Project Title: Shaft Design by Joe Donnelley Given Information

COMPUTER ASSISTED MECHANICAL DESIGN
Project Title: Shaft Design

By Joe Donnelley
My task as specified by my Professor C. Toma, is to design a shaft as per instructions.
Given Information:
Output Power: 5 hp (Spur Gear, B)
Input Power: 11 hp (Chain Sprocket, C)
Output Power: 3 hp (V- Belt, C)
Dimension D-E = 6in
Dimension B-C = 5 in
Dimension C-D = 8 in
Angle A C = 20 deg
Angle A E = 30 deg
Input Speed: 450 rpm
Material: AISI OQT 1200 4140
Design Life: 10,000 hrs
Safty factor will = 3
N := 3
Thickness of sprocket and gears will be 1" as specified by Professor C. Toma
Yield strength for given material as stated in the chart supplied on page A-11 Figure A4-4 THE
Sy( Yield Strength is 112000 psi.The Tensil Strength is 142000 psi as stated by the same chart.
The endurance strength for machined using the above data as stated in chart 5-9 on page 151 of
out text book will be 42000 psi
Sy := 112000
Cs := .85
Cr := .81
S 'n = Sn x Cs x Cr = 42000(machined) x 0.85 x 0.81
Sn1 := 42000 Cs Cr
4
Sn1 = 2.892 10
Procedure for shaft design as given on page 475 of out text book
Step 1
Rotational Speed of shaft is 450 rpm as specified in project handout/
Step 2
Calculate torque at each point on the shaft. Points B,C,D,E
TORQUE AT POINT B
5
TB := 63000
450
TB = 700
lb in
TORQUE AT POINT C
11
TC := 63000
450
3
TC = 1.54 10
lb in
TORQUE AT POINT D
TD := 63000
450
TD = 420
lb in
TORQUE AT POINT E
3
TE := 63000
450
TE = 420
lb in
Step 3
P = Power being transmitted in hp
n = rotational speed in rpm
T = torque on the gear in lb in
D = pitch diameter of the gear in inches
Calculate Forces:
Forces on Spur Gear B
T := 700
Using T = 63000 * P / n
Wt = T/ (D/2)
D := 3
Tangential Force
T
Wt :=
D
2

Wt = 466.667
lb in
Radial Force
Using Wr = Wt tan angle
Angle at B is 20 deg
Wr := Wt tan ( 20 deg )
Wr = 169.853
lb in
Forces on Chain Sprocket C
Using Equation 12-6
11
TC := 63000
450
3
TC = 1.54 10
lb in
Dc := 10
TC
Fc :=
Dc
Fc = 308
lb in
These are the bending loads on the shaft, the components are.
Fcx := Fc sin ( 20 deg )
Fcx = 105.342
lb
to the left
Fcy := Fc cos ( 20 deg )
Fcy = 289.425
lb
downward
Forces on V Belt sheave D
Dd := 4
Net driving force:
Fn = F1 - F2
Equation 12-7
The magnatude of the net force can be computed from the torque transmitted
Fn = T/(D/2)
TD
Fn :=
Dd
2

Fn = 210
lb
Net driving force
Equation 12-12
FD = 1.5 Fn
FD := 1.5 Fn
FD = 315
lb
Forces on V Belt sheave E
Net driving force:
De := 4
Fn = F1 - F2
Equation 12-7
The magnatude of the net force can be computed from the torque transmitted
Fn = T/(D/2)
TE
Fn :=
De
2

Fn = 210
lb
Net driving force
Equation 12-12
FD = 1.5 Fn
FE := 1.5 Fn
FE = 315
lb
bending force
FEx := FE cos ( 30 deg )
FEx = 272.798
lb
Towards the right
FEy := FEsin ( 30 deg )
FEy = 157.5
lb
Upward
Bending Moments for B,C,D,E as calculated by MD Solids
MB := 698.02 + 1801.92
MC := 721.27 + 1721.00
3
MB = 1.932 10
lb
MC = 1.866 10
lb
2
MD := 723.89 + 0
2
ME := 688.39 + 667.56
MD = 723.89
lb
ME = 958.915
lb
Point A Ball Bearing

Equation 12-16 will be used to calculate all the diameters, the equation
is given below
2.94 2.5 ( 450.48) 3
D1 :=
28921
D1 = 0.586
Since we have no moment at A (Moment will be zero) and we do not have a sholder, step or an
elementthe Kt factor will be zero. There is no torque at point A
Since the torque is steady I will mutiplying my calculated diameter by 6%
D1 = 0.586 x 6 % = .62116 in diameter. Standardized to .8 in
Point B at Spur Gear

is given below
To the left of point B we have a retaining ring. We also have to account for the key. A well
rounded radius will be specified where D1 joins D2
Kt factor for groove will be 3, tourque will be 0 lb an moment left of B will be 1932.00 lb
Kt2 := 2.5
Kt1 := 3
Kt3 := 1.5
T2R := 700
Use same equation 12-24
T2 := 0
M2 := 1932.00
2
2
T2
32N Kt1 M2
D21 :=

+ 0.75

Sy
Sn1
D2 =Calculated diameter = 1.83in
.3333
D21 = 1.83
At point B and to the right. The torque will be (700 lb in) same moment will be used (1932.00 lb)
different Kt factor will be used for the sq key (Kt2 2.5)
D3 = Calculated diameter = 1.722 in
2
2
T2R
32N Kt2 M2
D22 :=
+ 0.75
S
Sy
n1
.3333
D22 = 1.722
Standardized D3 will be 1.8 in

Since the worst case senario is to the right of B (Because of the 0 torque to the left) I will used the
above diameter of 1.722 in
Calculation for round fillet

Kt factor of 1.5 torque will be 700 lb in and moment will be 1932 lb
2
2
T2R
32N Kt3 M2
D23 :=
+ 0.75
S
Sy
n1
.3333
D23 = 1.453
Point C (Chain Sprocket) to the right and left and key

is given below
At point C we have 1 retaining ring. We also have to account for the square key for this area
Kt factor for well rounded fillet will be 1.5, tourque will be 700 lb in, for the round sholder to the left
of C AND 840 lb in to the right of C as calculated, moment at C will be 1866.00 lb
To the left of point C the Kt will be 1.5
To the left of C
Kt1 := 1.5
MC := 1866.00
T3 := 840
T4 := 840
Kt2 := 2.5
Kt3 := 3.0

2
2
T3
32N Kt1 MC
D3L :=
+ 0.75
S
Sy
n1
.3333
D3L = 1.436
At point C Kt factor will be 2.5 FOR THE KEY torque will be 840 lb and the moment will be
1866 lb.
2
2
T3
32N Kt2 MC
D3 :=

+ 0.75

Sy
Sn1
.3333
D3 = 1.702
To the right of C Kt factor of 3.0 for a retaing ring groove will be used. The torque and
moment will be the same as above.
2
T4
32N Kt3 MC
D3R :=

+ 0.75

Sy
Sn1
.3333
D3R = 1.809

I will use diameter 6 for my shaft because of the larger kt factor and torque at that point.
Point D(V-Belt Pully) left side

At point D we have two retaining rings and a sq key. The moment (MD) at this point is 723.89 lb
in, the torque is for the retaing groove to the left will be 840lbs for the ring to the right the torque
will be 420 lb for the ring to the right. For the key the torque will be 420 lb in Kt (Kt2) factor will be
2.5
is given below
MD := 723.89
T4L := 840
KT4 := 3
T4C := 420
2
2
T4L
32N KT4 MD
D4L :=
+ 0.75
S
Sy
n1
.3333
D4L = 1.321
At point D (Key)
2
2
T4C
32N Kt2 MD
D4C :=
+ 0.75
S
Sy
n1
.3333
D4C = 1.242
Point D right side

We will use the torque value of 450 lbs in because its to the right if D. The Kt factor and the
moment will remain the same
T4R := 450
2
2
T4R
32N KT4 MD
D4R :=
+ 0.75
S
Sy
n1
D 9 = Calculated diameter = 1.319 in
.3333
D4R = 1.319
I will use the diameter of D7 for my shaft becuase of the larger diameter because the calculations
were done using the larger torque and Kt factor
Point E(Second V-Belt Pully) and to the left and right

is given below
At point E we have a retaining ring on both sides and a Key. We will use the torque of 420lb for
calculations at E and to the left of E, but to the right the torque will be 0. The same Kt factor (Kt3)
will be used, the only change will be the moment. The moment at E is 958.915 lb in
ME := 958.915
KT5 := 3
T5R := 450
T6R := 0
To the left of E
2
2
T5R
32N KT5 ME
E5L :=
+ 0.75
S
Sy
n1
.3333
E5L = 1.449
At point E
Standardized D 10 will be 1.6 in
2
2
T5R
32N Kt2 ME
E5C :=
+ 0.75
S
Sy
n1
.3333
E5C = 1.364
To the right of E
2
2
T6R
32N KT5 ME
E5R :=
+ 0.75
S
Sy
n1
.3333
E5R = 1.449
I will use D 10 diameter because it was calculated in a higher torque and Kt factor area.
Point F Ball Bearing

is given below
2.94 2.5 ( 166.89) 3
D1 :=
28921
D1 = 0.357
Since we have no moment at A (Moment will be zero) and we do not have a sholder, step or an
elementthe Kt factor will be zero. There is no torque at point A
Since the Kt factor is zero I will substatute it by mutiplying my calculated diameter by 6%
D1 = 0.357 x 6 % = .37842 in diameter
SPECIFICATION OF VALUES
Diameter number is based on assigned number used for calculations. I only submitted the
relavent diameters for bearing ends also for the Spur gear, V- Belts, and Chain Sprocket
Mating Part
Diameter Number
Min Dia Specified Dia
D1
0.62116 in
0.8 in
Point A(bearing)
Spur Gear
D3
1.722
1.8 in
Chain Sprocket
D6
1.809 in
2.0 in
V-Belt Pully(D)
D7
1.321 in
1.4 in
V-Belt Pully (E)
D 10
1.449 in
1.6 in
Point F
D1
0.357 in
0.4 in
Note I will use the larger diameter of 1.6 inches for the distance to the right of C at to point F
Calculations for Bearing (A) and Bearing (F)

Calculating the bearing dimentions for this shaft. First will be bearing A
This is the torque that is acting to the right of bearing A is 0 moment is 0
TA := 0
This is the moment that is acting to the right of bearing A
2
RA := RAx + RAy
2
2
2
RA := 174.50 + 450.48
5
RA = 2.334 10
RAA := 2.224 10
RAA = 471.593
lb
Basic dynamic load rating
Ld = 10000 hrs
Ld = (h) x (rpm) x (60 mins)
k := 3
Ld := 10000 60 450
8
Ld = 2.7 10
lb
Pd := 471.593
lb
C := Pd
Ld
10
3
C = 3.048 10
lb
C = 3048 LB
lb
Bearing B will be 6305 with a C rating of 3350 lbs d = 0.9843 in D = 2.4409. Prefered sholder dia
of 1.220 for shaft and 2.165 in for housing. Bearing weight will be .44 lb
Calculating the bearing dimentions for this shaft. First will be bearing F
This is the torque that is acting to the right of bearing A is 0 moment is 0
2
RA := RFx + RFy
2
2
2
RA := 172.11 + 166.89
4
RA = 5.747 10
RAA := 5.747 10
RAA = 239.729
lb
Basic dynamic load rating
Ld = 10000 hrs
Ld = (h) x (rpm) x (60 mins)
k := 3
Ld := 10000 60 450
8
Ld = 2.7 10
lb
Pd := 239.729
lb
C := Pd
Ld
10
3
C = 1.549 10
lb
C = 1549 LB
lb
Bearing F will be 6305 with a C rating of 3350 lbs d = 0.9843 in D = 2.4409. Prefered sholder dia
of 1.220 for shaft and 2.165 in for housing. Bearing weight will be .44 lb
Designing the keys

Material for gears will be 8620 SOQT 300 as specified by the professor.
Tensile strength = 188 ksi or 188,000 psi Yield Strength will = 149 ksi or 149,000 psi
TABLE 11-1 KEY SIZE VS SHAFT DIAMETER
Keys for B, D,C AND E
TB := 700
DB := 1.8
Sy := 149000
H := 0.5
N := 3
For Key B
Shaft is less than 6.5 inches long so I will use a square key
L will be length of key
For shear and compression
Standardized to 0.0625 in
4 TB N
LB :=
Sy DB H
LB = 0.063
in
Choose material for Key. Start with cheepest 1020 CD Sy 51000 psi Syk for
key material
SYK := 51000
4 TB N
LB :=
SYK DB H
LB = 0.183
Standardized to 0.1875 in I will use 0.1875 in long key. This will be the length of my key.
For Key C
TC := 1541
DC := 1.4
Sy := 149000
H := 0.5
Keys for D,C AND E
N := 3
4 TC N
LC :=
Sy DC H
LC = 0.177
in
I will use a 0.5 in long key found in charts 13-1 to 13-3
key material
SYK := 51000
4 TC N
LB :=
SYK DC H
LB = 0.518
Standardized to 0.625 in This will be the length of my key.
For Key D
Keys for B, D,C AND E
TD := 450
DD := 1.4
Sy := 149000
H := 0.3125
N := 3
4 TD N
LD :=
Sy DD H
LD = 0.083
in
key material
SYK := 51000
4 TD N
LD :=
SYK DD H
LD = 0.242
For Key E
Keys for B,D,C AND E
TE := 450
DE := 1.6
Sy := 149000
H := 0.375
N := 3
4 TE N
LE :=
Sy DE H
LE = 0.06
in
Choose material for Key. Start with cheepest 1020 CD Sy 51000 psi Syk for key material
SYK := 51000
4 TE N
LE :=
SYK DE H
LE = 0.176
LOAD DIAGRAMS FOR X PLANE: Done in MD SOLIDS

PLEASE SEE HARD COPY FOR LOARGER DIAGRAMS
P 4 = REACTION FORCE AT A
P5 = REACTION FORCE AT B
P1 = FORCE AT SPUR GEAR
P2 = FORCE AT CHAIN SPROCKET
P4 = FORCE AT SECOND V-BELT SHEAVE
LOAD DIAGRAMS FOR Y PLANE: Done in MD SOLIDS

P 5 = REACTION FORCE AT A
P6 = REACTION FORCE AT B
P1 = FORCE AT SPUR GEAR
P2 = FORCE AT CHAIN SPROCKET
P3 = FORCE AT FIRST V-BELT SHEAVE
P4 = FORCE AT SECONT V-BELT SHEAVE
GENERAL FITS AND TOLERANCES

For B (Spur Gear)
This will have an R5 fit: (Medium running fit) Acurate machined parts.
D := 1.8in
Nominal Clearance fits from Table 13-6 for a shaft diameter of 1.8 inches
From 1.19-1.97
D Hole Max = 1.8 in +0016
-0
D Hole Min = 1.8 in
D Shaft Max = 1.8 in - 0.0020 in = 1.789 in

D Shaft Min = 1.8 in - 0.0030 in = 1.797 in
For C (Chain Sprocket)

D := 2.0in
From 1.19-3.15
-0
D Hole Min = 2.0 in

For D AND E (V Belt Shieve)
D := 1.6in
From 1.19-1.97
-0
D Hole Min = 1.6 in

For Keys
Key Length
Key at B 0.1875 in
Key at C 0.625 in
Key at D 0.25 in
Key at B 0.1875 in
Tolerance on key
+.000 - .002 in
+.000 - .002 in
+.000 - .002 in
+.000 - .002 in
Tolerance on Keyseat
-.000 + .002in
-.000 + .003in
-.000 + .003in
-.000 + .002in
Fit range
.000-.004 in
.000-.005 in
.000-.005 in
.000-.004 in

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COMPUTER ASSISTED MECHANICAL DESIGN

Project Title: Shaft Design

Bending Moments for B,C,D,E as calculated by MD Solids

Point A Ball Bearing

Point B at Spur Gear

D3 = Calculated diameter = 1.722 in

Standardized D3 will be 1.8 in

Calculation for round fillet

Point C (Chain Sprocket) to the right and left and key

D4 = Calculated diameter = 1.436 in

Standardized D6 will be 1.8 in

Point D(V-Belt Pully) left side

Point D right side

D 9 = Calculated diameter = 1.319 in

Point E(Second V-Belt Pully) and to the left and right

D10 = Calculated diameter = 1.449 in

Point F Ball Bearing

Calculations for Bearing (A) and Bearing (F)

Designing the keys

Standardized to 0.625 in This will be the length of my key.

Standardized to 0.25 in This will be the length of my key.

Standardized to 0.1875 in This will be the length of my key.

LOAD DIAGRAMS FOR X PLANE: Done in MD SOLIDS

LOAD DIAGRAMS FOR Y PLANE: Done in MD SOLIDS

GENERAL FITS AND TOLERANCES

D Shaft Max = 1.8 in - 0.0020 in = 1.789 in

For C (Chain Sprocket)

D Shaft Max = 2.0 in - 0.0025 in = 1.8875 in

D Shaft Max = 1.6 in - 0.0020 in = 1.598 in

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