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10-08-2017

SHAFTS
MCL2 11
DE PARTME N T OF MECHANICA L E NG IN E E RIN G
IIT DE L HI

Shafts
A shaft is
a rotating member,
usually of circular cross section,
used to transmit power or motion.
It provides
the axis of rotation of elements such as gears, pulleys,
flywheels, cranks, sprockets, and the like and controls the
geometry of their motion.

SHAFTS IIT DELHI

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Shafts
An axle is
a non-rotating member that carries no torque and is used to
support rotating wheels, pulleys, and the like.

SHAFTS IIT DELHI

Typical shaft arrangements

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Shaft Design
Material Selection
Geometric Layout
Stress and strength
Static strength
Fatigue strength
Deflection and rigidity
Bending deflection
Torsional deflection
Slope at bearings and shaft-supported elements
Shear deflection due to transverse loading of short shafts
Vibration due to natural frequency

SHAFTS IIT DELHI

Shaft Design
Stress at a section of interest is a function of local geometry.
Stress analysis at a specific point on a shaft can be made
using only the shaft geometry in the vicinity of that point.
Geometry of the entire shaft is not needed.
In design it is usually possible to locate the critical areas,
size these to meet the strength requirements.

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Shaft Design
Deflection is a function of the geometry everywhere.
The deflection and slope analyses cannot be made until the
geometry of the entire shaft has been defined.

SHAFTS IIT DELHI

Shaft Design
Shaft sizing
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.

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Shaft Materials
Deflection primarily controlled by geometry, not material
Stress controlled by geometry, not material
Strength controlled by material property

SHAFTS IIT DELHI

Shaft Materials
Shafts are commonly made from low carbon, CD or HR
steel, such as AISI 10201050 steels.
Fatigue properties dont usually benefit much from high
alloy content and heat treatment.
Surface hardening usually only used when the shaft is being
used as a bearing surface.

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Shaft Materials
Cold drawn steel typical for d < 3 in.
HR steel common for larger sizes. Should be machined all over.
Low production quantities
Lathe machining is typical
Minimum material removal may be design goal

High production quantities


Forming or casting is common
Minimum material may be design goal

SHAFTS IIT DELHI

Shaft loads
Torsion
Bending
Axial

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SHAFTS IIT DELHI

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Free-body diagrams of the forces and


moments acting upon two gears of a
simple gear train.

SHAFTS IIT DELHI

Resolution of gear forces.

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A gear train containing an idler gear.


(a) The gear train.
(b) Free-body of the idler gear.

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Bevel-gear tooth forces.

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(a) Bevel gearset.

SHAFTS IIT DELHI

(a) Bevel gearset.


(b) Free-body diagram of shaft CD.

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Tooth forces acting on a right-hand helical gear.

SHAFTS IIT DELHI

Drawing of the pitch cylinder of a worm, showing


the forces exerted upon it by the worm gear.

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The pitch cylinders of the worm gear train.

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Free-body diagram.

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Shaft loads

Typical shaft loading and deflection


SHAFTS IIT DELHI

Shaft loads
Torsion due to transmitted torque
Bending at transverse loads at gears teeth and sprockets.
Fluctuating stresses even under constant load.
Axial loads are introduced by helical and worm gears. Self
weight in vertical shafts and is present in turbines etc.
usually does not lead to significant stresses.

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Shaft loads
Stress concentrations due to keyways, splines, shoulders
and oil holes
Usually end up with combination of steady, time varying
torque, and bending loads
Even though the shaft is a common element, its design
leads to complex multi-axial stress analysis.

SHAFTS IIT DELHI

Shaft Layout
The general layout of a shaft to accommodate shaft
elements, e.g. gears, bearings, and pulleys, must be
specified early in the design process.
The geometry of a shaft is generally that of a stepped
cylinder.
The use of shaft shoulders is an excellent means of axially
locating the shaft elements and to carry any thrust loads.

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Shaft Layout
Issues to consider for shaft
layout
Axial layout of components
Supporting axial loads
Providing for torque
transmission
Assembly and Disassembly

A vertical worm-gear
speed reducer.

SHAFTS IIT DELHI

(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.

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(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.

SHAFTS IIT DELHI

Axial Layout of Components


Support load-carrying components between bearings rather
than cantilevered outboard of the bearings.
Pulleys and sprockets often need to be mounted outboard
for ease of installation of the belt or chain. The length of the
cantilever should be kept short to minimize the deflection.

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Only two bearings should be used in most cases.


For extremely long shafts carrying several load-bearing
components, it may be necessary to provide more than two
bearing supports.
In this case, particular care must be given to the alignment
of the bearings.

SHAFTS IIT DELHI

Shafts should be kept short to minimize bending moments


and deflections.
Some axial space between components is desirable to allow
for lubricant flow and to provide access space for
disassembly of components with a puller.
Load bearing components should be placed near the
bearings, again to minimize the bending moment at the
locations that will likely have stress concentrations, and to
minimize the deflection at the load-carrying components.

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Must be accurately located on the shaft to line up with other mating


components, and provision must be made to securely hold the
components in position.
The primary means of locating the components is to position them
against a shoulder of the shaft.
Shoulders can be constructed with retaining rings in grooves, sleeves
between components, or clamp-on collars for small forces.
In cases where axial loads are very small, it may be feasible to do
without the shoulders entirely, and rely on press fits, pins, or collars
with setscrews to maintain an axial location.

SHAFTS IIT DELHI

Supporting Axial Loads


To provide a means to transfer the axial loads into the shaft,
then through a bearing to the ground.
Necessary with helical or bevel gears, or tapered roller
bearings, as each of these produces axial force components.
Means of providing axial location, e.g., shoulders, retaining
rings, and pins, will be used to also transmit the axial load
into the shaft.

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Supporting Axial Loads


Axial loads must be supported through a bearing to the frame.
Generally best for only one bearing to carry axial load to shoulder.
Allows greater tolerances and prevents binding.

Tapered roller bearings used in a


mowing machine spindle.
This design represents good practice
for the situation in which one or more
torque transfer elements must be
mounted outboard.

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A bevel-gear drive in which both pinion


and gear are straddle-mounted.

SHAFTS IIT DELHI

Providing for Torque Transmission


Most shafts serve to transmit torque from an input gear or
pulley, through the shaft, to an output gear or pulley.
Necessary to provide a means of transmitting the torque
between the shaft and the gears.

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Common means of transferring torque to shaft


Keys
Splines
Setscrews
Pins
Press or shrink fits
Tapered fits

Keys are one of the most effective


Slip fit of component onto shaft for easy assembly
Positive angular orientation of component
Can design key to be weakest link to fail in case of overload

SHAFTS IIT DELHI

Alternative methods of shaft-hub connection.

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Keys for torque transmission


and component location.

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Pins for torque transmission


and component location.

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Snap rings or circlips.

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Assembly and Disassembly


Method of assembling the components onto the shaft, and
the shaft assembly into the frame.
Generally requires the largest diameter in the center of the
shaft, with progressively smaller diameters towards the
ends to allow components to be slid on from the ends.
If a shoulder is needed on both sides of a component, one
of them must be created by such means as a retaining ring
or by a sleeve between two components.

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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. Note the labyrinth seal on
the right.

The outer bearing rings are preloaded.

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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.
Note the floating right-hand bearing and the
grinding runout grooves in the shaft.

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.

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