Unit V

SHAFTS
Introduction: A shaft is usually referred as a rotating machine element, circular in cross
section, which supports transmission elements like gears, pulleys etc. The shaft is generally acted upon by bending moment, torsion and axial force. Design of shaft primarily involves in determining correct diameter for stresses at critical point in the shaft that is arising due to aforementioned loading and rigidity condition. Other two similar forms of a shaft are axle and spindle. Axle: An axle is a non-rotating member used for supporting rotating wheels etc. and do not transmit any torque, used for transmission of bending moments only. Spindle: Spindle is simply defined as a short shaft. That imparts motion either to a cutting tool (e.g. drill press spindles) or to a work piece (e.g. lathe spindles). However, design method remains the same for axle and spindle as that for a shaft.
Note: 1) The shafts are usually cylindrical, but may be square or cross-shaped in section. They are solid in cross-section but sometimes hollow shafts are also used

Standard sizes of Shafts

Generally, the steel shafts of length 5m, 6m and 7m are commercially available in market. Typical sizes of solid shaft that are available in the market are, Up to 25 mm 25 to 50 mm 50 to 100 mm 100 to 200 mm 0.5 mm increments 1.0 mm increments 2.0 mm increments 5.0 mm increments

Materials 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 are mild steel, and alloy steel such as nickel, nickel-chromium, and molybdenum steels. Shafts are generally formed by hot rolling and finished to size by cold drawing. The hallow shafts are usually used in marine work. These shafts are stronger per kg material and they may be forged on mandrel. This making the material more homogeneous then would be possible for a shaft. When the hallow shafts is to be made equal in strength to a solid shaft, the twisting moments of both the shafts must be same. 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.

Design considerations for shaft

For the design of shaft following two methods are adopted, Design based on Strength In this method, design is carried out so that stress at any location of the shaft should not exceed the material yield stress. However, no consideration for shaft deflection and shaft twist is included. Design based on Stiffness Basic idea of design in such case depends on the allowable deflection and twist of the shaft. Design based on Strength: 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. A) SHAFTS SUBJECTED TO TWISTING MOMENT ONLY Solid shaft: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

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,

So Hallow shaft:D= outer diameter of shaft d = inner diameter of shaft J= (D4-d4) mm4

here = permissible shear stress of the shaft material

[
But = then T = = =

, - ]

Let K= Ratio of in side diameter and outside diameter of the shaft =

T=

.D3[1-K4]

One important approach of designing a transmission shaft is to be use of ASME code. According to this code the permissible shear stress [] []= 0.3 y = 0.18 u (which ever is minimum) B) SHAFTS SUBJECTED TO TWISTING MOMENT ONLY Solid shaft: = Where M = Bending moment, I = Moment of inertia of cross-sectional area of the shaft about the axis of rotation, =

D4 mm4

y= d/2 i.e Distance from neutral axis to the outer-most fibre. b = Bending stress, and Substituting these values in above equation

Hallow shaft:D= outer diameter of shaft d = inner diameter of shaft

I=

(D4-d4) mm4

[
So = then M= =

, - ]

M=

b.D3[1-K4]

C) Shafts Subjected to Combined Twisting Moment and Bending 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 (for ductile materials like mild steel). 2. Maximum normal stress theory or Rankines theory (for brittle materials like 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,

But,

b =

and

So Or

The expression

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

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

The 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 [b(max)] equal to the allowable bending stress (b), then the above equation may be written as,

In case of hallow shafts

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. D) Shafts Subjected to Combined Torsion, Bending and Axial 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, in such cases the stress due to axial load must be added to the bending stress (b). We know that bending equation is

Stress due to axial load =

Resultant stress = Let

Then

R =

Hallow shaft:-

R =

Area A=

In the case of long shafts subjected to compressive loads, column factor () must be taken into account, Stress due to the compressive load, (for solid shaft)

c =

(for hallow shaft)

The value of column factor () for compressive loads may be obtained from the following relation: 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:

c =

( )

Where L = Length of shaft, K = Radius of gyration =

I = AK2

y = Compressive yield point stress of shaft material, and n = Coefficient in Euler's formula depending upon the end conditions.

N=0.25 n= 1 n=2 n=4

for one end fixed, other end free for both ends hinged for one end fixed, other end hinged for both ends fixed

E) Shafts Subjected to Fluctuating Load 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. In order to design such shafts like line shafts and counter shafts, the combined shock and fatigue factors must be taken into account for the computed twisting moment (T) and bending moment (M). Thus for a shaft subjected to combined bending and torsion, the equivalent twisting moment,

The equivalent bending moment,

Where Km = shock and fatigue factor for bending Kt = shock and fatigue factor for torsion. For steady loads Km = 1.5 and Kt = 1.0 Problem 1: A solid shaft transmits 50KW power at 200rpm. The material of the shaft is plain carbon steel of yield strength 400N/mm2 and the factor of safety is 4. Calculate the diameter of the shaft on the basis of shear strength. Solution: Given data: Power = 50KW, Speed N = 200 rpm, y = 400 N/mm2, F.S = 4 Let d = diameter of the shaft. Permissible shear strength of the shaft material

= 50N/mm2 = = 2.387 103 N-m

Torque transmitted T =

T = 2.387 106 N-mm We know that T=

d=

= 62.41mm

say d 65mm Problem 2: A solid shaft is used to transmit 25KW at 1500rpm. The material of the shaft is plain carbon steel having y = 300MPa. It is also subjected to a bending moment of magnitude of 100N-m. Find the diameter of shaft? The shock and fatigue factors are Km = 1.5 and Kt = 1.2 respectively. Solution: Given data: Power P = 25 KW, Speed N = 1500rpm, y= 300MPa, Moment M=100N-m, Km = 1.5, Kt = 1.2, Assume factor of safety F.S = 3 Torque transmitted T = = = 159.15 N-m

T = 159.15 103N-mm Permissible shear strength

= 50 N/mm2

Equivalent twisting moment Te = and Te = = 242.84 103N-mm So.. 242.84 103 = =

d= Say

= 29.13mm

d 30mm.

Problem 3: Compare the strength, stiffness and weight of a hallow shaft of the same external diameter as that of solid shaft. The inside diameter of the hallow shaft being half the external diameter. Both the shafts are same material. Solution: Given Data: D = outer diameter of hallow shaft = diameter of solid shaft d = inner diameter of hallow shaft = D/2 let K= = 0.5

Comparing the mass: W

solid

= W

hallow

= = 1-K2

])

So
W
hallow

= =

= 0.75 W
solid

Comparing the strength: For equal strength twisting moments should be same for both solid and hallow shaft.

Ts

=
= = Th =

Th

= 0.9375 Ts = (Stiffness)hallow from torsion equation

Comparing stiffness: (Stiffness)solid

( ) ( )

( ) ( )

= =

Sh

= 0.9375 Ssolid