AAiT

Mechanical Engineering Department

1-1 Introduction
1-2 Material selection
1-3 Geometric layout
1-4 Stress and strength
1-5 Static strength
1-6 Fatigue strength
1-7 Deflection and rigidity
1-8 Bending deflection
1.9 Torsional deflection
1.10 Slope at bearings and shaft-supported elements
1.11 Shear deflection due to transverse loading of short
shafts
1.12 Vibration due to natural frequency
 1-1 Introduction

A shaft is a rotating members, usually of circular cross-section, used to

transmit power or motion. It supports gears, sprockets, wheels, rotors,
etc., and provides the axis rotation of them.

types of shafts:-
An axle is a non-rotating member that supports rotating elements
such as wheels, pulleys, and carries no torque.
A spindle is a short shaft. Terms such as lineshaft, headshaft, stub
shaft, transmission shaft, countershaft, and flexible shaft are names
associated with special usage.
 Stub shaft- A shaft that is integral with a motor, engine or
prime mover and is of a size, shape, and projection as to permit
easy connection to other shafts.
Line shaft- A shaft connected to a prime mover and used to
transmit power to one or several machines
Jackshaft- (Sometimes called countershaft). A short shaft
that connects a prime mover with a line shaft or a machine
Flexible shaft- A connector which permits transmission of
motion between two members whose axes are at an angle with
each other
 1.2 Shaft Materials
Deflection is not affected by strength, but rather by stiffness(EI) as
represented by the modulus of elasticity, which is essentially constant for
all steels. For that reason, rigidity cannot be controlled by material
decisions, but only by geometric decisions.

Necessary strength to resist loading stresses affects the choice of

materials and their treatments.

Many shafts are made from low carbon, cold-drawn or hot-rolled steel

General Considerations for material selection:

A good practice is to start with an inexpensive, low or medium carbon
steel for the first time through the design calculations. If strength
considerations turn out to dominate over deflection, then a higher
strength material should be tried, allowing the shaft sizes to be reduced
until excess deflection becomes an issue(deflection 1/EI or 1/I). The
cost of the material and its processing must be weighed against the need
for smaller shaft diameters.
 Conti
In approaching material selection, the amount to be produced
is a salient factor:
For low production, turning is the usual primary shaping process. An
economic viewpoint may require removing the least material.
For High production may permit a volume conservative shaping method (hot
or cold forming, casting), and minimum material in the shaft can become a
design goal. Cast iron may be specified if the production quantity is high, and
the gears are to be integrally cast with the shaft.
Properties of the shaft locally depend on its historycold work, cold forming,
rolling of fillet features, heat treatment, including quenching medium, agitation,
and tempering regimen.
 1.3 Shaft Layout
Figure 1-2
(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.
(c) Choose fanshaft 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.
 there are no absolute rules for specifying the general layout to
shafts, but the following guidelines may be helpful
1.Axial Layout of Components
The axial positioning of components is often dictated by the layout of the housing and other
meshing components.
i. it is best to support load-carrying components between bearings, such as in Fig. 12a,
rather than cantilevered outboard of the bearings, such as in Fig. 12c.
ii. 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.
iii. 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.
iv. 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.
v. 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.
vi. The components must be accurately located on the shaft to line up with other mating
components. The primary means of locating the components is to position them against a
shoulder of the shaft.
vii. A shoulder also provides a solid support to minimize deflection and vibration of the
component.

viii.Sometimes when the magnitudes of the forces are reasonably low, shoulders can be
constructed with retaining rings in grooves, sleeves between components, or clamp-on
collars.

ix. 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. See Fig. 12b and 12d for examples of some of these means of axial location.
2. Supporting Axial Loads

In cases where axial loads are not trivial(with helical or bevel gears, or tapered roller
bearings), it is necessary to provide a means to transfer the axial loads into the shaft,
then through a bearing to the ground. Often, the same means of providing axial
location, e.g., shoulders, retaining rings, and pins, will be used to also transmit the
axial load into the shaft.

It is generally best to have only one bearing carry the axial load, to allow greater
tolerances on shaft length dimensions, and to prevent binding if the shaft expands due
to temperature changes. This is particularly important for long shafts.
3. 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. Of course, the shaft
itself must be sized to support the torsional stress and torsional
deflection.
It is also necessary to provide a means of transmitting the torque
between the shaft and the gears.
Common Torque Transfer Elements
Keys
Splines
Setscrews
Pins
Press or shrink fits
Tapered fits
Many of these devices are designed to fail if the torque exceeds acceptable
operating limits, protecting more expensive components.
 Common Types of Shaft Keys.

Keys and pins are used on shafts to secure rotating elements, such as gears,
pulleys, or other wheels. Keys are used to enable the transmission of torque
from the shaft to the shaft-supported element.
Common Types of Shaft Keys.
 Common Types of Shaft Pins.

Pins are used for axial positioning and for the transfer of torque or
thrust or both.

Pins are useful when the principal loading is shear and when both
torsion and thrust are present. Taper pins are sized according to the
diameter at the large end. The diameter at the small end of length L is
d= D 0.0208L
Common Types of Shaft Pins.
Common Types of Retaining or Snap Rings.
A retaining ring is used instead of a
shaft shoulder or a sleeve to axially
position a component on a shaft or
in a housing bore. A groove is cut
in the shaft or bore to receive the
spring retainer.
 Common Types of Splines.

Splines are teeth on a drive shaft that mesh with grooves

in a mating piece and transfer torque to it, maintaining the
angular correspondence between them. For instance, a gear
mounted on a shaft might use a male spline on the shaft that
matches the female spline on the gear.
Any one of a series of narrow keys (external splines)
formed longitudinally around the circumference of a shaft
that fit into corresponding grooves (internal splines) in a
mating part: used to prevent movement between two parts,
esp in transmitting torque
 18-3 Strength Constraints

The design of a shaft involves the study of

1. Stress and strength analyses: Static and Fatigue
2. Deflection and rigidity
3. Critical Speed
Static or Quasi-Static Loading on Shaft
 Static or Quasi-Static Loading on Shaft

The stress at an element located

on the surface of a solid round
shaft of diameter d subjected to
bending, axial loading, and
twisting is

32M 4 F
Normal stress x
d 3
d2
16T
Shear stress xy 3
d
12

x y x y
2

Non-zero principal A , B xy
2

stresses 2 2
 Static or Quasi-Static Loading on Shaft

2 1/2 2 1/2
' A A B B x 3 xy
2 2
Von Mises
stress 4
' 3 8M Fd 48T
2 2
1/2

A B
x 4 xy
1 2 2 12
Maximum max
2 2
Shear Stress
2 1/2

3
max 8M Fd 64T 2
2
Theory
d
 Static or Quasi-Static Loading on Shaft

Under many conditions, the axial force F in Eqs. (6-37) and (6-38) is
either zero or so small that its effect may be neglected. With F = 0,
Eqs. (6-37) and (6-38) become

Von Mises 16 2 1/2

' 3 4M 3T
2
(6-41)
stress d

Maximum
16 2 1/2
Shear Stress max M T
3
2
(6-42)
Theory d
 Static or Quasi-Static Loading on Shaft

Substitution of the allowable stresses from Eqs. 6-39 and 6-40 we find
1/3
16n
d 4M 3T
2 2 1/2
(6-43)
Von Mises S y
stress
1
n

16
d Sy
3 4M 3T
2 2 1/2
(6-44)

1/3
32n
d M T
2 2 1/2
(6-45)
Maximum S y
Shear Stress
Theory
1

n d Sy
32
3 M T
2 2 1/2
(6-46)
 Fatigue Strength

Bending, torsion, and axial stresses may be present in both

midrange and alternating components.

For analysis, it is simple enough to combine the different types of

stresses into alternating and midrange von Mises stresses.

It is sometimes convenient to customize the equations specifically

for shaft applications.

Axial loads are usually comparatively very small at critical locations

where bending and torsion dominate, so they will be left out of the
following equations.

The fluctuating stresses due to bending and torsion are given by

 Fatigue Strength

The fluctuating stresses due to bending and torsion are given by

where Mm and Ma are the midrange and alternating bending moments, Tm

and Ta are the midrange and alternating torques, and Kf and Kfs are the
fatigue stress concentration factors for bending and torsion, respectively.
Assuming a solid shaft with round cross section, appropriate geometry
terms can be introduced for c, I, and J resulting in
Assuming a solid shaft with round cross section, appropriate geometry terms
can be introduced for c, I, and J resulting in
Combining these stresses in accordance with the distortion energy failure
theory, the von Mises stresses for rotating round, solid shafts, neglecting axial
loads, are given by