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This document describes the design of a shaft that will transmit 40 HP between 100-3000 RPM. It discusses calculating torque and stresses on the shaft. Three potential materials are considered: aluminum alloy, titanium alloy, and steel. Steel is selected as it has the lowest deflection to prevent fatigue and achieve an infinite lifespan, despite being heavier. Calculations are shown for stresses, safety factors, and deflection for different shaft diameters and the selected steel material.

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Anan Aghbar
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38 views36 pages

Report Report Groupe

This document describes the design of a shaft that will transmit 40 HP between 100-3000 RPM. It discusses calculating torque and stresses on the shaft. Three potential materials are considered: aluminum alloy, titanium alloy, and steel. Steel is selected as it has the lowest deflection to prevent fatigue and achieve an infinite lifespan, despite being heavier. Calculations are shown for stresses, safety factors, and deflection for different shaft diameters and the selected steel material.

Uploaded by

Anan Aghbar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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University of Puerto Rico

Mayagez Campus
Department of Mechanical Engineering
Machine Component Design 1, 2007-I
INME 4011

Shaft Design for Transmission Application

Irmydel Lugo Velazquez


843-03-3851
Victor Molina Vargas
802-02-4285
Eladio Pereira Troche
843-00-5500

May 8, 2007

Objective

Design a shaft that transmits 40 HP with a fluctuating rotation of 100 to 3000 RPM. This shaft
will be designed for an infinite live with a safety factor. Other requirements of the design are
minimize the weight of the shaft and appropriate material selection.

Description
Design a shaft that will be used in some type of transmission application. This shaft is used to
transmit a maximum amount of power of 40 hp at 3000 rpm. This element is subjected to forces
applied when the gears its rotating. We have a restriction of length of 2 ft and a minimal
thickness of .25 inches. Another important aspect of this design is that we need choose a
material that holds all the stresses applied to it and must have a very high safety factor to assure
that the shaft will have infinite life. The material in addition must be as light weight as possible
and durable, endure other types of fatigue, although our design will take into consideration the
critical points of the shaft and optimize them.
The data given in this design submits the shaft to fluctuating stresses. The main idea is for the
shaft to withstand the change in loads, for example, rising from 1000 to 3000 RPM and back
again. The following figure is a description of the shaft that we must design.

Design Details

First we calculate the torque applied to the shaft at 3000 RPM:

Now we calculate the force due to the torque:

For the next step, we made a diagram show how the forces are applied at the point
of the spur gear, we assume the angle of attack for the teeth of the spur gear is
20:

Diagrams:
o X-Y Plane:

o X-Z plane:

o Stresses Obtained:

Moment of Inertia for each diameter:

First Moment of Area:

Stresses:
o Section with diameter of 2 in:

o Section with diameter of 4.8 in:

o Section with diameter of 6 in:

Principal Stresses:
o Section with diameter of 2 in:

o Section with diameter of 4.8 in:

o Section with diameter of 6 in:

Material Selection:

Boundary Conditions:
o

Substituting Constants:

Now we determine the material indices that minimize the mass of the shaft, so it will be
as light as possible:

To minimize the mass we have to minimize the relation

. So we maximize the inverse to

find appropriate materials in the Elasticity modulus-density graph. The graph tells us that the

best material is B4C, but a ceramic is not recommendable because its a very brittle and small
cracks will propagate very fast. Amongst the best materials to be used are aluminum alloys,
titanium alloys and steel. Also the ceramic and carbon fiber alloys, but due to the fact that the
forces and stresses are so high, it is not recommendable to use them. With the relation
mentioned before we obtain that aluminum has the lowest ratio with 1.68 followed by titanium
with 2.70 and finally steel with 2.85. We found some recommend materials to be used for this
application; which are the following; Aluminum 2024-T4, 1020 Steel and Beta Titanium Alloy.

For the fluctuating stresses we start out with the following graph to show Force vs RPM;

Deflection:

The maximum deflection occurs at

; where a and b are the distances between the

applied force and the supports, where b > a. In our design a is 9 in and b is 19 in.

At this point the maximum deflection is obtained by the following equation; where P is
168.064lb, I is .78233 in^4 and L is 28 in.

We obtained the value of E for Al-2024 T-4 (E = 10602 KSI), ASI-1020 (E = 29732 KSI) and Ti15Mo5Zr3Al ( titanium alloy) (E = 10878 KSI).

We can compare these values and find that the least probable to have deflection is steel followed
by titanium and finally aluminum.

Calculating Safety Factor:

In each of the previous tables, which we develop in excel, we can find all the calculations done
to obtain the safety factor for each material and different point on the shaft. The safety factor
was calculated by taken into consideration that we use infinite life as a goal of the design. The
highest safety factor was obtained by titanium, followed by steel and aluminum respectively.

Discussion
After compiling all the data, from the initial dimensions to the safety factor for each individual
material, we found that between zero and 100 rpm the forces are so great due to the fact that they
tend to infinity, with this it would not transfer the 40 hp required by the design. So we decided to
evaluate the design with fluctuating stresses relating from 100 rpm to 3000 rpm. In the material
selection we obtained various materials, but ceramics and carbon fibers were discarded due to
the fact that they would not withstand the forces exerted. The remaining materials were analyzed
to reduce weight and increase the safety factors. Steel is the best option, even though being the
heaviest of the materials; the reasons outweigh the weight reduction. For example, there is a big
difference between the deflection of the steel was of. 002736 in, and this is approximately 3.5
smaller times that that of titanium and that of aluminum. This is a determinant factor for design
a shaft since helps to reduce the fatigue and obtaining infinite life. Also cost comes into effect
because of the fact that both the titanium and aluminum considered are fairly expensive and rare.

A disadvantage that we confronted designing the shaft was the constants changes in diameters.
Because we have no radius to deal with, it became a challenge.

Conclusion
The shaft that we designed works for velocities between 100rpm to 3000rpm, generating a
constant power of 40 HP. This shaft was designed to minimize the weight and the cost of
manufacturing. To minimize the weight we selected diameters that will give small cross sections
and, that way, we use less material.

Our main objective was to make a shaft that will have infinite life. To achieve that, we searched
for materials that resist deflection, cracks and fatigue. We selected and analyzed three
preliminary materials: an aluminum alloy, a titanium alloy and a stainless steel. Our best option
was the steel AISI 1020, since it filled better the requisites. This material gave the lowest
possible deflection of the shaft, in comparison with the other two materials analyzed. The safety
factors were 2.43 for one critical section, and 6.78 for the other critical section studied. These
safety factors are good to make the shaft useful for infinite life. We calculated with the Von
Mises (equivalent), amplitude and mean stresses of each section. We found on tables the fatigue
limit stress (Sf) and the ultimate stress (Sut) of the materials, and with these quantities we
calculated the safety factor, using the Goodman model.

Appendix

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