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Definitions
A shaft is a rotating member, usually of circular cross section, used to transmit power or motion. It provides the axis of rotation, or oscillation, of elements such as gears, pulleys, flywheels, cranks, sprockets, and the like and controls the geometry of their motion.
Shaft Sizing
Stress Analysis
In design it is usually possible to locate the critical areas, size these to meet the strength requirements, and then size the rest of the shaft to meet the requirements of the shaft-supported elements.
Shaft Materials
Deflection is not affected by strength, but rather by stiffness as represented by the modulus of elasticity, which is essentially constant for all steels. For that reason, rigidity cannot be controlled by material decisions, but only by geometric decisions. Modulus of Elasticity
For most steels 200 GPa
Shaft Materials
A good practice for material selection:
Start with an inexpensive, low or medium carbon steel for the first time through the design calculations. If strength considerations turn out to dominate over deflection, then a higher strength material should be tried, allowing the shaft sizes to be reduced until excess deflection becomes an issue. The cost of the material and its processing must be weighed against the need for smaller shaft diameters.
Manufacturing of Shafts
For low production, turning is the usual primary shaping process. An economic viewpoint may require removing the least material. High production may permit a volume conservative shaping method (hot or cold forming, casting), and minimum material in the shaft can become a design goal.
Shaft Layout
Shaft, Bearings, Gears, Shoulder
Movie
4:18
Shaft Layout
In most cases, Only two bearings should be used in most cases. Load bearing components should be placed next to the bearings to minimize the bending due to large forces. Shafts should be kept short to minimize bending and deflection.
Shaft layout
Shoulder
It allows precise positioning Support to minimize deflection. In cases where the loads are small, positioning is not very important, shoulders can be eliminated.
Keyway
Spline
Spline Shaft
Flange
Torque
Torque causes shear stress. Shear due to torque is max at the outer surface
Bending Moment
Bending stress is determined from shear force and bending moment diagrams. In most cases forces on the shaft exist in two planes. As a result, moments are added as vectors.
Shaft Stresses
The fluctuating stresses are:
Shaft Stresses
According to Von Mises:
Factor of Safety
Modified Goodman
Goodman
Gerber
ASME Elliptic
Soderberg
Example
Notch sensitivity
Grooves
By examining typical retaining ring specifications in vendor catalogs, it can be seen that the groove width is typically slightly greater than the groove depth, and the radius at the bottom of the groove is around 1/10 of the groove width. From Figs. A1516 and A1517, stress concentration factors for typical retaining ring dimensions are around 5 for bending and axial, and 3 for torsion. Fortunately, the small radius will often lead to a smaller notch sensitivity, reducing Kf .
Deflection Consideration
Allowable deflections will depend on many factors, and bearing and gear catalogs should be used for guidance on allowable misalignment for specific bearings and gears.
Deflection Consideration