CHAPTER 1

Shaft DESIGN
Dejene (M.Sc.)

EIT-M
School of mechanical and industrial Engineering

Slide 1
Introduction

Shaft is used to transmits rotational motion and power.

Shaft is integral to any mechanical system in which power is

transmitted from a prime mover, such as an electric motor or an
engine, to other rotating parts of the system.

Some mechanical systems incorporating rotating elements that

transmit power are: gear-type speed reducers, belt or chain drives,
conveyors, pumps, fans, agitators, and many types of automation
equipment.
Slide 2
 Types of shafts
• Some common shaft arrangements are:

• Too much deflection can for example degrade gear performance, and cause noise and vibration.
• The maximum allowable deflection of a shaft is usually determined by:
o limitations set on the critical speed,
o minimum deflections required for gear operation and
o bearing requirements.

Slide 3
 Types of shafts
• Example

In designing shafts on the basis of strength,

cases considered are:
 Shafts subjected to twisting moment or torque
• The shafts may be designed on the only,
 Shafts subjected to bending moment only,
basis of:  Shafts subjected to combined twisting and
1. Strength bending moments, and
2. Fluctuating loads, and  Shafts subjected to axial loads in addition to
3. Rigidity and stiffness combined torsional and bending loads.

Slide 4
 General Considerations for Shaft Design
Material selection
 Geometric layout
Stress and strength
• Static strength
• Fatigue strength
Deflection and rigidity
• Bending deflection
• Torsional deflection
• Slope at bearings and shaft-supported elements
• Shear deflection due to transverse loading of short
shafts
Vibration due to natural frequency

Dejene (M.Sc.) Slide 5

Shaft Materials
 Necessary strength to resist loading stresses affects the choice of
materials and their treatments.
 Many shafts are made from low carbon, cold-drawn or hot-rolled
steel, such as ANSI 1020-1050 steels.
 A good practice is to 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.

Slide 6
 Shaft Layout and Geometric Configuration

Figure
(a) Choose a shaft configuration to
support and locate the two gears
and two bearings.
(b) Solution uses an integral pinion,
three shaft shoulders, key and
keyway, and sleeve. The housing
locates the bearings on their
outer rings and receives the
thrust loads.
(c) Choose fan shaft configuration.
(d) Solution uses sleeve bearings, a
straight-through shaft, locating
collars, and setscrews for collars,
fan pulley, and fan itself. The fan
housing supports the sleeve
bearings.

Slide 7
 Strength Constraints
The design of a shaft involves the study of

1) Stress and strength analyses: Static and Fatigue considerations.

2) Deflection and rigidity

3) Critical Speed

Therefore, the design of transmission shaft consists of determining the correct

shaft diameter from strength and rigidity considerations.

Slide 8
 Static Loading on Shaft
 A static load is a stationary force
or couple applied to a member.
 To be stationary, the force or
couple must be unchanging in
magnitude, point or points of
application, and direction.
 A static load can produce axial
tension or compression, a shear
load, a bending load, a torsional
load, or any combination of
these.

Slide 9
 Static Loading on Shaft
The stress at an element located on the surface of a solid round shaft of diameter d
subjected to bending, axial loading, and twisting is

32 𝑀 4 𝐹
Normal stress 𝜎 𝑥 = 3
+ 2
𝜋𝑑 𝜋𝑑

16 𝑇
Shear stress 𝜏 𝑥𝑦 = 3
𝜋𝑑

) [( ]
1

( )
2
Non-zero principal
𝜎 𝑥 +𝜎 𝑦 𝜎𝑥− 𝜎𝑦 2 2
𝜎 𝐴 , 𝜎 𝐵= ± +𝜏 𝑥𝑦
stresses 2 2

Slide 10
Static Loading on Shaft

2 1/2 2 1/2
𝜎′ = [ 𝜎 𝐴 −𝜎 𝐴 𝜎 𝐵+𝜎 𝐵 ] =[ 𝜎 𝑥 +3𝜏 𝑥𝑦 ]
❑ 2 2
Von Mises Stress

Maximum Shear
Stress Theory

𝜎 1
+ √𝜎 +4 𝜏
2 2
𝜎 max =
Maximum 2 2

√((
Normal
( ) ) ( ))
2 2
1 32 𝑀 1 32 𝑀 16 𝑇
Stress ¿= + +4
2 𝜋 𝑑3 2 𝜋𝑑
3
𝜋𝑑
3
Theory
¿
Slide 11
 Static Loading on Shaft

Under many conditions, the axial force F in the eqs. is either zero or so small that its
effect may be neglected. With F = 0, the Eqs. become

Von Mises stress

where is equivalent torque

Slide 12
Static Loading on Shaft
Maximum Shear Stress Theory

but

Slide 13
 Static Loading on Shaft
Maximum Normal Stress Theory

But

Where is equivalent bending moment

Slide 14
 Static Loading on Shaft
Substitution of the allowable stresses

[ ]
1/3
16𝑛 2 2 1/2
Von Mises stress
❑
𝑑= ( 4 𝑀 +3𝑇 )
𝜋 𝑆𝑦

[ ]
1/3
32𝑛 2 2 1/2
Maximum Normal Stress
𝑑= ( 𝑀 +𝑇 )
Theory
𝜋 𝑆𝑦
[ ]
1
1 64 𝑀 1
Maximum Shear Stress
= 3 + √ 𝑀 +𝑇
2 2 2
Theory 𝑛 𝜋 𝑑 𝑆𝑦 2 2
Slide 15
 Fatigue Strength
In shafts subjected to fluctuating loads, while designing the combined
shock and fatigue factors must be taken in to account. Thus for a shaft
subjected to fluctuating loads;

Equivalent torque:
√ 2
𝑇 𝑒= ( 𝐾 𝑚 𝑀 ) + ( 𝐾 𝑡 𝑇 )
2

Equivalent bending moment

Where: Km = Combined shock and fatigue factor for bending
and Kt = Combined shock and fatigue factor for torsion

1
[ √ 2
𝑀 𝑒= 𝐾 𝑚 𝑀 + ( 𝐾 𝑚 𝑀 ) + ( 𝐾 𝑡 𝑇 )
2
2
] Slide 16
 Table : Combined Shock and Fatigue Factor
• The recommended values of Km and Kt for different
working condition of a shaft are listed below.
Nature of loading Km Kt
Stationary shafts
Gradually applied
1.0 1.0
load
Suddenly applied load 1.5 to 2 1.5 to 2
Rotating shafts
Steady or gradually applied load 1.5 1.0
Steady applied loads, minor shock
1.5 to 2 1.0 to 1.5
only
Steady applied loads, heavy shocks 2.0 to 3.0 1.5 to 3.0

Dejene (M.Sc.) Slide 17

 Column Factor
The above relation holds true only for the case of shorter shafts.
For longer shafts:

𝛼4𝐹
For solid shafts 𝜎 𝑐= 2
𝜋𝑑
𝛼4𝐹
For hollow shafts 𝜎 𝑐=
𝜋 𝑑 1 −𝑘 )
(
2 2
𝑜
The expression (column factor) can be calculated from the empirical relation
given in the next slide.

Slide 18
Column Factor

Where: l – Shaft length between supports

K – Least radius of gyration
E – Modulus of elasticity
- Compressive yield point stress of shaft material
C – Coefficient of Euler = 1 for hinged (movable) ends
= 2.25 for fixed ends
= 1.6 for bearing supported ends
Slide 19
 Tip as a summery

General equations that consists all cases; for fluctuating torsional and bending
load with the addition of axial load for hollow shaft:

For ductile material

√[ ]
2 2
𝛼 𝐹 𝑑 𝑜 (1+ 𝑘 )
𝑇 𝑒= 𝐾𝑚 𝑀 + +¿ ¿
8

For Brittle material

[ √( ) ]
2 2 2
1 𝛼 𝐹 𝑑 𝑜 (1+𝑘 ) 𝛼 𝐹 𝑑 𝑜 (1+𝑘 ) 2
𝑀 𝑒= 𝐾 𝑚 𝑀 + + 𝐾 𝑚 𝑀+ +( 𝐾 𝑡 𝑇 )
2 8 8

Slide 20
Fatigue Analysis of Shafts
The Other Method

Slide 21
 Fatigue Strength
 Bending, torsion, and axial stresses may be present in
both midrange and alternating components.
 For analysis, it is simple enough to combine the
different types of stresses into alternating and
midrange von Mises stresses
 It is sometimes convenient to customize the equations
specifically for shaft applications.
 Axial loads are usually comparatively very small at
critical locations where bending and torsion dominate,
so they will be left out of the following equations.

Slide 22
 Fatigue Strength
 The fluctuating stresses due to bending and torsion are given by

where Mm and Ma are the midrange and alternating bending moments, Tm and Ta are
the midrange and alternating torques, and Kf and Kfs are the fatigue stress concentration
factors for bending and torsion, respectively.

Slide 23
 Fatigue Strength
Assuming a solid shaft with round cross section, appropriate geometry terms can
be introduced for c, I, and J resulting in:

Slide 24
 Fatigue Strength
Combining these stresses in accordance with the energy failure theory, the von
Mises stress distortions for rotating round, solid shafts, neglecting axial loads, are
given by:

Slide 25
 Fatigue Strength
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:

Slide 26
 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 𝑴 𝒂 ❑ 𝟑𝟐 𝑴 𝒎
𝝈 =𝑲 𝒇
𝒂 𝝈 𝒎 =𝑲 𝒇
𝑰 𝑰
Mm: Midrange bending moment, σm: Midrange bending stress
Ma : alternating bending moment, σa: alternating bending stress
Tm: Midrange torque, τm: Midrange shear stress
Ta : alternating torque, τm: Midrange shear stress
Kf: fatigue stress concentration factor for bending
Kfs: fatigue stress concentration factor for torsion
Slide 27
 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:

2 1/ 2
𝜎 ′ 𝑎 =[ 𝜎
❑
𝑥𝑎
2
+3 𝜏 𝑥𝑦 𝑎 ] =16 / 𝜋 𝑑 ¿ ¿ 3

where A and B are defined by the radicals in Eq. as

𝐴= ¿ ¿
The Gerber fatigue failure criterion

+
𝑆𝑒 𝑆𝑢𝑡( )
𝑆𝑎 𝑆𝑚 2 𝑛 𝜎 ′ 𝑎 𝑛𝜎 ′ 𝑚 2 16 𝑛𝐴
=
𝑆𝑒
+
𝑆𝑢𝑡
= 3( )
+
16 𝑛𝐵 2
3
𝜋 𝑑 𝑆𝑒 𝜋 𝑑 𝑆𝑢𝑡
=1
( )
Slide 28
 Fatigue Analysis of shafts
The critical shaft diameter is given by:
or, solving for 1/n, the factor of safety is given by:

{[ )] }
1 /3
2 1/ 2

𝑑=
8 𝑛𝐴
𝜋 𝑆𝑒
1+ 1+
2 𝐵 𝑆𝑒
𝐴 𝑆𝑢𝑡 ( 1
=
8𝐴
𝑛 𝜋 𝑑 𝑆𝑒
3
1 + 1+
2 𝐵 𝑆𝑒
𝐴𝑆 𝑢𝑡 {[ ( )]
2 1 /2

}
where

𝐴= √ 4¿¿ Slide 29
 Fatigue Analysis of shafts
Particular Case
❑
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 = 0 and Ta = 0,
𝐴 =2𝐾 𝑓 𝑀 𝑎
which simply drops out some of the terms.

{[ )] }
1/3
2 1/ 2
Critical Shaft
Diameter
𝑑=
16𝑛 𝐾 𝑓 𝑀 𝑎
𝜋 𝑆𝑒
1 + 1 +3
(
𝐾 𝑓𝑠 𝑇 𝑚 𝑆 𝑒
𝐾 𝑓 𝑀 𝑎 𝑆𝑢𝑡

{[( )] }
2 1/ 2
1 16 𝐾 𝑓 𝑀 𝑎 𝐾 𝑓𝑠 𝑇 𝑚 𝑆𝑒
Safety Factor = 1+ 1+
𝑛 𝜋 𝑑 𝑆𝑒
3
𝐾 𝑓 𝑀 𝑎 𝑆𝑢𝑡

Slide 30
 Shaft Diameter Equation for the DE-Elliptic
Criterion
Remember

2 1/ 2
𝜎 ′ 𝑎 =[ 𝜎❑
𝑥𝑎
2
+3 𝜏 𝑥𝑦 𝑎 ] 3
=16 / 𝜋 𝑑 ¿ ¿
where A and B are defined by:

𝐴= ¿ ¿
The Elliptic fatigue-failure criterion is defined by:

( )( ) ( )( )(
2 2 2 2

)( )
𝑆𝑎 𝑆𝑚 𝑛 𝜎 ′𝑎 𝑛𝜎 ′ 𝑚 16 𝑛𝐴
2
16 𝑛𝐵
2
+ = + = + =1
𝑆𝑒 𝑆𝑦 𝑆𝑒 𝑆𝑦 3
𝜋 𝑑 𝑆𝑒
3
𝜋 𝑑 𝑆𝑦

Slide 31
 Shaft Diameter Equation for the DE-Elliptic
Criterion
Substituting for A and B gives expressions for d, 1/n and r:
Critical Shaft Diameter

{ [() ( ) ( ) ( )] }
1/3
2 2 2 2 1/2
16𝑛 𝐾 𝑓 𝑀 𝑎 𝐾 𝑓𝑠 𝑇 𝑎 𝐾 𝑓 𝑀𝑚 𝐾 𝑓𝑠 𝑇 𝑚
𝑑= 4 +3 +4 +3
𝜋 𝑆𝑒 𝑆𝑒 𝑆𝑦 𝑆𝑦
Safety Factor

[ ( ) ( ) ( ) ( )]
2 2 2 2 1/2
1 16 𝐾 𝑓 𝑀𝑎 𝐾 𝑓𝑠 𝑇 𝑎 𝐾 𝑓 𝑀𝑚 𝐾 𝑓𝑠 𝑇 𝑚
= 3 4 +3 +4 +3
𝑛 𝜋𝑑 𝑆𝑒 𝑆𝑒 𝑆𝑦 𝑆𝑦

√
2 2
𝜎 ′𝑎 𝐴 4 ( 𝐾 𝑓 𝑀 𝑎 ) +3 ( 𝐾 𝑓𝑠 𝑇 𝑎)
𝑟= = =
𝜎 ′𝑚 𝐵 4 ( 𝐾 𝑓 𝑀 𝑚 )2 +3 ( 𝐾 𝑓𝑠 𝑇 𝑚 )2 Slide 32
 Shaft Diameter Equation for the DE-Elliptic 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.

Slide 33
For the Gerber-Langer intersection the strength components Sa and Sm are given:

Slide 34
For the DE-Elliptic-Langer intersection the strength components Sa and Sm
are given by:

Slide 35
 Shaft Diameter Equation for the DE-Elliptic Criterion
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.

Slide 36
Shaft Diameter Equation for the DE-Elliptic Criterion

Slide 37
 Shaft Diameter Equation for the DE-Elliptic Criterion

 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 σ’max can be obtained by simply

adding σa and σm . (σa + σm ) will always be greater than or equal to σ’max, and will
therefore be conservative.

CH-18 LEC 30 Slide 38 Slide 38

Slide 39
 Shaft Design Based on Rigidity

In cases of precision machine tools and heavy duty equipment,

design for strength (i.e. for torsion and bending stresses) may
not be satisfactory.

Rigidity becomes vital for the life of the designed shaft and the
precision of the work piece to be processed on the designed
shaft.

Rigidity is of two types generally; torsional and lateral of which

torsional is very sensitive.

Slide 40
 Shaft design based on rigidity
Rigidity of the shaft is also a major concern for several reasons:

1. Excessive radial deflection of the shaft may cause active elements to become misaligned, resulting in poor performance or accelerated wear.

2. The recommended limits for bending and torsional deflection of a shaft according to its intended precision.

3. Shaft deflection is also an important contributor to a tendency for shafts to vibrate as they rotate.

• A flexible shaft will oscillate in both bending and torsional modes, causing movements that are greater than the static deflections due just to gravity and

applied loads and torques.

4. The shaft itself and the elements mounted on it should be balanced.

• Any amount of unbalance causes centrifugal forces to be created that rotate with the shaft.

• Large unbalances and high rotating speeds may create unacceptable force levels and shaking of the rotating system.

5. The dynamic behavior of the shaft may become dangerously destructive if it is operated near its critical speed.

• At critical speed, the system is in resonance, the deflection of the shaft continues to increase virtually without bound, and it will eventually self-destruct.

Slide 41
 Shaft design based on rigidity
• Critical speed: natural frequency (Ꙍn) of the shaft while carrying the static weight of
elements such as gears, sprockets, and pulleys.

where k is the stiffness of the shaft and m is its mass.

• It is desirable to have a high critical speed, well above operating speed, so stiffness
should be high and mass low.
• The primary variables over which a designer has control are the material and its modulus
of elasticity, E, its density, ρ, the shaft diameter, D, and the shaft length, L.

where the symbol ∝ indicates proportionality among the variables.

• It is desirable to reduce the deflection of the shaft to produce a high critical speed.
Slide 42
Shaft design based on rigidity
Other options are:
1. Making the shaft more rigid can prevent undesirable dynamic behavior
2. Larger shaft diameters add rigidity
3. Shorter shaft lengths reduce deflections and raise critical speeds.
4. Placing active elements on the shaft close to support bearings is
recommended.
5. Reducing the weight of elements carried by the shaft reduces static deflection
and raises critical speed.
6. Selection of a material for the shaft with a high ratio of E/ρ (modulus of
elasticity/density) is desirable.
7. Bearings should have a high stiffness in terms of radial deflection as a function
of load.
8. Mountings for bearings and housings should be designed with high rigidity.

Slide 43
 Shaft Design Based on Rigidity
From torsion equation: 𝑇 𝐺 𝜃⇒ 𝜃= 𝑇𝑙 and J=
= 𝐽𝐺
𝐽 𝑙
For solid shafts; 𝑇𝑙 32𝑇𝐿
𝜃= 4 = 4 Where, J – polar moment of area
G – modulus of rigidity
𝜋 𝑑 𝜋 𝐺𝑑 – angle of twist
𝐺
32
For hollow shafts;
𝑇𝑙 32𝑇𝐿
𝜃= = 4 4
𝜋𝐺 4 4 𝜋𝐺𝑑𝑜 (1−𝑘 ) And di = k x do
𝑑𝑜 (1−𝑘 )
32
Slide 44
 Checking for critical speed

While rotating, a shaft is encountered for certain amount

of vibration frequency. This frequency (in rpm) should be
considerably above or below the operating rpm of the
shaft.

𝑓 𝑐=
1
2𝜋
𝑔
√
𝑊 1 𝑦 1 +𝑊 2 𝑦 2+..............𝑊 𝑛 𝑦 𝑛
2 2
𝑊 1 𝑦 1 +𝑊 2 𝑦 2+...........𝑊 𝑛 𝑦 𝑛
 N c  60 f
2

Accordingly; Nc > > N OR Nc < < N

Slide 45
The end!

Slide 46