UNIVERSITY OF SOUTHERN PHILIPPINES FOUNDATION.

COLLEGE OF ENGINEERING AND ARCHITECTURE.

Course: BSME.

Subject: Machine Design 1. (ME 412)

Topic: Shaft Design.

-pure bending

- pure torsion

-combined loads (torsion, bending/axial)

-shaft design using codes (ASME, PSME)

Submitted By: Submitted to:

Owia Jason Engr. Alfredo B. Arenajo.

Introduction

Shaft is a common and important machine element. It is a rotating member, in

general, has a circular cross-section and is used to transmit power. The shaft may
be hollow or solid. The shaft is supported on bearings and it rotates a set of gears or
pulleys for the purpose of power transmission. The shaft is generally acted upon by
bending moment, torsion and axial force.

Design of shaft primarily involves in determining stresses at critical point in the shaft
that is arising due to aforementioned loading. Other two similar forms of a shaft are
axle and spindle. Axle is a non-rotating member used for supporting rotating wheels
etc. and do not transmit any torque. Spindle is simply defined as a short shaft.
However, design method remains the same for axle and spindle as that for a shaft.

1. Pure bending

 ( Theory of simple bending) is a condition of stress where a bending moment is

applied to a beam without the simultaneous presence of axial, shear, or torsional
forces.

Pure bending occurs only under a constant bending moment (M) since the shear
force (V), which is equal to dM/dx =v, has to be equal to zero.

In reality, a state of pure bending does not practically exist, because such a state
needs an absolutely weightless member. The state of pure bending is an
approximation made to derive formulas.
In pure bending the axial lines bend to form circumferential lines and transverse
lines remain straight and become radial lines.Axial lines that do not extend or
contract form a neutral surface.

2. Pure Torsion.

Shear Stress in the Shaft

When a shaft is subjected to a torque or twisting a shearing stress is produced in the
shaft. The shear stress varies from zero in the axis to a maximum at the outside
surface of the shaft.

In general two types of stresses are induced in shaft.

1. Torsional (Shear) stresses because of transmission of torque.
2. Bending stresses because of weight of pulley, gear etc mounted on shaft.
A circular shaft is said to be in the state of pure torsion when it is subjected to torque,
without being acted upon by any bending of the moment or axial force.
OR; if shaft is subjected to the two opposite turning moment it is said to be in pure
torsion. And it will exhibit tendency of shearing off at every cross section that is
perpendicular to longitudinal axis

The shear stress in a solid circular shaft in a given position can be expressed as:

τ = T r / J                              (1)

where

τ = shear stress (Pa, lbf/ft2 (psf))

T = twisting moment (Nm, lbf ft)

r = distance from center to stressed surface in the given position (m, ft)

J = Polar Moment of Inertia of Area (m4, ft4)

Note


the "Polar Moment of Inertia of an Area" is a measure of a shaft's ability to
resist torsion. The "Polar Moment of Inertia" is defined with respect to an axis
perpendicular to the area considered. It is analogous to the "Area Moment of
Inertia" - which characterizes a beam's ability to resist bending - required to
predict deflection and stress in a beam.
 1 ft = 12 in
 1 ft4 = 20736 in4
 1 psf (lbf/ft2) = 144 psi (lbf/in2)
"Polar Moment of Inertia of an Area" is also called "Polar Moment of Inertia",
"Second Moment of Area", "Area Moment of Inertia", "Polar Moment of Area" or
"Second Area Moment".

Polar Moment of Inertia vs. Area Moment of Inertia


"Polar Moment of Inertia" - a measure of a beam's ability to resist torsion -
which is required to calculate the twist of a beam subjected to torque
 "Area Moment of Inertia" - a property of shape that is used to predict
deflection, bending and stress in beams
Circular Shaft and Maximum Moment or Torque
Maximum moment in a circular shaft can be expressed as:

Tmax = τmax J / R                               (2)

where

Tmax = maximum twisting torque (Nm, lbf ft)

τmax = maximum shear stress (Pa, lbf/ft2)

R = radius of shaft (m, ft)

Combining (2) and (3) for a solid shaft

Tmax = (π / 16) τmax D3                            (2b)

Combining (2) and (3b) for a hollow shaft

Tmax = (π / 16) τmax (D4 - d4) / D                             (2c)

Circular Shaft and Polar Moment of Inertia

Polar Moment of Inertia of a circular solid shaft can be expressed as

J = π R4 / 2

   = π (D / 2)4 / 2

   = π D4 / 32                          (3)

where

D = shaft outside diameter (m, in)

Polar Moment of Inertia of a circular hollow shaft can be expressed as

J = π (D4 - d4) / 32                          (3b)

where

d = shaft inside diameter (m, ft)

Diameter of a Solid Shaft

Diameter of a solid shaft can calculated by the formula

D = 1.72 (Tmax / τmax)1/3                            (4)

Torsional Deflection of Shaft

The angular deflection of a torsion shaft can be expressed as

α = L T / (J  G)                                  (5)

where

α = angular shaft deflection (radians)

L = length of shaft (m, ft)

G = Shear Modulus of Rigidity - or Modulus of Rigidity (Pa, psf)

The angular deflection of a torsion solid shaft can be expressed as

α = 32 L T / (G π D4)                             (5a) 

The angular deflection of a torsion hollow shaft can be expressed as

α = 32 L T / (G π (D4- d4))                              (5b)

The angle in degrees can be achieved by multiplying the angle θ in radians with 180 / π.

Solid shaft (π replaced)

   αdegrees ≈ 584 L T / (G D4)                              (6a) 

Hollow shaft (π replaced)

   αdegrees ≈ 584 L T / (G (D4- d4)                            (6b) 

Example - Shear Stress and Angular Deflection in a Solid Cylinder

A moment of 1000 Nm is acting on a solid cylinder shaft with diameter 50 mm (0.05 m) and length 1 m. The shaft is
made in steel with modulus of rigidity 79 GPa (79 109 Pa). 

Maximum shear stress can be calculated as

τmax = T r / J

  = T (D / 2) / (π D4 / 32)

  = (1000 Nm) ((0.05 m) / 2) / (π (0.05 m)4 / 32)

  = 40764331 Pa

  = 40.8 MPa

The angular deflection of the shaft can be calculated as

θ = L T / (J G) 

  = L T / ((π D4 / 32) G)

  = (1 m) (1000 Nm) / ((π (0.05 m)4 / 32) (79 109 Pa))

  = 0.021 (radians)

= 1.2  o

Example - Shear Stress and Angular Deflection in a Hollow Cylinder

A moment of 1000 Nm is acting on a hollow cylinder shaft with outer diameter 50 mm (0.05 m), inner diameter 30
mm (0.03 m) and length 1 m. The shaft is made in steel with modulus of rigidity 79 GPa (79 109 Pa). 
Maximum shear stress can be calculated as

τmax = T r / J

  = T (D / 2) / (π (D4 - d4) / 32)

  = (1000 Nm) ((0.05 m) / 2) / (π ((0.05 m)4 - (0.03 m)4) / 32)

  = 46.8 MPa

The angular deflection of the shaft can be calculated as

θ = L T / (J G) 

  = L T / ((π D4 / 32) G)

  = (1 m) (1000 Nm) / ((π ((0.05 m)4 - (0.03 m)4) / 32) (79 109 Pa))

  = 0.023 radian)

  = 1.4  o

Example - Required Shaft Diameter to Transmit Power

A 15 kW electric motor shall be used to transmit power through a connected solid shaft. The motor and the shaft rotates
with 2000 rpm. The maximum allowable shear stress  - τmax - in the shaft is 100 MPa.

The connection between power and torque can be expressed

P = 0.105 nrpm T                    (7)

where 

P = power (W)

nrpm = speed of shaft (rpm)

Re-arranged and with values - the torque can be calculated

T = (15 103 W) / (0.105 (2000 rpm))

   = 71 Nm

Minimum diameter of the shaft can be calculated with eq. 4

D = 1.72 ((71 Nm) / (100 106 Pa))1/3   

   = 0.0153 m

   = 15.3 mm
Torsion Resisting Moments from Shafts of Various Cross Sections

Maximum Torsional
Resisting Moment
Shaft Cross Section Area Nomenclature
- Tmax  -
(Nm, lbf  ft)

(π / 16) τmax (2 r)3
Solid Cylinder
Shaft   = (π / 16) τmax D3

(π / 16) τmax ((2 R)4 - (2
Hollow Cylinder r)4) / (2 R)
Shaft
    = (π / 16) τmax (D4 -
d4) / D

h = "height" of shaft
2
Ellipse Shaft (π / 16)  τmax  b   h b = "width" of shaft
h>b
 Maximum Torsional
Resisting Moment
Shaft Cross Section Area Nomenclature
- Tmax  -
(Nm, lbf  ft)

Rectangle Shaft (2 / 9)  τmax  b2  h h>b

Square Shaft (2 / 9)  τmax  H3

b = length of triangle
Triangle Shaft (1 / 20)  τmax  b3
side

0.123  τmax  D3
Hexagon Shaft
What do you mean by pure torsion?
In general two types of stresses are induced in shaft.
1. Torsional (Shear) stresses because of transmission of torque.
2. Bending stresses because of weight of pulley, gear etc mounted on shaft.
A circular shaft is said to be in the state of pure torsion when it is subjected to torque,
without being acted upon by any bending of the moment or axial force.
OR; if shaft is subjected to the two opposite turning moment it is said to be in pure
torsion. And it will exhibit tendency of shearing off at every cross section that is
perpendicular to longitudinal axis.

3. Combined load (torsion, bending/axial)

Combined loading occurs when a set of different types of loads are applied, for

example, bending moments, axial forces, torsion, and transverse forces .

Combined Bending & Torsion : Cases arise such as in propeller shafts of ships

where a shaft is subjected to direct thrust in addition to bending moment
and torsion. In such cases the direct stresses due to bending moment and the axial
thrust have to be combined into a single resultant.

Example of shaft with combined loads .

A.S.M.E. code (American Society of Mechanical Engineers) is one of the approaches
followed in design oftransmission shaft .

4. ASME Code states that for shaft made of specified ASTM steel: ... Shaft

design includes the determination of shaft diameter having the strength and rigidity
to transmit motor or engine power under various operating conditions. Shafts are
usually round and may be solid or hollow

In design of transmission shaft according to this code, the permissible shear stress
for shaft without keyways is taken as30% of the yield strength in tension (Syt), or
18% of the ultimate tensile strength of material (Sut), whichever islower. Therefore,
the permissible shear stress (σd) is If shafts have keyways
these values have to be reduced by 25%.
To account for these, A.S.M.E code incorporates multiplication factors k band kt for
bending and torsional moments respectively.
P.S.M.E. code (Philippines Society of Mechanical Engineers) is one of the
approaches followed in mechanical engineering to design machines.