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Shaft Design
ME2850 - Fundamentals of Machine Element Design

H.D.V. Amarathunga
Lecturer ( Temporary )
Department of Mechanical Engineering
University of Moratuwa

Outline
➢ Introduction
❖Material selection for shafts
❖Types of shaft and applications
❖Standard size of shafts

➢ Identification of different shaft loading conditions

➢ Design of shaft
❖Design Standards and Consideration
❖Design of shaft subjected to static loads (on the basis of strength)
❖Design of shaft subjected to fluctuating loads (on the basis of strength)
❖Design of shafts on the basis of rigidity

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Introduction
❖ A shaftis a rotating machine element used to transmit power.
❖Power is delivered to the shaft by a tangential force and the resultant torque
enables to transfer power to other machine parts.
❖Usually supported by bearings.

❖Power transmission elements, such as gears, belt pulleys, chain sprockets,

couplings and so on are attached to the shafts by keys, splines, pins and
other devices.

Material Selection for shafts

❖ It should have high strength.
❖ It should have good machinability.
❖ It should have good heat treatment properties.
❖ It should have high fatigue and wear resistant properties
❖ It should have low notch sensitivity.

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Types of shaft and applications

❖Depend on the loads they carry in the shaft, shafts can be classified in to
following categories.
▪ Transmission shaft – carry torsional and bending moments
▪ Axles – carry bending moment only
▪ Spindle – carry torsional moment only

Types of shaft and applications continued..

Transmission shaft
❖rotating machine element, circular in cross-section, which supports
transmission elements like gears, pulleys and sprockets and transmits
power.
❖The shaft is always stepped with maximum diameter in the middle portion
and minimum diameter at the two ends, where bearings are mounted.
❖The steps on the shaft provide shoulders for positioning transmission
elements like gears, pulleys and bearings
❖Applications – Counter shaft, Jack shaft, line shaft, Propeller shaft

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Types of shaft and applications continued..

Axle shaft
❖The term ‘axle’ is used for a shaft that supports rotating elements like
wheels, hoisting drums or rope sheaves.
❖Usually fitted to the housing by means of bearings.
❖In general, an axle is subjected to bending moment due to transverse loads
like bearing reactions and does not transmit any useful torque, ex:- rear
axle of a railway wagon.
❖Occasionally, the axle also transmits torque, e.g., automobile rear axle.
❖ An axle may rotate with the wheel or simply support a rotating wheel

Types of shaft and applications continued..

Spindle shaft
❖ A spindle is a short rotating shaft.
❖ The term ‘spindle’ originates from the round tapering stick on a spinning wheel, on
which the thread is twisted.
❖ Spindles are used in all machine tools such as the small drive shaft of a lathe or the
spindle of a drilling machine

Lathe Spindle

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Types of shaft and applications continued..

Machine shaft
❖These shafts form an integral part of the machine itself. ex: crank shaft

Standard size of shafts

❖Commercial shafts, used for structural and general engineering purposes,
are available in standard sizes
❖For transmission shafts,
▪ 25 mm to 60 mm with 5 mm steps
▪ 60 mm to 110 mm with 10 mm steps
▪ 110 mm to 140 mm with 15 mm steps
▪ 140 mm to 500 mm with 20 mm steps

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Identification of different shaft

loading conditions

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Design Standards and Consideration

❖Maximum permissible working stresses for transmission shaft
▪ According to American Society of Mechanical Engineers (ASME), the
maximum permissible working stresses in tension or compression
o 112 MPa for shafts without allowance for keyways.
o 84 MPa for shafts with allowance for keyways
❖The maximum permissible shear stress for Transmission Shafts
▪ According to American Society of Mechanical Engineers (ASME),
o 56 MPa for shafts without allowance for key ways.
o 42 MPa for shafts with allowance for keyways

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Design Standards and Consideration continued..

❖Shafts must be designed so that:

▪ The deflections are within acceptable levels
 High deflections cause noise and vibration while in operation
▪ Avoid Critical speed
 Start vibrating violently (Resonance)
❖Design Considerations:
▪ Size and spacing of components, tolerances
▪ Type of material to be used
▪ Deflection and rigidity
▪ Stress and strength (static strength, fatigue, reliability)
▪ Type of loading (static, shock or cyclic)
▪ Manufacturing constraints

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Design Standards and Consideration continued..

❖The shafts may be designed on the basis of

1. Strength
2. Rigidity and stiffness

❖ Designing for strength,

a) Shafts subjected to twisting moment or torque only,
b) Shafts subjected to bending moment only,
c) Shafts subjected to combined twisting and bending moments, and
d) Shafts subjected to axial loads in addition to combined torsional and
bending loads

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Design of shaft subjected to static loads (on the basis of strength) continued..

Shafts subjected to twisting moment only

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Shafts subjected to twisting moment only continued..

❖J – Polar moment of inertia, for solid shaft

❖For a hollow shaft,

❖ Then the twisting moment acting upon a hollow shaft,

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Shafts subjected to twisting moment only continued..

❖When a hollow shaft is to be made equal in strength to a solid shaft

❖Factor of safety :
The structural capacity of a system beyond the expected loads or actual
loads. Essentially, how much stronger the system is than it usually needs to
be for an intended load
Absolute tensile strength
FOS =
Actual applied load
or
Material strength
FOS =
Design load
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Shafts subjected to twisting moment only continued..

Examples
1) A line shaft rotating at 200 r.p.m. is to transmit 20 kW. The shaft may
be assumed to be made of mild steel with an allowable shear stress of 42
MPa. Determine the diameter of the shaft, neglecting the bending
moment on the shaft. (Ans. 50mm)

2) A solid shaft is transmitting 1 MW at 240 r.p.m. Determine the diameter

of the shaft if the maximum torque transmitted exceeds the mean torque
by 20%. Take the maximum allowable shear stress as 60 Mpa. (Ans.
160mm)
3) Find the diameter of a solid steel shaft to transmit 20 kW at 200 r.p.m.
The ultimate shear stress for the steel may be taken as 360 MPa and a
factor of safety as 8. If a hollow shaft is to be used in place of the solid
shaft, find the inside and outside diameter when the ratio of inside to
outside diameters is 0.5.(Ans. 50mm , 25mm)

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Design of shaft subjected to static loads (on the basis of strength) continued..

Shafts subjected to bending moment only

❖When the shaft is subjected to a bending moment only, then the maximum
stress (tensile or compressive) is given by the bending equation.

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Shafts subjected to bending moment only continued..

❖Then,

❖ For a hollow shaft

❖ Then

❖The axles are used to transmit bending moment only. Thus, axles are
designed on the basis of bending moment only, in the similar way as discussed
above
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Shafts subjected to bending moment only continued..

Examples
1) A pair of wheels of a railway wagon carries a load of 50 kN on each axle
box, acting at a distance of 100 mm outside the wheel base. The gauge of
the rails is 1.4 m. Find the diameter of the axle between the wheels, if the
stress is not to exceed 100 Mpa. (Ans. 80 mm)

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Design of shaft subjected to static loads (on the basis of strength) continued..

Shafts Subjected to Combined Twisting

and Bending Moment
❖When the shaft is subjected to combined twisting moment and bending moment,
then the shaft must be designed on the basis of the two moments
simultaneously.

❖ Two important theories in analyzing combined stresses,

1) Maximum shear stress theory or Guest's theory. It is used for ductile

materials such as mild steel.

2) Maximum normal stress theory or Rankine’s theory. It is used for

brittle materials such as cast iron

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Shafts Subjected to Combined Twisting and Bending Moment continued..

❖Let,

❖According to maximum shear stress theory the maximum shear stress in

the shaft, τ𝑚𝑎𝑥

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Shafts Subjected to Combined Twisting and Bending Moment continued..

❖Substituting the values of τ and σ𝑏 ,

❖ By limiting the maximum shear stress (τ𝑚𝑎𝑥 ) equal to the allowable

shear stress (τ),

from this, the diameter of the shaft can be found

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Shafts Subjected to Combined Twisting and Bending Moment continued..

❖According to maximum normal stress theory, the maximum

normal stress in the shaft

❖Or,

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Shafts Subjected to Combined Twisting and Bending Moment continued..

M𝑒 = The equivalent bending moment

The equivalent bending moment may be defined as that moment
which when acting alone produces the same tensile or compressive
stress (σ𝑏 ) as the actual bending moment
❖ By limiting the maximum normal stress σ𝑏,𝑚𝑎𝑥 equal to the allowable
bending stress σ𝑏

❖ For hollow shafts, T𝒆 and M𝒆 can be written as,

❖It is suggested that diameter of the shaft may be obtained by

using both the theories and the larger of the two values is
adopted.
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Shafts Subjected to Combined Twisting and Bending Moment continued..

Examples
1) A solid circular shaft is subjected to a bending moment of 3000Nm and a
torque of 10,000Nm. The shaft is made of 45C8 steel having ultimate
tensile stress of 700MPa and a ultimate shear stress of 500MPa.
Assuming a factor of safety 6, determine the diameter of the shaft.
2) A solid circular shaft is subjected to a bending moment of 3000Nm and a
torque of 10,000Nm. The shaft is made of 45C8 steel having ultimate
tensile stress of 700MPa and a ultimate shear stress of 500MPa.
Assuming a factor of safety 6, determine the diameter of the shaft.
3) A line shaft is driven by means of a motor placed vertically below it. The
pulley on the line shaft is 1.5 meter in diameter and has belt tensions 5.4
kN and 1.8 kN on the tight side and slack side of the belt respectively.
Both these tensions may be assumed to be vertical. If the pulley be
overhang from the shaft, the distance of the centre line of the pulley from
the centre line of the bearing being 400 mm, find the diameter of the
shaft. Assuming maximum allowable shear stress of 42 MPa.
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Shafts Subjected to Combined Twisting and Bending Moment continued..

4) A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter

pulley is mounted at a distance of 300 mm to the right of left hand bearing
and this drives a pulley directly below it with the help of belt having
maximum tension of 2.25 kN. Another pulley 400 mm diameter is placed 200
mm to the left of right hand bearing and is driven with the help of electric
motor and belt, which is placed horizontally to the right. The angle of contact
for both the pulleys is 180° and ratio of belt tensions (between tight side and
slack side) = 2.127 for both pulleys. Determine the suitable diameter for a
solid shaft, allowing working stress of 63 MPa in tension and 42 MPa in
shear for the material of shaft. Assume that the torque on one pulley is equal
to that on the other pulley.

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Design of shaft subjected to static loads (on the basis of strength) continued..

Shafts Subjected to Axial Load in addition

to Combined Torsion and Bending Loads
❖The stress due to axial load must be added to the bending stress (σ𝑏 ).
❖ From the bending equation,

❖ And stress due to axial load,

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Shafts Subjected to Axial Load in addition to Combined Torsion and Bending Loads continued..

❖Resultant stress (tensile or compressive) for solid shaft,

❖ In case of a hollow shaft, the resultant stress

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Shafts Subjected to Axial Load in addition to Combined Torsion and Bending Loads continued..

❖For long shafts (slender shafts) subjected to compressive loads, a factor

known as column factor(α) must be introduced to take the column effect into
account
❖Therefore stress due to compressive load becomes

❖Column factor for compressive loads,

❖This expression is used when slenderness ratio L/K < 115

where, K = radius of gyration
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Shafts Subjected to Axial Load in addition to Combined Torsion and Bending Loads continued..

❖When the slenderness ratio L/K > 115

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Shafts Subjected to Axial Load in addition to Combined Torsion and Bending Loads continued..

Examples
1) A hollow shaft is subjected to a maximum torque of 1.5 kNm and a
maximum bending moment of 3 kNm. It is subjected, at the same time, to
an axial load of 10 kN. Assume that the load is applied gradually and the
ratio of the inner diameter to the outer diameter is 0.5. If the outer
diameter of the shaft is 80 mm, find the shear stress induced in the shaft.

2) A hollow shaft of 0.5 m outside diameter and 0.3 m inside diameter is

used to drive a propeller of a marine vessel. The shaft is mounted on
bearings 6 m apart and it transmits 5600 kW at 150 r.p.m. The maximum
axial propeller thrust is 500 kN and the shaft weighs 70kN. Determine,
a) The maximum shear stress developed in the shaft
b) The angular twist between the bearings

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Shafts Subjected to Axial Load in addition to Combined Torsion and Bending Loads continued..

Examples
3) A hollow steel shaft is to transmit 20 kW at 300 r.p.m. The loading is such
that the maximum bending moment is 1000 N-m, the maximum torsional
moment is 500 N-m and axial compressive load is 15 kN. The shaft is
supported on rigid bearings 1.5 m apart. The maximum permissible shear
stress on the shaft is 40 MPa. The inside diameter is 0.8 times the outside
diameter. The load is cyclic in nature and applied with shocks. The values
for the shock factors are Kt=1.5 and Km =1.6.

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Design of shaft subjected to fluctuating

loads (on the basis of strength)
❖In reality most of the times, shafts are subjected to fluctuating loads.
❖Therefore the combined shock and fatigue factors must be taken into account
for the computed twisting moment (T ) and bending moment (M)
❖Hence the equivalent twisting moment becomes,

❖Equivalent bending moment,

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Design of shaft subjected to fluctuating loads (on the basis of strength) continued..

❖Recommended values for K𝑚 and K𝑡

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Design of shaft subjected to fluctuating loads (on the basis of strength) continued..

Examples
1) Design a shaft to transmit power from an electric motor to a lathe head
stock through a pulley by means of a belt drive. The pulley weighs 200 N and is
located at 300 mm from the centre of the bearing. The diameter of the pulley is 200
mm and the maximum power transmitted is1 kW at 120 r.p.m. The angle of lap of
the belt is 180° and coefficient of friction between the belt and the pulley is 0.3. The
shock and fatigue factors for bending and twisting are 1.5 and 2.0 respectively. The
allowable shear stress in the shaft may be taken as 35 Mpa.
2) A solid steel shaft is supported on two bearings 1.8 m apart and rotates at 250 r.p.m.
A 20° involute gear D (refer the figure), 300 mm diameter is keyed to the shaft at a
distance of 150mm to the left on the right hand bearing. Two pulleys B and C are
located on the shaft at distances of 600 mm and 1350 mm respectively to the right of
the left hand bearing. The diameters of the pulleys B and C are 750 mm and 600
mm respectively. 30 kW is supplied to the gear, out of which 18.75kW is taken off at
the pulley C and 11.25 kW from pulley B. The drive from B is vertically downward
while from C the drive is downward at an angle of 60° to the horizontal. In both
cases the belt tension ratio is 2 and the angle of lap is 180°. The combined fatigue
and shock factors for torsion and bending may be taken as 1.5 and 2 respectively.
Design a suitable shaft taking working stress to be 42 MPa in shear and 84 MPa in
tension. 37

Design of shafts on the basis of rigidity

Torsional Rigidity
❑ Important in cam shafts where the valve timing can be effected. Here The
permissible amount of twist should not exceed 0.25° per meter length.
❑ For line shafts or transmission shafts, deflections 2.5° to 3° degree per
meter length may be used
❑ Widely used deflection for the shafts is limited to 1 degree of twist in a
shaft with a length equal to twenty times its diameter
❑ The torsional deflection may be obtained by using the torsion equation,

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Design of shafts on the basis of rigidity continued..

Lateral Rigidity
❖ It is important in case of shafts running at high speed
❖ Small lateral deflection would cause huge out of balance forces
❖ It is important to maintain proper bearing clearances and correct gear
teeth alignment
❖If the shat is of uniform cross-section the lateral deflection of a shaft may
be obtained by using the deflection formula
❖But when the shaft is of variable cross section, then the lateral deflection
may be obtained from the fundamental equation for the elastic curve of a
beam

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Design of shaft subjected to fluctuating loads (on the basis of strength) continued..

Examples
1) A steel spindle transmits 4 kW at 800 rpm. The angular deflection should
not exceed 0.25° per meter of the spindle. If the modulus of rigidity for the
material of the spindle is 84GPa, find the diameter of the spindle and the shear
stress induced in the spindle.
2) Compare the weight, strength and stiffness of a hollow shaft of the same
external diameter as that of solid shaft. The inside diameter of the hollow shaft
being half the external diameter. Both the shafts have the same material and
length
3) A shaft is supported on bearings A and B, 800mm between centers. A 20°
straight tooth spur gear having 600mm pitch diameter, is located 200mm to the
right of the left hand bearing A, and a 700mm diameter pulley is mounted
250mm towards the left of bearing B. The gear is driven by a pinion with a
downward tangential force while the pulley drives a horizontal belt having 180°
angle of wrap. The pulley also serves as a flywheel and weighs 2000N. The
maximum belt tension is 3000N and the tension ratio is 3:1. determine the
maximum bending moment and the necessary shaft diameter if the allowable
shear stress of the material is 40 Mpa. 40

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Recommended Text
• Design of Machine Elements by Bhandari, V.B (Third Edition)
• Analysis and Design of Machine Elements by Wei Jiang

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THANK YOU

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Any Questions??

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