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ME 307

Machine
Design I

Dr. A. Aziz Bazoune


King Fahd University of Petroleum &
Minerals
Mechanical Engineering Department

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 1
ME 307
Machine
Design I

18-1 Introduction .922


18-2 Geometric Constraints .927
18-3 Strength Constraints .933
18-4 Strength Constraints Additional Methods .940
18-5 Shaft Materials .944
18-6 Hollow Shafts .944
18-7 Critical Speeds (Omitted) .945
18-8 Shaft Design .950

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 2
ME 307
Machine
Design I

18-1 Introduction .922


18-2 Geometric Constraints .927
18-3 Strength Constraints .933

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 3
ME 307
Machine
Design I
Fatigue Analysis of shafts
Neglecting axial loads because they are comparatively very small at critical
locations where bending and torsion dominate. Remember the fluctuating
stresses due to bending and torsion are given by

MaC MmC
a Kf m Kf
I I
TaC TmC
a K fs m K fs
J J
Mm: Midrange bending moment, m: Midrange bending stress
Ma : alternating bending moment, a: alternating bending stress
Tm: Midrange torque, m: Midrange shear stress
Ta : alternating torque, m: Midrange shear stress
Kf: fatigue stress concentration factor for bending
Kfs: fatigue stress concentration factor for torsion

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 4
ME 307
Machine
Design I
Fatigue Analysis of shafts
For solid shaft with round cross section, appropriate geometry terms can be
introduced for C, I and J resulting in

32 Ma 32 Mm
a Kf m Kf
I I
16Ta 16Tm
a K fs m K fs
J J
Mm: Midrange bending moment, m: Midrange bending stress
Ma : alternating bending moment, a: alternating bending stress
Tm: Midrange torque, m: Midrange shear stress
Ta : alternating torque, m: Midrange shear stress
Kf: fatigue stress concentration factor for bending
Kfs: fatigue stress concentration factor for torsion

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 5
ME 307
Machine
Design I Fatigue Analysis of shafts
Combining these stresses in accordance with the DE failure theory the von-
Mises stress for rotating round, solid shaft, neglecting axial loads are given by

' a xa 2 3 2 1/2 16 / d 3 4(K f Ma )2 3(K fsTa )2 1/2 16 A / d 3


xya
(18-12)
' m xm2 3 2 1/2 16 / d 3 4(K f Mm )2 3(K fsTm)2 1/2 16B / d 3
xym

where A and B are defined by the radicals in Eq. (8-12) as

A 4(K f Ma )2 3(K fsTa )2 1/2


B 4(K f Mm )2 3(K fsTm )2 1/2
The Gerber fatigue failure criterion
2 2 2
Sa Sm n 'a n 'm 16nA 16nB
3 1
Sut d Se d Sut
3
Se Sut Se

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 6
CH-18 LEC 30 Slide 6
ME 307
Machine
Design I Fatigue Analysis of shafts

The critical shaft diameter is given by


1/3
1/2

2BSe
2
8nA
d 1 1 (18-13)
Se ASut

or, solving for 1/n, the factor of safety is given by

2

1/2

1 8A 2BSe

1 1 (18-14)
n d Se ASut
3

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 7
CH-18 LEC 30 Slide 7
ME 307
Machine
Design I
Fatigue Analysis of shafts

where

A 4(K f Ma )2 3(K fsTa )2

B 4(K f Mm )2 3(K fsTm )2 (18-15)

'a A
r
'm B

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 8
ME 307
Machine
Design I
Fatigue Analysis of shafts
Particular Case
A 2K f Ma
For a rotating shaft with constant bending and torsion, the
bending stress is completely reversed and the torsion is
steady. Previous Equations can be simplified by setting Mm
B 3 KfsTm
= 0 and Ta = 0, which simply drops out some of the terms.
1/3
2

1/2

16nK f Ma K fsTmSe
Critical Shaft d
1 1 3 (18-16)
Diameter Se K f MaSut

2

1/2

1 16K f Ma K fsTmSe
Safety Factor 1 1
(18-17)

n d Se K f MaSut
3

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 9
ME 307
Machine
Design I
Fatigue Analysis of shafts

'a 2K f Ma
r (18-18)

'm 3K fsTm

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 10
ME 307
Machine Shaft Diameter Equation for the DE-Elliptic
Design I
Criterion
Remember

' a xa 2 3 2 1/2 16 / d 3 4(K f Ma )2 3(K fsTa )2 1/2 16 A / d 3


xya
(18-12)
' m xm2 3 2 1/2 16 / d 3 4(K f Mm )2 3(K fsTm)2 1/2 16B / d 3
xym

where A and B are defined by

A 4(K f Ma )2 3(K fsTa )2 1/2


B 4(K f Mm )2 3(K fsTm )2 1/2
The Elliptic fatigue-failure criterion is defined by
2 2 2 2 2 2
Sa Sm n 'a n 'm 16nA 16nB
3 3 1
Se Sy Se Sy d Se d Sy

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 11
CH-18 LEC 30 Slide 11
ME 307
Machine Shaft Diameter Equation for the DE-Elliptic
Design I
Criterion
Substituting for A and B gives expressions for d, 1/n and r:
Critical Shaft Diameter
1/3
K M 2 2 2 2

1/2

16n K T K M K T
d 4 f a 3 fs a 4 f m 3 fs m (18-19)
S S S S
e e y y

Safety Factor

1/2
2 2
K f Mm
2
K fsTm
2

1 16 K f Ma K fsTa

3 4 3 4 3 (18-20)
n d Se Se Sy Sy

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 12
ME 307
Machine Shaft Diameter Equation for the DE-Elliptic
Design I
Criterion

4 K f Ma 3 K fsTa
2 2
'a A
r
'm B 4 K f Mm 3 K fsTm
2 2

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 13
ME 307
Machine Shaft Diameter Equation for the DE-Elliptic
Design I
Criterion

Particular Case
For a rotating shaft with constant bending and torsion,
the bending stress is completely reversed and the
A 2K f Ma
torsion is steady. Previous Equations can be simplified
by setting Mm = 0 and Ta = 0, which simply drops out B 3 KfsTm
some of the terms.
1/3
K M 2 2

1/2

16 n K T
Critical Shaft Diameter d 4 f a 3 fs m (18-21)
S
Se y

1/2
2
K fsTm
2

1 16 K f Ma
Safety Factor 3 4 3 (18-22)
n d Se Sy

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 14
ME 307
Machine Shaft Diameter Equation for the DE-Elliptic
Design I
Criterion

4 K f Ma
2
'a A 2K f Ma
r
'm B 3 K fsTm
2
3K fsTm

At a shoulder Figs. A-15-8 and A-15-9 provide information about Kt and


Kts.
For a hole in a solid shaft, Figs. A-15-10 and A-15-11 provide about Kt and
Kts .
For a hole in a solid shaft, use Table A-16
For grooves use Figs. A-15-14 and A-15-15

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 15
ME 307
Machine Shaft Diameter Equation for the DE-Elliptic
Design I
Criterion

The value of slope at which the load line intersects the junction of
the failure curves is designated rcrit.
It tells whether the threat is from fatigue or first cycle yielding
If r > rcrit, the threat is from fatigue
If r < rcrit, the threat is from first cycle yielding.

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 16
ME 307
Machine Shaft Diameter Equation for the DE-Elliptic
Design I
Criterion

For the Gerber-Langer intersection the strength components Sa and


Sm are given in Table 7-10 as

2
S 2
2Se Sy
Sm 1 1
ut
1
2Se Sut Se
(18-23)

Sa Sy Sm
Sa Sy Sm Sy
rcrit 1
Sm Sm Sm

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 17
ME 307
Machine Shaft Diameter Equation for the DE-Elliptic
Design I
Criterion

For the DE-Elliptic-Langer intersection the strength components Sa


and Sm are given by

2Sy Se2
Sa
S S
2
e
2
y

Sm Sy Sa (18-24)

Sa Sa
rcrit
Sm Sy Sa

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 18
ME 307
Machine
Design I

Note that in an analysis situation in which the diameter is known and the
factor of safety is desired, as an alternative to using the specialized equations
above, it is always still valid to calculate the alternating and mid-range
stresses using the following Eqs.

and substitute them into the one of the equations for the failure criteria ,
Eqs. (7-48) to (7-51) and solve directly for n.

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 19
ME 307
Machine
Design I

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 20
ME 307
Machine
Design I

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 21
In a design situation, however, having the equations pre-solved for
ME 307
Machine
Design I
diameter is quite helpful.
It is always necessary to consider the possibility of static failure in
the first load cycle.
The Soderberg criteria inherently guards against yielding, as can
be seen by noting that its failure curve is conservatively within the
yield (Langer) line on Fig. 727, p. 348.
The ASME Elliptic also takes yielding into account, but is not
entirely conservative throughout its range. This is evident by
noting that it crosses the yield line in Fig. 727.
The Gerber and modified Goodman criteria do not guard against
yielding, requiring a separate check for yielding. A von Mises
maximum stress is calculated for this purpose.

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 22
ME 307
Machine
Design I

To check for yielding, this von Mises maximum stress is compared to the
yield strength, as usual

For a quick, conservative check, an estimate for max can be obtained by


simply adding a and m . (a + m ) will always be greater than or equal
to max, and will therefore be conservative.

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 23
ME 307
Machine
Design I

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 24
ME 307
Machine
Design I
Example

Solution

7- 7-
20 20

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 25
ME 307
Machine
Design I

Figure 7-20

Figure 7-21

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 26
ME 307
Machine
Design I

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 27
ME 307
Machine
Design I

18-
22

18- 18- Sold


14 24 erbe
rg

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 28
ME 307
Machine
Design I

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 29
ME 307
Machine
Design I

Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts CH-18 LEC 30 Slide 30

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