AFA II + III CHAPTER: Shafts

Shafts
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In This Presentation

• Function
• Nomenclature
• Loading
• Manufacturing
• Operation
• Problems

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Functions

• Support Components
• Transmit Power & Motions
• Seal Oil in & Dirt out
• Pass Lube

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Nomenclature

Splines
Fillets

Tapers

Threaded Keyways Bearing

Section Surfaces Holes
Mounting surfaces for
bearings, gears, pulleys etc.

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Loads

• Bending

• Compression

• Tension

• Torsion
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Bending

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Compression
1 2 3 4

Longitudinal Transverse Longitudinal Shear stresses

Compression Tension Separation Split in 45°

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Compression
shear loads try to
make the shaft
separate at 45°
angles

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Tension

Longitudinal Tension Transverse brittle or ductile in

Transverse Compression Center ends with 45° Shear lip

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Torsion (Twist)

High tension at 45° in the general direction of

torsional load, and compression at 45° in the
direction opposite the torsional load

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Torsion (Twist)

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Torsion (Twist)

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Torsion (Twist)

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Torsional Shear
• Longitudinal

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Torsional Shear
• Transverse

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Torsional Loads

Torsional loads and resultant stresses

are highest at the surface and reduce
to zero as we approach the center of a
shaft

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Manufacturing

• Medium Carbon
• Boron Steel

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Grain Flow

Most shafts are made from rolled steel bar stock. Grain
flow is therefore usually in line with the length

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Machining
Before heat treating, most surfaces are
machined to final dimension

• Holes
• Keyways
• Splines

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Splines Cut

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Splines Rolled

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Splines Rolled

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Splines Rolled

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Splines Rolled

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Splines Rolled

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Heat Treat

• Induction
• Direct
• Case

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Heat Treat Induction

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Heat Treat Induction

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Heat Treat Heat-Treated Sections

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Torsional Strenght

• RC 50
• Specified Case Depth

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Case Depth
Compressive residual stresses in case
Residual tensile stresses in core

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Case Depth
Too shallow Longitudinal fracture near core
Too deep result in to high residual tensile
stresses in core

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Tempering

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Straightening

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Surfaces

• As rolled
• Machined
• Ground
• Polished
• Shot pened

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Grinding Bearing surface after heat treat

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Operation

Little if any wear if:

• Temperature
• Alignment
• Load
• Oil Quality
• Oil Quantity
Have been normal

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Normal Appearance

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Normal Appearance Seal Grooves

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Normal Appearance Spline Wear

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Normal Appearance Mounting Surfaces

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Normal Appearance Key Ways

Designed to carry
Torsional load

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Normal Appearance Key Ways

Tapered Shaft, designed just

to index gears etc.

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Abnormal Conditions

Wear
• Abrasive
• Adhesive
• Fretting Corrosion
• Contact Stress Fatigue

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Abnormal Conditions Abrasive Wear

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Abnormal Conditions Abrasive Wear

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Determine Source

• Use magnification
• Softer Parts
• Oil sumps
• Filters
• Grooves
• Holes

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Possible Sources

• Built in
• Cracked housing or hoses
• Failed seals
• Contaminated fill oil
• Missing breather

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Abnormal Conditions

Wear
• Abrasive
• Adhesive
• Fretting Corrosion
• Contact Stress Fatigue

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Abnormal Conditions Adhesive Wear

Reduced internal
clearance

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Abnormal Conditions

Wear
• Abrasive
• Adhesive
• Fretting Corrosion
• Contact Stress Fatigue

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Abnormal Conditions Fretting Corrosion

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Abnormal Conditions

Wear
• Abrasive
• Adhesive
• Fretting Corrosion
• Contact Stress Fatigue

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Abnormal Cond. Contact Stress Fatigue

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Abnormal Conditions

Fractures
• Brittle
• Ductile
• Fatigue

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Abnormal Conditions Brittle Fracture

Bending overload

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Abnormal Conditions Brittle Fracture

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Abnormal Conditions Brittle Fracture

No abnormal
Stress raiser
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Brittle

Compression
• Barrel Shape
• Longitudinal
• Buckling

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Buckling Compressive overload

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Buckling Brittle Fracture

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Buckling Brittle Fracture

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Brittle

• Torsion

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Brittle Torsional Fracture

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Brittle Torsional Fracture

Extreme torsional overload
or final fracture of fatigue
crack

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Abnormal Conditions

Fractures
• Brittle
• Ductile
• Fatigue

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Ductile

Torsional
• 45° tensile
• Longitudinal shear
• Transverse shear

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Ductile 45° Tensile Fracture

Torsional
Overload

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Ductile 45° Tensile Fracture

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Ductile Longitudinal Shear

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Ductile Longitudinal Shear

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Transverse Shear

• Smooth, silky
• Swirl pattern
• Final fracture subsurface
• At normal stress raiser
• Longitudinal or 45° initiation
• Barber poling

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Transverse Shear Torsional

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Transverse Shear Torsional

Smooth silky fracture
Swirl Pattern
Final fracture
In center

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Transverse Shear Single Torsional Overload

Spline deformation
High twisting forces

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Transverse Shear Torsional Overload

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Transverse Shear Torsional Overlaod

Smooth silky fracture
Swirl Pattern
Final fracture
In center

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Transverse Shear Torsional Overlaod

Barber poling

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Transverse Shear Torsional Overlaod

No final fracture

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Transverse Shear Torsional Overlaod

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Transverse Shear Torsional Overload

Failed at normal stress raiser

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Transverse Shear Torsional Overload

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Transverse Shear Torsional Overload

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Abnormal Conditions

Fractures
• Brittle
• Ductile
• Fatigue

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Fatigue Fractures

• Bending
• Reverse Bending
• Rotating Bending
• Torsional
• Tensile

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Bending Fatigue Cyclic overload

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Bending Fatigue Cyclic overload

Ratchet and beach marks
Starts at the surface

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Bending Fatigue Cyclic overload

Large final fracture indicates

Cyclic overload was severe

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Bending Fatigue Cyclic overload

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Bending Fatigue Cyclic overload

Small fatigue portion
Large final brittle fracture

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Bending Fatigue Cyclic overload

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Bending Fatigue Corrosion Fatigue

Shaft failed at fillet
Normal stress raiser

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Bending Fatigue Corrosion Fatigue

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Bending Fatigue Corrosion Fatigue

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Bending Fatigue High Cyclic Fatigue

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Bending Fatigue High Cyclic Fatigue

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Bending Fatigue High Cyclic Fatigue

No abnormal stress raisers

High Torsional Overload

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Bending Fatigue High Cyclic Fatigue

Other shafts also cracked

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Bending Fatigue Misalignment

Shaft fractured internally

In splined section

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Bending Fatigue Misalignment

Initiation near ends of

Several spline roots

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Bending Fatigue Misalignment

No abnormal stress raisers

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Bending Fatigue Misalignment

Two more cracks

not opened up yet

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Bending Fatigue Misalignment

Initiated longitudinal, changed

Direction 45° due to torsional tensile stresses
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Bending Fatigue Misalignment

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Bending Fatigue Misalignment

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Bending Fatigue Misalignment

Wear on both ends

of spline

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Bending Fatigue Assembly Problem

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Bending Fatigue Assembly Problem

Ratchet marks
Beach marks

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Bending Fatigue Assembly Problem

Gouge mark =
Abnormal stress raiser

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Bending Fatigue Reverse Bending

Ratchet marks, Beach marks
on both sides, ductile final
fracture

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Bending Fatigue Reverse Bending

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Bending Fatigue Rotating Bending

Fracture initiated
At a normal fillet

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Bending Fatigue Rotating Bending

Multiple initiation sites

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Bending Fatigue Rotating Bending

no evidence of pre
cracks or other
abnormal stress,
raisers

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Torsional Fatigue One direction

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Torsional Fatigue Two directions

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Torsional Fatigue Two directions

Reverse torsional overload

Initial cracks in spline root
Branch 45° due to tensile loads

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Torsional Fatigue
Transverse hole may
act as stress raiser

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Torsional Fatigue Cyclic torsional overload

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Torsional Fatigue Cyclic torsional overload

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Torsional Fatigue Cyclic torsional overload

4 fatigue fractures

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Torsional Fatigue Cyclic torsional overload

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Torsional Fatigue Reverse torsional fatigue

reverse torsional fatigue

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Torsional Fatigue Reverse torsional fatigue

Smooth and silky fracture

Indicating torsional shear

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Torsional Fatigue Reverse torsional fatigue

Flute corner in drilled

bolt hole act as stress
raiser

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Torsional Fatigue Reverse torsional fatigue

Other cracks growing

In 45° angles

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Torsional Fatigue Reverse torsional fatigue

Large 45° intersects with

other bolt hole. The transverse
shear is final fracture

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Torsional Fatigue Reverse torsional fatigue

“Monkey Face”

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Torsional Fatigue Reverse torsional fatigue

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Torsional Fatigue Reverse torsional fatigue

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Torsional Fatigue Reverse torsional fatigue

Peeling Fracture

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Torsional Fatigue Reverse torsional fatigue

Starry Fracture

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Torsional Fatigue Reverse torsional fatigue

45° fatigue cracks in both

tensile planes

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Torsional Fatigue Reverse torsional fatigue

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Torsional Fatigue

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Torsional Fatigue
Shaft fractured in
keyway slot

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Torsional Fatigue
Smoot surface, beach marks,
ratchet marks. Keyway slot
polished or fretted

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Torsional Fatigue
Tapered portion have
fretting marks

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Torsional Fatigue
Retaining nut is worn

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Torsional Fatigue
Wear mark in cotter
pin slots

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Torsional Fatigue
Fretting mark on nut face
last thread stripped

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Torsional Fatigue

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Torsional Fatigue

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Torsional Fatigue

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Reasons for Core Initiation

• Material not as strong

• Torsional load still high
• Residual compression in case
• Residual tension in core

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Other Possible Causes

Longitudinal Fatigue
• Inclusions, seams, pipe, etc
• Case depth too Shallow

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Shaft Problems

• Design
• Material
• Processing

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Shaft Problems Design

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Shaft Problems Design

Transverse Shear
Galling (Adhesive Wear)

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Shaft Problems Design

45° Tensile cracks in case

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Shaft Problems Design

Adhesive wear in bore

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Shaft Problems

• Design
• Material
• Processing

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Shaft Problems Material

45° Tensile fracture

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Shaft Problems Material

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Shaft Problems Material

Crack longitudinal with shaft

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Shaft Problems Material

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Shaft Problems Material

Stringer (Inclusions)

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Shaft Problems Material

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Shaft Problems Material

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Shaft Problems Material

Dendrites, casting void

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Shaft Problems

• Design
• Material
• Processing

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Shaft Problems Processing

Wheel spindle failed
in flute corners

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Shaft Problems Processing

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Shaft Problems Processing

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Shaft Problems Processing

Shaft failed in fillet radius

big part discolored

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Shaft Problems Processing

Smooth and light gray fracture face

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Shaft Problems Processing

Ratchet marks all around the

Circumference

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Shaft Problems Processing

Dished fracture face

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Shaft Problems Processing

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Shaft Problems Processing

Precrack introduce
during heat treat

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Shaft Problems Processing

Hydraulic cylinder
rod failed in fillet

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Shaft Problems Processing

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Shaft Problems Processing

No abnormal stressraiser
at crack initation

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Shaft Problems Processing

No abnormalities
on the other side

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Shaft Problems Processing

No fretting on nut face

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Shaft Problems Processing

Cyclically overloaded
Or fillet to sharp

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Shaft Problems Processing

Shaft fractured 25mm from

Splined section

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Shaft Problems Processing

Bright crystalline
fracture in center

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Shaft Problems Processing

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Shaft Problems Processing

Beach mark radiating

from inside out

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Shaft Problems Processing

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Shaft Problems Processing

To deep case depth causing
high residual stresses

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