Balochistan University of Information Technology Engineering and Management

Sciences, Quetta

Machine Design Complex Engineering Problems:

Submitted by:

Usama Chishti 48838

Tamoor Shahzad 48886

M. Yaseen 49641

Adeel Khan 5204

Submitted to
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Asif Hussain

Problem Statement: Choose your application for a shaft and specify details.

The functional requirements of a shaft and gear system include:

1. The material must be strong enough to support the loads but must also be cheap
2. Has a yield strength large enough to prevent against initial static yielding due to the
applied forces
3. Has an endurance strength large enough to ensure infinite life?
4. Has a factor of safety against failure from yielding of at least 2.2?
5. Has a factor of safety against failure from fatigue of at least 1.50?
6. Minimal friction loss in the bearings allowing for maximum transfer of torque between
the gears
7. The parts of the shaft assembly are of sizes that can be bought through specific vendors.
8. The pulleys and shaft behave as a rigid body (chose the Diameter of pulley according to
proposed application).
9. Choose the bearing for specific use.

Calculations:

Select any layout of shaft which include the components for torque transmission and axial
positioning of pulley, gears and bearings etc. Chose the load and position of pulleys according to
your own select an application and calculate the smallest safe shaft diameter for the shaft.
Provide a free body diagram and all necessary bending moments and torque diagrams.

Determine the minimum allowable diameter of the of the shaft based on

(a) A static yield analysis using the distortion energy theory and

(b) A fatigue-failure analysis.

Assume sharp fillet radii at the bearing shoulders for estimating stress-concentration factors

Solution:

Prior discussion:
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Consider the following diagram

In the double-reduction gear train shown, shaft “a” is driven by a motor attached by a
flexible coupling attached to the overhang. The motor provides a torque of 2500 lbf · in at a
speed of 1200 rpm to shaft “a”. The gears have 20° pressure angles, with diameters shown on the
figure.

Material selection:
Shaft material: s𝑡𝑒𝑒𝑙 (𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑑)
Ultimate tensile strength = 𝑆𝑢𝑡 = 560 𝑀𝑃𝑎
Yield strength = 𝑆𝑦 = 420 𝑀𝑃𝑎
Factor of safety = 2.2 (given)
Deflection of shaft is neglected
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Layout of shaft:

1. Gear is monted with help of key, so torque is transmitted form shaft to gear.

2. Gear is axialy postioned between sleeve and sholder

3. The two ball bearings are used, which are lightly pressed onto the shaft
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Force analysis of Spur Gear

As the spur gear “2” mounted on shaft “a” rotates anticlockwise direction, drives the gear “3”
mounded on the shaft “b” clock wise. Therefore, their free body diagram shown in following
diagram.
F r (43)
F t (43)

Gear 3

T 3=0

F t (23)
F r (23)

F r (32)
θ=20 °

F t (32)

Gear 2

T a 2=2500 lbs−¿
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Now the calculate the tangential component of force by using following formula as we know that
torque transmitted by gear is given by

d 4
T a 2=F t × 2500=F t × F =1250 lbs
2 2 t

Similarly, the radial component is given by

F r=F t . tan ∅ =1250 tan ( 20 )=455 lbf F r=455 lbf

The resultant force may be found by using

F=√ F2r + F 2t =√ 12502+ 4552 F=1330 lbf

Now to calculate the reaction produce by the bearing is given by

∑ M B=0
R A × 11−F × 2=0 \

R A × 11−1330 ×2=0

R A =242 lbs

Similarly, ∑ M A =0
R B × 11−F ×9=0

R B × 11−1330 × 9=0

R B=1088 lbs
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It may be noted that from bending moment diagram that maximum moment produce at point “C”
where gear is mounted, which is given by
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M c(max )=2178 lbs−¿

Critical Location:

By observation of the loading situation, the critical location is to be in the keyway for the
gear that is Point “C”. At this point there is a large stress concentration, a large bending moment,
and the torque is present.

The other locations either have small bending moments, or no torque. The stress
concentration for the keyway is highest at the ends. For simplicity, and to be conservative, we
will use the maximum bending moment, even though it will have dropped off a little at the end

of the keyway.

Working Formula:

1. For static analysis using the following distortion energy theory.

'
σ max=¿ ¿

Sy
2. n y= '
σ max
3. For Fatigue analysis using DE-ASME Elliptic Criterion: to calculate shaft diameter.

[ ( ) ( ) ( ) ( )]
2 2 2 2 1 /2
316 n Kf Ma K fs T a K f Mm K fs T m
d= 4 +3 +4 +3
π Se Se Sy Sy

Calculation:

At the gear keyway, approximately 9 in from the left end of the shaft, the bending is
completely reversed and the torque is steady. Therefore

M m=0 and T a=0

M a=2178 lbf ⋅ ⅈn T m=2500 lbf ⋅∈¿

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M a=246.08 N −m T m=282.46 N −m

: 1 N-m = 8.850746 [Link]

From table 7-1, for sharp fillet radius

Let us assume that

The theoretical stress concentration factors for bending =𝐾𝑡 = 𝟐.𝟕

The theoretical stress concentration factors for Shearing =𝐾𝑡s = 𝟐.2

Raddius of fillet r
And = =0.02…………………….(A)
Diameter of shaft d

Notch sensitivity (q) for steel we have figure 6-20, For sharp fillet radii.
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Notch sensitivityfor steel=q=0.84

let assume Notch sensitivityfor bending=q=0.65
Similarly, to calculate Notch sensitivity for shear “q fs” from graph 6.21 for sharp fillet we get

Assumed that Notch sensitivity for shear=q fs =0.7

Now to calculate fatigue stress-concentration factor for bending “ K f ” we have

K f =1+q (K t −1) K f =1+0.65 (2.7−1) K f =2.805

Similarly, to calculate fatigue stress-concentration factor for torsion “ K fs ”

K fs =1+ qfs (K ts −1) K fs =1+ 0.7(2.2−1) K fs =2.04

For Static Analysis Shaft Diameter:

'
σ max=¿ ¿

Putting the corresponding values in above formula we get

[( )]
2 1/ 2

) (
2
' 32(0+246.08) 16 (282.46+ 0)
σ max = 2.805 3
+3 2.04 3
πd πd

' 7032.86 5084.41 12117.27 ' 12117.27

σ max= 3
+ 3
= 3
σ max= 3
d d d d
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Sy 420000000
2.2=
We also know that n= ' 12117.27
σ max 3
d

d3 = 0.0000634 d = 0.0411 m = 41.1 mm

Calculation of the endurance limit ‘” Se ”

'
To calculate the endurance limit we have Se =k a k b k c k d k e k f S e………………..(B)

For steels, we will estimate the rotatory-beam test specimen endurance limit “ S'e ”is given by

' ' '

Therefore Se =0.5 Sut Se =0.5 (560) Se =280 Mpa

b
To calculate surface condition modification factor “k a” k a=a Sut

From table 6-2

For machined or cold drawing a=2.70 kpsi b=−0.265

−0.265
k a=2.70 ×560

Surface condition modification factor =k a=0.84

Now to calculate size factor “k b” for bending and torsion

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Let us assume that

¿ ¿ k b=0.85

Now to calculate load factor “k c” we have

Load factor “k c =1”

Let temperature factor “k d=1”

Now to calculate Reliability factor “k e” by considering the reliability 99 % we have table

Reliability facotr=k e=0.814

Put corresponding values in equal (A) to calculate the endurance limit

'
Se =k a k b k c k d k e k f S e =( 0.84 )( 0.85 )( 1 ) ( 1 )( 0.814 ) (1) (280 )

Se =162.7=163 Mpa
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Now put values in working formula no 3, to get diameter of shaft for fatigue analysis and using
DE-ASME Elliptic Criterion: to calculate shaft diameter.

[ ( ) ( ) ( ) ( )]
2 2 2 2 1 /2
3 16(2.2) K f Ma K fs T a K f Mm K fs T m
d= 4 +3 +4 +3
π Se Se Sy Sy

[( )]
2 1 /2

) ( ) ( ) (
2 2 2
3 16(2.2) 2.085(246.08) 2.04(0) 2.085 (0) 2.04 (282.46)
d= 4 6
+3 6
+4 6
+3
π 163 × 10 163 ×10 420× 10 420.10 6

16(2.2) 1 /2
d 3= [ 3.963 × 10−11 +0+ 0+5.647 ×10−12]
π
3
d =0.0000754

d=0.04225=42.25 mm

From equation (B)

Raddius of fillet r
= =0.02
Diameter of shaft d

Raddius of fillet r
= =0.02
Diameter of shaft 42.25

fillet radius=r=0.85 mm

Trail 2: if Fillet radius ¿ 0.85 mm

Notch sensitivity (q) for steel, from figure 6-20, For sharp fillet radii r =0.85 mm and
Sut =560 Mpa=0.6Gpa
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Notch sensitivityfor steel=q=0.84

Notch sensitivityfor bending=q=0.70

Similarly, to calculate Notch sensitivity for shear “q fs” from graph 6.21 For sharp fillet radii
r =0.85 mm and Sut =560 Mpa=0.6Gpa

Notch sensitivity for shear =q fs =0.75

Now to calculate fatigue stress-concentration factor for bending “ K f ”

K f =1+q (K t −1)

Now to calculate theoretical stress concentration factor for bending “ K t ”

D r 0.85
=1.10 = =0.02
d d 42.25
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Theoretical stress concentration factor “ K t =¿2.73 ¿”

Now to calculate fatigue stress-concentration factor for bending “ K f ” we have

K f =1+q (K t −1) K f =1+0.70 (2.73−1) K f =2.211

Similarly, to calculate fatigue stress-concentration factor for torsion “ K fs ”

K fs =1+ qfs (K ts −1)

Now to calculate theoretical stress concentration factor for torsion “ K ts ”

D r 0.85
=1.10 = =0.02
d d 42.25

Theoretical stress concentration factor for torsion “ K ts =2.19”

Fatigue stress-concentration factor for torsion “ K fs ”

K fs =1+ qfs (K ts −1) K fs =1+ 0.75(2.19−1) K fs =1.89

Calculation of the endurance limit ‘” Se ”

'
To calculate the endurance limit we have Se =k a k b k c k d k e k f S e………………..(B)
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'
Se =280 Mpa Remain same

Surface condition modification factor =k a=0.84 Remain same

Now to calculate size factor “k b” for bending and torsion for diameter of shaft d=42.25 mm

We get

−0.107 −0.107
¿ ¿ k b=1.24 d =1.24(42.25) =0.83

¿ ¿ 0.83

Load factor “k c =1” Remain same

Let temperature factor “k d=1” Remain same

Reliability facotr=k e=0.814 Remain same

Put corresponding values in equal (A) to calculate the endurance limit

'
Se =k a k b k c k d k e k f S e =( 0.84 )( 0.83 )( 1 ) ( 1 )( 0.814 ) ( 280 )

Se =158.9=159 Mpa

Now put values in working formula no 3, to get diameter of shaft for fatigue analysis and using
DE-ASME Elliptic Criterion: to calculate shaft diameter.

[ ( ) ( ) ( ) ( )]
2 2 2 2 1 /2
3 16(2.2) K f Ma K fs T a K f Mm K fs T m
d= 4 +3 +4 +3
π Se Se Sy Sy

[( )]
2 1/ 2

) ( ) ( ) (
2 2 2
3 16(2.2) 2.211(246.08) 2.04 (0) 2.085(0) 1.89 (282.46)
d= 4 6
+3 6
+4 6
+3
π 159 ×10 163 ×10 420 ×10 420.10 6
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16(2.2) 1/ 2
d 3= [ 4.684 ×10−11 +0+ 0+4.847 × 10−12 ]
π
3
d =0.0000806

d=0.04319=43.19 mm

From equation (B)

Raddius of fillet r Raddius of fillet r

= =0.02 = =0.02
Diameter of shaft d Diameter of shaft 43.19

fillet radius=r=0.86 mm

Trail 3: if Fillet radius ¿ 0.86 mm∧d=43.19

Notch sensitivity (q) for steel, from figure 6-20, For sharp fillet radii r =0.86 mm and
Sut =560 Mpa=0.6Gpa

Notch sensitivityfor steel=q=0.84

Notch sensitivityfor bending=q=0.70

Similarly, to calculate Notch sensitivity for shear “q fs” from graph 6.21 For sharp fillet radii
r =0.86 mm and Sut =560 Mpa=0.6Gpa
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Notch sensitivity for shear =q fs =0.75

Now to calculate fatigue stress-concentration factor for bending “ K f ”

K f =1+q (K t −1)

Now to calculate theoretical stress concentration factor for bending “ K t ”

D r 0.86
=1.10 = =0.0199=0.02
d d 43.19
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Theoretical stress concentration factor “ K t =¿2.73 ¿”

Now to calculate fatigue stress-concentration factor for bending “ K f ” we have

K f =1+q (K t −1) K f =1+0.70 (2.73−1) K f =2.211

Similarly, to calculate fatigue stress-concentration factor for torsion “ K fs ”

K fs =1+ qfs (K ts −1)

Now to calculate theoretical stress concentration factor for torsion “ K ts ”

D r 0.86
=1.10 = =0.0199=0.02
d d 43.19

Theoretical stress concentration factor for torsion “ K ts =2.19”

Fatigue stress-concentration factor for torsion “ K fs ”

K fs =1+ qfs (K ts −1) K fs =1+ 0.75(2.19−1) K fs =1.89

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Calculation of the endurance limit ‘” Se ”

'
To calculate the endurance limit we have Se =k a k b k c k d k e k f S e………………..(B)

'
Se =280 Mpa Remain same

Surface condition modification factor =k a=0.84 Remain same

Now to calculate size factor “k b” for bending and torsion for diameter of shaft d=42.25 mm

We get

−0.107 −0.107
¿ ¿ k b=1.24 d =1.24(42.25) =0.83

¿ ¿ 0.83

Load factor “k c =1” Remain same

Let temperature factor “k d=1” Remain same

Reliability facotr=k e=0.814 Remain same

Put corresponding values in equal (A) to calculate the endurance limit

'
Se =k a k b k c k d k e k f S e =( 0.84 )( 0.83 )( 1 ) ( 1 )( 0.814 ) ( 280 )

Se =158.9=159 Mpa

Now put values in working formula no 3, to get diameter of shaft for fatigue analysis and using
DE-ASME Elliptic Criterion: to calculate shaft diameter.

[ ( ) ( ) ( ) ( )]
2 2 2 2 1 /2
3 16(2.2) K f Ma K fs T a K f Mm K fs T m
d= 4 +3 +4 +3
π Se Se Sy Sy
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[( )]
2 1/ 2

) ( ) ( ) (
2 2 2
3 16(2.2) 2.211(246.08) 2.04 (0) 2.085(0) 1.89 (282.46)
d= 4 6
+3 6
+4 6
+3
π 159 ×10 163 ×10 420 ×10 420.10 6

16(2.2) 1/ 2
d 3= [ 4.684 ×10−11 +0+ 0+4.847 × 10−12 ]
π
3
d =0.0000806

d=0.04319=43.19 mm

From equation (B)

Raddius of fillet r
= =0.02
Diameter of shaft d

Raddius of fillet r
= =0.02
Diameter of shaft 43.19

fillet radius=r=0.86 mm

Result:

So, the Diameter of shaft at point “c” d=0.04319=43.19 mm

fillet radius=r=0.86 mm to provide the relief for stress concentration

The other diameter of the shaft may be found by using equation (C)

d1 d d1 d2
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D d 43.19
= = =1.10 d 1=39.26 mm
d d1 d1

D d1 39.26
Similarly, = = =1.10 d 2=35.69 mm
d d2 d2

Selection of Bearing:

From calculation of Gear force analysis, it is shown that due spur gear there is only radial load
applied on the shaft and there is no axial load at shaft. Therefore, we may select

1. Single row deep groove ball bearing on both end or

2. One single row deep groove ball bearing at one end and angular ball bearing on other side

The magnitude of radial load on shaft ¿ F r=455 lbf =455 × 4.448÷ 1000=2.02 kN

The bore diameter of bearing ¿ d 1=39.26 mm

Now from table 11-2 for 02 series deep groove ball bearing
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Bore diameter of bearing ¿ 40 mm

Outside diameter of bearing ¿ 80 mm

Width of bearing ¿ b=18 mm

Fillet radius of bearing ¿ r =1mm

Radial load ¿ F r=C 10=30.7 N >2.02 kN (Safe)