SHAFT DESIGN

Problem: Design for Shaft Diameter ---> Input Modified By:

---> Calculated Tim Sexton
Fall 2003
L y
W1
b
z
y a q W2
x
d
q

Rzg1 Rzg2
B C
D Ryg1
Ballbeari A
ngs Gear Gear 2 Ryg2
2
Gear
1 R2y
R1y Gear
1
Gear & Bearing Placement Shaft Material Properties (Steel) Surface Finish (pg378)
L 6.5 in E 3.00E+07 psi Ground = 1
a 2 in Sy 117 ksi Machined/Cold-drawn = 2
b 5 in Su 163 ksi Hot-rolled = 3
d (est.) 0.438 in [CHANGE] Surface* 1 see ----------------------------------------------------------------- As-forged = 4
I 0.001807 in4

Power, Torque, Loads Reactions W1y y

Angle q 20 degrees 0.349066 rad X-Y Plane X-Z Plane
Power, req 2 hp W1y 13.298176302 lbs W1z 36.5364391 lbs
rpms 1725 rpm W2y 26.5963526041 lbs W2z 73.0728782 lbs R1z W2y
Torque 73.07288 lb-in R1y 15.3440495793 lbs R1z 8.43148595 lbs z x
Tooth Loads R2y 24.5504793268 lbs R2z -44.9679251 lbs
W1 38.88127 lbs W2z
W2 77.76253 lbs Maximum Moments R2z
Pitch Diameters point B point C W1z
Dp1 4 in X-Y Plane 30.6880991586 in lbs X-Y Plane 36.825719 in lbs
Dp2 2 in X-Z Plane 16.8629718968 in lbs X-Z Plane -67.4518876 in lbs R1y
Resultant 35.0159856517 in lbs Resultant 76.8497932 in lbs
Endurance Limit
Se' 81.5 ksi <See Diagrams for Deflection and Slope>
Cload 1 (bending, torsion) R2y
Csize 0.941449 (From Estimated Diameter) DIAMETER

alternating stress (ksi)

Goodman
Goodman Soderberg Soderberg
Csurf Dist
0.869098 Max Shear Max Shear Dist Energy
Energy
A 1.34 Safety Factor 2 2 2 2 (Sa / sa) 25 Goodman Diagram
b -0.085 Maximum Ma 76.8497932 76.8497932 76.8497932 76.8497932 lb-in
Ctemp 1 (T < 840F) Maximum sa 9.31580689 9.31580689 9.31580689 9.31580689 ksi 20
Creliab 0.814 (99% reliab) Maximum t 4.42898279 4.42898279 4.42898279 4.42898279 ksi
Se 18.88034 ksi (Includes Kf) Calculated Diameter 0.43776268 0.43734211 0.4369453 0.43672683 in
15

Stress Concentration
Notch 0.01 in (Keyway) Goodman Line Yield Line Load Line Soderberg Line 10

q 0.75 (See figure 6-36, pg392) sm sa sm sa sm sa sm sa

r/d 0.022831 (Notch radius / Est. Diameter) 0 18.88 0 117 0 0 0 18.88034 5
Kt 3.5 (See figure 9-16, pg591) 163 0 117 0 9.32 9.32 117 0
Kf 2.875 (Affects Se above) 94.3435923 22.6564077 16.92 16.92
0
Goodman Line Yield Line
0 20 40 60 80 100 120 140(ksi) 160
mean stress 180
Calculated Sa 16.92 Load Line Soderberg Line
Calculated Nf 1.82
 Shear, Moment, Slope, Deflection DIAGRAMS C3
1.3778E-03
X values Shear (X-Y) Shear (X-Z) Magnitude Moment (X-Y) Moment (X-Z) Magnitude Slope (X-Y)
0 15.3440496 8.43149 17.50799 0.00000 0.00000 0.00000 -1.3778E-03
0.1625 15.3440496 8.43149 Shear
17.50799
Diagrams2.49341 1.37012 2.84505 -1.3741E-03
2.5000E-03
0.325 15.3440496
60.00000 8.43149 17.50799 4.98682 2.74023 5.69010 -1.3628E-03
Shear (lbs)

0.4875 15.3440496 8.43149 17.50799 7.48022 4.11035 8.53515 -1.3442E-03 2.0000E-03

50.00000
0.65 15.3440496 8.43149 17.50799 9.97363 5.48047 11.38020 -1.3180E-03
0.8125 15.3440496 8.43149 17.50799 12.46704 6.85058 14.22524 -1.2843E-03 1.5000E-03

Slope
40.00000
0.975 15.3440496 8.43149 17.50799 14.96045 8.22070 17.07029 -1.2432E-03
30.00000 1.0000E-03
1.1375 15.3440496 8.43149 17.50799 17.45386 9.59082 19.91534 -1.1946E-03
1.3 15.3440496
20.00000 8.43149 17.50799 19.94726 10.96093 22.76039 -1.1386E-03 5.0000E-04
1.4625 15.3440496 8.43149 17.50799 22.44067 12.33105 25.60544 -1.0750E-03
10.00000
1.7875 15.3440496 8.43149 17.50799 27.42749 15.07128 31.29554 -9.2551E-04 0.0000E+00
1.95 15.3440496
0.00000 8.43149 17.50799 29.92090 16.44140 34.14059 -8.3953E-04 0
-5.0000E-04
2.1125 2.04587328
0 -28.10495
1 2 28.17932 3 30.91826
4 13.70116
5 633.81805 7 -7.4764E-04
-10.00000
2.275 2.04587328 -28.10495 28.17932 31.25071 9.13411 32.55824 -6.5444E-04 -1.0000E-03
2.4375 2.04587328 -28.10495 28.17932 31.58317 4.56705 31.91167 -5.6024E-04
-20.00000
2.6 2.04587328 -28.10495 28.17932 31.91562 0.00000 31.91562 -4.6505E-04 -1.5000E-03
2.7625 2.04587328 -28.10495 28.17932
-30.00000 32.24808 -4.56705 32.56987 -3.6886E-04
-2.0000E-03
2.925 2.04587328 -28.10495 28.17932 32.58053 -9.13411 33.83671 -2.7168E-04
Slope (X-Y) Slope (X-Z)
-40.00000 Shear (X-Y) Shear (X-Z) Magnitude
3.0875 2.04587328 -28.10495 28.17932 32.91299 -13.70116 X 35.65090
(in) -1.7350E-04
3.25 2.04587328 -28.10495 28.17932 33.24544 -18.26822 37.93398 -7.4316E-05
Moment (in lbs)

3.4125 2.04587328 -28.10495 28.17932 33.57790 -22.83527 40.60696 2.5860E-05

3.575 2.04587328 -28.10495 28.17932 33.91035 -27.40233 43.59816 1.2703E-04 4.0000E-03
3.7375 2.04587328 -28.10495 Moment Diagrams
28.17932 34.24280 -31.96938 46.84668 2.2920E-04
100.00000

Deflection (in)
3.9 2.04587328 -28.10495 28.17932 34.57526 -36.53644 50.30268 3.3237E-04 3.0000E-03
4.0625 2.04587328 -28.10495 28.17932
80.00000 34.90771 -41.10349 53.92630 4.3653E-04
4.225 2.04587328 -28.10495 28.17932 35.24017 -45.67055 57.68595 5.4169E-04 2.0000E-03
60.00000
4.3875 2.04587328 -28.10495 28.17932 35.57262 -50.23760 61.55671 6.4785E-04
4.55 2.04587328 -28.10495 28.17932 35.90508 -54.80466 65.51889 7.5500E-04 1.0000E-03
40.00000
4.7125 2.04587328 -28.10495 28.17932 36.23753 -59.37171 69.55688 8.6315E-04
5.0375 -24.550479 44.96793 51.23320
20.00000 35.90508 -65.76559 74.92855 1.0821E-03 0.0000E+00
5.2 -24.550479 44.96793 51.23320 31.91562 -58.45830 66.60315 1.1838E-03 0
5.3625 -24.550479 44.96793 51.23320
0.00000 27.92617 -51.15101 58.27776 1.2735E-03
-1.0000E-03
0
5.525 -24.550479 1
44.96793 251.233203 4
23.93672 5
-43.84373 6 49.952377 1.3512E-03
-20.00000
5.6875 -24.550479 44.96793 51.23320 19.94726 -36.53644 41.62697 1.4170E-03
-2.0000E-03
5.85 -24.550479
-40.00000 44.96793 51.23320 15.95781 -29.22915 33.30158 1.4708E-03
6.0125 -24.550479 44.96793 51.23320 11.96836 -21.92186 24.97618 1.5127E-03
-3.0000E-03
6.0125 -24.550479 44.96793 51.23320
-60.00000 11.96836 -21.92186 24.97618 1.5127E-03
6.175 -24.550479 44.96793 51.23320 7.97891 -14.61458 16.65079 1.5426E-03
-80.00000
6.3375 -24.550479 Moment
44.96793(X-Y)51.23320 Moment (X-Z)
3.98945 Magnitude
-7.30729 8.32539 1.5606E-03 -4.0000E-03
X (in) Deflection (X-Y) Deflection
6.5 -24.550479 44.96793 51.23320 0.00000 0.00000 0.00000 1.5665E-03
 C3
-3.6299E-04
Deflection (X-Y) Slope (X-Z) Deflection (X-Z) Total Slope Total Deflection
0.0000E+00 3.6299E-04 0.0000E+00 0.0014248069 0
-2.2369E-04 3.6504E-04 Slope Diagram
5.9097E-05 0.0014217186 0.0002313637
2.5000E-03
-4.4616E-04 3.7120E-04 1.1886E-04 0.0014124906 0.0004617244
-6.6621E-04
2.0000E-03 3.8147E-04 1.7996E-04 0.0013972355 0.0006900857
-8.8261E-04 3.9585E-04 2.4306E-04 0.0013761495 0.0009154647
-1.0941E-03
1.5000E-03 4.1434E-04 3.0884E-04 0.0013495254 0.001136899
Slope

-1.2996E-03 4.3693E-04 3.7795E-04 0.001317773 0.0013534553

1.0000E-03
-1.4978E-03 4.6363E-04 4.5106E-04 0.0012814482 0.0015642371
-1.6875E-03
5.0000E-04 4.9444E-04 5.2885E-04 0.0012412927 0.0017683957
-1.8674E-03 5.2936E-04 6.1198E-04 0.0011982883 0.0019651411
-2.1933E-03
0.0000E+00 6.1152E-04 7.9693E-04 0.0011092862 0.0023336088
-2.3368E-03 0 6.5876E-04
1 2 9.0008E-04
3 0.0010671371
4 5 0.0025041781
6 7
-5.0000E-04
-2.4658E-03 7.0584E-04 1.0111E-03 0.0010281916 0.0026650619
-2.5798E-03
-1.0000E-03 7.4008E-04 1.1288E-03 0.0009879292 0.0028158827
-2.6785E-03 7.6062E-04 1.2509E-03 0.0009446746 0.0029561472
-2.7618E-03
-1.5000E-03 7.6746E-04 1.3752E-03 0.0008973694 0.0030852247
-2.8295E-03 7.6062E-04 1.4996E-03 0.000845338 0.0032023403
-2.0000E-03
Slope (X-Y) -2.8816E-03
Slope (X-Z) 7.4008E-04
Total Slope 1.6217E-03 0.0007883662 0.0033065759
-2.9178E-03 7.0584E-04 1.7393E-03 0.0007268529 0.0033968758
X (in)
-2.9379E-03 6.5792E-04 1.8503E-03 0.0006621012 0.0034720551
-2.9419E-03 5.9630E-04 1.9524E-03 0.0005968588 0.0035308099
Deflection Diagram
-2.9295E-03
4.0000E-03 5.2099E-04 2.0434E-03 0.00053625 0.0035717275
-2.9005E-03 4.3198E-04 2.1210E-03 0.0004890209 0.0035932972
Deflection (in)

-2.8549E-03
3.0000E-03 3.2928E-04
-2.7925E-03 2.1289E-04
-2.7130E-03
2.0000E-03 8.2807E-05
-2.6164E-03 -6.0971E-05
-2.5024E-03
1.0000E-03 -2.1844E-04
-2.3709E-03 -3.8961E-04
-2.0549E-03
0.0000E+00 -7.7206E-04
-1.8706E-03 0 -9.5829E-04 1 21.8534E-033 0.0015230336
-1.6708E-03 -1.1226E-03
-1.0000E-03
-1.4574E-03 -1.2650E-03
-1.2323E-03 -1.3855E-03
-2.0000E-03
-9.9751E-04 -1.4841E-03
-7.5494E-04 -1.5608E-03
-3.0000E-03
-7.5494E-04 -1.5608E-03
-5.0653E-04 -1.6156E-03
-4.0000E-03 -1.6484E-03
-2.5424E-04
Deflection (X-Y) Deflection (X-Z)
0.0000E+00 -1.6594E-03
2.1830E-03 0.0004678635 0.0035939208
2.2273E-03 0.0004856779 0.0035719225
2.2515E-03 0.0005479848 0.0035255581
2.2534E-03 0.0006507115 0.003453024
2.2309E-03 0.0007859677 0.0033524654
2.1817E-03 0.0009470083 0.0032219847
1.9943E-03 0.0013292932 0.0028635137
4 5 0.002633304
6 7
1.6840E-03 0.001697645 0.0023722423
1.4897E-03 0.0018509682 0.0020840544
1.2741E-03 0.0019818138 0.0017725288
1.0406E-03 0.0020894843 0.0014414998
7.9293E-04 0.0021735538 0.0010948342
7.9293E-04 0.0021735538 0.0010948342
5.3455E-04 0.0022337584 0.0007364227
2.6906E-04 0.0022699381 0.0003701723
Total Deflection X (in)
0.0000E+00 0.0022820071 0
Maximum Distortion Energy - Static
Failure
Maximum Shear Stress - S
1

τ max =R=
2 [( ) ]
σx 2 2
+τ
2

2 1
τ max =
[( ) ( ) ]
MC 2 TC
2I
+
J
2

2 1

[( ) ( ) ]
2
Let: τ max =
16 M 16 T
+ 3 2
d3 π d π

1
16
τ max = 3 ( M 2 +T 2 ) 2
d π

Sy
n=
2 τ max

Sy
τ max =
2n
1
S y 16
= ( M 2+ T 2 ) 2
2 n d3 π

2 1
3
d =
32 n
π [( ) ( ) ]
M 2 T
Sy
+
Sy
2

2 1
1 32
=
n d3 π [( ) ( ) ]
M 2 T
Sy
+
Sy
2
 2 1
d 3=
32 n
π [( ) ( ) ]
M 2 T
Sy
+
Sy
2

2 1
1 32
=
n d3 π [( ) ( ) ]
M 2 T
Sy
+
Sy
2

Maximum Distortion Energy - Fatigue Failure Maximum Shear Stress

(Soderberg Line) Line)
Replace Sy in static failure equation with Se and Sy: Replace Sy in static failure equation

2 1

[( ) ( ) ]
2
32 n M T
2 1 d 3= + 2

[( ) ( ) ]
2
32 n M 3 T π Se Sy
d 3= + 2
π Se 4 Sy

2 1

[( ) ( ) ]
2
1 32 M T 2
2 1 = +
1 32
=
n d3 π [( ) ( ) ]
M 2 3 T
Se
+
4 Sy
2 n d3 π Se Sy
 d =
π [( ) ( ) ]
Se
+
4 Sy
e y

2 1

[( ) ( ) ]
2
1 32 M T 2
2 1 = +
1 32
=
n d3 π [( ) ( ) ]
M 2 3 T
Se
+
4 Sy
2 n d3 π Se Sy

Maximum Distortion Energy - Fatigue Failure Maximum Shear Stres

(Goodman Line) Line)
Replace Sy in Soderberg equation with Su. Replace Sy in Soderberg equation w

2 1 2 1
3
d =
32 n
π [( ) ( ) ]
M 2 3 T
Se
+
4 Su
2 3
d =
32 n
π [( ) ( ) ]
M 2 T
Se
+
Su
2

2 1 2 1
1 32
=
n d3 π [( ) ( ) ]
M 2 3 T
Se
+
4 Su
2 1 32
=
n d3 π [( ) ( ) ]
M 2 T
Se
+
Su
2
mum Shear Stress - Static Failure
1

=R=
2 [( ) ]
σx 2 2
+τ
2

2 1
=
[( ) ( ) ]
MC 2 TC
2I
+
J
2

2 1

[( ) ( ) ]
2
16 M 16 T 2
= + 3
d3 π d π

1
16
= 3 ( M 2 +T 2 ) 2
d π

Sy
n=
2 τ max

Sy
τ max =
2n
1
16
3
( M 2+ T 2 ) 2
d π

2 1
32 n
π [( ) ( ) ]
M 2 T
Sy
+
Sy
2

2 1
2
3
π [( ) ( ) ]
M 2 T
Sy
+
Sy
2
 2 1
32 n
π [( ) ( ) ]
M 2 T
Sy
+
Sy
2

2 1
2
3
π [( ) ( ) ]
M 2 T
Sy
+
Sy
2

aximum Shear Stress - Fatigue Failure (Soderberg

ne)
place Sy in static failure equation with Se and Sy:

2 1

[( ) ( ) ]
2
32 n M T
d 3= + 2
π Se Sy

2 1

[( ) ( ) ]
2
1 32 M T 2
= +
n d3 π Se Sy
 e y

2 1

[( ) ( ) ]
2
1 32 M T 2
= +
n d3 π Se Sy

aximum Shear Stress - Fatigue Failure (Goodman

ne)
place Sy in Soderberg equation with Su.

2 1
3
d =
32 n
π [( ) ( ) ]
M 2 T
Se
+
Su
2

2 1
1 32
=
n d3 π [( ) ( ) ]
M 2 T
Se
+
Su
2