Dr. A. Aziz Bazoune: Mechanical Engineering Department

Dr. A.
Aziz Bazoune Chapter 18: Axles and Shafts

ME 307
Machine
Design I
Dr. A. Aziz Bazoune

King Fahd University of Petroleum & Minerals
Mechanical Engineering Department
CH-18 LEC 30 Slide 1
Dr. A. Aziz Bazoune Chapter 18: Axles and Shafts
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

ME 307
Machine
Design I
18-1 Introduction .922
18-2 Geometric Constraints .927
18-3 Strength Constraints .933

ME 307
Machine
Design I
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
Fatigue Analysis of shafts
a m
a f m f
a m
a fs m fs
M C M C
K K
I I
T C T C
K K
J J
o o
t t
= =
= =
M
m
: Midrange bending moment,
m
: Midrange bending stress
M
a
: alternating bending moment,
a
: alternating bending stress
T
m
: Midrange torque,
m
: Midrange shear stress
T
a
: alternating torque,
m
K
f
: fatigue stress concentration factor for bending
K
fs
: fatigue stress concentration factor for torsion
ME 307
Machine
Design I
For solid shaft with round cross section, appropriate geometry terms can be
introduced for C, I and J resulting in
32 32
16 16
a m
a f m f
a m
a fs m fs
M M
K K
I I
T T
K K
J J
o o
t t
= =
= =
M
m
: Midrange bending moment,
m
: Midrange bending stress
M
a
: alternating bending moment,
a
: alternating bending stress
T
m
: Midrange torque,
m
T
a
: alternating torque,
m
K
f
: fatigue stress concentration factor for bending
K
fs
: fatigue stress concentration factor for torsion
ME 307
Machine
Design I
2 2 1/2 3 2 2 1/2 3
2 2 1/2 3 2 2 1/2 3
' 3 16/ 4( ) 3( ) 16 /
' 3 16/ 4( ) 3( ) 16 /
xya
xym
a
xa f a fs a
m
xm f m fs m
d K M K A T d
d K M K T d B
o o t t t
o o t t t
( (
= + = + =

( (
= + = + =

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
2 2 2
3 3
' ' 16 16
1
a m a m
e ut e ut e ut
S S n n nA nB
S S S S d S d S
o o
t t
| | | | | |
+ = + = + =
| | |
\ . \ . \ .
The Gerber fatigue failure criterion
(18-12)
where A and B are defined by the radicals in Eq. (8-12) as
2 2 1/2
2 2 1/2
4( ) 3( )
4( ) 3( )
f a fs a
f m fs m
A K M K T
B K M K T
(
= +

(
= +

ME 307
Machine
Design I
1/3
1/2
2
2 8
1 1
e
e ut
BS nA
d
S AS t

(
| |

(
= + +
` |
(
\ .

)
(18-13)
The critical shaft diameter is given by
or, solving for 1/n, the factor of safety is given by
1/2
2
3
2 1 8
1 1
e
e ut
BS A
n d S AS t

(
| |

(
= + +
` |
(
\ .

)
(18-14)
ME 307
Machine
Design I
(18-15)
where
2 2
2 2
4( ) 3( )
4( ) 3( )
'
'
f a fs a
f m fs m
a
m
A K M K T
B K M K T
A
r
B
o
o
= +
= +
= =
ME 307
Machine
Design I
2
3
f a
fs m
A K M
B K T
=
=
Particular Case
Critical Shaft
Diameter
1/3
1/2
2
16
1 1 3
f a fs m e
e f a ut
nK M K T S
d
S K M S t

(
| |

(
= + +
|
`
|
(

\ .

)
(18-16)
Safety Factor
1/2
2
3
16
1
1 1
f a fs m e
e f a ut
K M K T S
n d S K M S t

(
| |

(
= + +
|
`
|
(
\ .

)
(18-17)
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 M
m

= 0 and T
a
= 0, which simply drops out some of the terms.
ME 307
Machine
Design I
2
'
'
3
f a
a
m
fs m
K M
r
K T
o
o
= =
(18-18)
ME 307
Machine
Design I
Shaft Diameter Equation for the DE-Elliptic
Criterion
2 2 1/2 3 2 2 1/2 3
2 2 1/2 3 2 2 1/2 3
' 3 16/ 4( ) 3( ) 16 /
' 3 16/ 4( ) 3( ) 16 /
xya
xym
a
xa f a fs a
m
xm f m fs m
d K M K A T d
d K M K T d B
o o t t t
o o t t t
( (
= + = + =

( (
= + = + =

Remember
2 2 2
2 2 2
3 3
' ' 16 16
1
a m a m
e y e y e y
S S n n nA nB
S S S S d S d S
o o
t t
| | | | | |
| | | | | |
+ = + = + =
| | |
| | |
| | |
\ . \ . \ .
\ . \ . \ .
The Elliptic fatigue-failure criterion is defined by
(18-12)
where A and B are defined by
2 2 1/2
2 2 1/2
4( ) 3( )
4( ) 3( )
f a fs a
f m fs m
A K M K T
B K M K T
(
= +

(
= +

ME 307
Machine
Design I
Criterion
Substituting for A and B gives expressions for d, 1/n and r:
(18-19)
Critical Shaft Diameter
1/3
1
2
2 2
2
/2
4 3 3
16
4
f m fs f a fs a
e e
m
y y
K M K T
S S
K M
S
n
K T
S
d
t
| | | |
+
| |

(

(
| | | |
+
| |
\ .
| |
\ . \ .
= +
`
(

)
\ .
Safety Factor
2
/2
2 2
1
2
3
4
6
4 3 3
1 1
f m fs m
y
a
e y
f fs a
e
K M K T
S S
K M K T
d S S n t
|
| | | |
+
| |
| |
\ . \ .
(
(
= +
| | |
+
| |
\ . \
(

.
(18-20)
ME 307
Machine
Design I
Criterion
( ) ( )
( ) ( )
2 2
2 2
4 3
'
'
4 3
f a fs a
a
m
f m fs m
K M K T
A
r
B
K M K T
o
o
+
= = =
+
ME 307
Machine
Design I
Criterion
2
3
f a
fs m
A K M
B K T
=
=
Particular Case
Critical Shaft Diameter (18-21)
Safety Factor
(18-22)
1/3
1/2
2
2
4
6
3
1
f a f
y e
s m
K T
n
d
K M
S S t
| |
| |
|
\ .

(

(
= +
`
|
|
\ .
(

)
1
2
/2
3
2
16
4
1
3
fs m
y
f a
e
K M
S n
T
d
K
S t
|
| |
(
(
= +
(

|
|
|
.
.
\
\
|
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 M
m
= 0 and T
a
= 0, which simply drops out
some of the terms.
ME 307
Machine
Design I
Criterion
( )
( )
2
2
4
2
'
'
3
3
f a
f a
a
m
fs m
fs m
K M
K M
A
r
B
K T
K T
o
o
= = = =
At a shoulder Figs. A-15-8 and A-15-9 provide information about K
t
and
K
ts
.
For a hole in a solid shaft, Figs. A-15-10 and A-15-11 provide about K
t
and
K
ts
.
For a hole in a solid shaft, use Table A-16
For grooves use Figs. A-15-14 and A-15-15
ME 307
Machine
Design I
Criterion
The value of slope at which the load line intersects the junction of
the failure curves is designated r
crit
.
It tells whether the threat is from fatigue or first cycle yielding
If r > r
crit
, the threat is from fatigue
If r < r
crit
, the threat is from first cycle yielding.
ME 307
Machine
Design I
Criterion
For the Gerber-Langer intersection the strength components S
a
and
S
m
are given in Table 7-10 as
2
2
2
1 1 1
2
1
y
ut e
m
e ut e
a y m
y m y
a
crit
m m m
S
S S
S
S S S
S S S
S S S
S
r
S S S
(
| | | |
(
= +
| |
(
\ . \ .

=
= = =
(18-23)
ME 307
Machine
Design I
Criterion
For the DE-Elliptic-Langer intersection the strength components S
a

and S
m
are given by
2
2 2
2
y e
a
e y
m y a
a a
crit
m y a
S S
S
S S
S S S
S S
r
S S S
=
+
=
= =
(18-24)
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.
ME 307
Machine
Design I
ME 307
Machine
Design I
ME 307
Machine
Design I
In a design situation, however, having the equations pre-solved for
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.
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.
ME 307
Machine
Design I
ME 307
Machine
Design I
Example
Solution
7-
20
7-
20
ME 307
Machine
Design I
Figure 7-20
Figure 7-21
ME 307
Machine
Design I
CH-18 LEC 30 Slide 27 CH-18 LEC 30 Slide 27
ME 307
Machine
Design I
18-
22
18-
14
18-
24
Sold
erbe
rg
ME 307
Machine
Design I
ME 307
Machine
Design I
CH-18 LEC 30 Slide 30 CH-18 LEC 30 Slide 30
ME 307
Machine
Design I
ME 307
Machine
Design I
ME 307
Machine
Design I
ME 307
Machine
Design I
ME 307
Machine
Design I
ME 307
Machine
Design I

Dr. A. Aziz Bazoune: Mechanical Engineering Department

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Dr. A.

Aziz Bazoune Chapter 18: Axles and Shafts

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