Shaft Design Safety Factor Analysis
Shaft Design Safety Factor Analysis
For questions: Ege ÖDEN Notch sensitivities for bending or axial loads q = 0.82 (Fig 6-20 in formula sheet)
Room: C-201 and for torsion q = 0.88 (Fig 6-21 in formula sheet), respectively. The theoretical
E-mail: egeoden@[Link] Date: 03/12/2025
stress-concentration factors are Kt =1.5 for bending (Fig A-15-9) and Kts =1.3 for
ME 307 – MACHINE ELEMENTS I torsion (Fig A-15-8). The fatigue stress-concentration factors are
TUTORIAL 9
“DESIGN OF SHAFTS” 𝐾 = 1 + 𝑞(𝐾 − 1) = 1 + 0.82(1.50 − 1) = 1.41
𝐾 = 1 + 𝑞(𝐾 − 1) = 1 + 0.88(1.3 − 1) = 1.264
Problem 1: The figure shows a section of an AISI 1050 CD steel shaft with
dimensions D = 30 mm and d = 25 mm. The shaft section at the shoulder is subject The bending stress for completely reversed bending moment is:
to a completely reversed bending moment of 60 N.m and a torsion fluctuating
between -30 and 50 Nm. Determine the factor of safety for infinite life based on the 32𝑀 32 ⋅ 60
modified Goodman diagram. (Operating temperature is 100°C and reliability is 𝜎 =𝐾 = 1.41 = 55.2𝑀𝑃𝑎, 𝜎 =0
𝜋𝑑 𝜋(2.5 ⋅ 10 )
%90).
The alternating and mean components of the torsional stress are:
50 + 30 50 − 30
𝑇 = = 40𝑁 ⋅ 𝑚, 𝑇 = = 10𝑁 ⋅ 𝑚
2 2
16 ⋅ 𝑇 16 ⋅ 40
𝜏 =𝐾 ⋅ = 1.264 ⋅ = 16.47𝑀𝑃𝑎
𝜋⋅𝑑 𝜋⋅ (2.5 ⋅ 10 )
16 ⋅ 𝑇 16 ⋅ 10
Solution: 𝜏 =𝐾 ⋅ = 1.264 ⋅ = 4.11𝑀𝑃𝑎
The tensile strength of AISI 1050 Cold-Drawn steel is 𝑆 = 690 MPa (Shigley Table 𝜋⋅𝑑 𝜋 ⋅ (2.5 ⋅ 10 )
A-20). From the same table, it can be assumed that the material is brittle by observing Based on the distortion-energy theory the equivalent stresses are:
its relatively low elongation (10%).
The endurance limit is 𝜎 = 𝜎 , + 3𝜏 , = 55.2 + 3 ⋅ 16.47 = 62.13𝑀𝑃𝑎
𝑆 = 0.5 𝑆 (𝑆 < 1400𝑀𝑃𝑎), 𝑆 = 0.5 ⋅ 690 = 345 𝑀𝑃𝑎 .
The endurance limit modifying factors are 𝜎 = 𝜎 + 3𝜏 = 0 + 3 ⋅ 4.11 = 7.11𝑀𝑃𝑎
, ,
𝑘 = 𝑎 · (𝑆 ) = 4.51 · (690) . = 0.798
𝑘 = 1.24(0.370𝑑) .
= 0.977 (6-20)(Table 6-3) According to the modified Goodman relation the factor of safety is
𝑘 =1 for bending
𝑘 = 1.02 T=100 C° (Table 6.4) 1 𝜎 𝜎 62.13𝑀𝑃𝑎 7.11𝑀𝑃𝑎 1
= + = + =
𝑘 = 0.897 for 90% reliability. 𝑛 𝑆 𝑆 246.1𝑀𝑃𝑎 690𝑀𝑃𝑎 3.81
𝑆 = 𝑘 ⋅ 𝑘 ⋅ 𝑘 ⋅ 𝑘 ⋅ 𝑘 ⋅ 𝑘 ⋅ 0.5 ⋅ 𝑆
𝑆 = 0.798 ⋅ 0.977 ⋅ 1 ⋅ 1.02 ⋅ 0.897 ⋅ 1 ⋅ 345𝑀𝑃𝑎 = 246.1𝑀𝑃𝑎
The reaction forces are needed to obtain the shear force diagram and the moment
d3 d2 d1 A B C D diagram of the shaft. The reaction forces will be calculated and the bending moment
diagram will be drawn in two orthogonal planes x-y and x-z planes. The analysis
in the x-y plane is as follows:
Figure 1 y Max Max
y y x
x Fr FBy FDy Fr
z Drum
z G1 𝐹 = 𝐹 = 15.50𝑘𝑁
𝐷
𝑀 =𝐹 ∗ = 14560 𝑁 ∗ 0.06𝑚 = 874 𝑁𝑚
2
V(kN) 15.5 kN
G1&G2 y
Fax
Fdrum Ft x
Fr
G3
Figure 2 Figure 3 X (m)
-15.5 kN
𝜎 = (𝐾 𝜎 ) + 3(𝐾 𝜏 ) where 𝜎 = 𝜎 𝜏 =𝜏
32𝑀 32 ∙ 4881 ∙ 10
𝜎 = = = 68.2𝑀𝑃𝑎
𝜋𝑑 𝜋 ∙ 90
Mc 32M Tc 16T
bending , twisting
I d 3
J d3
4 F 32 M 16T
x xz
d2 d3 d3
2 2
4 F 32M 16T
' 3
2 2
2 3
3 3
d d d
x xz
Solution: The diameter of the shaft can be found using the safety factor value.
a) The normal stress due to axial force is uniform over the area:
Sy
F 4F n
axial '
A d2
4 ∗ 100 32 ∗ 200 ∗ 10 16 ∗ 400 ∗ 10 Select an appropriate value for diameter from the table A-17 (Preferred Sizes and
𝜎 , = 1.51 + 1.47 + 3 1.28 Renard Numbers Table). Preferred size for shaft diameter is D = 40mm.
0.85𝜋𝐷 𝜋𝐷 𝜋𝐷
Note that, if both the alternative and mean stress components exist, the critical
section can be found by using one of the failure theorems.
Since the normal stress from axial loading is so small when compared with stress
due to bending moment, the axial stress term is neglected. 2 2
4 100
3
1.47 32 200 10 1.28 16 400 103
a , groove ' 1.51 2
3
3 3
(40 / 1.02) 0.85 (40 / 1.02) 0.85 (40 / 1.02)
29.3 ∗ 10 33.1 ∗ 10
𝜎 , = = a , groove ' 106 MPa
𝑑 𝐷
𝑆 187.5
𝑛= = = 1.769
Since, the stresses at the groove are more critical, those will be taken in consideration 𝜎 106
for the determination of shaft diameter. (It is better to select D=45mm)
The Endurance limit of the shaft is to be determined. The endurance limit of the test
specimen is:
The diameter of the shaft can be found using the safety factor value.
Since the mean stress is zero:
The deflections at the specified positions will be calculated considering the weights
are acting in the directions shown in Figure 4, which will result in the deflection
curve of the first mode shape given in Figure 3.
A B
F1 F2 F3 Figure 4
The figure shows a shaft with two gears and a drum mounted on it. All the
dimensions are known since the system is symmetric with respect to its mid-section. 𝐹 = 𝐹 = 𝑊 = 70𝑁
Gears 1 and 2 are identical with weight 70N. The weights of the drum is 100N. You 𝐹 = 𝑊 = 100 = 100𝑁
can neglect the weight of the shaft during the deflection analysis. Find the first
critical speed of the shaft using Rayleigh’s equation. (Flexural rigidity of the shaft: The shaft in the problem can be considered as an overhanging simply supported
EI=2.2x107 N.m2) beam. To find the deflections at position 2, the forces outside the supports will be
replaced with equivalent force and moment system at the supports. The deflections
Solution: will be determined by using the formula from the deflection table for simply
The Rayleigh’s equation gives the first critical speed of a shaft as: supported and cantilever beams.
F2
∑ th
𝜔 = ∑
where 𝑤 is the weight of the i element on the shaft and 𝑦 is the Meq
A B Meq
th
A B
deflection at the i body location. The shaft can be analysed by dividing it into 3
F1 F2 F3 Figure 5
elements as in Figure 2. The deflection of the gears, drum and each element on the FR FR Feq FR FR Feq
shaft are to be determined.
The positions 1 and 3 are the positions of the gears. Position 2 is the position of the 𝐹 = 𝐹 = 70 = 70 𝑁
drum. 𝑀 = 𝐹 ∙ 80 = 70 ∙ 80 = 5600 𝑁
Note that the sign of the end moment is taken as negative due to the sign convention
used in beam deflection formulas. Figure 7
B
F3
𝜃 = 𝑀𝐿 6𝐸𝐼 (from beam deflection tables)
𝜃 = −3.4 ∙ 10 𝑟𝑎𝑑 (slope at A due to end moment B)
𝜃 = − 𝑀𝐿 3𝐸𝐼 (from beam deflection tables) The deflections at 3 due to the moment inside the supports:
𝜃 = 6.8 ∙ 10 𝑟𝑎𝑑 (slope at B due to end moment B)
𝑦 = 𝜃 𝑥 , 𝑥 = 80 𝑚𝑚
Using the symmetry, 𝑦 = 0.962 𝑚𝑚
𝑦 = 𝑦 = −0.102 𝑚𝑚 (deflection at 2 due to end moment A) The deflections at 3 due to the concentrated force at 3:
𝜃 = −𝜃 = −6.8 ∙ 10 𝑟𝑎𝑑 (slope at A due to end moment A)
𝜃 = −𝜃 = 3.4 ∙ 10 𝑟𝑎𝑑 (slope at B due to end moment A) 𝑦 = 𝑃 6𝐸𝐼 (𝑥 − 3𝐿𝑥 ), 𝑃 = −70𝑁, 𝐿 = 80𝑚𝑚
𝑦 = 0.543 𝑚𝑚
The deflections at 2 and the slopes at A and B due to the center load:
The total deflections at 3:
𝑦 = 𝑃 48𝐸𝐼 (4𝑥 − 3𝐿 𝑥 ), (from beam deflection tables), 𝑃 = 100𝑁 𝑦 = 𝑦 + 𝑦 = 1.505 𝑚𝑚
𝑦 = −0.048 𝑚𝑚 (deflection at 2 due to force at 2)
𝑦 = 𝑦 = 1.505 𝑚𝑚
𝑤 = 𝑤 = 𝑊 = 70𝑁
𝑤 = 𝑊 = 100𝑁
The first critical speed of the shaft can be calculated using the Rayleigh’s equation.
Note that during the calculation of all the deflections, y axis has been selected as
pointing upwards. However, since Rayleigh’s equation is obtained from the equality
of potential energy and kinetic energy all the forces and deflections used in
Rayleigh’s equation should be taken as positive. Note that energy is a positive
quantity and it cannot be negative.