2.2.4.

SHAFT ANALYSIS

2.2.4.1. Material Selection

The material for the shaft is 1045 CD steel with Sut = 630MPa, Sy = 530MPa. 1045 CD steel
was chosen because of medium tensile low hardenability carbon steel supplied in cold drown or
turned end. It has a tensile strength of 600-950 MPa and Brinnel hardness range between 179 -
280. AISI 1045 steel is characterized by good strength and impact properties with good machine
ability and reasonable weldibility as supplied condition. It is also widely used for all industrial
application requiring more wear resistance and strength.
SHAFT 1

PINION 1

2.2.4.2. Forces Resolve at the Shaft and Free Body Diagram

2.2.4.3. Bending Load and Bending Moment Diagram
2.2.4.4. Proper Stress Concentration Factor Analysis

Estimate,

Kt = 1.7

Kts = 1.5

For quick conservation first pass, assume

Kt = Kf

Kts = Kfs

Endurance Limit Modifying Factor

Se = ka kb kc kd ke kf Se

Se = 0.5 (Sut)

= 0.5 (630)

= 315 MPa
Surface Condition Modification factor, ka

Ka = a (Sut)b

= (4.51) (630)-0.265

= 0.817

Size Factor, kb

Assume kb = 0.9 , check later when d is known

Loading Factor, ke = Temperature Factor,kd = Reliability Factor,ke = Miscellaneous

Effects Factor, kf

ke = kd = ke = kf = 1

Se = ka kb kc kd ke kf Se

= (0.817) (0.9) (315)

= 231.62 MPa
2.2.4.5. Minimum Diameter Required at Each Gear

Use DE Goodman Criterion, assume minimum safety factor is 2

The value was taken at critical location where it will be usually on outer surface, torque is
present, and bending moment is large.

Figure A-15-8

Kts = 1.2
Figure A-15-9

Kt = 1.64

Figure 4.1

q = 0.74
Figure 4.2
qs = 0.76

Kf = 1 + q (kt 1)\

= 1+ 0.74(1.64-1)

= 1.4736

Kfs = 1 + qs(kts-1)

= 1 + 0.76(1.2 -1)

= 1.152
Surface Condition Modification factor, ka

Ka = a (Sut)b

= (4.51) (630)-0.265

= 0.81

Size Factor

kb = 1.24(d) - 0.107

= 1.24(9) - 0.107

= 0.98
Assume reliability is 99%

ke = 0.814

Se = ka kb kc kd ke kf Se
= (0.817) (0.98) (0.814) (315)
= 205.30 MPa

Shaft Stresses (Von Misses Stress)

2.2.4.6 Fatigue and Yield Factors of Safety

Fatigue Factors of Safety

Using DE-Goodman Criterion,

Yielding Factors of Safety

2.2.4.7 Tolerances and Fitting Analysis

Table 6.3

Table A-11
Table A-12
SHAFT 2

GEAR 1

2.2.4.2. Forces Resolves At The Shaft And Free Body Diagram

2.2.4.3. Bending Load and Bending Moment Diagram
2.2.4.4. Proper Stress Concentration Factor Analysis

Table 6.1

Estimate,
Kt = 1.7
Kts = 1.5
For quick conservation first pass, assume
Kt = Kf
Kts = Kfs

Endurance Limit Modifying Factor

Se = ka kb kc kd ke kf Se
Se = 0.5 (Sut)
= 0.5 (630)
= 315 MPa
Surface Condition Modification factor, ka

Table 4.1

Ka = a (Sut)b
= (4.51) (630)-0.265
= 0.817

Size Factor, kb
Assume kb = 0.9 , check later when d is known

Loading Factor, ke = Temperature Factor,kd = Reliability Factor,ke = Miscellaneous

Effects Factor, kf

ke = kd = ke = kf = 1

Se = ka kb kc kd ke kf Se
= (0.817) (0.9) (315)
= 231.62 MPa
2.2.4.5. Minimum Diameter Required at Each Gear

Use DE Goodman Criterion, assume minimum safety factor is 2

A typical D/d ratio for support at shoulder is

Typical Ration, D = 14

Assuming fillet radius , r/d = 0.1

The value was taken at critical location where it will be usually on outer surface torque is present
and, bending moment is large.

Figure A-15-8
Kts = 1.38
Figure A-15-9
Kt = 1.68

Figure 4.1
q = 0.76
Figure 4.2
qs = 0.79

Kf = 1 + q (kt 1)\
= 1+ 0.76(1.68-1)
= 1.52

Kfs = 1 + qs(kts-1)
= 1 + 0.79(1.38 -1)
= 1.30
Surface Condition Modification factor, ka

Table 4.1

Ka = a (Sut)b
= (4.51) (630)-0.265
= 0.817

Size Factor

kb = 1.24(d)-0.107
= 1.24(13)-0.107
= 0.942
Assume reliability is 99%
2.2.4.6 Fatigue and Yield Factors of Safety

Fatigue Factors of Safety

Using DE-Goodman Criterion,

Yielding Factors of Safety

2.2.4.7 Tolerances and Fitting Analysis

Table 6.3

Table A-11
Table A-12
PINION 2

2.2.4.4. Proper Stress Concentration Factor Analysis

Table 6.1

Estimate,
Kt = 1.7
Kts = 1.5
For quick conservation first pass, assume
Kt = Kf
Kts = Kfs
Endurance Limit Modifying Factor

Se = ka kb kc kd ke kf Se
Se = 0.5 (Sut)
= 0.5 (630)
= 315 MPa

Surface Condition Modification factor, ka

Table 4.1

Ka = a (Sut)b
= (4.51) (630)-0.265
= 0.817

Size Factor, kb

Assume kb = 0.9 , check later when d is known

Loading Factor, ke = Temperature Factor,kd = Reliability Factor,ke = Miscellaneous
Effects Factor, kf

ke = kd = ke = kf = 1

Se = ka kb kc kd ke kf Se
= (0.817) (0.9) (315)
= 231.62 MPa

Minimum Diameter Required at Each Gear

Use DE Goodman Criterion, assume minimum safety factor is 2

A typical D/d ratio for support at shoulder is

Typical Ration, D = 19

Assuming fillet radius, r/d = 0.1

The value was taken at critical location where it will be usually on outer surface, torque is

present, and bending moment is large.

Figure A-15-8

Kts = 1.38

Figure A-15-9

Kt = 1.68
Figure 4.1

q = 0.78

Figure 4.2

qs = 0.8
Kf = 1 + q (kt 1)\

= 1+ 0.78(1.68-1)

= 1.53

Kfs = 1 + qs(kts-1)

= 1 + 0.8(1.38 -1)

= 1.30

Surface Condition Modification factor, ka

Table 4.1

Ka = a (Sut)b

= (4.51) (630)-0.265

= 0.817
Size Factor

kb = 1.24(d)-0.107

= 1.24(16)-0.107

= 0.92

ke = 0.814

Se = ka kb kc kd ke kf Se

= (0.817) (0.92) (0.814) (315)

= 192.72 MPa
Shaft Stresses (Von Misses Stress)

2.2.4.6 Fatigue and Yield Factors of Safety

Fatigue Factors of Safety

Using DE-Goodman Criterion,

Yielding Factors of Safety
2.2.4.7 Tolerances and Fitting Analysis

Table 6.3

Table A-11
Table A-12
SHAFT 3

GEAR 2

2.2.4.2. Forces Resolve at the Shaft and Free Body Diagram

2.2.4.3. Bending Load and Bending Moment Diagram
Consider z-x plane
2.2.4.4. Proper Stress Concentration Factor Analysis

Table 6.1

Estimate,

Kt = 1.7

Kts = 1.5

For quick conservation first pass, assume

Kt = Kf

Kts = Kfs

Endurance Limit Modifying Factor

Se = ka kb kc kd ke kf Se

Se = 0.5 (Sut)

= 0.5 (630)

= 315 MPa
Surface Condition Modification factor, ka

Table 4.1

Ka = a (Sut)b

= (4.51) (630)-0.265

= 0.817

Size Factor, kb

Assume kb = 0.9 , check later when d is known

Loading Factor, ke = Temperature Factor,kd = Reliability Factor,ke = Miscellaneous

Effects Factor, kf

ke = kd = ke = kf = 1

Se = ka kb kc kd ke kf Se

= (0.817) (0.9) (315)

= 231.62 MPa
2.2.4.5. Minimum Diameter Required at Each Gear

Use DE Goodman Criterion, assume minimum safety factor is 2

A typical D/d ratio for support at shoulder is

Typical Ration, D = 19
The value was taken at critical location where it will be usually on outer surface, torque is

present, and bending moment is large.

Figure A-15-8

Kts = 1.38
Figure A-15-9

Kt = 1.68

Figure 4.1

q = 0.78
Figure 4.2

qs = 0.8

Kf = 1 + q (kt 1)\

= 1+ 0.78(1.68-1)

= 1.53

Kfs = 1 + qs(kts-1)

= 1 + 0.8(1.38 -1)

= 1.30
Surface Condition Modification factor, ka

Table 4.1

Ka = a (Sut)b

= (4.51) (630)-0.265

= 0.817

Size Factor

kb = 1.24(d)-0.107

= 1.24(19)-0.107

= 0.905
Assume reliability is 99%

ke = 0.814

Se = ka kb kc kd ke kf Se

= (0.817) (0.905) (0.814) (315)

= 189.586 MPa

Shaft Stresses (Von Misses Stress)

2.2.4.6 Fatigue and Yield Factors of Safety

Fatigue Factors of Safety

Using DE-Goodman Criterion,

Yielding Factors of Safety

2.2.4.7 Tolerances and Fitting Analysis

Table A-11
Table A-12
Summary of the Shaft Analysis
2.2.5. BEARING ANALYSIS

Bearing Type: Deep Groove Ball Bearing, Single row

Shaft 1
Bearing A

Bearing B
Shaft 2
Bearing C

Bearing D
Shaft 3