AbuDhabiUniversity

CollegeofEngineering&ComputerScience

DepartmentofMechanicalEngineering
Assignment3ShaftDesign

MEC430MachineDesign
(DueDate:WedJune03,2015by3:00pm)

[1] Size a rotating SAE 1035 steel shaft to transmit 15,000 lb.in of mean torque, 10,000 lb.in of
alternating bending moment and 8,000 lb.in of steady bending moment at a cross-section with a
key way. The fillet radius of the key way is given by
0.05 where d is the shaft diameter
and a notch radius of 0.02 in is assumed. The operating temperature of the shaft is 500 and
the material properties are given by:
95,000 ;
0.5 ;

65,000 .
Suggest an appropriate material and fabrication method for the shaft.

[2] An ANSI 1020 cold drawn shaft with the geometry shown in figure carries a transverse load
of 10kN and a torque of 100 N.m. The largest allowable deflection for the shaft is 0.5% of the
overall shaft length. Check the design of the shaft from both the rigidity and strength
considerations by finding the factors of safety in each case. If the shaft is not safe, what would
you recommend to correct the problem or increase the factor of safety?
Note: Use appropriate proportions for fillet radii, key ways, and other missing dimensions.

[3] Size a rotating SAE 1040 cold drawn steel shaft to transmit 9,000 lb.in of mean torque, and
1,200 lb.in of steady bending moment at a cross-section with a key way. The fillet radius of the
key way is given by
0.04 where d is the shaft diameter and a notch radius of 0.04 in is
assumed. The operating temperature of the shaft is 200 and the material properties are given
by:
103,000 ;
0.5 ;

84,000 .

[4] The figure shows a shaft that is rotating with 100 rpm and is exposed to uniformly distributed
load of 150 lb/in and a torque of 5,000 lb.in. The material of the shaft is an alloy steel with the
following data:

50,000 ;

30 10 ,


90,000

45,000 .
Find the diameter d of the shaft such that the maximum deflection doesnt exceed 0.015 inch.
Based on strength considerations, find the minimum value for the diameter d.
Note: Use appropriate proportions for fillet radii, key ways, and other missing dimensions.

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[5] The figure shows a shaft contained in a helical gear reduction unit in which a force
F = - 1700i + 6400j - 2300k lb is applied to gear B as shown. The forces FA and FC of equal
magnitudes resist the applied force. The direction of these two forces can be determined by the
unit vectors NA = 0.470i - 0.342j + 0.814k and vectors NC = -0.470i - 0.342j + 0.814k. The
dashed vectors on gears 3 and 4 represent the components of the forces FA and FC. The shaft
dimensions shown in the figure locate the effective load centers of the bearings and gears.
The following data is available:
- Shaft material is SAE-1035 with:
Ultimate strength: Su = 95 ksi (95,000 psi),
Yield Strength:
Sy = 65 ksi (65,000 psi),
Endurance limit (before modification)
S'e = 0.5 Su
- At the critical section of the shaft, a fillet radius of the keyway is given by r/d = 0.05
where d is the shaft diameter and a notch radius of 0.02 in is assumed.
- The operating temperature of the shaft is 500o F.
It is required to:
(a) Identify possible critical section(s) on the shaft and find the internal forces at each.
(b) Find the minimum diameter of the shaft (use appropriate stress concentration factors from
tables, neglect axial forces in the x-direction, and base calculations on fatigue).
(c) Suggest an appropriate method of fabrication to the shaft.

10
16
16
10
Gears 5
24 Dia

2300 lb

Gears 3 and 4
12 Diameter
6400 lb

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