Full name : Nguyễn Đức Hiếu

Student ID : 20215700
Class :

GENERAL MECHANICAL EXERCISES

Topic 5: Shaft 1

* CHAPTER 1 : Introduction
1.1 Overview of shaft details.
The shaft is a machine part with a common use, used to support rotating parts,
working parts (such as cutting tools, stirring blades, compression heads,...), gears,.... or to
drive.
 1.2 Classify.
1.2.1 According to load-bearing characteristics.
+ Center axis - the axis can rotate (train axis) and not rotate (vertical support axis),
the center axis only bears bending moment.
+ Transmission shaft – used to support the machine part and transmit torque, that is,
subject to both bending and torque.
1.2.2 According to the axial centerline shape.
+ The axis is straight, with a straight center line.
+ Crankshaft, the axis with a folded centerline. The crankshaft is used in machines
with pistons (internal combustion engines, piston pumps,...).
+ The axis is soft, the centerline of the shaft can change with shape during work.

1.2.3 According to the axial structure.

 + The axis is smooth, which is an axis with only a single segment, the diameter size
from end to end is the same. Shaft construction is simple, easy to machine but difficult to
fix other machine parts on the shaft.
+ Step axis, consisting of many concentric axis segments, segments of different
diameters. The step shaft has a complex structure, difficult to process, but it is easy to fix
the machine parts to the shaft.
+ Solid shafts and hollow shafts, when there is a requirement for shaft volume or
shafts, are installed with additional details and structures.
 In this exercise, I will focus on the step shaft, the drive shaft is the axis that
drives movement between machine parts or from the engine to the parts, the parts
need movement. The shaft is subjected to force, torque, torque bending during
work.
1.3 The structure of the step shaft.
The structure of the shaft is usually cylindrical in cross section, on the axis there are
grooves, threads, nuts,... to fix the details to the shaft. The step shaft is usually associated
with the resource (motor) with the working parts. Therefore, the step shaft is commonly
used because it can fix parts firmly and easily.

+ The head of the shaft, which is the two sides of the shaft.
+ Body shaft , shaft part to install details on the shaft.
+ Axle (shaft neck), which is the axle segment used to install a slide or roller bearing.
+ The step of shaft – is the transition between two axle segments of different diameters.
To reduce the stress concentrated in the cross section, the step of shaft is usually angled
with the largest possible radius but if the angle is too large, the details will not be able to
fit close to the shoulders of the shaft.
+ The shoulder of shaft, which is the ground to fix the machine parts installed on the shaft
vertically.
+ The key groove, which is used for assembly, is fixed on the axis of the machine parts
in a normal direction
+ The center hole, used to install the anticentric nose, positions the center of the shaft on
a machining machine or tester.
1.4 The use of the step shaft.
Shaft in general and shaft in particular are general use details, they are present in
industries such as cars, ships, large engines. They are used to support the rotating parts of
the machine (pulley, gearbox, flywheel,...). The step shaft not only supports rotating parts
but also transmits torque and force between parts. For example, the drive shaft system in
cars, ships, is the propulsion shaft in the hydraulic system, the air force.
1.5 Technical requirements.
Since the shaft usually works under extreme conditions such as high temperatures, large
external forces lead to the shaft often failing in some of the following types of failure:
+ Shaft fracture: due to overload for a long time, due to deviations in stress calculation
(due to the quality of manufacture, shaft order distribution,....); due to the shaft structure
(borehole, ring groove, glide angle,...); technical error-improper assembly.
+ Shaft wear: Due to miscalculation, the material selection is not correct with the
working intensity, not lubricated. Thus, in the process of working the shaft will be
friction and wear out quickly.
+ Insufficient rigidity of the shaft: Deformed under the effect of load, causing destruction
of the bearing, surfaces of the drive part, loss of accuracy and original gloss. The shaft is
deformed when working with a large rotational velocity causing fluctuations. Extremely
dangerous to the user and the life of the machine.
Therefore, a good step shaft must meet the following requirements.
1. High strength and good wear resistance. Guaranteed for the shaft to work in great
intensity, long time.
2. Reasonable shaft design, crane line accuracy. This makes the shaft work
smoothly, flexibly, and accurately, while helping the product operate more stably..
 3. Low residual stress, high torsion resistance. Due to the working characteristics of
the shaft with a lot of bending torque and large torque, the shaft needs to be
designed, manufactured, and selected materials correctly to reduce stress, increase
the load capacity of the shaft.
4. Good machinability.
CHAPTER II. SELECTION OF FABRICATION MATERIALS.
2.1 The step shaft needs to fully meet the following:
Mechanical properties:
+ High surface hardness, wear resistance against deformation of the shaft, causing large
tolerances during operation affecting the entire system.
+ The elongation is relatively low, because the shaft is subjected to a lot of external
forces such as bending moment, torsion, compressive force, stretching, less stress
concentration.
+ High strength and good wear resistance.
+ Low residual stress, high torsion resistance.
Physical properties;
+ Low expansion.
+ Good heat resistance.

Chemical properties:
+ Anti-corrosion, due to the working environment of the shaft may be exposed to
chemicals or due to the lack of protection from the external environment.
+ Good acid resistance.
2.2 Analysis, calculation of material selection.
The material for making the shaft is selected based on the working capacity standards of
the shaft, the materials selected are mainly carbon steel and alloy carbon steel.
+ When the shaft is not under great stress - such as small motors, pumps, CT5 steel can
be used without heat treatment to manufacture. For larger load-bearing shafts, we use
steel C35, C45, C50,... heat treatment.

Mác thép %C %Si %Mn %Ni %Cr %P %S

 CT5 0.29-0.37 0.15-0.35 0.50-0.80 Max 0.045 Max 0.045

C35 0.32-0.38 0.15-0.35 0.30-0.60 Max 0.03 Max 0.035

C45 0.42-0.48 0.15-0.35 0.60-0.90 0.2 0.2 Max 0.03 Max 0.035

C50 0.52-0.60 0.15-0.35 0.60-0.90 Max 0.03 Max 0.045

C55 0.52-0.58 0.15-0.35 0.60-0.90 Max 0.030 Max 0.035

These steel grades are usually organized in the form of peclite or ostenit, which is a
medium carbon steel, withstands high loads, resists oixification well, resists impact, after
surface treatment such as tempering, ram, carbursion, nitrogen,... will reach hardness,
abrasive overlap. High-tech, easy to process.

+ In case of large loads, working in important machines, the shaft is made of structural
alloy steel with the advantages of working with large tonnage, requires rigidity, wear
resistance, needs elasticity. For example: 40Cr, 40CrNi, 20CrNi, 35CrMnNi ... I improve
the surface or I by high frequency current. Alloy steel is a material with heat resistance
up to 5500 – 6000. This type of shaft is often found in thermal power plants, is the shaft
of turbines in boilers, working at high temperatures, high pressure.
+ If the shaft rotates quickly, installs a sliding bearing, the shaft needs high rigidity, wear
resistance, creates the main, when rotating at a large speed does not create fluctuations,
then we use steel grade C20, 20Cr absorbed with coal, cyanide and then me. If under high
stress, rotating at high speeds, use 12Cr, Ni3A, 12Cr2N4A steel soaked with coal or
cyanua.
⇨ So the material to use is 40Cr steel.
2.2.1 Introduction about 40Cr Steel
40Cr steel is a high alloy steel, low carbon, chromium - Molip - Medium nickel. Steel
after oil and ram smelting reaches a hardness of 28-34 HRC. Steel 40Cr annealed steel
can reach a maximum hardness of 250 HB. Steel has a low carbon content so it can be
welded.
2.2.2 The chemical composition of steel 40Cr.

2.2.3 Physical-mechanical properties of steel 40Cr.

2.2.4 Application of steel 40Cr.

40Cr steel is widely used for a variety of applications used in the automotive industry and
engineering for tool owners and other such components. Typical applications such as
valve bodies, pumps and fittings, Shafts, high loads of wheels, bolts, double-ended bolts,
gears, etc.

CHAPTER III. PRODUCT FABRICATION – SINGLE-UNIT

MANUFACTURING.
Dựa vào kích thước trục đề bài đã cho:
- Đường kính lớn nhất: θ150 mm.
- Đường kính cổ trục: θ75 mm.
- Rãnh then: DxRxS = 55x15x10 mm.
- Chiều dài trục: 1000 mm.
Đây là trục làm việc trong các bộ phận lớn như hộp điều tốc trong tuabin quạt gió, máy
phát điện, trong tubin thủy điện cỡ nhỏ,…..Với điều kiện làm việc:
+ Nhiệt độ trung bình ( 200-3000).
+ Tốc độ quay thấp (75rpm- 1500rpm).
+ Mômen uốn, Mômen xoắn trung bình-cao.
+Đảm bảo độ chính xác cao, tốc độ quay của thiết bị.
+Độ nhám bề mặt Ra=0.6.
+Độ cứng HRC 48-52.

3.1 Select the material.

+The material to choose as a workpiece is 40Cr structural alloy steel.
Tensile strength ≥ 550 MPA
Flow limit ≥ 385 MPA
The length is relatively low ≤ 10%.
Impact toughness: 47 J
+ Workpiece size: Cylindrical
3.2. Machining
3.2.1 Fabrication of workpieces.
Request.
*Dimensions: - diameter: θ170mm∓5mm.
- Length: 1050mm∓5mm.
*Has a shape that closely resembles the detail.
* Low cost.
3.2.1.1. Workpiece casting
*Sand molding.
Description: cylindrical, large-sized workpiece we use the sand molding method. Then
forge stamping to increase durability, creating a round cylinder for the workpiece.
It is possible to manufacture workpieces with almost the same shape as parts, simple
equipment with low investment capital. The shape accuracy is not high, leading to a large
amount of residual work, low quality of workpieces, often with slag holes, pitting gas,
low surface quality.
+ Principle 1: Create a mold. Dimensions:DxRxC=170x170x1500 mm.
+ Principle 2: Smelting metal.
+ Principle 3: Pour molten metal into the mold.
+ Principle 4: Clean the casting.
+ Principle 5: Heat. (about 10000C)
+ Principle 6: Forging and stamping molded products from rectangular boxes into round
cylinders.
*Metal molding.
Description: High precision, tight smooth metal organization, easy to mechanize and
automate. But limited in the volume of molded products, it is impossible to cast objects
with complex shapes, thin walls, it is necessary to accurately calculate the required
volume of metal, high cost. Surfaces that are often hardened after casting need annealing
to increase ductility for subsequent machining steps.
+ Original1: Preparation of molds, cleaning of injection molds coated with surface
additives.
+ Raw material 2: Smelting raw materials.
+ Principle 3: Pour raw materials into molds.
+ Principle 4: Remove the molded product from the mold.
3.2.1.2. Rolled workpieces.
Good mechanical properties, uniform surface, rolled steel has a size shape, horizontal
cross section and length according to standards, high accuracy, relatively stable chemical
composition. The size and shape of the workpiece are almost identical to the details. The
amount of chip is small.
+ Principle 1: Choose rolling materials.
+ Principle 2: Rolling materials.
3.2.1.3 Stamped workpiece (hot).
The workpiece is stamped under the action of external forces, the organization in the steel
is oriented and stretched according to the fibers that create the fiber organization. This
increases the resistance of longitudinal grain scissors, which are cut in horizontal grains.
But it reduces the plasticity of the material, increasing the surface hardness. When using
mechanical stamping workpieces of enhanced materials, the shape, quality, and size reach
high accuracy. Thus reducing the processing time.
+ Principle 1: Choose the material, cut into the same size as the detail.
+ Principle 2: Heat the material with high-frequency induction current (About 1000o).
+ Principle 3: Stamping materials in a perpendicular direction to the axis.
+ Principle 4: Cool down to ensure that the cell organization does not change (avoid the
marteniste form).
Conclude:
The amount of waste produced by the processes is in turn molded>rolled>stamped. And
efficiency in the production process. We choose the Forging method to produce
workpieces.
3.2.2. Cutting processing.
Description: Using cutting processing methods to shape the product, requiring accuracy
in shape and parameters on the drawing, tolerances allowed.

Drawings for making step shaft

+ Principle 1: Nude head - drill the center hole.

* Choose wind steel knife, 1225rpm rev speed.
 -Step 1: Get your head covered.
-Step 2: Drill the center hole.
+ Principle 2: Convenience.
* Choose a lathe knife with hard alloy attachment T15K6, main angle of inclination 900.
Rotation speed limit of 2000rpm.
-Step 1: Turning rough surface shaft θ150mm
-Step 2: Hold 1 end of the shaft in place, turn the other end of the shaft.
Step 2.1: Turning the θ120mm shaft surface rough
Step 2.2: Turning the θ100mm shaft surface rough
Step 2.3: Turning the θ75mm shaft surface rough
-Step 3: Turn the shaft head, keep the shaft fixed and turn the other end of the shaft like
step 2.
+ Principle 3: Turning the shaft face and beveling the edge.
* Choose a lathe knife with hard alloy attachment T15K6, main tilt angle 900. Rotation
speed limit of 2000rpm.
-Step 1: Turning the surface of the axis θ150mm.
-Step 2: Turning the surface of the θ120mm shaft
-Step 3: Turning the surface of the θ100mm shaft
-Step 4: Turning the surface of the θ75mm shaft
-Step 5: Bevel the beveled edges of the 2mm x 450 shaft
+ Principle 5: Processing then.
-Step 1: Machining the hole starts milling the key groove
-Step 2: Milling the rough key groove with dimensions DxRxS: 55mm x 15mm x
10mm.
-Step 3: The cutter bevels the edge of the key groove
-Step 4: Complete the key groove milling
+ Principle 6: Heat treatment.
Stee Tippi Annealling Normalizing Quenching Tempering Mechanical properties
 l ng 0
C Cooli Hardne 0
C Hardn 0
C Coolin 0
C Coolin σb σ δ γ Ak
grad point ng ss (HB) ess g g
e Ac1, (HB) Mp Mpa % % %
Ac3, a
Ms

40C 743- 820- Stove ≤207 83 ≤250 830- Water, 400- Water, ≥9 ≥78 ≥9 ≥45 ≥59
r 782 840 0- 860 oil 600 oil 80 4
88
0

+ Principle 7: Rough grinding.

+ Principle 8: Sharpening.
CHAPTER IV . SURFACE TREATMENT.
Request:
*HRC surface hardness 48-52.
*roughness= 0.6.
4.1 Incubation
*Concept: It is a method of heating steel to a certain temperature (from 200 –
10000C), retaining heat for a long time and then cooling slowly along with the
furnace to achieve stable organization.
*Purpose:
• Reduce hardness for easy cutting processing.
• Increase ductility to make it easier to conduct, rolling and pulling steel in a cold
state.
• Reduce or lose internal stress after mechanical processing and molding and
welding.
• Small steel beads if the previous work made large beads.
*Process:
-Step 1: Heat the shaft slowly to 850°C
-Step 2: Brew in the oven within about 4 hours
 -Step 3: Slow cool down slowly in the oven.

4.2 . Cyanide permeability.

The depth is from 0.1-0.2 mm but resists surface corrosion while increasing hardness
very well.
4.3 Metal permeability.
Permeate the surface of other metals to increase hardness, corrosion resistance, and rust
resistance.
4.4 Spray coating.
+ High-speed spraying.
+ Arc spraying.
+ Laser tape spraying.
Create a surface layer with special properties, working in a special environment. but the
cost is high.
 Based on the working environment and quality requirements of the transmission shaft
part. the method of me and cyanide permeability is the most optimal method.
CHAPTER V. CONCLUSION.
In the above presentation, I gave a full and detailed introduction of the rank axis
product, namely the general introduction, use and meaning of the rank axis;
thereby giving analysis to make a tiered axis product.
Shaft details are very important and common in practice. Is the connection between
the details in the machine. Therefore, the design and calculation for the axis need
to be very accurate to ensure the optimization and efficiency of products with axial
details.
In addition, it is also very important to calculate materials, technologies and
manufacturing methods, each method brings its own benefits to increase economic
efficiency, reduce product costs, increase accuracy, stability and increase the life of
parts. To do so, designers must have a knowledge base, always update new
technologies, know how to apply to products. In this way, it is necessary to
produce quality products with Vietnamese brands to go international.