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Chapter 1 # Machine Element at 2016

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21 views

Chapter 1 # Machine Element at 2016

Uploaded by

dagim zeynu
Copyright
© © All Rights Reserved
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Download as PPTX, PDF, TXT or read online on Scribd
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University of Gondar

Institute of Technology
Mechanical Engineering Department
Machine Elements II
(MEng 4151)

Chapter # 1

Prepared by: Andebet T.


Design of Shafts
February 2024
1
Shaft Design
• A shaft is a rotating member usually of circular cross-section (solid or hollow), which is used to transmit power
and rotational motion.
• Shaft design consists primarily of the determination of the correct shaft diameter to ensure satisfactory strength
and rigidity when the shaft is transmitting power under various operating and loading conditions.
 Machine elements of shaft such as gears, pulleys, flywheels, clutches, and sprockets are mounted on the shaft
and are used to transmit power from the driving device (motor or engine) through a machine.
 The rotational force (torque) is transmitted to these elements on the shaft by press fit, keys, dowel, pins and
splines.
 The shaft rotates on rolling contact or bush bearings.
• Various types of retaining rings, thrust bearings, grooves and steps in the shaft are used to take up axial loads and
locate the rotating elements.
• Couplings are used to transmit power from drive shaft (e.g., motor) to the driven shaft
(e.g. gearbox, wheels).
Design procedures of shaft
1. Select material and specify its condition(suggested materials is: AISI 1040.4140,, 4340,
4640, 5150, 6150 and 8650)Then determine
2. Determine appropriate, RPM of shaft, power torque and design stress, considering the
manner of loading(shock, smooth)
3. Analyze each critical point of shaft then decide which point safer(determine: part
mounted on shaft, gear belt, location of bearing, key fillet
4. Specify the final dimensions
Shaft Materials
• Steel (low to medium-carbon steel), Cast iron, Bronze or stainless steel, and Case hardened steel
The materials for the shaft would be required to posses
 High strength
 Low-notch sensitivity
 Ability to be heat and case-hardened to increase the wear resistance of journals, and
 Good machinability
Attachments and Stress Concentrations
• Steps and shoulders are used to locate attachments (gears, sheaves, sprockets) Keys, snap rings,
cross pins (shear pins), tapered pins
• Use generous radii to reduce stress concentrations, Clamp collars, Split collars, Press fits, and
shrink fits
Types of Shafts
Various types of shafts are:
1. Transmission Shaft:- are used for transmitting power between one source to the other machine
absorbing power. They are stepped.
E.g. Overhead shafts, line shafts, countershafts, and all factory shafts.
2. Axle Shaft:- supports rotating elements such as wheel and can fit in the housing with bearing but
the axle is a non-rotating element. These are mostly used in vehicles.
Example: Axle in automobiles.
3. Spindle Shaft:- the rotating part of the machine; it holds the tool or workspace. They are short
shaft which is used in machines.
Example: Spindle in lathe machine
4. Machine Shaft:- are inside part of the assembly and are integral parts of the machine.
Example: The crankshaft in a car engine is a machine shaft.
• Bearings may be located by the use of snap rings, but only one bearing is fixed Issues - axial
location, disassembly, and element phasing
(e.g., alignment of gear teeth for timing)

Various method of attachments


Maximum permissible working stresses for Transmission shafts
 According to the American Society of Mechanical Engineers (ASME) code for the design of
transmission shafts, the maximum, the maximum permissible working stresses in tension or
compression may be taken as
A) 112 Mpa for shaft without allowance for keyways
B) 84 Mpa for shafts with allowance for keyways
For the shaft purchased under definite physical specification, the permissible tensile stress () may be
taken as 60 % of the elastic limit in tension (), but not more than 36 % of the ultimate tensile strength ().
In other words the permissible tensile stress
=0.6, Whichever is less
The maximum permissible shear stress may be taken as
C) 56 Mpa for shaft without allowance for keyways
D) 42 Mpa for shafts with allowance for keyways
For shafts purchased under definite physical specifications, the permissible shear stress may be taken as
30 % of the elastic limit in tension but not more than 18 % of the ultimate tensile strength.
In other words, the permissible shear stress
or 0.18 , whichever is less.
Standard sizes of transmission shafts
The standard sizes of transmission shafts are
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 and 140 mm to 500 mm with 20 mm steps
The standard length of the shafts are 5 m, 6 m , and 7 m.

Design of shafts
The shafts may be designed on the basis of
1. Strength and 2. Rigidity and stiffness
In designing shafts on the basis of the strength, the following cases may be considered;
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
A). Shaft Strength Under Torsional Load
The shafts are always subjected to fatigue load hence they must be calculated for fatigue strength under
combined bending and torsion loading. However, the initial estimate of diameter is obtained from the
torque that is transmitted by the shaft. The bending moment variation along the length of the shaft is
established after fixing some structural features like the distance between supporting bearings and the
distance between points of application of forces and bearings.
Torque Equation
…………………………..(i) for solid and Hollow shaft
Where, T is torque or twisting moment (N.m)
J is polar moment of inertial (m)
is shear stress induced in the shaft (N/m2) r= d/2 or do/2
G=modules of rigidity of a shaft material (N/m2)
= angle of twist, l= length of the shaft
I. For pure torsion
for solid shaft and
J= for hollow shaft

hence k
For hollow shaft

is allowable shear stress of the shaft material(N/


For solid shaft

d ----------------------(ii)

B) For pure Bending


In this case, the shaft is loaded by only Tensile and compressive forces.
where I is moment of inertial offered by the shaft (
z is section modulus ()
y for hollow and solid shafts respectively.
I

I for hollow shaft


For Hollow shaft

is allowable normal stress of the shaft material.


--------------------------------------------------(iii)

For solid shaft

----------------------------------------------------------(IV)
C). Shaft subjected to combined loads
1. Apply maximum normal stress theory or Rankine’s theory. It is used for brittle materials such
as cast iron
; ;
----------------------------------------------------------(V)

2. Apply maximum shear stress theory or Guest’s theory.


It is used for ductile materials such as mild steel.

-----------------------------------(VI)

for Maximum normal stress theory


For Solid shaft (k=0)
d
for Maximum shear stress theory
.
Shafts subjected to Fluctuating Loads
Standard alternating and midrange stresses can be calculated

where and are the midrange and alternating bending moments, and are the midranges and
alternating torques, and and are the fatigue stress-concentration factors for bending and
torsion, respectively.

,
,
,
,
Calculating von Mises Stresses
These equivalent alternating and midrange stresses can be evaluated using an appropriate failure curve on
the modified Goodman diagram

Substitution of , and from the above

For design purpose, it is also desirable to solve the equation for the diameter. This results in

A von Mises maximum stress is calculated for this purpose

To check for yield for yielding, this von Mises maximum stress is compared to strength, as usual

For a quick, conservative check, an estimate for can be obtained by simply adding and () will always
be greater than or equal to and will therefore be conservative.
The Gerber and modified Goodman criteria do not guard against yielding, requiring a
separate check for yielding. A von Mises maximum stress is calculated for this purpose
Critical Speeds for Shafts

• All structures exhibit one or more natural, or resonant frequencies.


• When a shaft rotates at speeds equal or close to the natural frequencies, resonance may occur.
• This is usually to be avoided, although some designs feature resonance.

The Rayleigh Equation


ncr = (1/2)[ (gW)/(W2)]1/2
• Generally the designer tries to keep the speed at least 25% lower than o. But in some cases, the
operating speed is higher.

• When geometry is simple, as in a shaft of uniform diameter, simply supported, the task is easy. It can be
expressed as
• Where m is the mass per unit length,
Design of shaft based on Torsional Rigidity
• Torsional rigidity is defined as the torque required to produce a torsional deflection or an angle of
twist of one radian in the shaft
, radians
• This equation is used to design the shaft on the basis of torsional rigidity.
• The permissible angle of twist for machine tool applications is 0.25 per meter length. For line shaft, 3
per meter length is the limiting value. Modulus of rigidity for steel is 79300 N/

Design of shaft based on lateral Rigidity


• Lateral rigidity of the shaft at a given location is the lateral force required to produce a lateral
deflection of one unit

• This equation is used to design the shaft on the basis of lateral rigidity, e.g. for the cantilever beam
maximum deflection is given by
.

Thank you

For your attention

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