Shafts 285

5 List the factors that affect the fatigue strength of a shaft. If a shaft does not have
sufficient fatigue strength, what measures can be taken to satisfy the strength
requirement?

Objective Questions
1 When a shaft carries combined bending and torsional stresses, a factor 𝛼 is intro-
duced in the stress calculation because ___________.
(a) a deviation exists between theoretical and experimental results
(b) the torsional shear stress maybe not a completely reversed stress
(c) the bending stress maybe not a completely reversed stress
(d) the shaft has stress concentration

2 The purpose of increase a fillet radius in shoulder design is ___________.

(a) to ensure a reliable circumferential location
(b) to ensure a reliable axial location
(c) to facilitate manufacture
(d) to reduce stress concentration and to improve fatigue strength of shaft

3 Which of the following could not effectively improve the rigidity of a shaft?
_________
(a) Use high-strength alloy steels.
(b) Change the structure of shaft.
(c) Change the diameter of shaft.
(d) Change the bearing position of shaft.

4 In Figure P10.1, the width of the element installed on the shaft is B. The length of the
mating shaft segment is L. In order to locate the element axially on the shaft securely,
the relationship between B and L should be___________
(a) B < L
(b) B = L
(c) B > L
(d) there is no relationship between B and L

Figure P10.1 Illustration for Objective Question 4.

286 Analysis and Design of Machine Elements

Calculation Questions
1 The total weight of a railway freight car and the goods it carries is G = 800 kN. The
carriage is supported by eight wheels installed on four axles and the load acting on
each axle is shown in Figure P10.2. The distance between the loading point and rail
centre line is s = 220 mm. Select a load factor of K A = 1.2. The axle is made from
tempered medium-carbon steel, with an allowable stress of [𝜎 −1b ] = 75 MPa. Decide
the diameter of the axle at wheel installation.
Figure P10.2 Illustration for Calculation
Question 1.

2 A machined shaft shoulder is shown in Figure P10.3. The small diameter d is 60 mm,
the large diameter D is 72 mm and the fillet is r = 6 mm. The shoulder carries a bend-
ing moment of 103 000 N mm and a steady torsion moment of 741 000 N mm. The
heat-treated carbon steel shaft has an ultimate strength of 𝜎 b = 600 MPa, endurance
limit in tension 𝜎 −1 = 275 MPa and in shear 𝜏 −1 = 155 MPa, respectively. Determine
the fatigue safety factor of the shaft.

Figure P10.3 Illustration for Calculation Question 2.

3 The shaft in Figure P10.4 is driven by a driver B at a speed of n = 300 r min−1 . The
input power is PB = 10 kW. The output power from the driven gears are PA = 6 kW,
PC = 4 kW, respectively. The allowable shear stress of the shaft is [𝜏] = 40 MPa and
the allowable unit length angular deflection is [𝜑] =1∘ m−1 . The shear modulus of the
shaft is G = 8 × 104 MPa. Decide the shaft diameter by strength and rigidity analysis,
respectively.
Figure P10.4 Illustration for Calculation
Question 3.
 Shafts 287

4 A shaft with a diameter of 60 mm rotates at 1250 rpm. Three discs are mounted
on the shaft, with weight of w1 = 10 N, w2 = 25 N and w3 = 7 N, respectively, as
shown in Figure P10.5. The deflection at the corresponding mounting locations are
y1 = 0.305 mm, y2 = 0.457 mm and y3 = 0.178 mm, respectively. Estimate the funda-
mental critical speed and comment on its acceptability.

y1 y3
y2

w1 w3
w2
150 350 300 100

Figure P10.5 Illustration for Calculation Question 4.

Design Problems
1 Design the output shaft in the gear reducer in Figure P10.6. The rotational speed of
the shaft is 80 rpm. The power transmitted by the shaft is P = 3.15 kW. The parame-
ters of the gear are: mn = 3 mm, helix angle 𝛽 = 12∘ , the number of teeth z = 94 and
the face width b = 72 mm.

Figure P10.6 Illustration for Design

Problem 1.

2 A spur pinion and a helical gear is mounted on a shaft carried by two bearings
in Figure P10.7. The radial loads on both gears are in the same plane and are
3000 N for the spur pinion and 1000 N for the helical gear. A thrust load of 500 N
on the helical gear is carried by the right bearing. The shaft rotates at a speed of
1000 rpm. Design the shaft. Draw a sketch to scale of the shaft showing all proposed
dimensions.
288 Analysis and Design of Machine Elements

Figure P10.7 Illustration for Design Problem 2.

3 In a double-reduction gear reducer in Figure P10.8, the input shaft is driven by a

motor through a belt drive, transmitting a power of 25 kW at a speed of 750 rpm.
Gears in the reducer have parameters as z1 = 21, z2 = 77, mn1 = 3 mm, 𝛽 1 = 11.478∘
and face width b2 = 80 mm; z3 = 23, z4 = 74, mn3 = 4 mm, 𝛽 3 = 14.07∘ and face width
b4 = 120 mm. Design the countershaft with an application factor of 1.5 by performing
the following tasks:
(1) Propose a shaft layout, including means to locate the gears and bearings;
(2) Perform a force analysis and generate shear and bending moment diagrams;
(3) Determine the fatigue and static strength at the critical locations of the shaft;
(4) Specify diameters and length of each segment of the shaft, sketch the shaft to scale
showing all fillet sizes, keyways, shoulders, diameters and so on;
(5) Check the deflection at the gear, and the slopes at the gear and the bearings;
(6) Make appropriate changes if either stresses or deflections exceed recommended
limits.

Figure P10.8 Illustration for Design Problem 3.

 Shafts 289

Structure Design Problems

1 Find the errors in the design in Figure P10.9 and correct them.

Figure P10.9 Illustration for Structure Design Problem 1.

2 Please mark the errors in Figure P10.10 and correct them.

Figure P10.10 Illustration for Structure Design Problem 2.

3 A spur gear is mounted on a shaft that is supported by a pair of deep groove ball
bearings. Each bearing retains one directional movement. The gear is lubricated by
lubricant oil and bearings by grease. Complete the design of the shaft system.