shaft design flow chart
DESCRIPTION
NotesTRANSCRIPT
ME2 Design & Manufacture
Shaft Design
Shafts
PLAIN TRANSMISSION
STEPPED SHAFT
MACHINE TOOL SPINDLE
RAILWAY ROTATING AXLE
NON-ROTATING TRUCK AXLE
CRANKSHAFT
CIRCLIPS
GEAR PULLEY
KEY
KEY
SHAFT HUBHUB
FRAME
WOODRUFF
PROFILED
P. Childs, 2014, Mechanical Design Engineering Handbook
Chapter 7
TRANSVERSELOAD
LOADTRANSVERSE
TRANSVERSELOAD
TORSIONALLOAD
AXIALLOAD
LOADTORSIONAL
AXIALLOAD
TWISTDUE TO
TORSIONALLOAD
DEFLECTION DUE TOBENDING MOMENT
Shaft Design Procedure Flow Chart for Shaft Strength & Rigidity (Beswarick 1994)
DETERMINEEXTERNAL LOADS
CHOOSE PRELIMINARYSHAFT DIMENSIONS
IDENTIFY CRITICALSHAFT SECTIONS
INTERNAL FORCESAND MOMENTS
COMBINEDSTRESSES
SET FACTOROF SAFETY
COMPARE FACTOREDSTRESSES WITH
MATERIAL STRENGTH
IS SHAFT SECTIONSATISFACTORY
SPECIFY SHAFT
TRANSVERSE FORCES,AXIAL FORCES ANDBENDING MOMENTS
DIRECT STRESS
CHOOSE MATERIAL
STRENGTH MODULUS
DEFLECTION
SHEAR FORCES ANDTWISTING MOMENTS
SHEAR STRESS
NO 1st OPTIONNO 2nd OPTION
YES
DETERMINE DETERMINEDETERMINE
DETERMINE
DETERMINE
DETERMINE
DETERMINE
DETERMINE
Determine External Loads
• Shaft rotational speed?
• Power or torque to be transmitted by the shaft?
• Belt / Chain tension?
• Gear & Pinion loading?
Choose (Preliminary) Shaft Dimensions
• Determine dimensions of components mounted on shaft
• Specify locations for each device
• Specify the locations of the bearings / support
• Propose a general form or scheme for geometry
• Size restrictions
• (Easily) available materials and/or components
Identify Critical Shaft Sections
Free Body Diagram:
• Determine magnitude of torques throughout shaft
• Determine forces exerted on shaft
Identify Critical Shaft Sections
• Where are the loads applied?
• Where are the dimensions smallest?
• Where are the stresses / deflections large?
• Stress-raisers?
– Slots, holes & keyholes
– Sharp corners
– Rough surfaces
Determine Internal Loads
Produce shearing force and bending
moment diagrams so that the
distribution of bending moments in
the shaft can be determined.
Shear and Moment Diagrams
𝑑2𝑦
𝑑𝑥2=𝑀
𝐸𝐼
𝑑𝑦
𝑑𝑥=
𝑀
𝐸𝐼𝑑𝑥 slope
𝑦 = 𝑀
𝐸𝐼𝑑𝑥 deflection
with: 𝑀 = 𝑉𝑑𝑥 and V = − 𝑞𝑑𝑥
M M+dM V V+dV
q
R
1V
R
R
1H
gm gR
2H
2V
Ft
Fr
1T
m gp
T2
Combining Normal Stresses
Vertically
Horizontally
1VR
A
L1
B L2
L
R2V
C
3
rF g+m g mpg
80
BEARING
120
GEAR
BEARING
DRIVEBELT
100
GEAR
1HR
A
21L B L
tF
3
R2H
L
C
T
Combining Normal Stresses
Vertical Bending Moments
Horizontal Bending Moments
1VR
A
L1
B L2
L
R2V
C
3
rF g+m g mpg
1HR
A
21L B L
tF
3
R2H
L
C
T
Vertically
Horizontally
A
5
B 3
C A
30
10
B C
Combining Normal Stresses
Vertical Bending Moments
Horizontal Bending Moments
21110522 .BM
13030322
.CM
Combined:
I
cM
A
5
B 3
C A
30
10
B C
A
30.1
11.2
B C
Normal stress & Shear stress
dx
dx
Normal Stress or Shear Stress?
Normal Stress or Shear Stress?
Shear stresses
• Shear stresses due to:
– Shear forces ( shear force diagram)
– Torque
• Power = Torque x Angular velocity
𝑃 = 𝑇 ∙𝑑𝜃
𝑑𝑡= 𝑇 ∙ 𝜔 = 𝑇 ∙ 2 ∙ 𝜋 ∙ 𝑓
• Shear stress: Torsion Formula 𝜏 =𝑇∙𝑟
𝐽
J: polar moment of inertia
r: radius
Mohr's Circle
Combining and visualising the normal and shear stress components
x
y
txy
txy
tx'y' x'
• Normal stresses σx & σy and
shear stress τ known.
• Average normal stress
𝜎𝑎𝑣𝑔 =𝜎𝑥 + 𝜎𝑦
2
• Actual combined stress
𝑅 =𝜎𝑥 + 𝜎𝑦
2
2
+ 𝜏𝑥𝑦2
Mohr's Circle
Combine and visualise the normal and shear stress components
• Normal stresses σx & σy and
shear stress τ are known.
• Average normal stress
𝜎𝑎𝑣𝑔 =𝜎𝑥 + 𝜎𝑦
2
• Actual combined stress
𝑅 =𝜎𝑥 + 𝜎𝑦
2
2
+ 𝜏𝑥𝑦2
• Principal stresses σ1 and σ2
t
avg
R
1 2
x y
txy
http://moodlepilot.imperial.ac.uk/pluginfile.php/12151/
mod_resource/content/1/out/index.html
Choose Material
• Maximum principal stresses
• Introduce safety factor
• Select a material to match design stress
– steel, low- or medium-carbon
– high quality alloy steel, usually heat treated (critical applications)
– brass, stainless steel (corrosive environments)
– aluminium (light weight)
– polyamide (Nylon®) or POM (Polyoxymethylene/Acetal, Delrin®)
small, light-duty shafts, electronics applications, food industry
eqyield n
Typical Safety Factors
1.25 to 1.5 reliable materials under controlled conditions subjected to
loads and stresses known with certainty
1.5 to 2
2 to 2.5
2.5 to 3
3 to 4 well-known materials
under uncertain conditions of load, stress and environment
untried materials
under mild conditions of load, stress and environment
Growing uncertainty
Fatigue - Correction Factors
with k < 1, and depending on:
• Surface
• Size
• Temperature
• Stress concentrations
• …
σe′ = k ∙ σe σe = 0.5 ∙ σuts
Shaft Design Procedure Flow Chart for Shaft Strength & Rigidity (Beswarick 1994)
• Analyse all the critical points on the shaft and
determine the minimum acceptable diameter
at each point to ensure safe design
• Determine the deflections of the shaft at critical
locations and estimate the critical frequencies
• Specify the final dimensions of the shaft
Critical Deflections for Efficiency & Performance
• Gears:
– deflection < 0.13 mm
– slope < 0.03°.
• Rolling element bearings:
– non self aligning - slope < 0.04°
– self aligning - slope < 2.5° - 3°
Shaft-Hub Connection
• Power transmitting components such as gears, pulleys and sprockets need to be mounted on shafts securely and located axially.
• In addition a method of transmitting torque between the shaft and the component is required.
• The hub of the component contacts with the shaft and can be attached to, or driven by the shaft by
– keys
– pins
– set screws
– press and shrink fits
– splines
– taper bushes
Shaft-Hub Connection after Hurst (1994)
Pin
Gru
b
scre
w
Cla
mp
Pre
ss fit
Shrink f
it
Splin
e
Key
Taper
Bush
High torque capacity x x x
Large axial loads x x x x
Axially compact x x x
Axial location provision x x
Easy hub replacement x x x
Fatigue x x x x
Accurate angular
positioning x x x x ()
Easy position
adjustment x x x x x
Example: What to do
when a shaft deflects too much
Choose the appropriate answer(s) from:
Use High Grade Steel, such as 30CrNiMo8
Increase the diameter of the shaft
Add bearings for extra support
Reduce the load bearing length of the shaft
Some general design considerations
IE
LF
3
3
Overhung layout
More robust layout
Ø=0.04 m
140 N 130 N 150 N
=0.15 m L 1
=0.08 m =0.14 m L 2
L 3
=0.07 m L 4
Example
Example
• As part of the preliminary design of a machine shaft, a check is to undertaken to determine the deflections
• The components on the shaft can be represented by three point masses.
• Assume the bearings are stiff and act as simple supports.
• The shaft diameter is 40 mm and the material is steel with a Young’s modulus of 200 GPa.
Example
=0.15 m
O
x
1 R
L 1
Ø=0.04 m
R 2
=0.08 m
140 N 130 N
=0.14 m L 2
1 W
L 3
2 W
150 N
=0.07 m L 4
3 W
Solution
Macaulay's Method
• Resolving vertical forces:
R1+R2=W1+W2+W3.
• Clockwise moments about O:
W1L1+W2(L1+L2)-R2(L1+L2+L3)+W3(L1+L2+L3+L4) =0
• Hence 321
43213212112
LLL
)L+L+L+(LW+)L+(LW+LWR
Solution cont.
• Calculating the moment at XX:
MXX = -R1x + W1[x-L1] + W2[x-(L1+L2)] - R2[x-(L1+L2+L3)]
• Relation between bending moment and deflection
• This equation can be integrated once to find
the slope θ = dy/dx
and twice to find the deflection y.
x
x
Mxx Vxx
Mdx
ydEI
2
2
Solution cont.
MXX = -R1x + W1[x-L1] + W2[x-(L1+L2)] - R2[x-(L1+L2+L3)]
x
x
Mxx Vxx
Mdx
ydEI
2
2
1
2
32122
2122
11
2
1 CLLLx2
RLLx
2
WLx
2
W
2
xR
dxMdx
dyEI
2
2
CxCLLLx6
RLLx
6
WLx
6
W
6
xR
xMdEIy
1
3
32123
2123
11
3
1
Note that in Macaulay's Method
terms within square brackets to be ignored
when the sign of the bracket goes negative.
Boundary conditions
Assuming: deflection at the bearings is zero
• y(x=0) = 0 → C2 = 0
• y(x=L1+L2+L3) = 0 →
321
3
36
3
326
3
3216
1
211
LLL
LLLLLLC
WWR
321
3
36
3
326
3
3216211
LLL
LLLLLLLLLx
2
R
LLx2
WLx
2
W
2
xR
dx
dyEI
WWR2
3212
2
2122
11
2
1
xLLL
LLLLLLLLLx
6
R
LLx6
WLx
6
W
6
xREIy
WWR3
3212
3
2123
11
3
1
321
3
36
3
326
3
3216211
Solving for deflections
Forces: W1=130 N, W2=140 N, W3=150 N,
Geometry: =4 mm,
Material E=200,000 MPa
Substitution of these values gives:
R1=79.2 N
R2=340.8 N
Deflections:
at x=0.15 m, y=5.110-3 mm
at x=0.29 m, y=2.810-3 mm
at x=0.44 m, y=-1.210-3 mm
=0.15 m
x
1 R
L 1
R 2
=0.08 m =0.14 m L 2
L 3
=0.07 m L 4
44744
mm57.12m102566.164
04.0
64
dI
Also check the slope of the shaft at the critical locations
Hollow v Solid
0
20
40
60
80
100
0 20 40 60 80 100
Re
lati
ve P
ola
r M
om
en
t o
f In
ert
ia [
%]
Wall Thickness / Shaft Radius [%]
Hollow v Solid
0
20
40
60
80
100
0 20 40 60 80 100
Re
lati
ve P
ola
r M
om
en
t o
f In
ert
ia [
%]
Relative Mass [%]
Hollow v Solid
0
20
40
60
80
100
0 20 40 60 80 100
Re
lati
ve P
ola
r M
om
en
t o
f In
ert
ia [
%]
Relative Mass [%]
Danger of buckling?
Some Concluding Remarks - I
Shaft Design Considerations
• size and spacing of components
• material selection, material treatments
• deflection and rigidity
• stress and strength
• frequency response
• assembly, manufacturing & servicing constraints
Some Concluding Remarks – II
1. Minimize deflections and stresses: short shaft, overhangs only if necessary
– Deflection of cantilever beam > deflection of simply supported beam
for the same dimensions and loading)
– But think about assembly and serviceability
2. Stress-raisers (i.e. keys, sharp corners) should not be placed in critical regions:
– minimize effects with a radius (standard values!) or a chamfer.
3. Low carbon steel is often as good as higher strength steels since deflection is
typical the design limiting issue.
4. Limiting deflections
– Gears: deflection < 0.13 mm and slope < 0.03°.
– Rolling element bearings
non self aligning: slope < 0.04°
self aligning: slope < 2.5° (depending on model / configuration)
5. Hollow shafts have better stiffness to mass (specific stiffness) and higher natural
frequencies than solid shafts, but are more expensive and typically have a larger
diameter.
6. Natural frequency of shaft should be >> highest excitation frequency in service.
Q&A 27 Oct 2014
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