METU ME 307 Machine Elements I Fall 2011

1
Prepared by: Hseyin Enes Salman
Room: G-156 Phone: 5246
E-mail: salman@metu.edu.tr Date: 02/12/2011

ME 307 MACHINE ELEMENTS I
TUTORIAL 9
DESIGN OF SHAFTS

Problem 1:
The shaft in the figure is subjected to the loadings as shown. The flywheel is
mounted on the shaft by means of the key and the snap ring (retaining ring) which is
set on the groove to secure the flywheel on the + x direction. The material of the
shaft is annealed AISI 1050 HR. The surface of the shaft is machined. Determine the
diameter of the shaft for:
a.) a factor of safety of 2.5, if the loads are static.
b.) a factor of safety of 2, if the loads are completely reversed with the
given magnitudes. Take 0.85
b
k = and the reliability is 95 percent.
(Take: r/d=0.10, D/d=1.02, t/D=0.125, b/D=0.25)


100 , 200 , 400 F N M N m T N m = = =


Solution:
a.)
The normal stress due to axial force is uniform over the area:
2
4
axial
F F
A d
o
t
= =
The maximum stresses due to the bending moment and the twisting torque are:

bending
Mc
I
o = ,
twisting
Tc
J
t =
The Maximum torsional shear due to the twisting torque occurs at the outer surface of
the cross-section and the maximum normal stress due to bending occurs on the stress
element at the upper point of the shaft for static loading. So this point is the critical
point. The stresses at this point due to these loadings can be expressed in terms of the
diameter as:

3
32
bending
Mc M
I d
o
t
= = ,
3
16
twisting
Tc T
J d
t
t
= =

The total normal stress and the shear stresses are:
2 3
4 32
x
F M
d d
o
t t
= +
3
16
xz
T
d
t
t
=

Using the distortion-energy theory,
2 2
2 2
2 3 3
4 32 16
' 3 3
x xz
F M T
d d d
o o t
t t t
| | | |
= + = + +
| |
\ . \ .


The material properties from Table A-18 (Shigley 8
th
Edition)
620
ut
S MPa = , 340
y
S MPa =
The diameter of the shaft can be found using the safety factor value.
'
y
S
n
o
=
M
T
T
M
x
y
z
F F
b
t
r
Snap ring
Flywheel
d
D

METU ME 307 Machine Elements I Fall 2011
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2 2
2 3 3
2.5
4 32 16
3
y
S
F M T
d d d t t t
=
| | | |
+ +
| |
\ . \ .

2 2
3 3
2 3 3
2.5
4 100 32(200 10 ) 16 400 10
3
y
S
d d d t t t
=
| | | |
+ +
| |
\ . \ .

which gives 31.1 d mm = , by iteration.
Note that, taking the axial force as 0 F = , 31.0 d mm = can be found. This value
can be used as an initial value to the iterations.

Then, by using the given diameter ratio D/d=1.02, shaft diameter, D is found as
31.7mm. Select an appropriate value for diameter from the table A-17 (Preferred
Sizes and Renard Numbers Table). Preferred size for shaft diameter is D = 32mm.

Also, note that, stress calculations on the section where the keyway is located are
performed by using the whole shaft area. Since, the area at the keyway is very small
compared to the shaft cross-section as shown below, the area of the shaft is used in
calculations.

2 2
0.25 0.125
0.04
4 4
key
shaft
A
b t D D
D D A t t

= = =



b.)
For the fatigue case the points at the keyway and at the groove of the snap-ring
should be investigated to determine the critical section. The stress formulations used
above will be the alternating stress for this case. The mean components of the
stresses will be zero due to completely reversed loading.

The stress calculation at the keyway:
Since, both the axial loading and bending moment cause normal stress on the cross-
section, it is assumed that
1 f
K can be taken as the stress concentration factor for
axial loading as well.

1 2 3
4 32
a f
F M
K
D D
o
t t
| |
= +
|
\ .

2 3
16
a f
T
K
D
t
t
| |
=
|
\ .

Alternating component of the von Mises stress is:
2 2
2 2
, 1 2 2 3 3
4 32 16
' 3 3
a keyway a a f f
F M T
K K
D D D
o o t
t t t
( ( | | | |
= + = + +
| | ( (
\ . \ .

where

1 f
K (stress concentration factor for bending for profile keyways): 1.6
2 f
K (stress concentration factor for torsion for profile keyways): 1.3
(From Stress Concentration Factors for Threads and Keyways Table under the Useful
Information link of the course web page)

2 2
3 3
2 2
, 2 3 3
4 100 32 200 10 16 400 10
' 3 1.6 3 1.3
a keyway a a
D D D
o o t
t t t
( ( | | | |
= + = + +
( ( | |
\ . \ .
Since the normal stress from axial loading is so small when compared with stress due to
bending moment, the axial stress term is neglected. So,
12
, 6
31.6 10
'
a keyway
D
o

=
The stress calculation at the groove:

3 2 3
4 32
a f
F M
K
d d
o
t t
| |
= +
|
\ .

3 3
16
a f
T
K
d
t
t
| |
=
|
\ .

Alternating component of the von Mises stress is:
2 2
4 5 2 2
, 3 2 3 3
4 32 16
' 3 3
f f
a groove a a f
b
b
K K
F M T
K
k
d d k d
o o t
t t t
( (
= + = + +
( (



From Figure 7-14 in the Formula Sheet, q is taken as 0.95 assuming that notch radius is 3
mm.
1.60
t
K = (from Figure A-13-13 in the Formula Sheet, grooved round bar in tension)
1.55
t
K = (from Figure A-13-14 in the Formula Sheet, grooved round bar in bending)
1.30
ts
K = (from Figure A-13-15 in the Formula Sheet, grooved round bar in torsion)

METU ME 307 Machine Elements I Fall 2011
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So,
3
1 ( 1) 1 0.95(1.60 1) 1.57
f t
K q K = + = + =
4
1 ( 1) 1 0.95(1.55 1) 1.52
f t
K q K = + = + =
3
1 ( 1) 1 0.95(1.30 1) 1.28
f ts
K q K = + = + =

2 2
3 3
, 2 3 3
4 100 1.52 32 200 10 1.28 16 400 10
' 1.57 3
0.85 0.85
a groove
d d d
o
t t t
( (
= + +
( (


Since the normal stress from axial loading is so small when compared with stress due
to bending moment, the axial stress term is neglected.

12 12
, 6 6
41.5 10 42.3 10
'
a groove
d D
o

= =
Since, the stresses at the groove are more critical, those will be taken in
consideration for the determination of shaft diameter.

The Endurance limit of the shaft is to be determined. The endurance limit of the test
specimen is:
' 0.5 0.5 620 310
e ut
S S MPa = = =

The endurance limit modifying factors are:

0.75
a
k = for 620
ut
S MPa = and machined surface.
0.85
b
k = given in the problem.
0.868
c
k = for 95% reliability.
1
d
k = nothing mentioned.
1
e
k = since stress concentrations are considered in stress
calculations.
1
f
k = nothing mentioned.
0.75 0.85 0.868 1 1 1 310 172
e
S MPa MPa = =
The diameter of the shaft can be found using the safety factor value.
Since the mean stress is zero:
'
e
a
S
n
o
=
12
6
172
2
42.3 10
MPa
N
D
=

which gives D=42.28 mm


Select an appropriate value for diameter from the table A-17 (Preferred Sizes and
Renard Numbers Table). Preferred size for shaft diameter is D = 45mm.

Note that, if both the alternative and mean stress components exist, the critical section
can be found by using one of the failure theorems.


Note that, if the neglected term of axial stress is included in the equations, a factor of
safety of 1.9 is determined.

2 2
3 3
, 2 3 3
4 100 1.52 32 200 10 1.28 16 400 10
' 1.57 3
(42.28 / 1.02) 0.85 (42.28 / 1.02) 0.85 (42.28 / 1.02)
a groove
o
t t t

= + +
( (
( (


,
' 90.52
a groove
MPa o =

172
1.9 2
' 90.52
e
a
S
n
o
= = = ~


METU ME 307 Machine Elements I Fall 2011
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Problem 2 : In the figure; the shaft transmits 7.5 kW from the pulley P to the gear G
at 900 rev/min under steady load conditions. The shaft is machined. The ultimate
tensile strength is 590 MPa and the yield point in tension is 380 MPa. The pulley
diameter is 250 mm and the pitch diameter of the gear is also 250 mm. The mass of
the pulley P and the gear G are both 12.2 kg. Neglect the weight of the shaft. The
ratio of the belt tensions is T
1
/T
2
= 2.5. The gear pressure angle is 20
o
. Take reliability
as 0.99 and working temperature is 100 C
o
. Neglect the effect of keyway. Factor of
Safety is 1.5.
Determine the shaft size, d.

























Solution:
k
a
=0.75 (Fig 7-8, machined)
k
b
=0.85 Same for bending and torsion, assuming 8<d<50 for all sections on shaft
k
c
=0.814 (Table 7-7, 99% Reliability)
k
d
=0.9 (T=100 C
o
)

0.5
e a b c d ut
S k k k k S =
(0.75)(0.85)(0.814)(0.9)(590)(0.5) 138
e
S MPa = =

The torque M
t
on the shaft is found from:

2
, 7500 , 900 / min
60
t
NM
P P W N rev
t
= = =

So, 79.6 .
t
M N m =

The belt forces are found from:

1 2
( )( )
t
T T R M = or
1 2
( )(0.125) 79.6 T T = and
1 2
/ 2.5 T T =

From which:

1
1060 T N = ,
2
424 T N =

The weights of the gear and the weight of the pulley are each 12.2 x 9.81 = 119.6 N;
say 120 N.
The tangential gear force / 79.6/ 0.125 636.8
t t
F M R N = = =
The vertical force is tan 636.8tan20 231.8
o
r t
F F N | = = =
The loading and bending moment diagrams are shown with the figure; the belt forces
and gear forces are assumed concentrated as shown. The weight of the pulley and gear
are included.

METU ME 307 Machine Elements I Fall 2011
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Consider the section at the gear first.
The stress concentration factor in bending due to the fillet where the shaft portion of
diameter d joins with the shaft diameter 2d depends upon the radius of the fillet.
Even if the ratio of the radius of the fillet to the shaft d is specified to obtain the
theoretical stress concentration factor K
t
, the actual stress concentration factor K
f

depends upon the notch sensitivity, which is a function of the radius of the fillet.
Thus it is necessary to use a trial and error solution, by approximating the diameter d
and the radius of the fillet and checking with the calculated value of d. The values
used in the following calculations are those which agree with the final values:

r/d= 0.1, for which r=2.4 mm

For r/d = 0.1, D/d = 2, and r=2.4 mm:

K
ts
=1.47 K
t
=1.71 q
1
=0.8 q
2
=0.94

1
1 ( 1) 1 0.8(1.71 1) 1.568
f t
K q K = + = + =

2
1 ( 1) 1 0.94(1.47 1) 1.442
fs ts
K q K = + = + =

The bending is constant, 65.6 N.m but a particle on the surface is subjected to a
complete reversal of stress. The mean bending stress is zero. The variable stress is:


3 3 3
32 (32)(65.6) 1048
(1.568)
a f
M
K
d d d
o
t t
= = =

The shear stress due to torsion is constant, since the torque is constant. The variable
shear stress is zero. The mean shear stress is:


3 3 3
16 (16)(79.6) 584.6
(1.442)
m fs
T
K
d d d
t
t t
= = =

K
fs
is used in mean shear stress for additional safety although material is not a
particularly high strength material.
Based on the distortion-energy theory the equivalent stresses are:

'
a a
o o =
2
3
1012.6
' 3
m m
d
o t = =

Using modified Goodman relation:

' ' 1
a m
e ut
n S S
o o
= +
3 3
6 6
1 1048/ 1012.6/
1.5 138 10 590 10
d d
= +



d=24.1 mm; r=2.41 mm are found.

The shaft at the right bearing will be analyzed next. Specifically, the section with
diameter d at the fillet will be considered, with the bending moment at the centerline of
the bearing taken as acting at the section with the fillet.

The stress concentration factor K
f
cannot be determined directly here. The same
procedure as used at the section with the gear will be used, trial and error, with final
values given
r/d= 0.1, for which r=3.5 mm

For r/d = 0.1, D/d = 2, and r=3.5 mm:

K
ts
=1.47 K
t
=1.71 q
1
=0.83 q
2
=0.96
1
1 ( 1) 1 0.83(1.71 1) 1.589
f t
K q K = + = + =
2
1 ( 1) 1 0.96(1.47 1) 1.451
fs ts
K q K = + = + =

The mean bending stress is zero.

3 3 3
32 (32)(223) 3609
(1.589)
a f
M
K
d d d
o
t t
= = =

The variable shear due to torque stress is zero. The mean shear stress is:


3 3 3
16 (16)(79.6) 588.2
(1.451)
m fs
T
K
d d d
t
t t
= = =

Based on the distortion-energy theory the equivalent stresses are:

METU ME 307 Machine Elements I Fall 2011
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'
a a
o o =
2
3
1018.8
' 3
m m
d
o t = =

Using modified Goodman relation:

' ' 1
a m
e ut
n S S
o o
= +
3 3
6 6
1 3609/ 1018.8/
1.5 138 10 590 10
d d
= +



d=34.731 mm; r=3.47 mm are found.

Use

The size of trhe shaft is then determined by the stresses acting in the shaft at the
right bearing.

Problem 3:
The figure shows a shaft with two gears and a drum mounted on it. Gears 1 and 2 are
identical with weight 70N. The weights of the shaft and the drum are 140N and
100N, respectively. Find the first critical speed of the shaft using Rayleighs equation.
Take the flexural rigidity of the shaft as
11 2
4 10 EI N mm = .







Solution:
The Rayleighs equation gives the first critical speed of a shaft as:

where

is the weight of the i

th
element on the shaft and

is the
deflection at the i
th
body location. The shaft can be analyzed by dividing it into 3
elements as in Figure 2. The deflection of the gears, drum and each element on the shaft
are to be determined.



The positions 1 and 5 are the positions of the gears. The positions 2, 3 and 4 are the
centers of the 3 elements of the shaft. Position 3 is also the position of the drum.
Note that the lowest critical speed of the shaft is related with the first bending mode of
the shaft. The shape of the first mode is given in Figure 3.





The deflections at the specified positions will be calculated considering the weights are
acting in the directions shown in Figure 4, that will result in the deflection curve of the
first mode shape given in Figure 3.



20 100
140
280
G
1
G
2
Drum

Figure 1
Figure 2
50 50 40 40 50 50
1 2 3 4 5
A B
Figure 3
A B
Figure 4 F1 F2 F3 F4 F5
A B
35 d mm =

METU ME 307 Machine Elements I Fall 2011
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The shaft in the problem can be considered as an overhanging simply supported
beam. To find the deflections at position 3, the forces outside the supports will be
replaced with equivalent force and moment system at the supports. The deflections
will be determined by using the formula from the deflection table for simply
supported and cantilever beams.

Using the equivalent system in Figure 5, the deflection at position 3 can be
calculated. Superposition of the three loadings; two end moments and the center
load will give the total deflection. Also for the positions outside the supports, the
slopes at the supports due to these loads are needed.




Figure 6 shows the superposition of the loads over the shaft. Note that equivalent
force due to overhanging forces will not make any deflection or slope, since they are
acting on the supports.

The deflection at 3 and the slopes at A and B due to end moment at B:

), (from beam deflection tables)

,, ,

Note that the sign of the end moment is taken as negative due to the sign convention
used in beam deflection formulas.

(from beam deflection tables)

(from beam deflection tables)

The deflections at 3 and the slopes at A and B due to end moment at A:
Using the symmetry,

The deflections at 3 and the slopes at A and B due to the center load:

), (from beam deflection tables),

(from beam deflection tables)

(from beam deflection tables)

Figure 5 F1 F2 F3 F4 F5
A B
A
B
FR FR
FR FR
Feq
F3
Meq
Meq
A
B
Feq Feq
F3
Meq
Meq
A
B
Meq
A
B
Meq
F3
A B
A
B
Feq Feq
Feq
Figure 6

METU ME 307 Machine Elements I Fall 2011
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To find the deflections outside the supports, the slope at supports A and B of the
simply supported beam given in Figure 6 is obtained and the deflection of the
overhanging locations due to these forces are obtained by simply multiplying the
distance with the slope. In addition to this, the overhanging forces are considered as
they are acting on a beam cantilevered at the support locations. Therefore, the total
defections at the overhanging parts are obtained by simply adding the deflections
due to the slope of simply supported beam (including moments) and the cantilever
beam.
It will be sufficient to find the deflections at positions 4 and 5, because of symmetry.
These deflections will be the same as that of 2 and 1, respectively.



The deflections at 4 and 5 due to the forces inside the supports:

The deflections at 4 and 5 due to the concentrated force at 4:

), ,

The deflections at 4 and 5 due to the concentrated force at 5:

), ,

), ,

The total deflections at 4 and 5:

The total deflections at 1 and 2:

The weight at each position is also needed.

The first critical speed of the shaft can be calculated using the Rayleighs equation. Note
that during the calculation of all the deflections, y axis has been selected as pointing
upwards. However, since Rayleighs equation is obtained from the equality of potential
energy and kinetic energy all the forces and deflections used in Rayleighs equation
should be taken as positive. Note that energy is a positive quantity and it cannot be
negative.

Figure 7
uB
F5 F4

METU ME 307 Machine Elements I Fall 2011
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The analysis can be simplified if the shaft masses for the overhanging locations are
lumped onto the positions of the gears. This way, deflections of only 3 locations are
to be found, i.e. the locations of the gears and the drum.