TARLAC STATE UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

TARLAC CITY

SHAFT DESIGN
MACHINE DESIGN 1
MODULE

GROUP 2
Submitted by: Submitted to:
Leader: Engr. Elmer P. Tolenada
John Michael G. Manalang
Members:
Julius Caesar A. Domingo
John Renzel Gacayan Enrina
John Michael De Leon
Phil John D. Fernandez
Arond Fer T. Erjas
 ACKNOWLEDGEMENT
If the words are considered as symbols of approval and tokens of acknowledgement,
first and foremost, we praise the GOD ALMIGHTY for the grace he showered on us during the
work of this module.

We would like to place our heartfelt thanks to Engr. Elmer P. Tolenada our professor for
Machine Design 1 in Mechanical Engineering Department for giving us this opportunity to do
this module. It is a pleasure to be indebted to our guide for his valuable support, advice and
encouragement.

We would also like to thank our parents and friends who have prayed and helped us
during the work for this module.

Introduction
 Shaft must have adequate torsional strength to transmit torque and not be over
stressed.
 Shafts are mounted in bearings and transmit power through devices such as gears,
pulleys, cams and clutches.
 Components such as gears are mounted on shafts using keys.
 Shaft must sustain a combination of bending and torsional torsional loads.

OBJECTIVES
• Compute forces acting on shafts from gears, pulleys, and sprockets.
• Find bending moments from gears, pulleys, or sprockets that are transmitting loads to
or from other devices.
• Compare combined stresses to suitable allowable stresses, including any required stress
reduction factors such as stress concentration factors and factors of safety.
• Determine suitability of shaft design and/or necessary size of shafting.
 SHAFT DESIGN
What is a shaft?
A shaft is a rotating machine element, usually circular in cross section, which is used
to transmit power from one part to another, or from a machine which produces power to a
machine which absorbs power.[1] The various members such as pulleys and gears are mounted
on it.

Types of shaft?

They are mainly classified into two types.

 Transmission shafts are used to transmit power between the source and the machine
absorbing power; e.g. counter shafts and line shafts.
 Machine shafts are the integral part of the machine itself; e.g. crankshaft.

Materials used:

The material used for ordinary shafts is mild steel. When high strength is required, an alloy
steel such as nickel, nickel-chromium or chromium-vanadium steel is used.
Shafts are generally formed by hot rolling and finished to size by cold
drawing or turning and grinding.

Standard sizes

Machine shafts

 Up to 25 mm steps of 0.5 mm

Transmission shafts

 25 mm to 60 mm with 5 mm steps
 60 mm to 110 mm with 10 mm steps
 110 mm to 140 mm with 15 mm steps
 140 mm to 500 mm with 20 mm steps
The standard lengths of the shafts are 5 m, 6 m and 7 m.

Stresses
The following stresses are induced in the shafts.

1. Shear stresses due to the transmission of torque (due to torsional load).

2. Bending stresses (tensile or compressive) due to the forces acting upon the machine
elements like gears and pulleys as well as the self weight of the shaft.
3. Stresses due to combined torsional and bending loads.

Design Stresses
The maximum permissible (design) stresses in bending (tension or compression) may be taken
as:

1. 112 N/mm2 for shafts with allowance for keyways.

2. 84 N/mm2 for shafts without allowance for keyways.
The maximum permissible (design) shear stresses may be taken as:

1. 56 N/mm2 for shafts with allowance for keyways.

2. 42 N/mm2 for shafts without allowance for keyways.
HOLLOW ROUND SHAFT
 It is used where we have to transmit high power. The advantage of hollow shaft over
simple shaft is it have greater value of strength and higher value of rigidity. Because of
the weight is low as compared to simple shaft it is more useful.

ADVANTAGES OF HOLLOW ROUND SHAFT

 In comparison to a solid shaft, a hollow shaft is of less weight, for a given length and
diameter. This is pretty obvious and wont be requiring any further explanation.
Moreover it’s a good idea to go ahead with hollow shafts, if we our emphasis is
on weight reduction and cost-cutting.

 Hollow shafts are much better to take torsional loads compared to solid shafts. As
shown in the figure, shear stress in a “shaft subjected to torsion” varies linearly
from zero at the center to the maximum at the boundary. Inside a solid shaft, most
of the material experiences / carries a shear stress whose value is much below the
maximum shear stress [Interior portion of the shaft]. But at the same they are
adding to the weight, without contributing much to the capability of the shaft to
carry torsional load.

SQUARE SHAFTS

 Most of the time square shafts are used to insert into square holes or sockets for
drilling, boring or tightening. The four corners of the square shaft are the 4 pressure
points to deliver the force to turn the object needed to be turned.

 Probably the only advantage of square shaft is that it can fit into square hole and easily
lock there without any additional parts transmitting motion. But from strength of
materials point of view these shafts are much worse (stress concentration at corners).
They are also less stable in high speed rotation and worse for manufacturing (standard
circular shaft can be turned easily)
 Formula’s

Pure Torsional Shear Stress(solid)

𝑇𝑐 16𝑇
𝑆𝑠 = =
𝐽 𝜋𝐷3
Where:
𝑆𝑠 = torsional shear stress( Mpa or psi )
𝑇 = torque (N-mm or lb-in.)
𝐽 = polar moment of inertia (𝑚𝑚4 or 𝑖𝑛.4 )
𝑐 = distance from the neutral axis to the outermost fiber ( mm or in. )

Pure Torsional Shear Stress(hollow)

16𝑇𝐷
𝑆𝑠 =
𝜋(𝐷4 − 𝑑4 )
Where:
𝑆𝑠 = torsional stress( Mpa or psi )
𝑇 = torque (N-mm or lb-in.)
𝐷 = outside diameter (mm or in.)
𝑑 = inside diameter ( mm or in. )
Angular Deformation

𝑇𝐿
𝜃=
𝐽𝐺
Where:
𝜃 = angular deformation or torsional deflection ( Mpa or psi )
𝑇 = torque (N-mm or lb-in.)
𝐿 = length (mm or in. )
𝐽 = polar moment of inertia (𝑚𝑚4 or 𝑖𝑛.4 )
𝐺 = modulus of rigidity ( Gpa or psi )

Pure Flexural or Bending Stress(solid)

𝑀𝑐 32𝑀
𝑆𝑓 = =
𝐼 𝜋𝐷3
Where:
𝑆𝑓 = flexural or bending stress( Mpa or psi )
𝑀 = bending moment (N-mm or lb-in.)
𝐼 = moment of inertia (𝑚𝑚4 or 𝑖𝑛.4 )
𝐷 = diameter ( mm or in. )
𝑐 = distance from the neutral axis to the outermost fiber ( mm or in. )

Combined Stress
  Combined Axial and Flexural Stresses(solid)

𝐹 𝑀𝑐
𝑆= ±
𝐴 𝐼
Where:
𝑆 = combined stress
𝐹 = applied axial force (tensile or compressive)
𝐴 = cross sectional area
𝑐 = distance from neutral axis to the outermost fiber
𝐼 = moment of inertia
Note: use(+) when axial force is in tension
use(−) when axial force is in compression

 Combined Axial and Torsional Stresses(solid)

𝑆𝑡 𝑆𝑡2
𝑆𝑡𝑚𝑎𝑥 = ± √ + 𝑆𝑠2
2 4

𝑆𝑡2
𝑆𝑠𝑚𝑎𝑥 = ±√ + 𝑆𝑠2
4
Where:
𝑆𝑡 = tensile stress induced
𝑆𝑠 = shearing stress induced
𝑆𝑡𝑚𝑎𝑥 = maximum axial (tensile or compressive) stress caused by the induced stresses
𝑆𝑠𝑚𝑎𝑥 = maximum shearing stress caused by the induced stresses

 Combined Torsional and Flexural Stresses(solid)

 16 2 + 𝑇2]
𝑆𝑡𝑚𝑎𝑥 = [𝑀 + √ 𝑀
𝜋𝐷3
16 2 + 𝑇2
𝑆𝑠𝑚𝑎𝑥 = √ 𝑀
𝜋𝐷3
Where:
𝑀 = bending moment
𝑇= twisting moment
𝑆𝑡𝑚𝑎𝑥 = maximum axial stress caused by the induced stresses
𝑆𝑠𝑚𝑎𝑥 = maximum shearing stress caused by the induced stresses

 Combined Axial ,Torsional and Flexural Stresses(solid)

16 𝐹𝑎 𝐷 𝐹𝑎 𝐷 2
𝑆𝑡𝑚𝑎𝑥 = 3
[(𝑀 + ) + √(𝑀 + ) + 𝑇2]
𝜋𝐷 8 8

16 𝐹𝑎 𝐷 2
𝑆𝑠𝑚𝑎𝑥 = 3
+ √(𝑀 + ) + 𝑇2
𝜋𝐷 8
Where:
𝐹𝑎 = axial force
𝑀 = bending moment
𝑇 = torque or torsional moment
𝐷 = diameter
𝑆𝑡𝑚𝑎𝑥 = maximum axial (tensile or compressive) stress caused by the induced stresses
𝑆𝑠𝑚𝑎𝑥 = maximum shearing stress caused by the induced stresses

POWER TRANSMITTED BY THE SHAFT

The main purpose of a shaft is to transmit its power to another member. Let a rotating shaft
transmitting power from one of its ends to another be considered.
P = HP= 2π(F)(r)(n)

2𝜋𝑇𝑛 𝑇𝑛
𝑃 = 𝐻𝑃 = =
𝑘 63000
Where:
𝑘=compression factor
1HP-min = 33000 ft-lb
T = Torque , Nm
n = Speed , revolution per second

Octahedral-shear theory Maximum Shear Theory

Where:
N = design factor
𝑆𝑒 = equivalent stress
𝑆𝑒𝑠 = equivalent shearing stress
𝑆𝑛 = endurance strength
SHEAR AND MOMENT DIAGRAMS
• In order to design a shaft, it is necessary to determine the maximum shear and moment
in the beam
• Express V and M as functions of arbitrary position x along axis.
• These functions can be represented by graphs called shear and moment diagrams
• Engineers need to know the variation of shear and moment along the beam to know
where to reinforce it
• Shear and bending-moment functions must be determined for each region of the shaft
between any two discontinuities of loading

IMPORTANT
• Shaft are long straight members that carry loads perpendicular to their longitudinal axis.
They are classified according to how they are supported.
• To design a shaft, we need to know the variation of the shear and moment along its axis
in order to find the points where they are maximum
• Establishing a sign convention for positive shear and moment will allow us to draw the
shear and moment diagrams

Procedure for analysis

• Shear and moment functions
• Section beam perpendicular to its axis at each distance x
• Draw free-body diagram of one segment
• Make sure V and M are shown acting in positive sense, according to sign convention
• Sum forces perpendicular to beam’s axis to get shear
• Sum moments about the sectioned end of segment to get moment

Procedure for analysis

Shear and moment diagrams
• Plot shear diagram (V vs. x) and moment diagram (M vs. x)
• If numerical values are positive, values are plotted above axis, otherwise, negative values
are plotted below axis
• It is convenient to show the shear and moment diagrams directly below the free-body
diagram
 Figure of Shear and Moment Diagram of Shaft

Equivalent Shearing Stress Equivalent Stress

Where:
𝑆𝑛𝑠 = endurance shear stress 𝐾𝑓𝑠 = stress concentration factor for profile keyways
𝑆𝑦𝑠 = yield shear stress 𝐾𝑠 = stress concentration factor for profile keyways
𝑆𝑎𝑠 = alternating shear stress
𝑆𝐹= size factor
𝑆𝑚𝑠 = mean shear stress
𝑆𝑎 = alternating stress
Shaft Design by Code
 Permissible shear stress for shaft without keyways
𝜏𝑑 𝑜𝑟 𝑆𝑠𝑑 = (0.3)(𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑦𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ)
or
𝜏𝑑 𝑜𝑟 𝑆𝑠𝑑 = (0.18)(𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ)

Where:
𝜏𝑑 𝑜𝑟 𝑆𝑠𝑑 = Shear Design Stress
Note:
Both formulas are usable but only choose whichever gives the smallest value.

 Permissible shear stress for shaft without keyways (bending only)

𝜎𝑑 𝑜𝑟 𝑆𝑑 = (0.6)(𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑦𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ)
or
𝜎𝑑 𝑜𝑟 𝑆𝑑 = (0.36)(𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ)
Where:
𝜎𝑑 𝑜𝑟 𝑆𝑑 = Normal Design Stress
Note: Both formulas are usable but only choose whichever gives the smallest value.

 Permissible shear stress for shaft with keyways

𝑆𝑠𝑑 with keyway = (0.75)(𝑆𝑠𝑑 without keyway)
Where:
𝑆𝑠𝑑 = Shear Design Stress
  Permissible shear stress for shaft with keyways (bending
only)
𝑆𝑑 with keyway = (0.75)(𝑆𝑑 𝑤𝑖𝑡ℎ𝑜𝑢𝑡 𝑘𝑒𝑦𝑤𝑎𝑦)
Where:
𝑆𝑑 = Normal Design Stress
 If shaft material is not given or stated, always assume commercial steel shafting or
commercial shafting
𝑆𝑑 𝑜𝑟 𝑆𝑠𝑑 = 8,000 𝑝𝑠𝑖 𝑓𝑜𝑟 𝑠ℎ𝑎𝑓𝑡 𝑤𝑖𝑡ℎ𝑜𝑢𝑡 𝑘𝑒𝑦𝑤𝑎𝑦 or 𝑆𝑑 𝑜𝑟 𝑆𝑠𝑑 =
6,000 𝑝𝑠𝑖 𝑓𝑜𝑟 𝑠ℎ𝑎𝑓𝑡 𝑤𝑖𝑡ℎ 𝑘𝑒𝑦𝑤𝑎𝑦
Where:
𝑆𝑠𝑑 = Shear Design Stress 𝑆𝑑 = Normal Design Stress

Graphical Integration

 The change in slope between any two points:

Where:
M = moment
EI = Flexural Rigidity
= change in slope between points A and B
A, B = points on the elastic curve
Deflection formula (𝒚𝑨/𝑩 ) :
𝑩
𝑴
̅∫
𝒚 𝑨 ⁄𝑩 = 𝒙 𝒅𝒙
𝑨 𝑬𝑰
Where:
 M = moment
 EI = Flexural Rigidity
 𝑦𝐴⁄𝐵 = deviation of tangent at point A with respect to the tangent at point B
 A, B = points on the elastic curve
 𝑥̅ = centroid

Scale of the ordinate of the integral:

𝑺𝒂 = 𝑯𝑺𝒚 𝑺𝒙
Where:
𝐻 = pole distance
𝑆𝑥 = scale of x in units of x per measurement
𝑆𝑦 =scale of y in units of y per measurement
 TERMS AND DEFINITION
 Mechanics – deals with the effects of forces in causing or preventing motion.
 Static – is that branch of mechanics which deals with bodies in equilibrium.
 Dyanamics – is that branch of mechanics that deals with bodies not in equilibrium.
 Kinetics – is that branch of mechanics that deals with both the forces acting on bodies
and the motion which they cause.
 Kinematics – is that branch of dynamics which deals only the motions of the bodies
without the reference of the forces that cause them.
 Force – is simply push or pull.
 Work – is the product of force times distance.
 Power – is the product of force times distance divided by time.
 Horsepower – is a unit of power that has been adopted for engineering work.
 Torque – is a measure of a tendency of the force to rotate the body upon which acts
about an axis.
 Couple – two forces equal in magnitude, parallel, and in opposite direction.
 Coplanar – forces in the same plane.
 Components – the separate forces which can be so combined.
 Motion – is a progressive change of position of a body.
 Velocity – is the rate of change in position.
 Free body diagram – determines the effect of forces on the motion of a body it is
necessary to resort.
 Strength of materials – deals with the relations between the external forces applied to
the elastic bodies and the resulting deformations and stresses.
 Stress – is a total resistance that a material offers to an applied load.
 Untimate stress – is the stress that would causes failure.
 Yield stress – is the maximum stress without causing deformation.
 Allowable stress – the ultimate stress/factor of safety.
 Design stress – is the stress use to determining the size of amember.
 Working stress – actually accuring under operating conditions.
 Fatigue limit – the maximum stress that will not cause failure when the force is reverse
indefinitely.
 Elastic limit – is the maximum stress to which a standardized test specimen may be
subjected without a permanent deformation
 Proportional limit – is the stress a which the stress strain curve deviates from a straight
line.
 Strength – is the a ability of the metal to withstand loads without breaking down.
 Shear strength – is the ability of a metal to withstand forces thus following a number of
twist.
 Strain – is the total deformation measured in the direction of the line of stress.
 Modulus of elasticity – is the ratio of stress to the strain.
 Compressive strength – is the ability of amaterial to resist being crushed.
 Bending strength – is the quality of the material which resists forces from causing a
member to bend or deflect in the direction in which the load is applied.
 Shaft – is a rotating member that is used to transmit power.
 Axle – a stationary member carrying rotating wheel, pulleys.
 Machine shafts – is a shaft which is an integral part of the machine.
 Line shaft – is a transmission shaft driven by a prime mover.
 Counter shaft – is transmission shaft intermediate between the line shaft and the driven
machine.
 Spindles – is a short axles and shafts.
 Transmission shafts – is a shaft to tranfer power between the source and the machines
absorbing the power, and include countershafts, line shafts, head shafts and all factory
shafting.
 Key – a demountable machinery part which, when assembly into keyseats, provides a
positive means for transmitting torque between the shaft or hub.
 Keyseat – an axially located rectangular groove in a shaft or hub.
 Roller – a ring or thimble which turns over a bushing.
 Bushing – a cylindrical bearing in which the pin turns.
 Brittleness – the tendency to fracture without appreciable deformation.
 Ductility – is that properly that permits permanent deformation before fracture in
tension. Is the opposite of brittleness.
 Elasticity – is the ability of a material to be deformed and to return to its original shape.
 Embrittlement – involve the loss of ductility because of the physical or chemical change
of the material.
 Plasticity – is the ability of a metal to be deformed considerably without rupture. The
material does not return to its original shape.
 Poisson’s ration – the ratio of lateral starin to the longitudinal strain when the element
is loaded with a longitudinal tensile force.
 Residual stress – are those not due to applied load or temperature gradients.
 Stiffness – is the ability to resist deformation. It is measured by the modulus of elasticity
in the elastic range.
 Strain hardening – is increasing the hardness and strength by plastic deformation at
temperature lower that the re-crystallization range.
 Toughness – is the capacity of material withstand a shoch load without breaking.
 Traverse strength – refers to the results of a transverse bend test, the specimen being
mounted as a simple beam.
 Work hardening – is the same a strain hardening.
 Wrought steel – is a steel that has been hammered, rolled, or drawn in the process of
manufacture. It may be plain carbon or alloy steel.
 Case hardening – prcess of hardening the surface or case of ametal to provide a hard,
wear resistant surface while retaining toughness in the core.
 Problems with solution
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