SHIGLEY'S MED · CHAPTER 7 · SHAFT DESIGN

Problem 7-3 — Complete Solution Guide

From first principles · DE-ASME Elliptic Criterion · Full iteration

00 Problem Statement & Given Information

KNOWN VALUES

SYMBOL DESCRIPTION VALUE SOURCE

T Applied torque 3000 lbf·in Problem statement

F Tangential gear force 1064 lbf Computed below

L Moment arm 4 in Problem statement

Sut Ultimate tensile strength 80 kpsi Problem / material

Sy Yield strength 60 kpsi Problem / material

n Design safety factor 2.5 Problem statement

Fillet type Sharp shoulder fillets — Problem statement

01 Compute the Applied Loading

GEAR FORCE FROM TORQUE

A helical/spur gear transmits torque through a tangential force. With pressure angle φ = 20°:

Fo rce eq uil ibr ium

\[ F\cos(20°)\cdot\frac{d}{2} = T \quad\Rightarrow\quad F = \frac{2T}{d\cos 20°} =

\frac{2(3000)}{6\cos 20°} \]

F F = 1064 lbf

BENDING MOMENT AT CRITICAL SECTION

\[ M_C = F \times L = 1064 \times 4 \]

MC M = 4257 lbf·in

LOADING CLASSIFICATION (FOR FATIGUE)

For a rotating shaft with constant load direction:

COMPONENT MEAN (SUBSCRIPT M) AMPLITUDE (SUBSCRIPT A)

Bending moment M Mm = 0 Ma = 4257 lbf·in

Torque T Tm = 3000 lbf·in Ta = 0

Rotating shaft → bending stress is fully reversed (mean=0, amplitude=full). Torque is steady (mean=full,
amplitude=0).
02 Stress Concentration Factors

THEORETICAL FACTORS — TABLE 7-1 (SHARP FILLET AT SHOULDER)

FACTOR TYPE VALUE

Kt Bending (theoretical) 2.7

Kts Torsion (theoretical) 2.2

NOTCH SENSITIVITY — FIGS. 6-20 & 6-21 (SUT = 80 KPSI)

SYMBOL DESCRIPTION VALUE

q Notch sensitivity (bending) 0.8

qs Notch sensitivity (shear/torsion) 0.9

FATIGUE STRESS CONCENTRATION — EQ. 6-32

Eq . 6 -32

\[ K_f = 1 + q(K_t - 1) = 1 + (0.8)(2.7 - 1) = 1 + 1.36 \]

KF Kf = 2.4

Eq . 6 -32 (s hea r)

\[ K_{fs} = 1 + q_s(K_{ts} - 1) = 1 + (0.9)(2.2 - 1) = 1 + 1.08 \]

KFS Kfs = 2.1

03 Endurance Limit Se

UNCORRECTED ENDURANCE LIMIT

Eq . 6 -8 — f or S u t ≤ 200 k psi

\[ S_e' = 0.5\, S_{ut} = 0.5(80) = 40\text{ kpsi} \]

MARIN CORRECTION FACTORS

FACTOR NAME FORMULA / SOURCE VALUE

ka Surface (machined) 2.70 · Sut−0.265 — Table 6-2 0.845

kb Size factor (d/0.3)−0.107 — Eq. 6-20 0.816

assume d = 2 in initially

kc Load Bending = 1 1.0

kd Temperature Room temp = 1 1.0

ke Reliability 50% = 1 (unless stated) 1.0

kf Miscellaneous =1 1.0

Eq . 6 -18 — Cor rected e nduran ce lim it

\[ S_e = k_a\,k_b\,k_c\,k_d\,k_e\,k_f\,S_e' = (0.845)(0.816)(1)(1)(1)(1)(40) \]

SE Se = 27.6 kpsi
04 Part (a) — Static Analysis Using Fatigue Factors

Uses the von Mises maximum stress approach with M = Mm + Ma and T = Tm + Ta. Since this is a
static check with fatigue concentration factors, set M = Ma = 4257 lbf·in and T = Tm = 3000 lbf·in.

VON MISES STRESS — EQ. 7-15

Eq . 7 -15 — Von Mises a lterna ting s tress a mplitude

\[ \sigma'_{max} = \left[\left(\frac{32\,K_f M}{\pi d^3}\right)^2 + 3\left(\frac{16\,K_{fs}\,T}{\pi

d^3}\right)^2\right]^{1/2} \]

SAFETY FACTOR — EQ. 7-16

Eq . 7 -16

\[ n = \frac{S_y}{\sigma'_{max}} \]

SOLVE FOR DIAMETER D

Re arr ang ed for d

\[ d = \left\{\frac{16\,n}{\pi\,S_y}\left[4(K_f M)^2 + 3(K_{fs}\,T)^2\right]^{1/2}\right\}^{1/3}

\]

Su bst itu tin g v alues

\[ d = \left\{\frac{16(2.5)}{\pi(60\,000)}\left[4(2.4\times4257)^2 +
3(2.1\times3000)^2\right]^{1/2}\right\}^{1/3} \]

ANS (A) d = 1.700 in

Static check with fatigue factors

05 Part (b) — DE-ASME Elliptic Fatigue Criterion

The ASME Elliptic criterion is more accurate than Goodman for ductile steels. It uses both Se and Sy as
boundaries.

DE-ASME ELLIPTIC — EQ. 7-12 (WITH MM = TA = 0)

Eq . 7 -12 — Gen eral for m

\[ \frac{1}{n} = \left[\left(\frac{32\,K_f M_a}{\pi d^3 S_e}\right)^2 +

\left(\frac{16\,K_{fs}\,T_m}{\pi d^3 S_y}\right)^2\right]^{1/2} \cdot \frac{\pi d^3}{1} \]

Eq . 7 -12 — Sol ved for d

\[ d = \left\{\frac{16\,n}{\pi}\left[4\left(\frac{K_f M_a}{S_e}\right)^2 +
3\left(\frac{K_{fs}\,T_m}{S_y}\right)^2\right]^{1/2}\right\}^{1/3} \]

ITERATION 1 — INITIAL ESTIMATE (D = 2 IN ASSUMED FOR KB)

Su bst itu tin g S e = 27 .6 kp si, S y = 6 0 kpsi

\[ d = \left\{\frac{16(2.5)}{\pi}\left[4\left(\frac{2.4(4257)}{27\,600}\right)^2 +
3\left(\frac{2.1(3000)}{60\,000}\right)^2\right]^{1/2}\right\}^{1/3} \]

D ITER 1 d = 2.133 in

ITERATION 2 — REVISE KB WITH D = 2.133 IN

 \[ k_b = \left(\frac{2.133}{0.3}\right)^{-0.107} = 0.809 \] \[ S_e = 0.845(0.809)(40) = 27.3\text{
kpsi} \]

\[ d = \left\{\frac{16(2.5)}{\pi}\left[4\left(\frac{2.4(4257)}{27\,300}\right)^2 +
3\left(\frac{2.1(3000)}{60\,000}\right)^2\right]^{1/2}\right\}^{1/3} \]

ANS (B) d = 2.138 in

Converged — no further iteration needed

06 Summary & Design Decision

Part (a) — Static Check

d = 1.700 in

Uses Sy as failure boundary. Conservative for static overload only.

Part (b) — Fatigue (ASME Elliptic)

d = 2.138 in

Uses Se and Sy. Governs because fatigue is more critical here.

⚠ Part (b) governs — d = 2.138 in is larger, meaning fatigue failure controls the design. Always use the larger of
the two calculated diameters.

FULL SOLUTION ROADMAP

Find F, M, T → Get Kt, Kts → Find q, qs → Calc Kf, Kfs → Find Se → Apply Eq. 7-12 → Iterate d

07 Quick-Reference Tables

TABLE 6-2 — SURFACE FACTOR KA = A · SUTB

SURFACE FINISH A (KPSI) B

Ground 1.34 −0.085

Machined / Cold-drawn 2.70 −0.265

Hot-rolled 14.4 −0.718

As-forged 39.9 −0.995

TABLE 7-1 — STRESS CONCENTRATION FACTORS FOR SHOULDER FILLETS

FILLET TYPE KT (BENDING) KTS (TORSION)

Sharp (r/d ≈ 0.02) 2.7 2.2

Well-rounded (r/d ≈ 0.1) ~1.65 ~1.5

SIZE FACTOR KB — EQ. 6-20

RANGE FORMULA

0.11 ≤ d ≤ 2 in k = 0.879 d−0.107

b

2 < d ≤ 10 in k = 0.91 d−0.157

b
or equivalently kb = (d/0.3)−0.107

SHIGLEY 'S M ECHANIC AL ENG INEERING DES IGN · PROB LEM 7-3 · CO MPLETE REFERE NCE GUIDE