ABSTRACT

Shafts are the most common and important machine element. Shafts are widely used mechanical components which are used to transmit power through devices such as gears and pulleys. The shaft is generally acted upon by bending moment, torsion and axial force. Design of shaft primarily involves in determining stresses at critical point in the shaft that is arising due to aforementioned loading. The friction and other losses in this type of power transmission equipment are comparatively very low. In this Mini Project we use a software called MATLAB to write a program to design a shaft. MATLAB stands for MATrix LABoratory. Hence, as the name suggests, here you play around with matrices. MATLAB is a numerical computing environment and fourth-generation programming language developed by Math Works. MATLAB allows matrix manipulations, plotting of functions and data, implementation of algorithms, creation of user interfaces, and interfacing with programs written in other languages, including C, C++, Java and FORTRAN.

MATLAB is extensively used for scientific and research purposes. It is accurate and also has a number of built in functions which makes it versatile. Still MATLAB is not effectively being used in mechanical engineering field. Our MATLAB code works for all solid shafts mounted with number of pulleys and gears. The program is user friendly one & when executed it ask the inputs and performs the necessary design calculations and gives necessary output values. We have taken both maximum shear stress theory and maximum normal stress theory into consideration. It also generates the diagrams for horizontal, vertical and resultant bending moments over the lengths of the shaft. As computers are used to perform the task of shaft design becomes simple, fast, friendly and error free.

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) setup within the shaft permits the power to be transferred to various machines linked up to the shaft. In order to transfer the power from one shaft to another, the various members such as pulleys, gears etc. are mounted on it. These members along with the forces exerted upon them causes the shaft to bending. In other words, we may say that a shaft is used for the transmission of torque and bending moment. The various members are mounted on the shafts by means of keys or splines. The shafts are usually cylindrical, but may be square or crossed-shaped in section. They are solid in crosssections but sometimes hollow shafts are also used. An axle, though similar in shape to the shaft, is a stationary machine element and is used for the transmission of bending moment only. It simply acts as a support for some rotating body such as hoist drum, a car wheel or a rope sheave. A spindle is a short shaft that impart motions either to a cutting tool (e.g. drill press spindle) or to a work piece (e.g. lathe spindle). Shafts must have adequate torsion strength to transmit torque and not to be over stressed. Components such as gears are mounted on shafts using keys. Shaft must sustain a combination of bending and torsion loads. In a highly competitive manufacturing industry, the total cost of design and manufacturing can be reduced and hence increase the competitiveness of the products if computers can solve the whole working procedures

MATERIAL USED FOR SHAFTS :

The ferrous, non-ferrous materials and non metals are used as shaft material depending on the application. Some of the common ferrous materials used for shaft are discussed below. 1. Hot-rolled plain carbon steel These materials are least expensive. Since it is hot rolled, scaling is always present on the surface and machining is required to make the surface smooth. 1.3.2 Cold-drawn plain carbon/alloy composition Since it is cold drawn it has got its inherent characteristics of smooth bright finish. Amount of machining therefore is minimal. Better yield strength is also obtained. This is widely used for general purpose transmission shaft. 1.3.3 Alloy steels Alloy steel as one can understand is a mixture of various elements with the parent steel to improve certain physical properties. To retain the total advantage of alloying materials one requires heat treatment of the machine components after it has been manufactured. Nickel, chromium and vanadium are some of the common alloying materials. However, alloy steel is expensive. These materials are used for relatively severe service conditions. When the situation demands great strength then alloy steels are used. They have fewer tendencies to crack, warp or distort in heat treatment. Residual stresses are also less compared to CS (Carbon Steel).

The material used for shaft should have the following properties : 1. 2. 3. 4. 5. It should have high strength. It should have good machinability. It should have low notch sensitivity factor. It should have good heat treatment properties. It should have high wear resistance properties.

MANUFACTURING OF SHAFTS :
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. The residual stresses may cause distortion of the shaft when it is machined, especially when slots or keyways are cut. Shafts of larger diameter are usually forged and turned to size in a lathe.

TYPES OF SHAFTS :
The following two types of shafts are important from our point of view : 1. Transmission shafts : These shafts transmit power between the source and the machines absorbing power. The counter shafts, line shafts, over head shafts and all factory shafts are transmission shafts. Since these shafts carry machine parts such as 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.

STANDARD SIZES OF TRANSMISSION SHAFTS :

Typical sizes of solid shaft that are available in the market are, 1. Up to 25 mm 0.5 mm increments 2. 25 to 50 mm 1.0 mm increments 3. 50 to 100 mm 2.0 mm increments 4. 100 to 200 mm 5.0 mm increments

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 loads.

MAXIMUM PERMISSIBLE WORKING STRESSES FOR TRANSMISSION SHAFTS :

According to American Society of Mechanical Engineers (ASME) code for the design of transmission shafts, the maximum permissible working stresses in tension or compression may be taken as (a) 112 MPa for shafts without allowance for keyways. (b) 84 MPa for shafts with allowance for keyways. For shafts purchased under definite physical specifications, the permissible tensile stress ( a) may be taken as 60 per cent of the elastic limit in tension (Syt), but not more than 36 per cent of the ultimate tensile strength (Sut). In other words, the permissible tensile stress,

a = 0.6 Syt or 0.36 Sut, whichever is less.

The maximum permissible shear stress may be taken as (a) 56 MPa for shafts without allowance for key ways. (b) 42 MPa for shafts with allowance for keyways. For shafts purchased under definite physical specifications, the permissible shear stress () may be taken as 30 per cent of the elastic limit in tension (Syt) but not more than 18 per cent of the ultimate tensile strength (Sut). In other words, the permissible shear stress,

= 0.3 Syt or 0.18 Sut, whichever is less.

DESIGN OF SHAFTS :
The shafts may be designed on the basis of 1. Strength 2. Rigidity and stiffness. In designing shafts on the basis of strength, the following cases may be considered : (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, and (d) Shafts subjected to axial loads in addition to combined torsional and bending loads.

DESIGN OF SHAFTS SUBJECTED TO TWISTING MOMENT 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. We know that, (T/J) = (r/) Where, T = Twisting moment (or torque) acting upon the shaft, J = Polar moment of inertia of the shaft about the axis of rotation,

= Torsional shear stress,

and r = Distance from neutral axis to the outer most fibre = d / 2; where d is the diameter of the shaft.

We know that for round solid shaft, polar moment of inertia, J = (/32)* d^4 This equation may now be written as T=(/16)**d^3 From this equation, we may determine the diameter of round solid shaft ( d ).

It may be noted that, 1. The twisting moment (T) may be obtained by using the following relation : We know that the power transmitted (in watts) by the shaft, P = (2**N*T) *60 Or T = (P*60)/2**N

Where, T = Twisting moment in N-m, and N = Speed of the shaft in r.p.m.

2. In case of belt drives, the twisting moment ( T ) is given by T = (T1 T2 ) R where T1 and T2 = Tensions in the tight side and slack side of the belt respectively, and R = Radius of the pulley.

DESIGN OF SHAFTS SUBJECTED TO BENDING MOMENT ONLY :

When the shaft is subjected to a bending moment only, then the maximum stress (tensile or compressive) is given by the bending equation. We know that, (M/I) = (b/Y) Where, M = Bending moment, I = Moment of inertia of cross-sectional area of the shaft about the axis of rotation,

b = Bending stress, and

y = Distance from neutral axis to the outer-most fibre. We know that for a round solid shaft, moment of inertia, I = (/64)*d^4 and Substituting these values in equation , we have M= (/32)* b*d^3 From this equation, diameter of the solid shaft (d) may be obtained. y = d/2

DESIGN OF SHAFTS SUBJECTED TO COMBINED BENDING AND TWISTING 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. 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 Rankines theory. It is used for brittle materials such as cast iron.

Let

= Shear stress induced due to twisting moment, and

b = Bending stress (tensile or compressive) induced due to bending moment.

According to maximum shear stress theory, the maximum shear stress in the shaft,

max = (1/2) [{b}^2+4{}^2]

Substituting the values of

and b,

max = (1/2) [(32M/*d^3)^2 + 4(16T/*d^3)^2]

Or, Or,

max = (16/d^3)[ (M^2 + T^2) ]

(/16)*

max*d^3= (M^2 + T^2)

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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 () as the actual twisting moment. By limiting the maximum shear stress ( max) equal to the allowable shear stress () for the material, the above equation may be written as, Te = (M^2 T^2) = (/16)**d^3 From this expression, diameter of the shaft ( d ) may be evaluated Now according to maximum normal stress theory, the maximum normal stress in the shaft, b max = 0.5b + 0.5 [(b)^2 + 4()^2] = 0.5 (32M/*d^3) + 0.5 [(32M/*d^3)^2 +4(16T/*d^3)^2] = (32/*d^3)[0.5{M + (M^2 + T^2)}] (/32)* b max*d^3 = 0.5 [M + (M^2 + T^2)]

Or,

The 0.5[M + (M^2 + T^2)] expression is known as equivalent bending moment and is denoted by Me. The equivalent bending moment may be defined as that moment which when acting alone produces the same tensile or compressive stress (b) as the actual bending moment. By limiting the maximum normal stress [bmax)] equal to the allowable bending stress (b), then the above equation may be written as Me = 0.5 [M + (M^2 + T^2)] = (/32)*b*d^3 From this expression, diameter of the shaft ( d ) may be evaluated.

NOTE: 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

SHAFTS SUBJECTED TO AXIAL LOAD IN ADDITION TO COMBINED TORSION AND BENDING LOADS :

When the shaft is subjected to an axial load (F) in addition to torsion and bending loads as in propeller shafts of ships and shafts for driving worm gears, then the stress due to axial load must be added to the bending stress (b). We know that bending equation is M/I= b/Y Or b= 32M/*d^3

and stress due to axial load, =F/(/4)*d^2 = 4F/*d^2 therefore, Resultant stress (tensile or compressive) for solid shaft, 1=(32M/*d^3) + (4F/*d^2) = (32/*d^3)*(M + (F*d/8)) =32M1/*d^3 M1= M + (F*d/8)

Or Where,

In case of long shafts (slender shafts) subjected to compressive loads, a factor known as column factor () must be introduced to take the column effect into account. Stress due to the compressive load, c=*4F/*d^2 The value of column factor () for compressive loads* may be obtained from the following relation : Column factor, =1/(1-0.0044(L/K)) This expression is used when the slenderness ratio (L / K) is less than 115. When the slenderness ratio (L / K) is more than 115, then the value of column factor may be obtained from the following relation : Column factor, = (y(L/K)^2)/C*E*^2

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where

L = Length of shaft between the bearings, K = Least radius of gyration, y = Compressive yield point stress of shaft material, and C = Coefficient in Euler's formula depending upon the end conditions.

The following are the different values of C depending upon the end conditions. C =1, for hinged ends, = 2.25, for fixed ends, = 1.6, for ends that are partly restrained as in bearings. Note: In general, for a hollow shaft subjected to fluctuating torsional and bending load, along with an axial load, the equations for equivalent twisting moment (Te) and equivalent bending moment (Me) may be written as,

It may be noted that for a solid shaft, k = 0 and d0 = d. When the shaft carries no axial load, then F = 0 and when the shaft carries axial tensile load, then = 1.

DESIGN OF SHAFTS ON THE BASIS OF RIGIDITY:

Sometimes the shafts are to be designed on the basis of rigidity. We shall consider the following two types of rigidity:

1. Torsional Rigidity. The torsional rigidity is important in the case of camshaft of an I.C. engine where the
timing of the valves would be effected. The permissible amount of twist should not exceed 0.25 per metre length of such shafts. For line shafts or transmission shafts, deflections 2.5 to 3 degree per metre length may be used as limiting value. The widely used deflection for the shafts is limited to 1 degree in a length equal to twenty times the diameter of the shaft. The torsional deflection may be obtained by using the torsion equation, T/J=(G*)/L Or =(T*L)/(J*G) where = Torsional deflection or angle of twist in radians, T = Twisting moment or torque on the shaft, J = Polar moment of inertia of the cross-sectional area about the axis of rotation, G = Modulus of rigidity for the shaft material, and L = Length of the shaft.

2. Lateral rigidity. It is important in case of transmission shafting and shafts running at high speed, where
small lateral deflection would cause huge out-of-balance forces. The lateral rigidity is also important for maintaining proper bearing clearances and for correct gear teeth alignment. If the shaft is of uniform cross-section, then the lateral deflection of a shaft may be obtained by using the deflection formulae as in Strength of Materials. But when the shaft is of variable cross-section, then the lateral deflection may be determined from the fundamental equation for the elastic curve of a beam, i.e. d^2y/dx^2=M/E*I

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DESIGN OF SHAFTS IN ACTUAL PRACTICE :

In the previous articles we have 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 because of change of power and loads due to voltage variations, and the surroundings nature like non-uniformity of roads as in case of automobiles. Hence for designing such shafts, subjected to this type of fluctuating loads, certain safety factors called shock and fatigue factors may be taken into account. Let Km = Combined shock and fatigue factor for bending. Kt = Combined shock and fatigue factor for torsion. By including the above factors, the equivalent torque Te, may be changed as Te = [(Km*M)^2 + (Kt*T)^2] And the equivalent bending moment Me, may be changed as, Me = 0.5 [(Km*M) + {(Km*M)^2 + (Kt*T)^2}]

Table: Shock and Fatigue factors Nature of load 1. Stationary shafts : (i) Gradually applied load (ii) Suddenly applied load 2. Rotating shafts : (i) Gradually applied load (ii) Suddenly applied load with minor shock (iii) Suddenly applied load with major shock 1.5 1.5 to 2.0 2.0 to 3.0 1.0 1.0 to 1.5 1.5 to 3.0 1.0 1.5 to 2.0 1.0 1.5 to 2.0 Km Kt

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MATLAB :
MATLAB stands for MATrix LABoratory. Hence, as the name suggests, here you play around with matrices. MATLAB is a numerical computing environment and fourth-generation programming language. Developed by Math Works, MATLAB allows matrix manipulations, plotting of functions and data, implementation of algorithms, creation of user interfaces, and interfacing with programs written in other languages, including C, C++, Java and FORTRAN. MATLAB is a high-performance language for technical computing. It integrates computation, visualization, and programming in an easy-to-use environment where problems and solutions are expressed in familiar mathematical notation. Typical uses include:1. Math and computation 2. Algorithm development 3. Data acquisition 4. Modeling, simulation, and prototyping 5. Data analysis, exploration, and visualization 6. Scientific and engineering graphics 7. Application development, including graphical user interface building

MATLAB is an interactive system whose basic data element is an array that does not require dimensioning. This allows you to solve many technical computing problems, especially those with matrix and vector formulations, in a fraction of the time it would take to write a program in a scalar noninteractive language such as C or Fortran. The name MATLAB stands for matrix laboratory. MATLAB was originally written to provide easy access to matrix software developed by the LINPACK and EISPACK projects. Today, MATLAB engines incorporate the LAPACK and BLAS libraries, embedding the state of the art in software for matrix computation. MATLAB has evolved over a period of years with input from many users. In university environments, it is the standard instructional tool for introductory and advanced courses in mathematics, engineering, and science.

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In industry, MATLAB is the tool of choice for high-productivity research, development, and analysis. MATLAB features a family of add-on application-specific solutions called toolboxes. Very important to most users of MATLAB, toolboxes allow you to learn and apply specialized technology. Toolboxes are comprehensive collections of MATLAB functions (M-files) that extend the MATLAB environment to solve particular classes of problems. Areas in which toolboxes are available include signal processing, control systems, neural networks, fuzzy logic, wavelets, simulation, and many others.

There are 4 main windows: Command window: This is the main window where you write the commands, as well as see the outputs. In Other words, here is your interaction with the software. Command History: As the name suggests, it shows the list of the commands recently used in chronological order. Hence, you can double click on a command to execute it again. Current directory: It is the default directory (folder) for saving your files. All the files which you make (like mfiles) are saved here and can be accessed from here directly. The location of the current directory is shown in the toolbar at the top. You can change it by changing the address here. Workspace: It displays the list of the variables defined by you in the current session of MATLAB.

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THE MATLAB SYSTEM

The MATLAB system consists of five main parts:-

Development Environment: This is the set of tools and facilities that help you use MATLAB functions and
files. Many of these tools are graphical user interfaces. It includes the MATLAB desktop and Command Window, a command history, an editor and debugger, and browsers for viewing help, the workspace, files, and the search path.

The MATLAB Mathematical Function Library: This is a vast collection of computational algorithms
ranging from elementary functions, like sum, sine, cosine, and complex arithmetic, to more sophisticated functions like matrix inverse, matrix eigen values, Bessel functions, and fast Fourier transforms.

The MATLAB Language: This is a high-level matrix/array language with control flow statements, functions,
data structures, input/output, and object-oriented programming features. It allows both "programming in the small" to rapidly create quick and dirty throw-away programs, and "programming in the large" to create large and complex application programs.

Graphics: MATLAB has extensive facilities for displaying vectors and matrices as graphs, as well as annotating
and printing these graphs. It includes high-level functions for two-dimensional and three-dimensional data visualization, image processing, animation, and presentation graphics. It also includes low-level functions that allow you to fully customize the appearance of graphics as well as to build complete graphical user interfaces on your MATLAB applications.

The MATLAB Application Program Interface (API): This is a library that allows you to write C and
Fortran programs that interact with MATLAB. It includes facilities for calling routines from MATLAB (dynamic linking), calling MATLAB as a computational engine, and for reading and writing MAT-files.

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SCRIPTS AND FUNCTIONS IN MATLAB

MATLAB is a powerful programming language as well as an interactive computational environment. Files that contain code in the MATLAB language are called M-files. You create M-files using a text editor, then use them as you would any other MATLAB function or command. There are two kinds of M-files: 1. Scripts: which do not accept input arguments or return output arguments. They operate on data in the workspace. When you invoke a script, MATLAB simply executes the commands found in the file. Scripts can operate on existing data in the workspace, or they can create new data on which to operate. Although scripts do not return output arguments, any variables that they create remain in the workspace, to be used in subsequent computations. In addition, scripts can produce graphical output using functions like plot. 2. Functions: which can accept input arguments and return output arguments. Internal variables are local to the function. The names of the M-file and of the function should be the same. Functions operate on variables within their own workspace, separate from the workspace you access at the MATLAB command prompt. If you're a new MATLAB programmer, just create the M-files that you want to try out in the current directory. As you develop more of your own M-files, you will want to organize them into other directories and personal toolboxes that you can add to your MATLAB search path. If you duplicate function names, MATLAB executes the one that occurs first in the search path.

DESIGNING USING MATLAB :

In this project we are going to design a MATLAB code and a MATLAB script file is developed to design a solid shaft mounted with gears and pulleys and generates bending moment diagrams. Inputs used in this work are speed, length of the shaft, diameter, weight, and power for gears and pulleys, distances of pulleys and gears to the right of the left hand bearing, allowable shear and tensile stresses etc. for the given shaft.

MATLAB OUTPUT WINDOW :

The MATLAB code we designing takes the input values and the logic that we have formulated gives the output values such as torque, tangential, radial force for gears, torque, total vertical and horizontal loads for pulleys and maximum bending moments, torques and the final standard diameter of the shaft. It also generates horizontal, vertical and resultant bending moment diagrams over the length of the shafts.

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DESIGNING OF SOLID SHAFT BY MATLAB PROGRAMMING:

This mini project presents a computer-aided technique in solving solid shafts design problems . The work was done using MATLAB programming. This project idea was tested on a number of benchmark shaft design problems in the determination of shaft diameter, and other design parameters. The results obtained were highly accurate and it also exhibited a very high efficiency. In our 1st Mini projects presentation, we are going to solve some fundamental problems of shaft designs to demonstrate our main idea behind our project. In this presentation we are solving a problem based on goodmans line of shaft subjected to varying loads and a solid shaft subjected to reverse axial load considering various factors such as surface finish factor, size factors, reliability factors etc.

PROBLEM 1: A steel shaft is subjected to a reverse axial load of 180 KN. find the diameter of shaft for factor of safety of 2 . The material has a Sut of 1070 MPa and Syt of 910 MPa. The endurance strength in reversed bending may be taken as 1/2th of the ultimate tensile strength. other correction factor may be taken as follows: factor for axial loading is 0.7, for size is 0.85 and for stress conc. for fatigue load is 1

Analytical Solution 1: By solving this problem analytically, we get the values for actual endurance limit, Se= 226.01 Mpa , permissible stress= 112.56 Mpa and the diameter of shaft for safe design is found to be 38.88 mm

Solving By Matlab: (a)Algorithm Design: 1. Input variables such as factor of safety (f.s), Sut, Syt, Se_standard (endurance limit for a standard specimen of same material), Kl (factor for axial loading), size factor (kb), stress conc factor for fatique load (kf) 2. solving for surface finish factor, actual endurance limit (Se) and diameter for safe design (diam) 3. print diameter, actual endurance limit, all factors, allowable stress as output in MATLAB output window

(b) Programming Codes: 1st FILE:function shaftdesigner_1(p,fs,sut,syt,kl,kb,kf) global diam %Se_standard: se_standard=0.5*sut %various factors: ka=4.51*(sut)^(-0.265) kb

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kl kd=1/kf %se: se=kl*kb*kd*ka*se_standard %permissible_stress: permissible_stress=se/fs %diameter for safe design: diam=sqrt((p*fs)/se) end

2nd FILE:clear all clc global diam p=180000; fs=2; sut=1070; syt=910; kl=0.7; kb=0.85; kf=1; err=1; while err>0.01 err=diam; shaftdesigner_1(p,fs,sut,syt,kl,kb,kf) err=abs(diam-err)/diam; end

OUTPUT BY MATLAB:By solving it by above mentioned MATLAB code the values we get are: se_standard = 535 Mpa ka = 0.7102 kb = 0.8500 kl = 0.7000 kd = 1 se = 226.0792 Mpa

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permissible_stress = 113.0396 Mpa diam = 39.9044 mm

Problem 2: A shaft of circular cross-section is subjected to alternating tensile force varying from 200kN to a max of 500KN. It is to be manufactured of a material of sut=900MPa and Se= 700 MPa. find diameter of the shaft using factor of safety 3.5 related to ultimate tensile strength and 4 related to endurance limit. stress concentration factors of 1.65 for fatigue load. use goodman straight line as a design basis. Analytical Solution 2: By solving this problem analytically using goodmans criterion, we get the values for actual endurance limit, Se= 424.24 Mpa , kd=0.60 and the diameter of shaft for safe design is found to be 59.44 mm

Solving By Matlab: (a)Algorithm Design: 1. Input variables such as maximum and minimum alternating forces (pmax and pmini), factor of safety for both sut and se (fs_se and fs_sut), Sut, Se_standard (endurance limit for a standard specimen of same material), stress conc factor for fatique load (kf) 2. solving for actual endurance limit (Se), mean stress, amplitude stress and diameter for safe design (diam) using goodmans criterion 3. printing diameter, actual endurance limit, all factors, and other data as output in MATLAB output window

(b) Programming Codes: 1st FILE:function shaftdesigner_2(pmini,pmax,sut,se_standard,fs_se,fs_sut,kf) global diam %maximum and minimum alternating force: pmini pmax %ultimate tensile strenght: sut %theoritical endurance strength: se_standard %factor of safety: fs_se fs_sut %stress conc factor for fatique load:

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kf %kd: kd= 1/kf

%actual endurance strength: se=kd*se_standard

%Mean stress: sigma_mean=(pmax+pmini)/2*diam;

%Amplitude stress: sigma_amp=(pmax-pmini)/2*diam;

%diameter for safe design: diam= sqrt((2*(fs_se*se*(pmax+pmini)+fs_sut*sut*(pmax-pmini)))/(pi*sut*se))

end 2nd FILE:clear all clc global diam pmini=200000; pmax=500000; sut=900; se_standard=700; fs_se=3.5; fs_sut=4; kf=1.65; err=1; while err>0.01 err=diam; shaftdesigner_2(pmini,pmax,sut,se_standard,fs_se,fs_sut,kf) err=abs(diam-err)/diam; end

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OUTPUT BY MATLAB:By solving it by above mentioned MATLAB code the values we get are: pmini = 200000 N pmax = 500000 N sut = 900 Mpa se_standard = 700 Mpa fs_se = 3.5 fs_sut = 4 kf = 1.6500 kd = 0.6061 se = 424.2424 Mpa diam = 59.4453 mm

Problem 3: A 50 mm diameter shaft is made from carbon steel having ultimate tensile strength of 630 MPa and yield tensile strength of 510 MPa. it is subjected to a torque which fluctuatebetween 2000 Nm to -800 Nm. Using soderberg method, calculate factor of safety. assume suitable values from any other data needed. Analytical Solution 2: By solving this problem analytically using Soderbergs criterion, we get th e values for maximum and minimum torque equal to 81.48 Mpa and -32.55MPa, mean and amplitude shear stress of 24.44 MPa and 57.04 Mpa and factor of safety = 2.21

Solving By Matlab: (a)Algorithm Design: 1. Input variables such as maximum and minimum torque, diameter of shaft, sut, syt 2. solving for actual endurance limit (Se), mean shear stress, amplitude shear stress and factor of safety for safe design (fs) using soderbergs criterion 3. printing all parameters required as output in MATLAB output window

(b) Programming Codes: 1st FILE:function shaftdesigner_3(diam,sut,syt,torque_max,torque_mini) global fs diam torque_max torque_mini sut syt

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%Se: se=0.5*sut %yield strength in shear: ssy=0.5*syt %endurance strength in shear: sse=0.5*se %maximum and minimum shear stress: tau_max=(16*torque_max)/(pi*(diam^3)) tau_mini=(16*torque_mini)/(pi*(diam^3)) %mean and amplitude shear stress: tau_mean=(tau_max+tau_mini)/2 tau_amp=(tau_max-tau_mini)/2 %factor of safety: fs=(ssy*sse)/((tau_mean*sse)+(tau_amp*ssy)) 2nd FILE:clear all clc global fs diam=50; sut=630; syt=570; torque_max=2000000; torque_mini=-800000;

err=1; while err>0.01 err=fs; shaftdesigner_3(diam,sut,syt,torque_max,torque_mini) err=abs(fs-err)/fs; end

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OUTPUT BY MATLAB:By solving it by above mentioned MATLAB code the values we get are: diam = 50 mm torque_max = 2000000 Nm torque_mini = -800000 Nm sut = 630 MPa syt = 570 Mpa se = 315 Mpa ssy = 285 Mpa sse = 157.5000 Mpa tau_max = 81.4873 MPa tau_mini = -32.5949 MPa tau_mean = 24.4462 MPa tau_amp = 57.0411 Mpa fs = 2.2324

RESULT AND DISSCUSSION:

The answers generated by MATLAB code are verified with the textbook answers and are proved to be correct. MATLAB code can also works for any solid shaft simply supported on bearings carrying number of gears and pulleys. Test aimed at investigating the operational efficiency of the developed computer program to determine the efficiency of the computer program in determining the diameter of the shaft and other parameters. The input design parameters needed to carry out the design specifications of a processing machine were determined using the developed computer program.

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CONCLUSION :
The programme was designed and implemented using MATLAB language. The structure of the program is such that there are three stages. These stages include the input stage, analysis and output stage.

Input stage:
At this stage, the user enters the required information about the design parameters of the shaft, in the input interface form. The program is well written in such a way that the computer program requires minimal input to carry out its analysis.

Analysis stage:
After the required data is in entered, the analysis carried out. Once the data is entered, the MATLAB computes all the parameters required in analyzing the design parameters of the shaft in less than 1 seconds depending on the speed of the processor.

Output stage:
The software is designed such that the shaft design parameters are outputted numerically and graphically with the accompanying description of the result. From the results obtained from the computer program, it can be deduced that the shaft diameter can be Determined at ease using the MATLAB program.

At Our Final Mini Project presentation, we will solve number of more complex problem of designing of solid shafts on different concepts and taking various factors into consideration. This Presentation is just to demonstrate the idea behind our project. By solving above fundamental problems by MATLAB, it is clear that MATLAB is a very effective and useful tool in Mechanical design engineering industries. It solves our problem effectively as well as more quickly.

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REFERENCES:
[1] Shigley, J.E. and Uicker,J.J.,Theory of machines and mechanisms, Mc-Graw Hill, 1986 [2] R.S. KHURMI and J.K. GUPTA, Theory Of Machine, S.Chand Publications,Edition 16 reprint (2008), pp.382-397 [3] Rudra Pratap, Getting started with MATLAB Oxford university Press, updated for Version 7.8 (2009). [4] Machine Design by S.Md.Jalaludee, Anuradha Publications (2009) [5] Design Data Hand Book for Mechanical Engineers By K.Mahadevan & K.Balaveera Reddy. [6] Chang K.Y, Gene E.J, Kevin C. M (2002): An Integrated Computer-Aided System and Parts Component Repository For Shaft Design Automation, Journal of Marine Science and Technology, Vol. 10(1), pp. 68-76. [7] Khurmi, R.S and Gupta J.K (2005) A Textbook of Machine Design, Fourteenth Edition, S. Chand and Company Limited, New Delhi. [8] Oko, C.O.C (2005) Engineering Thermodynamics: An Algorithmic Approach, Worldwide Communication Limited, Lagos. [9] Rajput, R.K (2006) Strength of Materials, Fourth Edition, S. Chand and Company Limited, New Delhi. [10]Umezurike, C. (2010) A Lecture Manual on Theories of Elasticity and Plasticity, Department of Mechanical Engineering, University Of Port Harcourt [11] Bhandari, V.B. Third Reprint(2011), Design Of Machine Elements, McGraw Hill, New Delhi

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