Shafts

VedatTemiz Assistant Professor ofMachine Design

Introduction
Ashaftisarotatingmachineelementwhichisusedto transmitpowerfromoneplacetoanother. Thepowerisdeliveredtotheshaftbysometangentialforce andtheresultanttorque(ortwistingmoment)setupwithin theshaftpermitsthepowertobetransferredtovarious machineslinkeduptotheshaft. shaft Inordertotransferthe powerfromoneshafttoanother,thevariousmemberssuch asp pulleys, y ,gears g etc., ,aremountedonit.Thesemembers alongwiththeforcesexerteduponthemcausestheshaftto bending. Inotherwords,wemaysaythatashaftisusedforthe transmissionoftorqueandbendingmoment.Thevarious members b aremounted t donthe th shaft h ftby b meansof fk keysor splines.

Introduction
Notes Theshaftsareusuallycylindrical,butmaybesquareorcross shapedinsection.Theyaresolidincrosssectionbut sometimeshollowshaftsarealsoused. Anaxle, thoughsimilarinshapetotheshaft,isastationary machine hi element l tand dis i used dfor f th thet transmission i i of fb bending di momentonly.Itsimplyactsasasupportforsomerotating bodysuchashoistingdrum, drum acarwheeloraropesheave. sheave Aspindleisashortshaftthatimpartsmotioneithertoa cutting gtool( (e.g. g drillp pressspindles) p )ortoaworkpiece p (e.g. g lathespindles)

Material Used for Shafts

Thematerialusedforshaftsshouldhavethefollowing properties: 1.Itshouldhavehighstrength. 2 Itshouldhavegoodmachinability. 2. machinability 3.Itshouldhavelownotchsensitivityfactor. 4 Itshouldhavegoodheattreatmentproperties. 4. properties 5.Itshouldhavehighwearresistantproperties.

Manufacturing g ofShafts
Shaftsaregenerallymanufacturedbyhotrollingand finishedtosizebycolddrawingorturningand grinding. grinding Thecoldrolledshaftsarestrongerthanhotrolled shafts h f b butwith i hhigher hi h residual id lstresses. Theresidualstressesmaycausedistortionofthe shaftwhenitismachined,especiallywhenslotsor keywaysarecut. Shaftsoflargerdiameterareusuallyforgedand turnedtosizeinalathe.

Types yp ofShafts
1 1.Transmissionshafts. shafts Theseshaftstransmitpowerbetween thesourceandthemachinesabsorbingpower.Thecounter shafts, ,lineshafts, ,overheadshaftsandallfactory yshaftsare transmissionshafts.Sincetheseshaftscarrymachineparts suchaspulleys,gearsetc.,thereforetheyaresubjectedto bendinginadditiontotwisting. 2.Machineshafts.Theseshaftsformanintegralpartofthe machineitself.Thecrankshaftis anexampleofmachineshaft.

StandardSizesofTransmissionShafts Th Thestandard t d dsizes i of ftransmission t i i shafts h ft are: 25mmto60mmwith5mmsteps;60mmto 110mmwith10mmsteps;110mmto140 mmwith15mmsteps;and140mmto500 mmwith20mmsteps. The h standard d dlength l hof fthe h shafts h f are5m,6m and7m.

Stresses inShafts
Thefollowingstressesareinducedintheshafts: 1.Shearstressesduetothetransmissionoftorque (i due (i.e. d totorsional i l load). l d) 2.Bendingstresses(tensileorcompressive)dueto theforcesactinguponmachineelementslikegears, pulleysetc.aswellasduetotheweightoftheshaft itself. g 3.Stressesduetocombinedtorsional andbending loads

MaximumPermissibleWorkingStresses forTransmissionShafts
AccordingtoAmericanSocietyofMechanical Engineers(ASME)codeforthedesignoftransmission shafts,themaximumpermissibleworkingstressesin tensionorcompressionmaybetaken as (a)112MPa forshaftswithoutallowancefor keyways. keyways (b)84MPa forshaftswithallowanceforkeyways.

MaximumPermissibleWorkingStresses forTransmissionShafts
Forshaftspurchasedunderdefinitephysical specifications,thepermissibletensilestress(t)may betakenas60percentoftheelasticlimitintension (el),butnotmorethan36percentoftheultimate tensilestrength(u). ) Inotherwords, words thepermissible tensilestress, t =0.6 0 6el or0.36 0 36u,whichever hi h i isless. l

MaximumPermissibleWorkingStresses forTransmissionShafts
Themaximumpermissibleshearstressmaybetakenas (a)56MPa forshaftswithoutallowanceforkeyways. (b)42MPa forshaftswithallowanceforkeyways keyways. Forshaftspurchasedunderdefinitephysicalspecifications, thepermissibleshearstress()maybetakenas30percentof theelasticlimitintension(el)butnotmorethan18percent oftheultimatetensilestrength(u).Inotherwords,the permissibleshearstress, =0.3el or0.18u,whicheverisless.

Design g ofShafts
Theshaftsmaybedesignedonthebasisof 1.Strength,and2.Rigidityandstiffness. Indesigningshaftsonthebasisofstrength, strength thefollowing casesmaybeconsidered: (a)Shaftssubjectedtotwistingmomentortorqueonly, only (b)Shaftssubjectedtobendingmomentonly, (c)Shaftssubjectedtocombinedtwistingandbending moments,and (d)Shaftssubjectedtoaxialloadsinadditiontocombined torsional andbendingloads.

ShaftsSubjectedtoTwisting M Moment tO Only l

Whentheshaftissubjectedtoatwistingmoment(ortorque)only,then th diameter the di t of fthe th shaft h ftmayb beobtained bt i dby b using i the th torsion t i equation. ti Weknowthat

T=Twistingmoment(ortorque)actingupontheshaft, J=Polarmomentofinertiaoftheshaftabouttheaxisofrotation, =Torsional shearstress,and r=Distancefromneutralaxistotheoutermostfibre =d/2;wheredisthediameteroftheshaft.

Weknowthatforroundsolidshaft,polarmomentofinertia,

Finalequation

ShaftsSubjectedtoTwisting M tO l Moment Only

Wealsoknowthatforhollowshaft,polarmomentofinertia,

do anddi =Outsideandinsidediameteroftheshaft,andr=do /2.

Substitutingthesevaluesinshearstressequation

ShaftsSubjectedtoBending M Moment tO Only l (Axles) (A l )

Whentheshaftissubjectedtoabendingmomentonly, only then themaximumstress(tensileorcompressive)isgivenbythe bending gequation. q Weknowthat
M=Bending B di moment, t I=Momentofinertiaofcrosssectionalareaoftheshaftabouttheaxis ofrotation, b =Bending stress,and fibre y=Distancefromneutralaxistotheoutermostfibre.

Weknowthatforaroundsolidshaft,momentofinertia,

Finalequation q
Fromthisequation,diameterofthesolidshaft(d)maybeobtained.

ShaftsSubjectedtoCombinedTwisting MomentandBendingMoment
Whentheshaftissubjectedtocombinedtwistingmoment andbendingmoment,thentheshaftmustbedesignedonthe basisofthetwomomentssimultaneously. y Varioustheorieshavebeensuggestedtoaccountforthe elasticfailureofthematerialswhentheyaresubjectedto varioustypesofcombinedstresses. Thefollowingtwotheoriesareimportantfromthesubject pointofview: 1.MaximumshearstresstheoryorGuest'stheory.Itisused f d for ductile il materials i l such hasmild ildsteel. l 2.MaximumnormalstresstheoryorRankines theory.Itis usedforbrittlematerialssuchascast iron. iron

ShaftsSubjectedtoCombinedTwisting MomentandBendingMoment
Let =Shearstressinducedduetotwistingmoment,and b =Bendingstress(tensileorcompressive)induceddueto bendingmoment. Accordingtomaximumshearstresstheory, theory themaximum shearstressintheshaft,

Substitutingthevaluesof b and

ShaftsSubjectedtoCombinedTwisting MomentandBendingMoment
The expression isknownasequivalenttwistingmomentandisdenotedbyTe. Theequivalenttwistingmomentmaybedefinedasthattwisting moment,whichwhenactingalone,producesthesameshear stress()astheactualtwisting gmoment.By ylimiting gthemaximum shearstress(max)equaltotheallowableshearstress()forthe material,thefirstequationmaybewrittenas

Fromthisexpression,diameteroftheshaft(d)maybe evaluated.

ShaftsSubjectedtoCombinedTwisting MomentandBendingMoment
Nowaccordingtomaximumnormalstresstheory theory,the maximumnormalstressintheshaft,

ShaftsSubjectedtoCombinedTwisting MomentandBendingMoment
The expression isknownasequivalentbendingmomentandisdenotedbyMe.The equivalentbendingmomentmaybedefinedasthatmomentwhich whenactingaloneproducesthesametensileorcompressivestress (b)astheactualbendingmoment.Bylimitingthemaximumnormal stress[b(max)]equaltotheallowablebendingstress(b),thenthe fi tequation ti may be b written itt as first

p ,diameteroftheshaft(d)may ybe Fromthisexpression, evaluated.

ShaftsSubjected j toFluctuating gLoads

Inthepreviouscalculations,wehaveassumedthattheshaftis subjectedtoconstanttorqueandbendingmoment. moment Butinactualpractice,theshaftsaresubjectedtofluctuating torque q andbending gmoments. Inordertodesignsuchshaftslikelineshaftsandcounter shafts,thecombinedshockandfatiguefactorsmustbetaken intoaccountforthecomputedtwistingmoment(T)and bendingmoment(M). Thusforashaftsubjectedtocombinedbendingandtorsion, theequivalenttwistingmoment

ShaftsSubjected j toFluctuating gLoads

Th Thusfor f ashaft h ftsubjected bj t dto t combined bi dbending b di and dtorsion, t i theequivalenttwistingmoment

and d equivalent i l b di moment, bending

Km =Combinedshockandfatiguefactor forbending,and Kt =Combinedshockandfatiguefactorfor torsion. torsion

ShaftsSubjected j toFluctuating gLoads

Recommended R d dvalues l for f Km and dKt.

Design g ofShaftsonthebasisofRigidity g y
1 1.Torsional rigidity. rigidity Thetorsional rigidityisimportantinthecaseof camshaftofanI.C.enginewherethetimingofthevalveswouldbe effected.Thepermissibleamountoftwistshouldnotexceed0.25 per meterlengthofsuchshafts. shafts Forlineshaftsortransmissionshafts, shafts deflections2.5to3degreepermeterlengthmaybeusedaslimitingvalue. Thewidelyuseddeflectionfortheshaftsislimitedto1degreeinalength equal ltotwentytimesthe h diameter d of fthe h shaft. h f Thetorsional deflectionmaybeobtainedbyusingthetorsionequation,

g oftwistinradians, , =Torsional deflectionorangle T=Twistingmomentortorqueontheshaft, J=Polarmomentofinertiaofthecrosssectionalareaabouttheaxisofrotation, G=Modulusofrigidityfortheshaftmaterial,and L=Lengthoftheshaft.

Design g ofShaftsonthebasisofRigidity g y
2.Lateralrigidity.Itisimportantincaseoftransmissionshaftingand shaftsrunningathighspeed,wheresmalllateraldeflectionwouldcause hugeoutofbalanceforces. forces Thelateralrigidityisalsoimportantfor maintainingproperbearingclearancesandforcorrectgearteeth alignment.Iftheshaftisofuniformcrosssection,thenthelateral d fl i of deflection fashaft h f mayb beobtained b i dby b using i the h deflection d fl i formulae f l as inStrengthofMaterials.Butwhentheshaftisofvariablecrosssection, thenthelateraldeflectionmaybedeterminedfromthefundamental equationfortheelasticcurveofabeam,i.e.