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OptimizationofshaftdesignunderfatigueloadingusingGoodmanmethod

InternationalJournalofScientific&EngineeringResearchVolume2,Issue8,August2011 1
ISSN22295518

Optimizationofshaftdesignunderfatigue
loadingusingGoodmanmethod
DeepanMarudachalamM.G,K.Kanthavel,R.Krishnaraj
AbstractInthispaperfrequentfailureofashaftemployedinaspinningmachineisstudied.Failureoccurredatthevicinityofchangein
crosssectionoftheshaftwhereareliefgrooveispresent.Consideringthedrivesystem,forcesandthetorquesactingontheshaftare
determinedusingwhichthestressesoccurringatthefailuresectionarecalculated.Stressanalysisisalsocarriedoutbyusingfiniteelement
method(FEM)andtheresultsarecomparedwiththecalculatedvalues.Stressconcentrationfactorsatthefailurecrosssectionare
calculatedusingleastsquaremethodfromwhichfatiguestressconcentrationfactorsarecalculated.EndurancelimitusingGoodmansmethod,
fatiguefactorofsafetyandthetheoreticalnoofcyclessustainedbytheshaftbeforefailureisestimated.Inconclusionitisseenthatthe
increaseinfilletradiioftheshaftandchangeinthepositionofthesupportdecreasesthestressconcentrationfactor,increasethe
endurancelimitandfatiguefactorofsafetyoftheshaft.
IndexTermsShaft,Fatigue,Goodman,Reliefgroove,Stressconcentration,Filletradii,Support

1INTRODUCTION
shaftisarotatingmember,usuallyofcircularcrosssectionfortransmittingpower.Itissupportedbybearingsandsupportsgear,
sprockets,wheelsandrotors.Itissubjectedtotorsion,traverseoraxialloads,actinginsingleorincombination.Generally
shaftsarenotofuniformdiameterbutaresteppedtoprovideshouldersforlocatinggears,pulleysandbearings.Thestressonthe
shaftataparticularpointvarieswithrotationofshafttherebyintroducingfatigue.Thefirstscientificinvestigationonfatigue
failurewasmadebyAugustWohleronrailwayaxles.Evenaperfectcomponentwhenrepeatedlysubjectedtoloadsof
sufficientmagnitude,willeventuallypropagateafatiguecrackinsomehighlystressedregion,normallyatthesurface,until
finalfractureoccurs.Extensiveworkhasbeencarriedoutbyfailureanalysisresearchcommunityinvestigatingthenatureof
fatiguefailuresusinganalytical,semiempiricalandexperimentalmethods[1].AccordingtoOsgoodallmachineandstructural
designsareproblemsinfatigue[2].Failureofanelevatorshaftduetorsionbendingfatiguewasgivenin[3].Thefailureofa
shaftdueimproperfasteningofsupportwasexplainedin[4].Somegearshaftfailureshavebeenreportedandcommoncausesof
failurehavebeenhighstresses,frictionorfretting[57].J.FDarlingtonandJ.D.Brookerhaveproposedthatstressrelieving,
changetosimplysupported,increaseofdiameterandachangeof

DeepanMarudachalamM.GiscurrentlypursuingmastersdegreeprograminEngineeringDesigninAnnaUniversityoftechnology,Coimbatore,In
dia,PH919865052762.Email:deepan.mg@gmail.com
K.KanthaveliscurrentlyworkingasAssistantProfessorindepartmentofMechanicalengineeringinAnnaUniversityoftechnology,Coimbatore,
India,PH919894666288.Email:kanthavel_k@gmail.com

materialcanreducetheimpactoffatigueby45%,20%,
20%and10%respectively[8].Accuratestressconcentrationfactorsforshoulderfilletinroundandflat
barsfordifferentloadingconditionsaregivenin[9].Effectofsteadytorsiononfatiguecrackinitiationandpropagationunder
rotatingbendingsubjectedtomultiaxialfatigueandmixedmodecrackingisdiscussedin[10].Failureanalysisofalocomotive
turbochargermainshaftandrearaxleofanautomobilewerediscussedin[11,12].CelalettinKaraagacandM.EvrenToygar
consideredanagitatorshaftwithacircumferentialgrooveforwhichthefatiguelifehasbeenestimated[13].Michele
Zappalorto,FilippoBertoandPaoloLazzarinpredictedthenotchstressconcentrationfactorsofroundbarsundertorsion[14].

2SHAFTMODEL
Theshaftinvestigatedinthispaperfailedafter35daysofinstallationat24hrdutycycle.Thebasicdrivearrangementisshown
in(Fig.1)whichisrequiredtoliftaloadof960kg.Thedrivearrangementconsistsofa24Nmservomotor,torsionspringand
timingbeltdriveforpowertransmission.Thefunctionofthisarrangementistolifttheweightupanddownthroughadistanceof
230mm.Astheloadstartstomoveinupwarddirection
thetorsionspringuntwiststherebyincreasingtheload
ontheservomotorandsubsequentlyonthe22T90Tshaft
showninFig.2.Theloadmovesatavelocityof10mm/stherebyallowingtheshaftunderconsiderationtorotate
at4rpm.ThegeometryoftheshaftwithitscomponentsisshowninFig.2.Thematerialoftheshaftunderconsiderationis
C55Mn75(En9).ThemechanicalpropertiesareshowninTable1anditschemicalcompositionaccordingtoIS1570consistsof
CandMnin
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percentageof0.55and0.75respectively[15].Themicrostructurecorrespondingtothismaterialislamellarpearlitewithagrain
sizeof58ASTM.Sincetheshaftisworkinginatextilemilltheoperatingtemperatureisataround35C.Itcanbeseenthatthe
failurehastakenplaceatthereliefgroovethathasbeenprovidedintheshaftforbearingseatingasshowninFig.3werethe
stressconcentrationwouldbemoreduetoabruptchangeincrosssectionoftheshaft.

marksarenoticedalongthecircumferenceoftheshaft(Fig.3).Theboundariesbetweenadjacentfractureplanes,i.e.,between
eachpairofratchetmarksisafractureorigin,andastheseindividualcracksgrowinwardtheyeventuallyjointogetherona
singleplane.Thesmallinstantaneouszoneindicatesthestressatthetimewhentheshaftfinallybrokewaslow,butthe
multipleoriginsandtheratchetmarksshowthattherewasenoughstresstocausecrackingatmanypointsaroundtheperimeter
almostsimultaneously.Fromthisitcanconcludedthattheremusthavebeenasignificantstressconcentration.

Fig.1.Basicarrangementofdrivesystem

Fig.3.Fracturesurface

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Fig.4.Arielviewofshaft
Fig.2.Shaftanditscomponents

TABLE1
MECHANICALPROPERTIESOFSHAFT
Tensilestrength Yieldstrength
(MPa)

(MPa)

720

400

%Minimumelongation

13

Brinellhardness Poissions Modulusofelasticity

(BHN)

ratio

(GPa)

265

0.3

206

Itcanbeseenthatthefailurehastakenplaceatthereliefgroovethathasbeenprovidedintheshaftforbearingseatingasshown
inFig.4werethestressconcentrationwouldbemoreduetoabruptchangeincrosssectionoftheshaft.Fromvisualexamination
aseriesofratchet

3GOODMANMETHOD
ThefinalendurancelimitoftheshaftisfoundusingGoodmansequationbytakingmeanstress(M)intoaccount.Goodman
curveisaplotbetweenthemeanstressalongXaxisandamplitudestressalongYaxis.

3.1ForceAnalysis
FromdrivearrangementshowninFig.1theshaftunderconsiderationissubjectedtohorizontalandverticalcomponentof
forces,forboth22Tand90Tpulleys.Inadditiontotheabovetheshafthastotransmitsomeamountoftorquetolifttheweight.
Theforcesandtorqueontheshaftincreasesasthemassmovesinupwarddirectionandthesewouldbemaximumat230mm
traverseandminimumatinitialposition.Whenthemasstravelsthrough230mmthemainshaftand22T90Tshaftwouldrotate
by130.6and670degreesrespectively.The
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valuesofforcesandtorquesatinitialandfinalpositionsofthemassaregiveninTable2.
TABLE2
FORCESANDTORQUESACTINGONSHAFT
Lift

Forcedueto22Tpulley(N) Forcedueto90Tpulley(N) Torquetransmitted(Nm)

(mm)
Lift

(mm) Component

Component

Component

Component

104.2

468.5

66.2

167

10.31

230

827.2

3625.4

388.2

757.6

81.5

Torquetransmitted(Nm)

3.2 STRESSANALYSIS
Theshaftunderconsiderationisbeingsubjectedtobendingandshearstressduetoverticalandhorizontalcomponentforce,and
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shearstressduetotorquetransmission.Soastheshaftrotatesthereisafluctuationofstress,thepointwhichissubjectedto
maximumstressvalueisfoundandshowninFig.5.Thevariousbending(nom)andshearstress(nom)atthefailuresurfaceis
found.Accordingto[9]theaccuratestressconcentrationfactorscorrespondingtoshearandbendingstresscanbefoundusing
leastsquaremethod.Theradiiatreliefgroovewasfoundtobe0.6mmcorrespondingtoIS3428,correspondingtowhichstress
concentrationduetobending(Ktb)andstressconcentrationduetoshear(Kts)wasfoundtobe
2.85and1.91respectivelywhichwerecalculatedusing
[9].Fordynamicloading,weneedtomodifythetheoreti
calstressconcentrationfactorbasedonthenotchsensitiv
ityofthematerial.FatiguestressconcentrationfactorKf
canbecalculatedas[3]:
Kf=1+q(Kt1)(1)
whereqisthenotchsensitivityitcanbedefinedfromthe
KunnHardarthformulaintermsofNeubersconstant(a)
andthenotchradius(r).
q=1/(1+(a/r))(2)
Fromthevalueofacorrespondingtothegivenultimatestrengthwasfoundtobe0.062inch.Substitutingthevalueofaand
rinincheswegetq=0.712.Usingtheabovevaluesthefatiguestressconcentrationfactorduetobending(Kfb)andshear(Kfs)
werefoundtobe2.31and
1.64respectively.Theactualbending(actual)andtheshear
stress(actual)atthefracturessurfacewascalculatedbymultiplyingthestressesobtainedatthatsectionbythefatiguestress
concentrationfactorsKfbandKfsrespective
ly[3].Fig.6depictsthemagnitudeofthevariousstressesactingonthemaximumloadedpointatvariouspositionsoftheshaft.It
isseenthatthebendingstressduetoverticalforceispredominant.Theequivalentstressactingonshaftcanbecalculated
usingShapeDeformationEnergyHypothesis[3]as
EQ=((Kfb.actual.)2+3.(Kft.actual)2)(3)Fig.7showsthefluctuationofequivalentstresswiththedegreeofrotationofthe
shaftand,itisseenthatitsvaluewouldbemaximumatthetopmostpositionofthemass,forthepointunderinvestigation.

Fig.5.Determinationofpointsubjectedtomaximumloading

Fig.6.Fluctuationofstressesatdifferentpositionofshaft

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Fig.7.Fluctuationofequivalentstressesatdifferentpositionofshaft

3.3FatiguestrengthanalysisbyGoodmanmethod
Fatiguestrength(endurancelimitE)oftheshaft
materialwascalculatedas[3]
E=0.5.UTS=0.5.720=360N/mm2
Consideringthecorrectionsfactorsforendurancelimitwefindthenewendurance
limit(EI)as
EI=E.Cload.Csize.Csurf.Ctemp.Creliab(4)
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ThecalculatedcorrectionfactorsaregivenintheTable3.
TABLE3
CALCULATEDCORRECTIONFACTORS

Cload Csize Csurf Ctemp Creliab

1

0.843 0.788 1

0.814

UsingthevaluesgiveninTable3modifiedendurancelimitwascalculatedas195N/mm2.Fromourabovecalculationswe
knowthataveragestressvalue(M)isnotzero.TocalculateM,wehavetoconsiderthechangeofstressvalueoccurringatthe
fracturesurfaceintime.Fromourcalculationwefoundthatthevalueofstressinnotconstantwithtimeasshowninfig.7.
ThereforethisaccountsforaVariableamplitudestress.Tocalculateaveragestressvalue,wehavetotransformVariable
amplitudestressintoConstantamplitudestressbyconsideringthepointsubjectedtomaximumloadingshowninfig.5.Fig.7
showsthevariationofstresswiththerotationoftheshaftfromwhichtheaveragestresscanbefound.Inthiscaseaveragestress
valueis121.5
N/mm2.Consideringaveragestressvalue,earliercalculatedendurancelimitismodified.Bytheanalysis,criteriaofGoodman
[3]themodifiedendurancelimit(EII)iscalculatedas
(EII)=EI.(1(M/UTS))(5)Substitutingthevaluesfortheaboveexpressionthe
modifiedendurancelimitwasfoundtobe162N/mm2asshowninFig.8.Consideringthemodifiedendurancelimit(EII)andthe
maximumequivalentstress,fatiguesafetyfactor()canbecalculatedas[3]
=EII/EQ=162/228=0.71(6)

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Fig.8.EndurancelimitdeterminationusingGoodmanmethod

3.4Fatiguelifeanalysis
Forfurtherfatigueanalysis,stresscycle(SN)curveoftheshaftisestimated.TodrawtheSNcurveoftheshaft,stressvalue
(F)wherefatiguefailurecycleat103cyclesoccur,canbecalculatedas[3]
F=m.UTS(7)
wherem=0.9forbending.ThestressvalueatNf=103accordingEq.(7)is648N/mm2.Thesecondpointatthegraphisthe
endurancelimitvalue,whichis106cyclesforsteelcorrespondingtomodifiedendurancelimitcalculatedusingtheEq.5,162
N/mm2asshowninFig.9.Theshaftissubjectedtoamaximumstressvalueof228
N/mm2forthisstressvaluetheshaftlifewouldbe201342cyclesasshowninFig.9whichsupportsourthesis.

Fig.9.CalculatedSNcurve

4FINITEELEMENTANALYSIS
Toexaminestressdistributionatthefracturesurface,finiteelementmethod(FEM)wasemployed.ANSYSprogramwasused
foranalysistocrosscheckthecalculatedvaluesofstress.Theelementmeshesweregenerated,boundarycondition
correspondingtomaximumloadingconditionwasgivenandstressvaluesfortheinputconditionsareshowninfig.10.Stress
analysisthroughANSYSalsoshowthatmaximumvalueofstressoccursatthevicinityofchangeincrosssectionoftheshaft
whereareliefgrooveispresent.

Fig.10.Stressdistributionatthefracturezoneformaximumloadedcondition
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5RESULTANDDISCUSSION
Byincreasingradiusofcurvature(RC)attheshaftshoulder[8],stressesoccurringthefracturezonecanbedecreasedeffectively.
Theeffectoffatiguestressconcentrationondifferentradiiiscalculatedusing[9]andshowninFig.11.Astheshoulderfillet
radiiisincreasedfrom0.6to2thefatiguefactorofsafetyincreasesfrom
0.71to1.05showninFig.12.Tofurtherincreasethefatiguesafetyfactortheshaftsupportscanberedesignedtoasimply
supportedbeam[8]fromoverhungbeam.Thevariationofequivalentvaluesofstresswithangleofrotationoftheshaftfor
simplysupportedbeamisshownFig.13.Itwasobservedthatthefatiguefactorofsafetyof
2.04wasobtainedafterdoingtheabovesaidmodificationsintheshaftconfiguration.

Fig.11.Variationoffatiguestressconcentrationwithshaftshoulderradii
Fig.12.Effectofshoulderradiiwithfatiguesafetyfactor

Fig.13.Fluctuationofequivalentstressformodifiedsupportposition

6CONCLUSION
Failureanalysisoftheshaftisinvestigatedindetail.Mechanicalpropertiesoftheshaftaredetermined.Aftervisual
investigationofthefracturesurfaceitisconcludedthatthefailureoccurredduetotorsionalbendingfatigue.Fatiguecrackhas
initiatedatthereliefgroove.Forcesandtorquesactingontheshaftaredeterminedstressoccurringatthefracturesurfaceare
calculated.Endurancelimitandfatiguesafetyfactoriscalculated,fatiguelifeofshaftisestimated.Fractureoftheshaft
occurredduetofaultydesign,causingahighnotcheffect.Inconclusioneffectofchangeinradiusofcurvatureonstress
intensity,effectiveplacementsofsupportsandprecautionswhichhavetobetakentopreventasimilarfailureisclarified.

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