UNIT 8 SHAFTS AND COUPLINGS

Structure
8.1 Iiitroduction
Objectives

8.2 Types of Shaft

8.3 Materials for Shafts
8.4 Shaft Strength under Torsional Load
8.5 Stresses in Bending and Torsion
8.6 Shaft Loading
8.7 Shafts under Torsion and Bending
8.8 Stiffness of Shaft
8.9 Couplings
8.10 Summary
8.1 1 Key Words
8.12 Answers to SAQs

8.1 INTRODUCTION
Shafts form the important elements of machines. They are the elements that support
rotating parts like gears and pulleys and in turn are themselves supported by bearings
resting in the rigid machine housings. The shafts perform the function of transmitting
power from one rotating member to another supported by it or connected to it. Thus, they
are subjected to torque due to power transmission and bending moment due to reactions
on the members that are supported by them. Shafts are to be distinguished from axles
which also support rotating members but do not transmit power. Axles are thus subjected
to only bending loads and not to the torque.
Shafts are always made to have circular cross-section and could be either solid or hollow.
The shafts are classified as straight, cranked, flexible or articulated. Straight shafts are
commonest to be used for power transmission. Such shafts are commonly designed as
stepped cylindrical bars, that is, they have various diameters along their length, although
constant diameter shafts would be easy to produce. The stepped shafts correspond to the
magnitude of stress which varies along the length. Moreover, the uniform diameter shafts
are not compatible with assembly, disassembly and maintenance. Such shafts would
complicate the fastening of the parts fitted to them, particularly the bearings, which have
to be restricted against sliding in axial direction. While detemiining the form of a stepped
shaft it is borne in mind that the diameter of each cross-section should be such that each
part fitted on to the shaft has convenient access to its seat.
The parts carried by axle or shaft are fastened to them by means of keys or splines and
for this purpose the shaft and axle are provided with key ways or splines. The bearings
that support the shafts or axle may be of sliding contact or rolling contact type. In the
former case the journal of the shaft rotates freely on thin lubricant layer between itself
and bearing, while in the latter case the inner race of the beating is force fitted on the
journal of the shaft, thus, rotates with the shaft while outer race is supported in the
housing and remains stationary.
A shaft is joined with another in different ways and configurations. The coaxial shafts are
connected through c~uplingswhicb may be rigid or flexible.
1)r\ig11of' I'uwer Objectives
'1'1.a11smissio11
Devices
After studying this unit, you shsuld be able to
define types of shafts,
select materials for shaft,
explain how to estimate shaft diameters in different segments along length,
and
describe how to design couplings for shafts.

8.2 TYPES OF SHAFT

The types of shaft are mentioned in introduction. Figure 8. I (a) shows a stepped shaft
with three seats for supported parts which can be pulleys, gears or coupling. Two seats
for bearings are also indicated. These bearings will be rolling contact type. Figure 8. I(b)
shows a single crank shaft. The crank may be connected to another element like
connecting rod which may have a combined rotary and reciprocating motion. The
connection is through a bearing often called crank pin. The straight part of the shaft may
support a pulley or a gear. The connection will be through a key. Multiple crank shaft is
shown in Figure 8.1 (c). Each crank pin would carry a connecting rod and each crank pin
will be between the supporting bearings. The other shaft types are explanatory.
Keyway for

Steps or seats
for parts
(a) A Stepped Shaft
Bearing
Bearing

(b) A Single Crank Shaft

Pin

(c) Multiple Crank Shaft

- (d) Flexible Shaft

(e) Articulated Shaft

Figure 8.1 : Different Types of Shafts
The adjacent sections of shafts with different diameters are joined by smooth transition
fillet with as large radius as permitted by supported part or bearing that supports the
shaft. The larger radius of fillets will reduce stress concentration factor.
 -
Shafts and Coupling5
8.3 MATERIALS FOR SHAFTS
From the above discussion the materials for the shaft would be required to possess
(a) high strength,
(b) low notch sensitivity,

(c) ability to be heat treated and case hardened to increase wear resistance of
journals, and
(d) good machinability.
Shafts could be made in mild steel, carbon steels or alloy steels such as nickel,
! nickel-chromium or chrome-vanadium steels.
I Commercial shaftings (available in stock) are generally made in low carbon steel by hot
rolling. Such shaftings could be finished to size by cold drawing are machining (turning
and grinding). Cold drawing produces stronger shaft but generally introduces residual
b
stresses which nlay result in distortion of the shaft when subjected to unsymmetrical
machining like cutting a keyway. Table 8.1 describes shafting available commercially.
Table 8.1 : Standard Sizes of Commercial Shafting (Dia.)

Upto 25 rnm in increment of 0.5 mm

25 to 50 mm in increment of 1.0 mm
50 to I00 mm in increment of 2.0 mm
100 to 200 mm in increment of 5.0 mm
Carbon steel is frequently used as a shafting material and this material can be subjected
to heat treatment which can result into ultimate strength of about 800 MPa with yield
strength exceeding 550 MPa. Such steels can be tempered and hardened to a hardness of
40 to 50 RC to get a good wear resistance in the journal.
Heavily loaded shafts are often made in alloy steels which because of their high strength
would result in smaller diameters. These steels are capable of heat treatment and
especially high wear resistance in journal is obtainable by case hardening treatment.
However, designer has to be careful while choosing such steels because they will be
highly notch sensitive. These steels also are costly. Further, the smaller diameters of
shafts may not always be advantageous, because a strong enough shaft may not have
sufficient rigidity. Due to these reasons, the high strength alloy steels have limited scope
of utility. Carbon steels are largely replacing alloy steels because of development of
methods of heat treatment and case hardening. Special purpose and large diameter shafts
are often forged. Diameters larger than 125 mm are regarded as large in this respect. The
forged shafts are subsequently machined to size.
Ductile cast iron is also finding use as a shaft material because of its low notch sensitivity
and damping capacity.
Steel castings are also used as shaft material and their strength is comparable to mild
steel.

8.4 SHAFT STRENGTH UNDER TORSIONAL LOAD

The shafts are always subjected to fatigue load hence they must be calculated for fatigue
strength under combined bending and torsion loading. However, the initial estimate of
diameter is obtained from the torque that is transmitted by the shaft. The bending
moment variatior, along the length of the shaft is established after fixing some structural
features like distance between supporting bearings and distance between points of
application of forces and bearings.
Ilesign of Power Following notations will be used for shaft.
l'ransmission Devices
d = diameter of shaft,
M, = torque transmitted by the shaft,
H = power transmitted by the shaft (W),
N = rpm of the shaft,
r, = permissible shearing stress,
ah= permissible bending stress, and
Mh = bending moment.
Considering only transmissian of torque by a solid shaft.
The power transmitted by shaft and the torque in the shaft are related as
H=M,o
2n N
If H is in Watts and Mi in Nm.w is angular velocity in radls and equals -
60

The shearing stress and the torque are related as

If Mi is in Nm and d in mm.

From Eqs. (8.1 ) and (8.2)

In Eq. (8.3) H i s in W, r in ~ / m mN~ in, rpm and d in mm.

'
For calculating shaft diameter, d, we substitute the permissible value of shearing stress in
place of r. Table 8.2 describes permissible values for steel shaft under various service
conditions, when the bending loads are much smaller than torsional loads.
Table 8.2 :Allowable Shear Stress for Shafts
Service Condition 7, (MPa)
Heavily loaded short shafts canying 48- 106
no axial load 1
P

Multiple bearing long shafts carrying 13-22

no axial load
Axially loaded shafts (bevel gear 8-10
drive or helical gear drive)
Shafts working under heavy overloads 4.5-5.3
(stone aushers, etc.)
 Manufacturers, sonietinies making shaft routinely, like to use Eq. (8.3) with value for r Shafts and Couplings
substituted. For example for a heavily loaded short shaft, the first in Table 8.2, Eq. (8.3)
i will yield

For shaft working under heavy overload, the last of Table 8.2, using r = 4.9

t Suppose the manufacturer wants to find diameter of the shaft of machine which is short
and likely to be overloaded with nominal power of 15 kW at 300 rpm.

Thus, with handy formula the engineer can calculate the diameter in no time. Yet the
detailed calculations may have to be done for carefully designed shafts. We will consider
such design procedure now.

I
8.5 STRESSES IN BENDING AND TORSION
The shafts are circular section cylindrical parts that are rotating and supportedin
bearings. Most shafts are subjected to bending moment and torque simultaneously. The
bending moment at different sections has to be calculated and a bending moment diagram
is drawn to locate section where bending moment is highest. The torque at thir. i~crionis
also calculated. We will see in solved example how the bending moment diagram is
plotted along with torque. In this section let us assume that at any section the BM is M
and torque is MI. Then stresses due to M and MI can be calculated by nonnal bending and
torsion theories, at any point on the surface of the shaft. Figure 8.2 shows the stress
distribution over the cross-section and state of stress at a point on the surface at a radius
d
-. Apparently both bending stress o and shearing stress T (respectively due to M
2
and MI) have highest magnitudes or and T Iat surface or point A .

The maximum principal stress for state of stress at point A shown in Figure 8.2 is written
as
Design uf Power
Transmission Devices . . . (i)

[=p
)l. .-i-.-- @-J?-.- j--.
M M x-section Distribution
of stress

State of stress at point A.

Figure 8.2 : A Shaft under Bending and Torsion

If we assume that a bending moment Me, acting alone would induce a bending stress o,,,
at point A, then
- 32 M,o, . . . (ii)
op~ -
7rd3
Then the right hand sides of (i) and (ii) being equal we obtain
I

where Me is called equivalent bending moment.

Using equivalent bending mhment for designing the shaft is same as using nlaximum
normal stress theory ofjailure. If obdenote the permissible bending stress for the steel
shaft, then

For example, we can find diameter of a shaft at a section where M = 40 kNm and
M, = 20 kNm. Take o b = 50 ~ / m m ~ .
You should be careful about ;nits. Meis in Nmm and o h in ~ / m m in Eq.
~ (8.5).

= 10' x 4.236 Nmm

Using calculated value of Me and given value of obin Eq. (8.5)

or d = 94.6 mm
If we use maximum shearing stress theory then failure will occur when maximum
shearing stress becomes equal to permissible shearing stress. The maximum shearing
stress is
If we assume that a torque M,, acting along will cause same shearing stress as r,,,, then Sl~aflsand Coupling5

M, is called equivalent torque. Both M , and M,, can be used to calculate shaft diameter.
While solving an actual problem the designer will have to find bending moment and
torque at various sections of shaft. It may require complete understanding of how the
forces are transmitted to shafts from attached parts like gears, pulleys and chain sprockets
or coupling. It also needs understanding as to how bearings provide support to the shaft.
The shaft can be regarded as simply supported or fixed beam for determining the bending
moments. We will consider the shaft loading now.

8.6 SHAFT LOADING

The parts that are supported by shaft have already been mentioned as gear, pulley and
coupling. Figure 8.1(a) showed the seats for these parts on shaft. Figure 8.3(a) shows the
shaft on which gear, pulley and coupling are supported. It is also shown that the pulley
and coupling are connected to shaft through key which sits in the keyway.
Figure 8.3(b) shows yet another shaft that supports a worm wheel. Two roller bearings
support the shaft and themselves are supported in the casing.
I

(a) Shaft Carrying I Gear, 2 Pulley, 5 Coupling and Supported in 3 Sliding Contact Bearing
and in 4 Rolling Contact Bearing

(b) Shaft 1 Supports Worm Wheel, 2 and is Supported in Bearings, 3 and 4.

Bearings are Supported in the Housing 5
Figure 8.3
Design o f Power Calculations of forces coming upon the shaft from gear mav not be explaincd in detail.
'Transmission Devices We will draw upon the earlier understanding you might have developed in respect of
gear. The simplest gear is straight tooth spur gear, i.e. the pair of gears mounted on
parallel shaft with teeth parallel to the axes of the shafts. In helical spur gear the teeth are
inclined to the parallel axes of the shaft. In case of straight tooth spur gears the contacting
teeth are subjected to tangential and radial force components (tangent and radial in
respect of pitch circle of gear) denoted by P, and P,. PI will cause the torque and a
transverse force on the shaft. P, will act as a transverse force on the shaft. These forces
are shown in line diagram in Figure 8.4. The forces P,. and PI will act in two planes which
are mutually perpendicular. Thus, they will cause bending moment in mutually
perpendicular planes. The resultant bending moment can be found by combining bending
moments by usual method of finding resultant of two vectors along two mutually
perpendicular directions. Alternatively the resultant of P, and P,. can be found as P,, such
that
6 = P, cos a and 4. = 4, sin a so that P, = 6 tan a . . . (8.6)
Pitch circle
dia

..
Figure 8.4 :Loading o f Shaft by Gear

Here a is the pressure angle of gear teeth (You may like to revise your understanding of
pressure angle). For understanding occurrence of shaft torque two fictitious forces each
equal to Pt and opposite to each, may be assumed to act on the shaft parallel to Pt at gear
1
pitch circle as shown in Figure 8.4. Then the couple P, with arm equal to - of pitch
2

circle diameter will cause a torque equal to 2 . This is the torque transmitted by the
6-
2
shaft. Another PI at centre of the gear will act transversely to cause bending moment.
Perpendicular to the plane of P,, P, will act on the shaft in similar manner. The bending
moments MI and M,. will be calculated depending upon the distance between supports. If
the supporting bearings are narrow like ball or roller bearing, the supports may be
regarded as simple. If bearings are long like sliding contact then supports are regarded as
fixed.
A pulley is pulled by belt tension on two slides. The tensions on tight and slack sides of
belt, called TI and T2 are related as r, = epOwhere p is coefficient of friction between
-
T2
pulley surface and belt and 8 is angle of contact between belt and pulley (Figure 8.5).
This figure is representing the simplest case in which two belt sides are vertical, 0 being
n. The shaft will be subjected to load TI + T2 acting transversely. Additionally the weight
of pulley will also act at the same section. If the centre line of TI and T2 is inclined then
components in vertical and horizontal planes can be found and bending moment in
vertical plane is calculated by combining weight of the pulley with vertical component of
the'tension (TI + Tz). BM in horizontal plane is separately calculated and BM in
horizontal and vertical planes are combined, thereafter. The torque on shaft is calculated
D
as (T, - T2) - where D is the diameter of pulley.
2
/
in torque of
sprocket.
-
In case o l chain only force tangent to sprocket will act. If the force is P, then it will result
dP and transverse force P on shaft. d, is the pitch diameter of the
L
Shafts and CoupIi~~gr

Figure 8.5 : Loading of Shaft by Pulley

The coupling is the connection between coaxial shafts through discs (called flanges as
they are integral with hub). These discs are connected to shafts through keys and the
bolts connect the discs with each other. The shear force develops in each bolt and such
shear forces exert torque on the shaft. If there are n bolts at the pitch circle of diameter d,,
b nFd,
then the torque is -where F is shear force in each bolt. Figure 8.6 shows schematic
2
of coupling. No BM is caused by coupling.
Driver

Pitch circle

Figure 8.6 : Coupling

With calculation of load understood and supports of bearings known we can proceed to
make some calculations through solved examples.
Example 8.1
A shaft is required to transmit a power of 25 kN at 360 rpm. The force analysis due
to attached parts results in BM of 830 Nm at a section between bearings. If
permissible stresses in the shaft are : 60 ~ l m m in
' bending and 40 ~ l m m in
' shear
calculate the diameter of the shaft.

I
Solution
M = 830 Nm = 0.83 x lo6 ~ m m
271N 271 360
Power, H = 2 5 x 1 0 3 = M , o = - MI =- M, = 1271 Mt
60 60
25 lo'
.'. M, = = 663.15 Nm = 0.663 x lo6 Nmm
1271
:. Equivalent BM from Eq. (8.4)

Me = 946.15 Nm = 0.946 x lo6 Nmm . . . (i)

Design o f Power Equivalent torque from Eq. (8.6)
Transmission, Devices

= 1062.3 Nrn = 1.062 x 1o6 Nmm . . . (ii)

The equivalent BM will cause bending stress which is not allowed to exceed
permissible value.

.. d = 54.4 mm . . . (a)
The equivalent torque will cause shearing stress which is not allowed to exceed
permissible value. ,

.. d=51.33 mm . . . (b)
Out of (a) and (b) the larger diameter will be selected.
:. Shaft diameter Y = 54.4 rnm.
Example 8.2
A shaft cames a 1000 N pulley in the centre of two ball bearings which are
2000 mm apart. The pulley is keyed to the shaft and receives 30 kW. of power at
150 rpm. The power is transmitted from the shaft through a flexible coupling just
outside the right bearing. The belt derive is horizontal and the sum of the belt
tension is 8000 N. Calculate the diameter of the shaft if permissible stress in
bending is 80 ~ / m r n and
' in shear it is 45 ~ / m m ~ .
Solution
The belt tensions T I and T2 cause horizontal transverse force while weight of the
pulley causes vertical transverse force in the middle of the span as shown in
Figure 8.7. The BM diagrams in vertical and horizontal planes and torque
diagrams also shown.
Force in vertical plane = F , = 1000 N
Force in horizontal plane = FH= 8000 N
Both F , and FH act at the mid span. Maximum BM occurs at mid span, assuming
that the bearings behave as simple support

:. Resultant BM, M = -4 = 1o6 = 4.03 1 x 1o6 ~ r n m

H 30x10~
The shaft torque M , = -= = 1.91 x lo3 = 1.9 x lo6 Nmm
150
a 277~-
60
 Shafts and Cuupli~~gs
1000 rnrn -,1000 rnrn

Load in vertical plane

os~.rnrn
B.M. in vertical plane

Load in horizontal plane T, + T,

B.M. in horizontal plane

Torque

Figure 8.7

and Eq. torque M te = \=l = ,/- = lo6 Nmm

= 4.46 x lo6 Nmm

:. Permissible bending stress = 80

32Me
Nlmm 2 = -
71d3

. . . (a)
Permissible shearing stress = 45 ~16ME
~ / m r n= ---
nd3

d = 79.6 mm . . . (b)
Eq. (a) being larger diameter is acceptable, d = 81.5 mm
SAQ 1
(a) Describe different types of shafts. Sketch a stepped shaft to support a gear, a
pulley and coupling at one end. The shaft will be supported in ball bearings.
(b) Describe materials for shaft.
(c) What are the loads that come upon shaft?
(d) How will you calculate load upon a shaft if it supports a pulley or when it
supports a gear?
(e) Define equivalent bending moment and equivalent torque and state upon
which theories of failure they depend.
Design of Power
Transmission Devices
(f) A machine shaft is supported in ball bearings placed at a distance of
750 mm. The shaft carries a 450 mm diameter pulley at a distance of
200 mm on the right of right hand bearing and a straight tooth spur gear
200 mm pitch circle diameter on the right of left hand bearing at a distance
of 250 mm from it. 15 kW of power is supplied at spur gear at 600 rpm and
taken off at the pulley on which belt is mounted making an angle of 60" with
the horizontal. The ratio of the belt tensions is 3 : 1 and pulley weighs
800 N. The gear meshes with another gear directly located above the shaft.
The permissible bending stress is 100 MPa and permissible shearing stress is
55 MPa. The pressure angle of gear is 20". Determine the diameter of the
shaft.

8.7 SHAFTS UNDER TORSION AND BENDING

Most frequently shafts are loaded under torque and bending moment simultaneously. In
addition, the shafts may be loaded by axial load of tensile or compressive nature. The
bending moments on shaft may act in different planes and they have to be solved in two
mutually perpendicular planes and their resultant could be obtained by usual method.
If at any section of the shaft a bending moment Mb and a torque M, are acting, then by
maximum principal stress theory, the equivalent bending moment can be expressed as

The diameter of the shaft then can be calculated from well known equation of bending of
beam, that is,

obhere is permissible bending stress which could be taken as fatigue strength divided by
factor of safety.
Table 8.3 :Allowable Bending Stress for Steels

Steel Casting
500
I

1 120
I

70
I

40 1
l'lie torque transniitted by the shaft remains constant over a long period of time. It varies Shafts and Couplil~gs
ollly when power changes and power changes occurs only occasionally. Thus, the
shearing stress on the shaft cross-section changes much less frequently. On the other
hand the bending stress on the shaft cross-section changes in each cycle, which nieans
bending stress changes with frequency, which is equal to rpm of the shaft. Eq. (8.4),
though expresses bending stress, is function of both bending moment and torque and
hence is equally dependent upon both. It will be more logical to make it more dependent
upon bending moment and less upon the torque. This is done by multiplying torque by a
factor a where a < 1. Thus, the equivalent BM will be

M, = d m . . . (8.9)

Oh3
where a = - for pulsating torque and a = 1 for reversible torque.
(362

(361, (362 and (3h3 are described as pernlissible stresses under three respective conditions of
(i) constant load, (ii) pu~satingload, and (iii) reversible load. These permissible stresses
for some steels are described in Table 8.3.
Thus, Eq. (8.5) is rewritten as

Eq. (8.8) is used to determine shaft diameters at various sections along its length. The
method consists in plotting the bending moment diagrams in the plane of the forces,
resolving these bending moment diagrams into two mutually perpendicular planes and
combining then1 to calculate resultant bending moment. The torque diagram is similarly
plotted and equivalent bending moment is then calculated, which when substituted in
Eq. (8.10) would give the shaft diameter, d.
The axial thrust, that acts as a compressive force on the shaft cross-section, usually
causes stress that is in insignification in comparison with bending stress. However, if it is
considered, it reduces the tensile stress. If the axial load is tensile in nature, the resultant
stress may be taken as

where ol is the tensile stress and a, the same factor as defined earlier. Such designs of
shafts in which compressive axial force is produced are often preferred.
The diameters of such sections which cany keyed parts are often increased by 8 to 10%
in excess of those calculated by Eq. (8.10) to take care of the stress concentration
produced and cross-section reduced by keyway. The shaft journal diameters are also
calculated in the same way but their lengths are determined in conjunction with the
bearing. For rolling contact bearing, the length is selected, depending upon proper
bearing width. For sliding contact bearing, generally, the length varies from 0.4 to
1.5 tinies diameter. In revised calculation factor of safety at each critical cross-section is
checked.
8.7.1 ASME Formula
Yet another approach for shaft calculation is based upon maxinium shearing stress theory
whereby equivalent torque is given by

when M,, is used in torsion equation, shaft diameter

t, is permissible shearing stress.

Design of Power The equivalent torque method is recommended by American Society of Mechanical
'rransmissiOn Devices Engineering for calculation of shaft diameters. They suggest the modification of
equivalent torque as

Recommended values of K,,, and K, are described in Table 8.4 while permissible shearing
stress 7,to be used in Eq. (8.12) is chosen smaller of the following :

where o yis the yield strength and o, is the ultimate tensile strength.
These values may be further reduced by 25% if keyway is present.
Table 8.4 : Values of K, and K, in ASME Formula
Type of Loading K,, K, .
Stationary Shaft :
Load applied gradually I .O 1 .O
Load applihd suddenly 1.5-2.0 1.5-2.0
Rotating Shafk :
Load applied gradually 1.5 1 .O
Steady load 1.5 1 .O
Load applied suddenly
Minor shock 1.5-2.0 1 .O-1.5
Heavy shock
1
2.0-3.0 1.5-3.0

The design stress in Eq. (8.12) can be further reduced by 25% if shaft failure would cause
serious consequences.
Some times it is preferred to increase the torque by using a dividing factor, K to account
for presence of a keyway. If width of the key is w and h is its depth, then

Example 8.3
A shaft is supported in bail1 bearings which are placed 200 mm apart. The shaft
carries a straight tooth spur gear of 20" pressure angle at a distance of 50 mm from
right hand bearing between the supports. 3.9 kW of power is transmitted by the
shaft at 90 rpm. The pitch circle diameter of the gear is 125 mm which receives
power from a pinion placed in the same vertical plane above the gear and power is
taken off from right hand through a coupling. The shaft is to be made in steel
(carbon) for which ultimalte tensile strength is 700 MPa and permissible bending
stresses in pulsating and reversible bending loading respectively are 1 10 and
65 MPa. These permissible values take care of stress concentration, size and
surface finish. Find diameter of the section where gear is fitted on shaft through a
key, using both bending and torsional equivalence.
Solution
Before proceeding to calculate diameter, shaft loading has to be calculated.

. . . (i)
 125 Shafts u ~ l dCouplit~gs
The torque M, acts upon the gear at a radius of -mm .
2
If a tangential force P, acts upon the gear at this radius

This force will act on shaft transversely in horizontal plane (tangential force on
gear) at a distance of 50 mm from right hand bearing, which is regarded as simple
support along with left hand bearing. The schematic of the shaft is shown in Figure
8.8. The bending moment due to PI is calculated below.

e x 1 5 0 - 6.621x103x150=4~97x10~N
Reaction at RH bearing R, =
200 200

BM at section where gear sits, M I = 4.97 x lo3 x 50 = 248.3 x lo3 Nmm . . . (ii)
The gear will be subjected to a radial force component which will be transmitted to
the shaft as transverse load in vertical plane.

The radial force, P, = 4 tan a = 6.621 x lo3 x tan 20

P, =2.41 x lo3 N . . . (iii)

Pinion

X
Torque 9 150
diagram

B.M.D due
to gear
I
6.621 ~ 1
1
1
0
11
1
1
1 ~
414x10~

~
N-rnrn

1
tangential &
force

B.M.D due
to gear
redial force
t
Figure 8.8
BM due to P, in vertical plane in gear section
-2.41~10~~150~50
~ . x 1 5 0 x 5 0-
M, = = 90.4 x 10' Nmm
200 200
The torque BM in horizontal plane and BM in vertical plane are drawn in
Figure 8.8.
Hence, resultant BM in shaft at section where gear is mounted

M = \Im10' 4249.32= 264.24 x 10'

= Nmm
Uesigr~ol' Power
'I'ransrnissionDevices

1
M, = - [264.24 + d264.242 + (0.59 x 4 1 4 ) ]~x 10' = 254.7 x lo3 Nnlm . . . (iv)
2
Using MI, as defined in ASME formula. From Table 8.4 read for rotating shaft
and higher value for minor shock

K,,,=2.0, K , = 1 . 5

.. M, = &", MI' + (K, MI 1'

= d ( 2 x 264.24)' + (1.5 x 4 14)' x -/,
1o3 = x lo6

= 816 x lo3 Nnim

The values of M,, aqd M,, will be used for calculating diameter. With M, the
permissible stress will be fatigue strength in reversible stress cycle, i.e. 65 ~ / m m '
(given)

32M,
.. 65 = --- N/mm2
nd3

or

With M,, the perniissible stress will be fatigue strength in shear, i.e. 0.18 o,

r, = 0.18 x 700 = 126 N/mm2

To take care of keyway stress concentration this stress is reduced by 25%.

Hence, r, = 0.75 x 126 = 94.5 N/mm2

16M,
.. 94.5 = -nd3
CY

or

Out of two diameters (a) and (b) the higher value will be chosen.
.. d = 35.3 mm say 35.5 mm
The designed shaft will look like one shown in Figure 8.9.

Figure 8.9
 ....
Shafts and Cuuplir~gs
8.8 STIFFNESS OF SHAFT
bhafts are often designed for strength as illustrated in theory and solved examples so far.
But all shafts have to be stiff and rigid so that their deflection and twist are within
pemiissible limits. If the shaft exceeds in deflection and twist limits the diameter has to
be increased. We inust remember that tlie deflection and twists are inversely proportional
to cube of tlie diameter hence, lesser diameter will result in greater deflection and twist.
The probleni becomes iniportant when high strength steel is used for shaft. Such shaft
will result in smaller diameter and hence, larger deflection. Moreover, using high
strength steel requires greater care for its greater notch sensitivity.
The permissible values of displacenient (in bending and torsion) are decided with respect
ib the requirenients of machine in which shaft is placed, hence, such values vary from
inachine to machine. For example, pemiissible deflection of shaft in machine tool may
depend upon niodule of the gear fitted on the shaft while the limit in shaft of the rotor of
an electric motor will be the function of air gap. In general, however, the maxiniuni
deflection in shaft must not exceed 0.2% of the span between the bearings in case of
niacliines with gears niounted on shafts. The slope due to bending at the bearings must
also be limited. Following are the limits for precision machines :

I Slope I0.001 rad if bearing sliding contact type.

!
Slope I0.008 rad if bearing rolling contact type.
Slope 1 0 . 0 5 0 rad if bearing self aligning type.

I
The angular twist inay become basic design consideration for shaft such as in drilling
machine where the twist should not be greater than 0.035 radian over a length of
25 x diameter. The transmission shaft in a gantry crane is not allowed to twist more than
0.0 1 2 rad per meter length.
! .
In general, the deflection of shaft is reduced by
(a) making niounted parts lighter,
(b) keeping mounted parts balanced, and
(c) mounting parts close to bearing.
The angular displacement or twist 0 in radius is given by

where M, is torque acting over length 1.

The deflection can be calculated by such simple formula as

where W is the central load on shaft of span 1 and 6 is under the load.
G and E in above equations are modulus of rigidity and n~odulusof elasticity
respectively. The support slope of beam is calculated as

It is not surprising to note that most shafts in practice may not coincide with conditions
of simply supported beams for which Eqs. (8.17) and (8.18) have been written. For one
thing their diameter is not uniform along length hence you may have to resort to method
of integration or area moment method for calculation of slope and deflection. The
equations for area moment method are :
U L ' S ~01'
~ II'UI~L'C
I
'l'l.ansmission Devices

where I and 2 refer to two sections along the shaft, i and y denote the slope and
deflection and x is the distance of the section from the origin. A is the area of bending
moment diagram between sections I and 2 and x is the distance of centre of gravity ofA
from the origin. The calculation of i and y will depend upon judicious choice of the
origin.
Example 8.4
For the shaft of Example 8.2 of Section 8.7 calculate the maximum values of i
angular twist, defleation and slope. Assume E = 200 GPa and G = 80 GPa.
Solution
This is a simple case in which shaft is loaded like a simply supported beam with
1= 2000 mm while d was calculated as 8 1.5 mm. The central load is 8000 N in
horizontal and 1000 N in vertical plane.
Use Eq. (8.14) for 6
w13
6, =-
48 EI

1000 (2)3 I o9 64
and 6, = = 0.3875 mm
48x 2 x 1 0 ~~ ~ ( 8 1 . 5 ) ~
Hence, resultant deflection

6 = d m = + 0.3875
d 7 = 3.124 mni . . . (i)

This deflection is x 100) % of span =

:;:: a"
[- x I00 = 0.156% span . . . (ii)
The slope at the bearing, from Eq. (8.15)

.. I. I , + 1,
= J=-Jp' - 0.046~+ 0.0058~= 0.04636 rad . . . (iii)
The torque is constant from pulley to the coupling which is assumed at 10% of
span of shaft from RH bearing. So that the length of shaft to be twisted is
1000 +0.1 x 2000= 1200 mm.
Usel= 1200mm+M,=19.1 x 10~Nrnm,
G = 8 0 x l 0 ' ~ l r n r n ~ i (8.13)
n~~.
32 x 19.1 x lo5 x 1200
@=I = 0.0066 radlm length . . . (iv)
,80x lo3 x (81.5)~x
 Example 8.5 Shafts and Couplit~gr
I
3
A hollow shaft of diameter ratio - is required to transmit 600 kW at 1 10 rpm, the
8
maximum torque being 20% greater than mean. The shearing stress is not to
exceed 62 M N / ~and
I ~ twist in length of three metres is not to exceed 1.4 degrees.
Determine the diameter of the shaft. Assume modulus of rigidity for shaft material
as 84 CiN/rn2.
I Solution
Note that this problem requires consideration of stress and angle of twist. We have
to keep the angle of twist, 8 = 1.4 degree. We may also understand at this point
that Eq. (9.13) is applicable to solid shaft only. If we want to find 8 for hollow
shaft we have to recall the basic torsion formulae, i.e.

in which J is the moment of inertia of the shaft section. And if we denote outside
and inside diameters of hollow shaft with suffixes o and i on d ,

d; 3
The given value of - = - = 0.375
do 8

1 . 4 n~ MI
8 = -= 0.0244 rad =
'
180 GJ
where 1 = 3000 mm

The starting torque, M, = 1.2 M I [ = 62.52 x lo6 Nmm

The second consideration is based on stress,

.: Using z =- do
M, -
J 2

or = = 173.6 mm and d; = 65.1 mm . . . (b)

(2 x 0.0963 x 62
 of Power
I>r\igr~ From (a) and (b) we see that diameter from consideration of angle of twist is larger
'~ransmissionDevices lielice, this should be accepted. And then the stress will be lower than permissible
at

do = 175.6 mni, d j = 65.85 mm

How do you modify equivalent bending moment to take into consideration

that the bending moment varies at much higher frequency than the torque on
the shaft?
How do you account for the manner in which load is applied upon a
shaft-static, sudden or shock?
What is the stiffness of shaft in bending and torsion? How do you consider
the deflection and,twist in design of shaft?
Under what condition the deflection and twist of shaft become important?
A hollow shaft with diameter ratio 0.7 is required to transmit 500 kW at
300 rpm with a uniform twisting moment. Allowable shearing stress is
60 N/mm2 and twist in 2.0 nl length is not be exceed 1 degree. Calculate the
minimum external diameter and internal diameter of the shaft satisfying
these conditions and find actual value. G = 8.2 x lo4 ~ / m m ' .

8.9 COUPLINGS
In engineering applications there arise several cases where two shafts have to be
connected so that power from dkiving shaft is transmitted to driven shaft without any
change of speed. Such shafts are normally coaxial with slight or no misalignment and can
be connected through devices known as couplings. Permanent couplings, often referred
to as couplings, are the connectors of coaxial shafts and cannot be disengaged when
shafts are running. On the other hand, those couplings which can be readily engaged or
disengaged when driving shaft is running are termed as clutches. The power is
transmitted when a clutch is engaged and not transmitted when clutch is disengaged. In
this unit only permanent couplimgs will be considered. Figure 8.10 shows one such
coupling connecting the shaft of an electric motor with the shaft of a worm and worm
wheel reducer

Figure 8.10 :A Permanent Coupling Connecting Coaxial Shafts of an Electric Motor

and aWorm and Worm Wheel Reducer
Several types oi'couplings arc used in practice. A few are described here. Muff or sleeve Shafts and Coullli~igs
coupling is shown in Figure 8.1 1. It is the simplest form of a permanent coupling,
consisting of a steel or cast iron sleeve fitted on the ends of shaft to be connected. The
sleeve is connected to the shaft by means of keys. The length of sleeve can be taken as
(3.5 to 4) diameter of the shaft while the outer diameter of the muff or sleeve, D,is given
by

where d is the diameter of shaft in nim, 6, the thickness of the muff (Figure 8. I 1).
However, the shear stress in the muss must be checked by treating it as a hollow shat of
internal diameter d and external diameter D. The muff or sleeve coupling has the
advantage of simple design and easy manufacture. However, need of perfect alignment of
shafts is apparent and if not present the connection through a sleeve will induce bending
stresses in the shafts. Yet another disadvantage is that while removing the sleeve must
move on one of the shafts at least over a distance equal to half its length. This requires
the shaft to be longer by this much amount.
-
3.5 4d
k 4

d
S=-+lcm
3
Figure 8.1 1 :A Sleeve Coupling
In case of split muff coupling, the sleeve is made to have two halves which are held
together on two coaxial shafts by bolts. This coupling also known as clamp coupling is
shown in Figure 8.12. When the bolts are tightened a compression is induced between the
inner surface of sleeve and outer surface of shaft. This compressive force causes friction
between the muff and the shaft which transmit the torque form one shaft to the other. In
addition, a key is also used to connect the split muff with the two shafts.

(a) Split Muff wit! Bolts

u
(b) Split Muff Tightened on Two Coaxial Shafts
Figure 8.1 2

Split muff coupling has a distinct advantage over ordinary muff coupling as it can be
removed or disassembled without disturbing the shafts.
Design of Power The outer diameter of the muff, D, the length of the muff, L, and the bolt diameter db are
rransmissiOn IkviceS the dimensions required to be determined for split muff coupling. These dimensions can
be calculated from following empirical relations with shaft diameter, d.

The dimensions of the key can be calculated by strength consideration or selected from
standards. Such standards will be described later in this unit. Even if the bolt diameter in
split muff coupling is calculated from last of Eq. (8.22) it will be worthwhile to check
compression force and consequent frictional torque which results from tightening of
these bolts. I

8.9.1 Flange Coupling

Flange coupling, as was mentioned in Section 8.6 and shown in Figure 8.6 is used to
connect two strictly coaxial shafts. One such coupling is shown in Figure 8.10 and details
are shown in Figure 8.13. The iwo flanges are usually made in cast iron. These flanges
are separately keyed to driving ;and driven shafts.

Figure 8.13 : Flange Coupling

The two flanges are identical in all respects except that one has a circular projection and
other has a corresponding recess to make a register. When the two faces of flanges are
brought in contact the projection fits into recess ensuring condition of coaxiality. The
flanges are further connected through bolts placed near the periphery of the flanges. The
faces of flanges are machine finished true right angled to the axis of shafts. The power
may be transmitted by friction between the flange faces or by bolts in which case bolts
will be subjected to shearing stress.
Flange couplings are often employed to transmit great torque and are largely dependable
connections for shafts ranging in diameter between 18 mm to 200 mm. They are easily
designed and manufactured.
Flange coupling normally refemto unprotected types as shown in Figure 8.13. The bolt
head and nut, in this case are fully exposed and may present risk to operators. The bolt
heads and nuts are often protectdd by providing cover in the flange on them as shown in
Figure 8.14. This coupling is known as protected flange coupling.
While designing, the shaft diameter is calculated for transmission of torque, designated as
d. The hub diameter of the flange may be calculated by treating the hub as hollow shaft
but hub diameter D = 2d is often adopted and is found safe. The thickness of the flange
may be calculated by considering it to be in shear along the circumference where it joins
the hub. However, this thickness, t, is often taken as slightly greater than diameter of the
bolt.
 Shafts and Couplings

L- t
Cover in Flange /
(a) Cut View (b) Sectional View
Figure 8.14 :Protected Flange Coupling
The number of bolts which are placed symmetrically in a circle is determined in advance
by an empirical formula

where d is the shaft diameter in mm. The number of bolts normally varies between 4
I to 8.
The diameter of bolt, d l , is determined by yet another empirical formula to obtain
approximate value d l .

where d and d l are in mm.

The pitch circle diameter, D,, is then determined from,
D, = 2d + 2d, + 12 mm
The diameter of bolt is then accurately determined by taking it in single shear at the
interface of two flanges.

where r , ~is the perniissible shearing stress in bolt and M, is the torque transmitted. The
factor of safety for the bolt is higher as compared to other parts because it is subjected to
sudden load at the start.
The keys in the coupling are designed in the normal manner and its depth is selected on
the basis of shaft diameter which is calculated for transmission of torque only. The key
dinlensions for rectangular section.defined w x h (width x height) can be chosen from
Table 8.5.
Table 8.5 : Standard Key Section Dimensions
Design of Power Example 8.6
Transmission Devices
A driving shaft is joined with coaxial driven shaft through a muff coupling. The
shaft transmits 60 kW of power at 150 rpm. Design the shaft, key and muff.
Assume a factor of safety of 5 with following ultimate strength values.
Ultimate shear strength for shaft = 300 N/mm2
Ultimate shear $trength for key = 200 N/mm2
Ultimate shear strength for muff = 50 N/mmz
Ultimate compressive strength for key = 500 N/mmz
Solution
If torque transmitted by the shaft is M, Nm, power transmitted is H Watt and
angular velocity is o radls,

The stress caused by torque at outer surface of shaft of dia, d

This diameter is increased by 25% to take care of weakening by key so that

d = 85.9 mm say 86 mm.
From Table 8.5 choose a key with w = 24 mm and h = 14 nim. See Figure 8.15
below.

Figure 8.15 : Key

The length 1of key is calculated from shear force on it.

The shear force = F = 5 = 3819.7 1o3 = 88.83 x lo3 N

d
-
86
-
2 2
The shear area = w . I = 24 1 mrn2
200
The shear stress = = 40 N/mm2
The key has to be slightly less than the half muff length. The muff length = 3.5 d Shafts and CoupIi~lg\
to 4 d, i.e. 301 mm to 344 mm. Let's take muff length 301 mm, half of which is
150.5 mm hence, key length of 140 mm is safe.
We check height of the key against crushing under same force that causes

h 3
o, x - x l = F = 88.83 x I0 N
2

500
Permissible compressive stress = -= 100 N/mm 2
5
Thus, key is safe in crushing.
The muff is designed as hollow shaft with internal diameter as the diameter of the
shaft. The muff will transmit same power or torque as shaft.
With D as outside diameter

50
The permissible shear stress in muff = - = 10 ~ / n i m ~
5

o4- 1.95 x lo6 D = 54.7 x lo6 . . . (i)

This equation can be solved by trial and error and to get an idea of starting point
take D = 2.5 d = 21 5 mm. With this value, the term on right hand side can be
I
neglected resulting in D = (1950 x lo3): = 125 mm .
Choose value of 130, 140, 150,160 mm for D. Then for D = 140 mm,
D4 = 38.4 x lo7
:. Left hand side of (i) 384 x 1o6 - 273 x 1o6 = 3 1.5 x 1o6

:. Left hand side of (i) 285 x 1o6 - 253.5 x lo6 = 3 1.5 x lo6

For D = 135 mm, LHS = 332 x lo6 - 263 x lo6 = 69 x lo6

ForD = 132 mm, LHS = 303.6 x lo6 - 257.4 x lo6 = 46.2 x lo6

F o r D = 133 mm, LHS = 3 1 3 x lo6 - 2 5 9 . 4 ~lo6 =53.6x lo6

D = 133 mni comes closest to solution of (i).
The above trial and error method has been given to make reader familiar with such
method. We would rather select the outer diameter from empirical formula. ,,
D = 2 d +13mm=2x86+13=185mm
I)esig~iol' Power Example 8.7
'I'ra~~sniission
Devices
A shaft transmitting 150 kW is to be connected to a coaxial shaft through cast iron
flange coupling. The shaft runs at 120 rpm. The key and shaft are to be made of
same material for which permissible shearing stress is 60 N/mm2 and compressive
strength is 120 N/mm2. The steel bolts may be subjected to maximum shearing
stress of 26 N/mm2. Design protected type flange coupling.
Solution
Shaft Diameter d

For the shaft

Increase diameter by 25% to take care of keyway.

.. d = 125 mm . . . (i)
Bolt Diameter dl
Let there be n bolts clamping two flanges and let each bolt be subjected to
shearing stress TI.The force produced tangential to pitch circle of bolts (The
diameter of pitch circle is Dc from Figure 8.1 3)

The torque produced by F must be equal to torque transmitted by the shaft.

. . . (ii)
From Eq. (8.23)

Also from Eq. (8.24)

D, can be obtained form Eq. (8.25)

We calculate RH side of (ii) by using values of d l , D, and T, = 26 ~ / m m ~ .

Since this value ig greater than torque transmitted, 12 x lo6 Nmm,

n = 6 , d l =25.5mm,DC=313mm . . . (iii)
are acceptable values.
 Shafts and Couplings

The hub diameter can be taken as 2d, with internal diameter = d. Then
treating hub as hollow shaft under torque M,, the shear stress should be less
than 6.6 N/mni2 (shear stress in C.1).

r2 with D = 2d = 250 mm

This stress is less then 6.6 N/nini2,hence, D = 250 mm is safe.

. . (iv)
Length of'llub, L
Length of the hub is equal to length of the key.
From Table 8.5 for shaft diameter of 125 mm, find w = 36 mm, h = 20 mm.
d
You may also choose a square key with w = h = - = 31.25 mm
4
Shear stress in key is same as in shaft, r = 60 Nlrnndf

. . . (v)

Thickness of' Flange

There is possibility of failure by shear along the circumference where flange
joints the hub. If t is the thickness of the flange, the area over which shear
may occur is x D t. The shear force will be x D t r3, r3being the permissible
shearing stress in cast iron flange. This, will cause the torque equal to the
torque transmitted by the shaft

The bolts in holes of flange may be crushed. Of course the hole surface may
also be crushed but if bolts are safe then the hole surface will be safe since
the CI is stronger than steel in compression.
The area resisting crushing is d l t and force in n bolts is n d l t o,at a radius
Dc Thus, the torque is
of -.
2

This torque is much larger than 12 x 1o6 Nmm, and hence dimensions are
safe.
Thus, t = 18.5 mm . . . (vi)
Design of Power Other Dimensions
Transmission Devices
The outer diameter of flange is calculated from
Do = 20, - D = 2 x 313- 2 5 0 = 3 7 6 m m . . . (vii)
The diameter of register, D, = - - 188 mm
Do - . . . (viii)
2
Thickness of the protective cover on the top of the flange
d
tJ = - or t , Choose t/= t = 18.5 mm . . . (ix)
4
The extension of protection should be 5 mm greater than nut height on both
flanges.
Summary of Results
Shaft diameter d = 125 mm . . . (i)
Bolt diameter d l = 25.5 mm . . . (ii)
Number of bolts n=6 . . . (iii)
Pitch circle diameter of bolts D, = 3 13 mm . . . (iv)
Hub diameter D = 250 mm . . . (v)
Length of hub L = 89 mm . . . (vi)
Key dimensions w = 3 6 m m , h = 2 0 m m , L = 8 9 m m . . .(vii)
Thickness flange t = 18.5 mm . . . (viii)
Outer diameter of flange Do = 376 mm . . . (ix)
Diameter of register D, = 188 mm . . . (x)
Thickness of protective cover t/= 18.5 mm . . .(xi)
SAQ 3
(a) Sketch a muff aoupling and identify its advantages and disadvantages.
(b) Sketch a flange coupling and mention how strength of bolts and thickness of
the flange can be calculated.
(c) Mention materials for shaft, flange, keys and bolt.
(d) Show register in flange. What purpose does it serve?
(e) Design and draw a flange coupling, to connect two coaxial shafts of an
electric motor and worm and worm wheel reducer. The shafts transmit 7 kW
of power at 300 rpm. The permissible stresses are :
Shearing stress in shaft = 50 Nlmm2
Shearing stress in key = 25 ~ / m m '
Shearing stress in coupling = 3 N/mm2
Shearing stress in bolt = 25 Nlmm2
The results must consist of shaft diameter (d), which has to be increased by
25% to take care of keyway, number of bolds (n), diameter of bolts (dl),
pitch circle diameter of bolts (D,), diameter of hub (D), length of hub (L),
d
assume squarekey of size -, thickness of flange (t), outside flange
4
diameter (D,).
 Shafts and Couplings
8.10 SUMMARY
Shaft is an important machine element and transmits power. Shafts are of many types and
are made cylindrical. They are subjected to torque and bending moment, hence, at any
I point in the section of shaft there exists direct bending stress due to bending moment and
i shearing stress due to torque. They are designed against maximum principal stress or
maximum shearing stress. The load (comprising bending moment and torque) is
converted into equivalent bending moment or equivalent torque. The diameters are
calculated by modifying the expressions for equivalent bending moment and equivalent
torque by considering condition and manner of loading. The keyways become essential
feature of shafts because some part like gear or pulley has to be attached on it to transmit
power. The keys are standardised and can be selected from relevant table. There is yet
1
simpler method to use a square key of depth of - diameter of shaft. The shafts are often
4
I; made in carbon steel which can be heat treated. Alloy steel shafts are not uncommon if
b corrosive atmosphere exists. Cast iron shaft, though used rarely, will tend to become
heavier.
Couplings connect coaxial shafts. They are formed by two discs attached to shafts
through key and jointed by bolts, parallel to shaft axis. The discs are made as flanges
integral with the hub. The flanges are often made in cast iron. Muff couplings are thick
cylinders which could be used as sleeves or split to be bolted around the shaft. The
driving force in muff coupling is friction between the inner surface of muff and outer
surface of shaft. The muff can be a single piece sleeve keyed to shafts or split in halves
which are tightened by the bolts. The muff is made in cast iron.

8.1 1 KEY WORDS

t Shaft : A cylindrical machine part which transmits power
and is subjected to BM and torque.
: A part of rectangular cross-section which connects
gear or pulley to shaft.
Coupling : Device to connect coaxial shafts.
I
Muff : A hollow cylinder which may or may not be split
along central line.
Flange Coupling : Flanges integral with hub which connects to shaft
via key. Plane surfaces of two flanges on tw6 axial
shafts contact. The flanges are connected through
bolts.

ANSWERS TO SAQs
SAQ 1
(e) The shaft loading and BMD are shown in Figure 8.16. The pinion rotates
clockwise such that the line of centers of pinion and gear is perpendicular to
the shaft. The driving force P, acts tangential to gear at a radius of 100 mm,
so that torque given to shaft

AISO,Power H = M,o = M, 2 n x 6 0 0 = 1 5 ~ 1 0 w
3
60

M,= l5 lo' = 238.7 Nm = 238.7 x lo3 Nmm

20 x
Design of Power
Transmission Devices

P, is accompanied by a force component, radial to gear, in vertical direction

6 = 6 tan a = 2387 x tan 20 = 2387 x 0.3639 = 868.8 N . . . (ii)
The torque on 450 mm diameter pulley since T, = 3 T and Tz = T
450
M , = (3T - T) -Nmm = 238.7 x lo3
2

.. 4T = 2121.8 N . . . (iii)
This force acts transverse to the shaft at 60" to horizontal.
:. Vertical and horizontal components of 4T

4 = 4T sin 60' = 2 12 1.8 x 0.87 = 1837.5 N ? . . . (iv)

H I = 4T cos 60' = 2121.8 x 0.5 = 1061 N + . . . (v)
In horizontal plane the force P, on gear and force 4 T cos 60°, both act in the
same direction (Figure 8.16). For BM reactions at bearing are required call
them RI and R2 at RH and LH bearings as shown. Take moment about LH
bearing

So that R, = 2150 N, R, =3456 - 2 1 5 0 ~1306 N

Hence, BM at RH bearing = 1069 x 200 = 2.14 x lo5 N m m 2

BM at the section coinciding with mid thickness of gear

= - 1306 x 250 = - 3.26 x lo5 ~ m m ?

At pulley the vertical force upward 4 = 1837.5 N

Weight of pulley acts downward and is 800 N.
Net vertical force at pulley = 1837.5 - 800 = 1037.5 N ?
At gear downward vertical factor P, = 868.8 N 4
Figure 8.16 depicts the load on the shaft. To find BM we first determine
reactions at supports.
Take moments about LH bearing

So that R,' = 1024 N

and R; = 855.3 N ?

BM at RH bearing = 1037.5 x 200 = 2.075 x 10' Nmrn ?

BM at the section coinciding with mid thickness of gear

Apparently the BM at gear section will be highest.

 Shafts and Couplings

Vertical load '

I I
B M.DIVert Plane I
I
2 . 1 4 ~ 1 0m~m~t t 2 . 0 7 5 ~ 1 0N~mm

Figure 8.1 6
The resultant BM,
M = ,/(3.26)? x (2.14)' x 10' = 3.9 x 10' Nmm
The torque between the gear and pulley is constant at 2.4 x lo5 Nmm.
Use ASME formula with K,,, = 1.5, K, = 1,

T, = 0.18 x o, = 0.18 x 500 = 90 ~ l m m '

= 6.323 x 10' Nmm

This is the diameter at the section where gear is placed and due to keyway
the diameter is increased by 25%.
d =41.25say42mm . . . (a)
The diameter at RB bearing may also be calculated

M;, = ,/(I .5 x 3)' + (2.4)' x 10' = 5.1 x 10' Nmm

:. Diameter at RH bearing
1

There is no keyway at bearing but there is stress concentration due to press

fit and comer radius. The diameter is increased by 12.5%.
d ' = 34.875 say 35 mm
The diameter at LH bearing will be same as 35 mm.
Design of Power The diameter of overhang on right may be slightly less than 35 mm
Transmission Devices (Figure 8.17).
Gear

Figure 8.17 : Different Scales for Length and Diameter

SAQ 2
(e) Follow Example 8.2
Do = D, Di= 0.7 D

. . . (a)

MI 15.9 x lo6 x 2.0 x lo3 - -- n

Angle of twist, 8 = -L =
G J 8 . 2 ~ 1 0 ~ x 7 4 . 6 ~ 1 0 -180
~0~
1

D = (180 x 5.20 x 1 0 ~ =) 131.4

~ rnm . . . (b)

The diameter at (b) will be selected.

Do =131.5 mm, di =92rnrn
SAQ 3

(e) Follow Example 8.2 and match dimension with those shown in Figure 8.18.

Figure 8.18 I