MECH 2410

Machine Design

Lecture 7 Shaft Design

Content
Shaft Layout
Shaft Design Procedure
Associated Parts Design Procedure
Keys
Couplings

Shaft and Axels

Shaft is a rotating member and it provides axis of rotation

for gears, pulley, flywheels, cranks, sprockets.
Axels are non rotating member, carries no torque and it is
used to support rotating wheels.

Example: Gear Box

Shaft Sizing Considerations

Stress Analysis
In design it is usually possible to locate the critical areas, size these to
meet the strength requirements, and then size the rest of the shaft to
meet the requirements of the shaft-supported elements.
Deflection and Slope
They are a function of inertia. Inertia is a function of Geometry. For this
reason, shaft design allows a consideration of stress first. Then, after
tentative values for the shaft dimensions have been established, the
determination of the deflections and slopes can be made.

Example: Drawing

Shaft Layout: Shoulder

It allows precise positioning
Support to minimize deflection.
In cases where the loads are small, positioning is not very
important, shoulders can be eliminated.

Shaft Layout: Bearing

In most cases, Only two bearings should be used in most cases.
Load bearing components should be placed next to the bearings
to minimize the bending due to large forces.
Shafts should be kept short to minimize bending and deflection.

Shaft Layout: Mounting Elements

Shaft Layout: Mounting Elements

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Shaft Layout: Mounting Elements

Spacer

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Shaft Layout: Transmit Power

Keys

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Shaft Layout: Transmit Power

Spline

Shaft Layout: Transmit Power

Pulley

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Shaft Layout: Transmit Power

Coupling - Rigid

T
Dbc / 2

2T
F
T

2
As N (d / 4) Dbc N (d 2 / 4)

8T
Dbc N d

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Shaft Layout: Transmit Power

Coupling - Flexible

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Shaft Layout: Transmit Power

Coupling - Flexible

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Shaft Layout: Transmit Power

Coupling Universal Joint

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Shaft Design Procedure

Determine the rotational speed of the shaft
Determine the power or the torque to be transmitted by the shaft
Determine the design of the power-transmitting components or other
devices that will be mounted on the shaft, and specify the required
location of each device
Specify the location of bearings to support the shaft
The reactions on bearings supporting radial loads are assumed to
act at the midpoint of the bearings
If thrust (axial) loads exist in the shaft, you must specify which
bearing is to be designed to react against the thrust load
Bearings should be placed on either side of the power-transmitting
elements if possible to provide stable support for the shaft and to
produce reasonably well-balanced loading of the bearings
The bearings should be placed close to the power-transmitting
elements to minimize bending moments
The overall length of the shaft should be kept small to keep
deflections at reasonable level

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Shaft Design Procedure

Propose the general form of the geometry for the shaft, considering how
each element on the shaft will be held in position axially and how power
transmission from each element to the shaft is to take place.

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Shaft Design Procedure

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Shaft Design Procedure

Determine the magnitude of torque that the shaft sees at all points. It is
recommended that a torque diagram be prepared.
Determine the forces that are exerted on the shaft, both radially and
axially.
Resolve the radial forces into components in perpendicular directions,
usually vertically and horizontally.
Solve for the reactions on all support bearings in each plane.
Produce the complete shearing force and bending moment diagrams to
determine the distribution of bending moments in the shaft.

Spur Gear Forces

Directions of the forces are essential for the accurate analysis of
stress in a shaft.

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Shaft Design
When vertical shearing force is the only significant loading

When bending stress is repeated and reversed as the shaft

rotates, but the torsional shear stress is nearly uniform

sn' snCm Cst C R Cs

sn: endurance Strength
sn: effective endurance strength
Kt: stress concentration factor
Cm: material factor,
Cst: type of stress factor
CR: desired reliability factor,
Cs: Size factor

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Stress Concentration Factor, Kt

Retaining Ring Grooves: Kt = 3. Then add 6% to determine the nominal size for the
shaft.
www.efatigue.com/constantamplitude/stressconcentration/

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Shaft Design Procedure

Select the material from which the shaft will be made, and specify its
condition: cold-drawn, heat-treated, and so on. As indicated in Table 2
9, suggested steel materials for shafts are plain carbon or alloy steels
with medium carbon content, such as SAE 1040, 4140, 4340, 4640,
5150, 6150, and 8650. Good ductility with percent elongation above
about 12% is recommended.

Shaft Design Procedure

Determine the ultimate strength, yield strength, and percent elongation
of the selected material.
Determine an appropriate design stress, considering the manner of
loading (smooth, shock, repeated and reversed, or other).
Analyze each critical point of the shaft to determine the minimum
acceptable diameter of the shaft at that point in order to ensure safety
under the loading at that point. In general, the critical points are several
and include those where a change of diameter takes place, where the
higher values of torque and bending moment occur, and where stress
concentrations occur.
Specify the final dimensions, surface finishes, tolerances, geometric
dimensioning details, fillet radii, shoulder heights, keyseat dimensions,
retaining ring groove geometry, and other details for each part of the
shaft, ensuring that the minimum diameter dimensions are satisfied.

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Example 12-1

Design the shaft shown. It

is to be machined from
SAE 1144 OQT 1000 steel.
The shaft is part of the
drive for a large blower
system supplying air to a
furnace.
Gear A receives 200 hp
from gear P.
Gear C delivers the power
to gear Q.
The shaft rotates at 600
rpm.
DA = 20.00 in,
DC = 10.00 in.
Pressure angle = = 20

Example 12-1
Material properties:
sy = 83000 psi,
su = 118000 psi,
percent elongation is 19%.
Using Figure 58, we can
estimate
sn = 42000 psi.

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Example 12-1
Km = Kst = 1.0, Cs = 0.75, CR = 0.81
sn = snCsCR = (42 000)(0.75)(0.81) = 25500 psi

Example 12-1

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Example 12-1

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Example 12-1

Key Design Process

Design Shaft, specify the diameter
Select the key size from the given table. For diameter 6.5 in or
less, use square key. For diameter greater than 6.5 in, use
rectangular key
Specify key material, usually ANSI 1020 CD steel.
Determine yield strength of the material
Determine the minimal length. If the length is longer than hub
length, select higher strength material or multiple keys
Select the actual length of the key, make sure key seat does not
run into other parts
Complete the design of shaft and keyway in the hub

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Key size vs. Shaft Diameter

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Keys: N = 3 for regular industrial applications

Shearing Stress

T
D/2
2T
F
T

As ( D / 2)WL DWL
F

d 0.5S y / N

Compression Stress

F
T
4T

Ac ( D / 2) L( H / 2) DLH

d Sy / N
40

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Spline

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Spline Design

(D2 d 2 )
T 1000 N
8
N: number of splines
The society of Automotive Engineering (SAE)
specifies the torque capability for splines is based on
the limit of 1000 psi bearing stress on the sides of the
splines

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