MM324 Mechanical and

Engineering Design
Dr D R Aitchison
1

Determine the loads and moments on the shaft

Draw Free Body Diagram (see a below)
Plot a Bending Moment diagram (see b below)
Plot a Shear Force diagram (see c below)
Plot a Torque diagram (see d below)

General bending equation

Bending stress in beam, (N/m2)

Applied bending moment, (Nm)
4

2nd moment of area for circular shaft, =

64
Distance from point to neutral axis, (m)

Maximum stress condition

(m4)

32
=
=

Distance from extremity to neutral axis,

=
2

(m)

General torsion equation

Shear stress in shaft, (N/mm2)

Applied torque, (Nm)
4
Polar moment of inertia for circular shaft, = 32
Radial distance from point to shaft centre, (m)

Maximum shear stress condition

(m4)

16
=
=

Radial distance from extremity to shaft centre,

= (m)
2

Consider static and alternating stresses

Resultant alternating stress, =

a alternating stress amplitude

32
3

Resultant mid-range (static) stress, =

m midrange (steady state) stress
xy in x-y plane

Steady

Varying zero mean

and =
32
3

16
3

and =

16
3

Varying offset mean

5

Equivalent von Mises stresses (Distortion Energy, DE)

(Stresses grouped into alternating & mean components)

Alternating stress,
substitution gives

Mid-range stress,
substitution gives

= 2 + 32

32
3

= 2 + 3 2

32
3

16
+3
3

+3

16
3

Kf and Kfs Fatigue stress concentration factors

6

Soderberg

1
+
=

Goodman

1
+
=

Gerber

ASME-elliptic

Langer

+ =

Sy Yield strength
Sut Tensile strength (ultimate)
Se Endurance limit
n Factor of safety

=1

=1

Alternating stress,

Failure space

Design space

Gerber line

0
Mid-range stress,

Substitution into Gerber criteria equation gives

Design safety factor,

Shaft diameter,

1
8
2
= 3
1+ 1+

8
2
=
1+ 1+

Where:
=

+ 3

+ 3

2
10

For shaft with constant load and torque

= 0 and = 0 giving
Design safety factor,

Shaft diameter,

1
8
2
= 3
1+ 1+

8
2
=
1+ 1+

Where:
= 2

= 3
11

SAE
grade

Processing

Tensile strength
Sut , MPa

Yield strength
Sy , MPa

Brinell hardness

1020

HR

380

210

111

1020

CD

470

390

131

1030

HR

470

260

137

1030

CD

520

440

149

1040

HR

520

290

149

1040

CD

590

490

170

1050

HR

620

340

179

1050

CD

690

580

197

HR Hot rolled (up to ~150mm diameter),

CD Cold drawn (up to ~90mm diameter)

12

Fatigue strength against Number of Cycles

Fatigue strength (Sf) must be quoted with number of cycles (N)
Applies to ferrous metals only
Endurance limit (Se) - defined by knee in plot

Typical S-N curve

Completely reversing
axial load fatigue test
UNS G41300 steel,
normalized; Sut = 800 MPa

13

Endurance limit, Se (Tensile test data shown below)

Indicates stress level that allows infinite life (>10 6 cycles)
Se largely falls between 40% and 60% of Tensile strength, Sut
Data suitable for preliminary and prototype design work

Assume Se = Se
Note: At Sut = 1400 Mpa
scatter increases and
data becomes less
reliable

14

In vicinity of holes and groves stresses increase

Stress conc. factor,

# =

For static (non-cyclic) loading

Normal stress concentration factor,

Shear stress concentration factor,

Values determined from look-up charts.

15

Round shaft with shoulder fillet in bending

16

Round shaft with shoulder fillet in torsion

17

Fatigue stress concentration factors

For normal loading:
Normal notch sensitivity,

1
=
1

= 1 + 1

For shear loading:

Shear notch sensitivity,

1
1

= 1 + 1

18

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