DESIGN OF SHAFT

INTRODUCTION
• Shaft - It is a rotating member usually of circular
cross-section (solid or hollow), which is used to
transmit power and rotational motion.
▫ Shafts generally do not fall into the category of "off the
shelf“ standard component.
▫ A shaft is usually designed to perform a specific task
• Axle – It is Generally a stationary machine member
used as a support for rotating members such as
bearings, wheels, idler gears, etc.
• Spindle – It is a short shaft that imparts motion
either to a cutting tool or to a workpiece.
 INTRODUCTION
• Shaft provides the axis of rotation, or oscillation, of
elements such as gears, pulleys, flywheels, cranks,
sprockets, and the like and controls the geometry of
their motion.
SHAFT LOADING MECHANISMS
 EXAMPLES OF SHAFT

Tapered roller bearings used A bevel-gear drive in which both pinion

in a mowing machine spindle and gear are straddle-mounted.
 TYPES OF SHAFTS

• Transmission shafts-
eg. Line shaft, counter shaft

• Machine shafts-
eg. Crank shaft
Common Torque Transfer Elements

 Keys
 Splines
 Setscrews
 Pins
 Press or shrink fits
 Tapered fits

 The geometry of a shaft is that of a stepped

cylinder.
 Gears, bearings, and pulleys must always be
accurately positioned
COMMON TYPES OF SHAFT KEYS
COMMON TYPES OF SHAFT KEYS
COMMON TYPES OF SHAFT
KEYS

Wooduff Key
COMMON TYPES OF SHAFT PINS
COMMON TYPES OF SHAFT PINS
COMMON TYPES OF SPLINES
 RETAINING RINGS

Retaining rings: (a,b) external, (c,d) internal

VARIOUS METHODS TO ATTACH
ELEMENTS TO SHAFTS
 SHAFT LAYOUT
(a) Choose a shaft
configuration to support
and locate the two gears and
two bearings.
(b) Solution uses an integral
pinion, three shaft
shoulders, key and keyway,
and sleeve. The housing
locates the bearings on their
outer rings and receives the
thrust loads.
(c) Choose fan shaft
configuration.
(d) Solution uses sleeve
bearings, a straight-through
shaft, locating collars, and
setscrews for collars, fan
pulley, and fan itself. The
fan housing supports the
sleeve bearings.
 BEARING MOUNTING CONSIDERATIONS
Arrangement showing bearing
inner rings press-fitted to shaft
while outer rings float in the
housing. The axial clearance
should be sufficient only to
allow for machinery vibrations.

Similar to above the arrangement of

except that the outer bearing rings
are preloaded.
BEARING MOUNTING CONSIDERATIONS
This arrangement shows the inner
ring of the left-hand bearing is
locked to the shaft between a nut
and a shaft shoulder
The snap ring in the outer race is
used to positively locate the shaft
assembly in the axial direction.

This arrangement is similar to above in that the

left-hand bearing positions the entire shaft
assembly.
In this case the inner ring is secured to the shaft
using a snap ring.
Note the use of a shield to prevent dirt
generated from within the machine from
entering the bearing.
TECHNIUQUES OF REDUCING STRESS
CONCENTRATION

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
 MATERIAL USED FOR SHAFTS

• General low carbon, cold-drawn or hot-rolled

steel, such as ANSI 1020-1050 steels.
 Power-transmitting shafts and axles are most
commonly machined from plain carbon
(AISI/SAE 1040, 1045, and 1050) or alloy
(AISI/SAE 4140, 4145, 4150, 4340, and 8620)
steel bar stock.
 MATERIAL USED FOR SHAFTS
For shaft normally carbon steel grades of 40 C8,
45 C8, 50 C4 & 50 C12 are used.
The mechanical properties of material are:
Indian Ultimate Yield Strength
Standard Grade Tensile (Mpa)
Strength (Mpa)
40 C8 560- 670 320
45 C8 610- 700 350
50 C4 640- 760 370
50 C12 700 390
 MATERIAL USED FOR SHAFTS

 When high strength required alloy steel of

nickel, nickel- chromium or chrome- vanadium
may be used.

• Fatigue data is not always quoted and may have

to be assumed. In this case, calculate Fatigue
Ratio using the following relationships:
f e' = 0.5f u (for steels) f e' = 0.4 f u (for cast
irons)
 STANDARD SIZES OF SHAFTS
Typical sizes of solid shaft that are available in the
market are,
• Up to 25 mm 0.5 mm increments
• 25 to 50 mm 1.0 mm increments
• 50 to 100 mm 2.0 mm increments
• 100 to 200 mm 5.0 mm increments

• Standard length of the shaft are 5 m, 6 m and 7

m.
 CAUSES OF FAILURE IN SHAFTS
• The shaft usually fail due to fatigue, which arises
due to :
 Cyclic over loads
 Stress concentration
 Wrong adjustment of bearing, insufficient
clearances etc.
 STRESSES IN SHAFT

• Shear stress due to transmission of torque i.e.

torsional load.
• Bending stress due to forces acting upon
machine element i.e. bending load.
• Stresses due to combined bending and torsional
load
 DESIGN CONSIDERATION OF SHAFT
 Shaft design on basis of
- Strength
- Stiffness or rigidity

Design based on strength includes:

o Shaft subjected to twisting moment only
o Shaft subjected to bending moment only
o Shaft subjected to combined twisting and bending
moment
o Shaft subjected axial load in addition to combined
twisting and bending moment
DESIGN OF SHAFTS BASED ON PURE
BENDING LOAD
Maximum stress is given by bending equation
M/I = σ/y
Where;
M→ Bending Moment .
I → Moment of inertia of cross sectional area of shaft.
σ → Bending stress,
y → Distance from neutral axis to outer most fibre.

For round solid shafts, moment of inertia,

I = π/64* d^4

Therefore Bending equation is;

M / [π/64 * d^4 ] = σ/ (d/2)
Thus;

M = π/32* σ * d^4
 DESIGN OF SHAFTS BASED ON PURE
BENDING LOAD
For hollow Shafts, Moment of Inertia,
I = π / 64 [D^4 – d^4]

Putting the value, in Bending equation;

We have;

M / [π/64 { D^4 (1- k^4) }] = σ / (D/2)

Thus;
M = π/32* σ *D^3*(1 – k^4)

k → d/D
 EXAMPLE
• A pair of wheels of railway wagon carries a load
of 50 kN on each axle box, acting at a distance of
100 mm outside the wheel base. The guage of the
rails is 1.4m. Find diameter of axle between the
wheels if the stress is not to exceed 100 Mpa.
• Solution :
 DESIGN OF SHAFTS BASED ON PURE
TORSIONAL LOAD
Determination of diameter of Shafts, by using the Torsion
Equation,
T/J = τ/r
Where;
T- Twisting moment acting upon shafts.
J - Polar moment of inertia of shafts.
τ – Torsional shear stress.
r – Distance from neutral axis to outermost fibre.
For round solid Shafts, Polar Moment of inertia,
J = π/32*d^4
Now Torsion equation is written as,
T / [π/32*d^4] = τ / (d/2)
Thus;
T = π/16* τ * d^3
 DESIGN OF SHAFTS BASED ON PURE
TORSIONAL LOAD
For hollow Shafts, Polar Moment of inertia ,
J = π/32 [ (D^4) – (d^4) ]

Where ,
D and d – outside and inside diameter,
Therefore, torsion equation;
T / π/32[ D^4 – d^4 ] = τ/ (D/2)

Thus;
T = π/16* τ * D^3 * (1 – k^4)

Where, k = d/D
 DESIGN OF SHAFTS BASED ON PURE
TORSIONAL LOAD
▫ The torque is found for different drive
M t  T1  T 2 R p
1) For belt drive: N.m
where,
T1  tight side of belt on pulley, N
T2  lose side of belt on pulley, N
R p  radius of pulley,m
2) For gear drive:
M t  Ft R g N.m
F r  Ft tan 
where ,
Ft  tangential force at the pitch radius, N
Fr  radial force, N
R g  pitch radius of gear, m
  gear pitch angle, degrees
 EXAMPLE
• A solids shaft is transmitting 1MW at 240 rpm.
Determine the diameter of the shaft if the
maximum torque transmitted exceeds the mean
torque by 20%. Take the maximum allowable
shear stress as 60 Mpa.

• Solution :