ME 307

Machine
Design I

Dr. A. Aziz Bazoune

King Fahd University of Petroleum
& Minerals
Mechanical Engineering Department
Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

ME 307
Machine
Design I

18-1
18-2
18-3
18-4
18-5
18-6
18-7
18-8

Introduction .922
Geometric Constraints .927
Strength Constraints .933
Strength Constraints Additional Methods .940
Shaft Materials .944
Hollow Shafts .944
Critical Speeds (Omitted) .945
Shaft Design .950

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 2

ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 3

ME 307
Machine
Design I

Estimating Stress Concentration

The stress analysis process for fatigue is highly dependent on

stress concentrations.
Stress concentrations for shoulders and keyways are dependent on
size specifications that are not known the first time through the
process.

Fortunately, since these elements are

proportions, it is possible to estimate the
factors for initial design of the shaft. These
will be fine-tuned in successive iterations,
known.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

usually of standard
stress concentration
stress concentrations
once the details are

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ME 307
Machine
Design I

Estimating Stress Concentration

Shoulders for bearing and gear support should match the catalog
recommendation for the specific bearing or gear.
A look through bearing catalogs shows that a typical bearing calls
for the ratio of D/d to be between 1.2 and 1.5.
For a first approximation, assume D/d =1.5 can be assumed.
Fillet radius at the shoulder needs to be sized to avoid
interference with the fillet radius of the mating component. There
is a significant variation in typical bearings in the ratio of fillet
radius r/d versus bore diameter, with

typically ranging from

around 0.02 to 0.06.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 5

ME 307
Machine
Design I

Estimating Stress Concentration

Figures A-15-8 and A-15-9 show that the stress concentrations for
bending and torsion increase significantly in this range. For
example, with D/d = 1.5 for bending
r/d

0.02

0.05

0.1

Kt

2.7

2.1

1.7

In most cases the shear and bending moment diagrams show that
bending moments are quite low near the bearings, since the
bending moments from the ground reaction forces are small.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 6

ME 307
Machine
Design I

Estimating Stress Concentration

In cases where the shoulder at the bearing is found to be critical, the

designer should plan to select a bearing with generous fillet radius, or
consider providing for a larger fillet radius on the shaft by relieving it into
the base of the shoulder as shown in Fig. 7-9a.
This effectively creates ahead
zone in the shoulder area that
does not carry the bending
stresses, as shown by the stress
flow lines.
Fig. 7-9a.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 7

ME 307
Machine
Design I

Estimating Stress Concentration

A shoulder relief groove as shown in Fig. 7-9b can accomplish a similar

purpose. Another option is to cut a large-radius relief groove into the small
diameter of the shaft, as shown in Fig. 7-9c.

Fig. 7-9b.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

Fig. 7-9c.

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ME 307
Machine
Design I

Figure 7-9
Techniques for reducing stress concentration at a shoulder supporting a bearing
with a sharp radius. (a) Large radius undercut into the shoulder. (b) Large radius
relief groove into the back of the shoulder. (c) Large radius relief groove into
the small diameter.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 9

ME 307
Machine
Design I

This has the disadvantage of reducing the cross-sectional area, but is often
used in cases where it is useful to provide a relief groove before the
shoulder to prevent the grinding or turning operation from having to go all
the way to the shoulder.

For the standard shoulder fillet,

fillet for estimating Kt values for the first
iteration, an r/d ratio should be selected so Kt values can be obtained. For
the worst end of the spectrum, with r/d = 0.02 and D/d = 1.5, Kt values
from the stress concentration charts for shoulders indicate 2.7 for
bending, 2.2 for torsion, and 3.0 for axial.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 10

ME 307
Machine
Design I

A keyway will produce a stress concentration near a critical point where

the load transmitting component is located. The stress concentration in an
end-milled keyseat is a function of the ratio of the radius r at the bottom
of the groove and the shaft diameter d. For early stages of the design
process, it is possible to estimate the stress concentration for keyways
regardless of the actual shaft dimensions by assuming a typical ratio of r/d
= 0.02. This gives Kt = 2.2 for bending and Kts= 3.0 for torsion, assuming
the key is in place.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 11

ME 307
Machine
Design I

A keyway will produce a stress concentration near a critical point where

the load transmitting component is located. The stress concentration in an
end-milled keyseat is a function of the ratio of the radius r at the bottom
of the groove and the shaft diameter d. For early stages of the design
process, it is possible to estimate the stress concentration for keyways
regardless of the actual shaft dimensions by assuming a typical ratio of r/d
= 0.02. This gives Kt = 2.2 for bending and Kts= 3.0 for torsion, assuming
the key is in place.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 12

ME 307
Machine
Design I

Table 7-1
First iteration estimates for stress concentration factors Kt
Warning: These factors are only estimates for use when actual dimensions are not
yet determined. Do not use these once actual dimensions are available.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 13

Fatigue Analysis of Shafts

ME 307
Machine
Design I

The fatigue strength will be

determined using:
1.Distortion-Energy-Gerber
2

Distortion-Energy-Elliptic

Rotating Shaft under stationary

bending and torsional moments

xa

32 Ma
Kf
3

xym

16Tm
K fs
3

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 14

ME 307
Machine
Design I

Fatigue Analysis of Shafts

Safety Factor
2

Gerber

n 'a n 'm

1
Se
Su
2

ASME-Elliptic

Dr. A. Aziz Bazoune

n 'a
n 'm
1

Sy
Se
Chapter 18: Axles and Shafts

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ME 307
Machine
Design I

Problem 18-10

A geared industrial roll shown

in the figure is driven at 300
rev/min by a force F acting on
a 3-in-diameter pitch circle as
shown. The roll exerts a
normal force of 30 lbf/in of
roll length on the material
being pulled through. The
material passes under the roll.
The coefficient of friction is
0.40. Develop the moment
and shear diagrams for the
shaft modeling the roll force
as a concentrated force at the
center of the roll,

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 16

ME 307
Machine
Design I

Problem 18-10

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 17

ME 307
Machine
Design I

Problem 18-10

We have a design task of identifying

bending moment and torsion diagrams
which are preliminary to an industrial
roller shaft design.

Gear

Roller

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 18

ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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ME 307
Machine
Design I

This approach over-estimates the

bending moment at C, torque at C but
not at A.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 20

ME 307
Machine
Design I

Problem 18-11

1. Using a 1035 hot rolled steel, estimate the necessary diameter at the
locations of peak bending moment using a design factor of 2. These
are likely to be fillets at both ends of the right hand bearing seat,
where the bending moment is slightly less than the local extreme.
2. Estimating the fatigue stress-concentration factor as 2, and using a
design factor of 2, what is the approximate necessary diameter of
the bearing seat using the DE-elliptic fatigue failure criterion in
Problem 18-10?

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 21

ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Problem 18-11

Chapter 18: Axles and Shafts

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ME 307
Machine
Design I

Problem 18-11

From static Analysis

16n

2
2 1/2
d
4 M 3T

S y

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

1/3

0.6in

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LEC 31 Slide 23

ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Problem 18-11

Chapter 18: Axles and Shafts

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LEC 31 Slide 24

Hollow Shafts

ME 307
Machine
Design I

As an example equation 18-21 is modified to take into account the hollow

shaft case:

do

K fsTm
K f M a
16 n
4

3
4

(1 di do ) Se
S y

2 1/2

1/3

where di and do are respectively the inner and outer diameters of the
shaft.
With this, one can consider that the stress-strength analysis is
completed. You have obtained the minimum diameter at the critical
section that can withstand the applied loads.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 25

Shaft Design

ME 307
Machine
Design I

One approach is (See Lab Handbook):

1.
2.
3.
4.
5.
6.

Selecting a material (usually steel)

Drawing a free body diagram of the shaft
Performing static equilibrium analysis and
Locating the critical area
Performing static stress analysis to find a starting diameter size, d.
Using the value of d in calculating the endurance limit (a trial
diameter can also be used)
7. Estimating the critical value of the diameter, d, using DE-Gerber or DEASME-elliptic methods
8. Repeat step 6 if d different from d.
9. Building the rest of the shaft by considering the machine parts to be
mounted on the shaft (bearings, gears, pulleys, )
10. Performing deflection analysis
11. Performing Dynamic analysis
Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 26

Shaft Materials

ME 307
Machine
Design I

Shafts are usually made of ductile materials.

Small shafts with diameters less than 3.5 in (90 mm) are usually
made of Cold Drawn carbon steel (AISI 1018-1050).
Larger diameter shafts are machined from Hot Rolled steel.
Heat treated steels are also used when higher strengths are
necessary.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 27

Shaft

ME 307
Machine
Design I

Design?

find safety Factor, n

Find critical diameter, d

Shaft rotating?

Shaft rotating?

Static Analysis
Eq. 6-43 or 6-45
Fatigue Analysis

Reversed
bending & steady
torque?

Static Analysis
Eq. 6-44 or 6-46

Static Analysis
Eq. 6-42 or 6-44

d'

Fatigue Analysis

n
N

Y
Eq. 18-17 or 18-22

Eq. 18-14 or 18-20

Reversed
bending & steady
torque?

Eq. 18-16 or 18-21

Eq. 18-13 or 18-19

d
N

d. NE. d

Y
d = Critical shaft
diameter

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

Complete shaft
geometry & perform
Deformation analysis

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ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Geometric Constraints

Unlike stress, which is a function

of local geometry and load,
deflection is a function of the
geometry everywhere. Thus, The
task of deflection and rigidity
analyses can be started only when
the entire geometry of the shaft is
determined.

However the approach described

in section 18-2, which is based on
bearing slope constraints as
limiting, may be used first
assuming a uniform diameter shaft
and using equations 18-1 and 18-2
to find the diameters at the
bearings.

Chapter 18: Axles and Shafts

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ME 307
Machine
Design I

Stress Concentrations and Shaft Geometry

Shaft shoulders are used to position and provide necessary thrust supports
for elements such as bearings, gears, pulleys, Provisions must be made
for torque-transfer elements such as keys, splines, pins
The theoretical stress concentration factors for shoulders, grooves and
transverse holes can be obtained from appendix [A15+]. Others are
Kt = 2.0
Kt = 1.6

Sled runner
keyseat

Shoulders

for profile key seats

for sled runner keyseats

Shoulder

Groove
Shoulders

Profile keyseat

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 30

ME 307
Machine
Design I

Shaft Geometry

To determine the entire geometry of the shaft one has to rely on existing
models. Some of these models are given in figures 18-1 through 18-8 of
the Textbook. More shaft configurations can be found in the FAG
handbooks of the Design of Rolling Bearing Mountings.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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ME 307
Machine
Design I

Geometric Constraints: Shaft Deflection and Slopes

The transverse deflection of the elastic curve of the shaft can be
determined by any one of the methods studied in Chapter 5.

The

superposition

method,

which

utilizes

Appendix

A-9,

is

recommended. For complex shaft geometry the numerical integration

or computer program may be used.

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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ME 307
Machine
Design I

1.

Geometric Constraints: Shaft Deflection and Slopes

The slope at ball bearings should be limited at 0.25 deg the slope at roller
bearings and long journal bearings should be a lot less. For details on
acceptable slopes refer to FAG and SKF catalogs.

2.

For machinery shafting, the deflection should be no greater than 0.001

in/ft (0.075 mm/m) of shaft length between bearing supports.

3.

For shafts mounting good quality spur gears, the deflection at the gear
mesh should not exceed 0.005 in. (0.125 mm) or F/200 (F is the gear face
width in inches) and the slope should be limited 0.0286 deg.

4.

For shafts mounting good quality bevel gears, the deflection at the gear
mesh should not exceed 0.003 in. (0.076 mm).

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 33

ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Chapter 18: Axles and Shafts

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LEC 31 Slide 34