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Shaft
Design #5

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1) Shaft Design
The objective of this design practice is to design a shaft made of AISI 120 cold-draw steel. The
shaft is the drive shaft for a large bulk conveyor which the gear receives 40 hp with a period of 120 rpm.
Each chain sprocket delivers 20 hp to the conveyor. After specifying all the dimensions, include a scaled
drawing of the shaft.

2) Introduction
Mechanical shafts are devices that deliver motion and force through components like spur gears,
chain sprockets, agitators, fans, pumps and others. The delivery of power using rotational speed in shaft is
inherited in a torsional moment. Other elements like sheaves and gears causes transverse direction forces
which results in bending moments in a shaft.
On the design of the shaft, after specifying the material that will be used, it is important to
propose reasonable geometries for the shaft to carry a variety of power transmitting elements. Another
important factor is to calculate the forces acting on the shaft by gears, bearings and chain sprockets.
According to these forces, the bending moment and shearing forces diagram were calculated. This values
area a key component for sizing the diameter of the shaft in different sections so that it will support the
torque and shearing forces. Compare the minimum dimensions with the standard values of bearing
diameter table. With all the dimensions, adjust in the shaft can be made in order to minimize machining,
reducing the cost of the product. This shaft was sketched on scale with distance of the components, as
well as theyre sizes and shaft diameters in each section.

3) Procedure
3.1)

Specify the material and its mechanical properties:

3.2)

Find the Endurance Strength using the Endurance Strength Vs Tensile Strength for Wrought Steel
table.

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3.3)

Stipulate a size factor, Cs , for the shaft once its size is unknown. A Size Factor can be chosen
from the Size factor for shaft design graphic.

3.4)

Stipulate a reliability factor, Cr , according to the reliability factor table.

3.5)

Computing the Modified Endurance Strength, Sn:

S n S n Cs Cr (I),

3.6)

Stipulate a Design Factor, N:

3.7)

Compute the Torque, T, in the shaft from equation:

T 63000

( P)
(II), where P is the power and n is the period.
n

3.8)

Calculate forces on the shaft components:

A)

Forces on the Spur Gear A:

Wt

T
(III) ,where Wt is the tangential force and D is the pitch diameter.
D/2

Wr Wt tan( ) (IV) , where Wr is the radial load and is the pressure angle

B)

Forces on the Chain Sprockets C and D:

Fn

T
(V) ,where T is torque exerted on sprocket by the shaft.
D/2

Fn x Fn cos( ) (VI) which is the horizontal component of the normal pressure force.
Fn y Fn sin( ) (VII) which is the vertical component of the normal pressure force

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3.9)

Calculate the Load, shear and Moment Diagrams:

From the bending moment diagram,

M M 2 x M 2 y (VIII)

3.10)

Calculate the minimum diameter of each section on the shaft.

A) For the Spur gear

Sy

N 3
T
d

ZP

D3

(IX), where d is the distorted energy theory

(X)

16 ZP

(XI)

B) For the Sprocket

Kt M
32 N
D

S n

3 T

4 S y

1
3

(XII), where:

Kt = Shoulder fillets (2.5 for sharp fillet, and 1.5 for well-rounded fillet)

C) For the Bearing

There is no torque or bending moment for the bearing, but there is a vertical shearing
force equal to the reaction of the bearing.
2

Vx V y

(XIII), where V is the shearing force

4 V
(XIV), where is the vertical stress and A is the area,
3 A

D2
(XV), then
4

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4 A
(XVI),

3.11) Using the Basic Size table and the Bearing selection table specify the diameters of the shaft and
bearings.

3.12) Draft a scaled drawing of the shaft with the shaft design results.

4) Calculations:
4.1)

Specify the material and its mechanical properties:

Material: Cold-Drawn Steel AISI 1020
Yield Strength (Sy): 51 Kpsi
Tensile Strength (Su): 61 Kpsi
Percent Elongation: 15%

4.2)

Endurance Strength:
Sn = 24 Kpsi for a machined shaft

4.3)

Size Factor, Cs :
Cs = 0.88

4.4)

Reliability Factor, Cr :
Cr = 0.88

4.5)

Modified Endurance Strength, Sn:

S n 24000 0.88 0.81 17,107 psi

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4.6)

Design Factor, N:
N=3

4.7)

Torque, T:

T 63000

(40)
21,000 lb.in total in the shaft
120

Torque distribution on the shaft:

TAC TAD 63000

( 20)
10,500 lb.in from spur gear A to sprocket C and to sprocket
120

4.8)

Forces on the shaft components:

A)
Wt

Forces on the Spur Gear A:

21,000
2,625 lb.in (vertical component, FAy)
16 / 2

Wr 2625 tan(20) 955,4 lb.in (horizontal component, FAx)

B)

Forces on the Chain Sprockets C and D:

FnC FnD

10,500
1,500 lb.in net driving force
14 / 2

FCx FDx 1500 cos(180) 1,500 lb.in horizontal component Fn

FCy FDy 1500 sin(180) 0 lb.in vertical component of Fn

4.9)

Load, Shear and Moment Diagrams:

A) On X-axis,

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Where:
P1 (Spur Gear A) = Wr = 955.4 lb.in
A (Bearing B) = FBx = 2,614 lb.in
P2 (Sprocket C) = FCx = 1500 lb.in
P3 (Sprocket D) = FDx = 1500 lb.in
B (Bearing E) = FEx = 1,340 lb.in
X-Axis Load Diagram

Spur Gear A, VAx = -955.4 lb.in

Bearing B, VBx = 1,659.2 lb.in
Sprocket C, VCx = 159.2 lb.in
Sprocket D, VDx = -1,340.8 lb.in
Bearing E, VEx = 0 lb.in
X-Axis Shear Diagram

Spur Gear A, MAx = 0 lb.in

Bearing B, MBx = -636.9 lb.in
Sprocket C, MCx = 192.7 lb.in
Sprocket D, MDx = 670.4 lb.in
Bearing E, MEx = 0 lb.in

X-Axis Moment Diagram

A) On Y-axis,
Where:
P1 (Spur Gear A) = Wt = 2,625 lb.in
A (Bearing B) = FBy = 3,062 lb.in
P2 (Sprocket C) = FCy = 0 lb.in
P3 (Sprocket D) = FDy = 0 lb.in
B (Bearing E) = FEy = 437 lb.in
Y-Axis Load Diagram

Spur Gear A, VAy = -2,625 lb.in

Bearing B, VBy = 437.5 lb.in
Sprocket C, VCy = 437.5 lb.in
Sprocket D, VDy = 437.5 lb.in
Bearing E, VEy = 0 lb.in
Y-Axis Shear Diagram

Spur Gear A, MAy = 0 lb.in

Bearing B, MBy = -1,750 lb.in
Sprocket C, MCy = -1,531.3 lb.in
Sprocket D, MDy = -218.8 lb.in
Bearing E, MEy = 0 lb.in
Y-Axis Moment Diagram

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M A 0 2 x 02 y 0 lb.in (VIII)
M B 636.9 2 x 1750 2 y 1863.3 lb.in (VIII)
M C 192.7 2 x 1531.32 y 1543.4 lb.in (VIII)
M D 670.4 2 x 218.82 y 705.2 lb.in (VIII)
M E 02 x 02 y 0 lb.in (VIII)

4.10)

Minimum Diameter of each section on the shaft.

A) Spur gear diameter

51000 29427

9809 psi (IX)

3
3 3

ZP

21000
2.14 in3
9809

D3

16 2.14 3
10.9 2.22 in (XI)

(X)

B) Left and Right of Bearing B

32 3

DBL

1.5 1863.3

17107

3 21000

4 51000

1
3

0.16 2

0.127

30.6

0.27 2

0.127

1
3

30.6

30.6 0.39 3 2.27

in (XI),
32 3

DBR

2.5 1863.3

17107

3 21000

4 51000

in (XI).

C) Left and Right of Chain C

1
3

1
3

30.6 0.45 3 2.37

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32 3

DCL

2.5 1543.4

17107

1.5 1543.4

17107

3 10500

4 51000

3 10500

4 51000

1
3

0.23 2

0.03

30.6

0.14 2

0.03

1
3

30.6

30.6 0.29 3 2.05

in (XI),
32 3

DCR

1
3

1
3

30.6 0.22 3 1.88

in (XI).

D) Left and Right of Chain D

32 3

DDL

2.5 705.2

17107

1.5 705.2

17107

3 10500

4 51000

3 10500

4 51000

1
3

30.6

0.1 2

0.03

30.6

0.06 2

1
3

30.6 0.2 3 1.82

in (XI),
32 3

DDR

1
3

0.03

1
3

30.6 0.18 3 1.75

in (XI),

E) Left and Right of Chain E

32 3

DEL DER

2. 5 0

17107

3 10500

4 51000

1
3

30.6

0 0.03

1
3

30.6 .17 3 1.72

(XI),

F) For the Bearing E

There is no torque or bending moment for the bearing, but there is a vertical shearing
force equal to the reaction of the bearing.
V

1659.2 2 437.52 1715.9 lb.in (XII), where V is the shearing force

21000

4 1715.9
6863.6
A
0.11 in2 (XII)
3 A
63000

in

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0.11

D2
(XIII)
4

4 0.11
0.37 in (XIV),

4.11) According to the Bearing table and the standard diameter,

Sheave

DA

Diame
ter
Numb
er
2.22

Bearing

DBL

2.27

2 1/2

2.500

Nothing

DBR

2.37

2 1/2

2.500

Sprocket

DCL

2.05

2 1/4

2.250

Nothing

DCR

1.88

2.000

Sprocket

DDL

1.82

2.000

Nothing

DDR

1.75

2.000

Bearing

DEL

1.72

2.000

Sheave

DER

1.72

2.000

Mating
Part

Diame
ter
Ident.

Specified
Diameter
Fracti
Decim
on
al
2 1/4
2.250

4.12) See scaled Shaft sketch on page 11.

5) Results:
Data: AISI 1020 Cold Draw Steel
Yeld Strength Sy =
Tensile Strength Su =
Percent Enlongation =
Endurance Strength for a Machined Shaft Sn =
Size Factor Cs =
Reliability Factor Cr =

Calculated
51000 psi
61000 psi
15 %
24000 psi
0.88
0.88

B)

Modified Endurance Strength S'n =

17107

C)

Design Factor N =

D)

Torque T =
Torque Tac = Tad

E)

Horizontal Force on Spur Gear A Wt =

A)

psi

3
21000
10500

lb.in
lb.in

2.625

lb.in

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Vertical Force on Spur Gear A Wr =

F)

G)

H)

I)

5) Conclusions:

955.4

lb.in

1500

lb.in

1500

lb.in

lb.in

X-Axis Moment on:

Spur Gear A. Ma =
Bearing B. Mb =
Chain Sprocket C. Mc =
Chain Sprocket D. Md =
Bearing E. Me =

0
-636.9
192.7
670.4
0

lb.in
lb.in
lb.in
lb.in
lb.in

Y-Axis Moment on:

Spur Gear A. Ma =
Bearing B. Mb =
Chain Sprocket C. Mc =
Chain Sprocket D. Md =
Bearing E. Me =

0
1863.3
1543.4
705.2
0

lb.in
lb.in
lb.in
lb.in
lb.in

Net Driving Force on Chain Sprocket C & D

Fnc = Fnd =
Horizontal Force on Chain Sprocket C & D
Fxc = Fxd =
Vertical Force on Chain Sprocket C & D Fyc =
Fyd =

Minimum Diameters:
Sharp shoulder fillet. Kt =
Well-rounded shoulder fillet. Kt =
Spur Gear A. Da =
Left of Bearing B. Dbl =
Right of Bearing B. Dbr =
Left of Chain Sprocket C. Dcl =
Right of Chain Sprocket. Dcr =
Left of Chain Sprocket D. Ddl =
Right of Chain Sprocket D. Ddr =
Left of Bearing E. Del =
Right of Bearing E. Der =

J)

Vertical Shearing Force on Bearing E. Ve =

Minimum Bearing E diameter. De =

K)

Shaft Dimensions
Spur Gear A. Da =
Left of Bearing B. Dbl =
Right of Bearing B. Dbr =
Left of Chain Sprocket C. Dcl =
Right of Chain Sprocket. Dcr =
Left of Chain Sprocket D. Ddl =
Right of Chain Sprocket D. Ddr =
Left of Bearing E. Del =
Right of Bearing E. Der =

2.5
1.5
2.22
2.27
2.37
2.05
1.88
1.82
1.75
1.72
1.72
1715.9
0.37

2.250
2.500
2.500
2.250
2.000
2.000
2.000
2.000
2.000

in
in
in
in
in
in
in
in
in
lb.in
in

in
in
in
in
in
in
in
in
in

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A shaft with a larger diameter close to the source of torque would be thicker than the section close
to the chain sprockets C & D. A standard diameter size among the chain C and bearing E was used to
diminish machining. Components D and E would be held in place with keys.

6) AISI 1020 Cold-Draw Steel Shaft Sketch (scale: 1 = 1-0):