American Society of Mechanical Engineers
Tension or Compression
(a) 112 MPa for shafts without allowance for keyways.
(b) 84 MPa for shafts with allowance for keyways.

Shear Stress
(a) 56 MPa for shafts without allowance for key ways.
(b) 42 MPa for shafts with allowance for keyways.

8
 Design of Shafts
The shafts may be designed on the basis of

1. Strength

2. Rigidity and stiffness

(a) Shafts subjected to twisting moment or torque only,

(b) Shafts subjected to bending moment only,

(c) Shafts subjected to combined twisting and bending moments,

(d) Shafts subjected to axial loads in addition to combined

torsional and bending loads.

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1. Shafts Subjected to Twisting Moment

10
11
2. Shafts Subjected to Bending Moment

12
13
 Shafts Subjected to Combined Twisting
Moment and Bending Moment
When the shaft is subjected to combined twisting moment and bending
moment, then the shaft must be designed on the basis of the two moments
simultaneously. Various theories have been suggested to account for the
elastic failure of the materials when they are subjected to various types of
combined stresses.
1. Maximum shear stress theory
2. Maximum normal stress theory

14
15
 Design of Shafts on the basis of Rigidity
1. Torsional rigidity.
2. Lateral rigidity.
1. Torsional rigidity.

16
Design of Shafts

1
 Introduction
• Torque and Power Transmission
• Most of rotary prime movers either
motors or turbines use shaft to transfer
the power
• Bearings are required for support
• Shaft failure analysis is critical

2
 Shaft Design
• Material Selection (usually steel, unless you have good reasons)
• Geometric Layout (fit power transmission equipment, gears,
pulleys)
• Failure strength
– Static strength
– Fatigue strength
• Shaft deflection
– Bending deflection
– Torsional deflection
– Slope at bearings and shaft-supported elements
– Shear deflection due to transverse loading of short shafts
• Critical speeds at natural frequencies

ME 423: Machine Design

Instructor: Ramesh Singh
3
 Shaft Materials
• Deflection primarily controlled by geometry, not material
• Strain controlled by geometry but material has a role in stress
• Strength, Yield or UTS is a material property. Cold drawn steel
typical for d< 3 in.
• HR steel common for larger sizes. Should be machined all
over.
• Low production quantities: Machining
• High production quantities: Forming

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Instructor: Ramesh Singh
4
 Shaft Layout
• Shafts need to accommodate
bearings, gears and pulleys
which should be specified
• Shaft Layout
– Axial layout of components
– Supporting axial loads
(bearings)
– Providing for torque
transmission
(gearing/sprockets)
– Assembly and
Disassembly(repair &
adjustment)

5
 Axial Layout of Components
7–2
a shaft
n to support and
wo gears and two
Solution uses an
(a) (b)
on, three shaft
ey and keyway, and
housing locates the Fan
their outer rings
the thrust loads.
an-shaft
n. (d) Solution uses
ngs, a straight-
t, locating collars,
ws for collars, fan
an itself. The fan (c) (d)
ports the sleeve

6
 This design represents good
practice for the situation in

Supporting Axial Load

which one or more torque-
transfer elements must
be mounted outboard.
(Source: Redrawn from
material furnished by The
Timken Company.)
• Axial loads must be supported through a bearing to the frame
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• Generally best for only one bearing to carry axial load to

shoulder
Figure 7–4
364 Mechanical Engineering Design
A bevel-gear drive in
which both pinion and gear
Figure 7–3 are straddle-mounted.
Tapered roller bearings used (Source: Redrawn from
in a mowing machine spindle. material furnished by
This design represents good Gleason Machine Division.)
practice for the situation in
which one or more torque-
transfer elements must
be mounted outboard.
(Source: Redrawn from
material furnished by The
Timken Company.)

Figure 7–4 • Pins

• Press or shrink fits
• Tapered fits
In addition to transmitting the torque, many of these devic
the torque exceeds acceptable operating limits, protecting more
Details regarding hardware components such as keys, p
addressed in detail in Sec. 7–7. One of the most effective an
transmitting moderate to high levels of torque is through
7 a key
the shaft and gear. Keyed components generally have a slip fit o
 Torque Transmission
• Common means of transferring torque to shaft
– Keys
– Splines
– Setscrews
– Pins
– Press or shrink fits
– Tapered fits
• Keys are one of the most effective◦
– Slip fit of component onto shaft for easy assembly
– Positive angular orientation of component
– Can design the key to be weakest link to fail in case of overload

8
 Shaft Design for Stresses
• Stresses are only evaluated at critical location
• Critical locations are usually
– On the outer surface
– Where the bending moment is large
– Where the torque is present
– Where stress concentrations exist

9
 Bending, torsion, and axial stresses may be present in both midrange and alternating
ing magnitudes.
components. For analysis, it is simple enough to combine the different types of stresses
Shaft into
Stresses Shaft Stresses
alternating and midrange von Mises stresses, as shown in Sec. 6–14, p. 317.
It is sometimes convenient to customize the equations specifically for shaft applica-
Bending,
tions.torsion, and are
Axial loads axial stresses
usually may be present
comparatively in both
very small midrange
at critical and alternating
locations where
components. For torsion
bending and analysis, it is simple
dominate, enough
so they will betoleft
combine thefollowing
out of the differentequations.
types ofThe
stresses
Standard
into •alternating
fluctuating and stress
stressesmidrange equations
von and
due to bending Mises can are be
stresses,
torsion customized
as
given byshown in Sec. for shafts
6–14, p. 317.
It is sometimes convenient to customize the equations specifically for shaft applica-
• Axial loads are σgenerally
tions. Axial loads are usually
Ma c small so M
comparatively
Kf σmvery
only
mc bending and(7–1) torsion
= K fsmall at critical locations where
will
a =
bending be
and considered
I I
torsion dominate, so they will be left out of the following equations. The
fluctuating stresses due to bending Ta c Tm c
• Standard alternating
a τ = Kand torsion
f s and midrange
m fs τ are
= Kgiven by
stresses can be calculated (7–2)
J J
Ma c Mm c
σ
where Mm and Ma are the = K
a midrange
f σ =
and alternating
m Kbending
f moments, Tm and Ta are(7–1)
I I
the midrange and alternating torques, and K f and K f s are the fatigue stress-concentration
factors for bending and torsion, respectively.
Ta c Tm c
τ
Assuming a solid shaft = K τ =
a withf sround cross section,
m K fappropriate
s geometry terms can(7–2)
J J
be introduced for c, I, and J resulting in
where Mm and Ma are the midrange and alternating bending
32Ma 32Mm
moments, Tm and Ta are
the midrange and alternatingσtorques,
a = K f and K and K fKs fare the
σm = fatigue stress-concentration
(7–3)
πd 3 f πd 3
factors for bending and torsion, respectively.
Assuming a solid shaftτwith 16Tacross section, 16T
round appropriate geometry terms
(7–4) can
m
a = K fs 3
τm = K f s 3
be introduced for c, I, and J resultingπdin πd

32Ma 32Mm
σa = K f σm f (7–3)
πd 3 πd 3
10
16T 16T
 Design Stresses
Combining these stresses in accordance with the distortion energy failure theo
Calculating
von •Mises stresses vonMises Stresses
for rotating round, solid shafts, neglecting axial loads,
n by
!" #2 " #2 $1/2
′ 2 2 1/2 32K f Ma 16K f s Ta
σa = (σa + 3τa ) = 3
+3 3
(7
πd πd
!" #2 " #2 $1/2
′ 2 2 1/2 32K f Mm 16K f s Tm
σm = (σm + 3τm ) = 3
+3 3
(7
πd πd

e that the stress-concentration factors are sometimes considered optional for

range components with ductile materials, because of the capacity of the duc
erial to yield locally at the discontinuity.

11
 Shaft Stresses
Shaft Stresses
Modified Goodman
Substitute von Mises stresses into failure criteria equation.
example,
Substitute von Mises using modified
stresses Goodman
into failure line,
criteria equation. For
• example, usingvonMises
Substituting modifiedinto
Goodman
failure line,
criterion

• Solving for diameter

Solving for d is convenient for design purposes
Solving for d is convenient for design purposes

ME 423: Machine Design

Instructor: Ramesh Singh
12
Shigley’s Mechanical Engineering Design
 Design of shafts
• 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. For example, DE-Goodman, DE-Gerber, etc.
• In analysis situation, can either use these customized
equations for factor of safety, or can use standard approach
from Ch. 6.
• In design situation, customized equations for d are much
more convenient.

13
 Gerber
Shaft Stresses

DE-Gerber

where

ME 423: Machine Design

Instructor: Ramesh Singh
14
 where

Other Criteria
/
A = 4(K f Ma ) 2 + 3(K f s Ta ) 2
/
Shaft Stresses
B = 4(K f Mm ) 2 + 3(K f s Tm ) 2

• ASME Elliptic
DE-ASME Elliptic
DE-ASME Elliptic
$ % &2 % &2 % &2 % &2 '1/2
1 16 K f Ma K f s Ta K f Mm K f s Tm
= 4 +3 +4 +3
n πd 3 Se Se Sy Sy
(7–11)
⎧ $ % ⎫
⎨ 16n &2 % &2 % &2 % &2 '1/2 ⎬ 1/3
K f Ma K f s Ta K f Mm K f s Tm
d= 4 +3 +4 +3
⎩ π Se Se Sy Sy ⎭

(7–12)

• DE Soderberg
DE-Soderberg
DE-Soderberg 0 3
1 16 1 1 21/2 1 1 21/2
= 4(K f Ma )2 + 3(K f s Ta )2 + 4(K f Mm )2 + 3(K f s Tm )2
n πd 3 Se Syt
(7–13)
% 0
16n 1 1 21/2
d= 4(K f Ma )2 + 3(K f s Ta )2
π Se
3&1/3 (7–14)
1 1 2
2
2 1/2
+ 4(K f Mm ) + 3(K f s Tm )
Syt
Shigley’s Mechanical Engineering Design

15
m and Ta equal to 0, which simply drops out some of the terms.
 Rotating Shaft
• For rotating shaft with steady, alternating bending
and torsion
– Bending stress is completely reversed (alternating), since a
stress element on the surface cycles from equal tension to
compression during each rotation
– Torsional stress is steady (constant or static)
– Previous equations simplify with Mm and Ta equal to 0

16
 YieldingChecking
Check for Yielding in Shafts
• Always necessary to consider static failure, even in fatigue
situation Always necessary to consider static failure, even in fatigue
situation
• Soderberg criteria inherently guards against yielding
Soderberg criteria inherently guards against yielding
• ASME-Elliptic criteria takes yielding
ASME-Elliptic into account,
criteria takes yielding intobut is notbut is not
account,
entirely conservative
entirely conservative
• Gerber and modified
GerberGoodman
and modifiedcriteria
Goodmanrequire
criteriaspecific check check
require specific
for yielding yielding

Shigley’s Mechanical Engine

17
 Yield Check
Checking for Yielding in Shafts

• Use vonUse vonmaximum

Mises Mises maximum
stress tostress
checktofor
check for yielding,
yielding,

Alternate simple check is to obtain conservative estimate of s'm

• Alternate
by simple
summingcheck is tosobtain
s'a and 'm conservative estimate of
s'max by summing
s max sa sm

ME 423: Machine Design

Instructor: Ramesh Singh
18
 Deflection Considerations
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• Deflection analysis requires complete geometry & loading

information for the entire shaft
• Allowable deflections at components will depend on the
component manufacturer’s specifications. Shafts and Shaft Componen

Table 7–2 Slopes

Typical Maximum Tapered roller 0.0005–0.0012 rad
Ranges for Slopes and Cylindrical roller 0.0008–0.0012 rad
Transverse Deflections Deep-groove ball 0.001–0.003 rad
Spherical ball 0.026–0.052 rad
Self-align ball 0.026–0.052 rad
Uncrowned spur gear < 0.0005 rad

Transverse Deflections

Spur gears with P < 10 teeth/in 0.010 in

Spur gears with 11 < P < 19 0.005 in
Spur gears with 20 < P < 50 0.003 in

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7–5 Deflection Considerations
 Determination of deflections
• Linear & angular deflections, should be checked at gears and
bearings
• Deflection analysis is straightforward, but very lengthy and
tedious to carry out manually. Consequently, shaft deflection
analysis is almost always done with the assistance of
software(usually FEA)
• For this reason, a common approach is to size critical locations
for stress, then fill in reasonable size estimates for other
locations, then check deflection using FEA or other software
• Software options include specialized shaft software, general
beam deflection software, and finite element analysis (FEA)
software.

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 Critical Speeds
• For a rotating shaft if the centripetal force is equal to the
elastic restoring force, the deflection increases greatly and the
shaft is said to "whirl”
• Below and above this speed this effect is not pronounced
• This critical (whirling speed) is dependent on:
– The shaft dimensions
– The shaft material and
– The shaft loads

21
 Critical speeds of shafts
Force balance of restoring force and centripetal,
!"# $ = &$
k is the stiffness of the transverse vibration
&
" = 2 678 =
!
The critical speed for a point mass of m,
1 &
78 =
26 !
For a horizontal shaft,
1 :
78 =
26 $
Where y = the static deflection at the location of the concentrated mass

22
 # $2 # $2
π EI π gE I
ω1 = = (7–22
l m l Aγ
Ensemble of lumped masses
mass per unit length, A the cross-sectional area, and γ the specifi
ensemble
• Forofensemble
attachments, Rayleigh’s
of lumped massesmethod
Raleigh’sfor lumped
method masses gives
pf lumped
masses gives, & !
g wi yi
ω1 = ! 2
(7–23
wi yi
weight of the ith location and yi is the deflection at the ith body location
• where
use Eq. wi for
(7–23) is the
theweight
case of of the
Eq. ith location
(7–22) byand yi is the the shaft int
partitioning
deflection
lacing its weightatforce
the ithatbody
the location
segment centroid as seen in Fig. 7–12

23
 Beam Theory
• m = Mass (kg)
• Nc = critical speed (rev/s )
• g = acceleration due to gravity (m.s-2 )
• O = centroid location
• G = Centre of Gravity location
• L = Length of shaft
• E = Young's Modulus (N/m2)
• I = Second Moment of Area (m4)
• y = deflection from δ with shaft rotation = ω δ static
deflection (m)
• ω = angular velocity of shaft (rads/s)

24
 Whirling Speed
• The centrifugal force on the shaft = m ω 2(y + e) and the
inward pull exerted by the shaft, F = y48EI / L3 for simply
supported. For a general beam F= y K EI / L3
where K is constant depending on the loading and the end
support conditions

25
with a central mass K = 48 .. See examples below

Critical Speed
3 in the above equation for y results in the following equation
• The critical speed is given by
city with the deflection.

This curve shows the deflection of the shaft (from the static deflection position) at any speed ω in
terms of the critical speed.

When ω < ωc the deflection y and e have the same sign that is G lies outside of O. When ω26> ωc
then y and e are of opposite signs and G lies between the centre of the rotating shaft and the static
 eflection curve. At high speed G will move such that it tends to coincide with the static
eflection curve.

Critical speeds of some configurations

Cantilever rotating mass

Mass of shaft neglected

Central rotating mass- Long Bearings

Mass of shaft neglected

Central rotating mass - Short Bearings

Mass of shaft neglected

27
Mass of shaft neglected

Non-Central rotating mass - Short Bearings

Mass of shaft neglected

Cantilevered Shaft

28
 Cantilevered Shaft

Cantilevered Shaft

m = mass /unit length

m = mass /unit length

Shaft Between short bearings

Shaft Between short bearings

m = mass /unit length

m = mass /unit length

29
Shaft Between long bearings

m = mass /unit length

Combined loading

This is known as Dunkerley's method an is based on the theory of superposition....

ME 423: Machine Design

Instructor: Ramesh Singh
30
m = mass /unit length

Dunkerley’s Method
Combined loading

This is known as Dunkerley's method an is based on the theory of superposition....

31