DESIGN OF MACHINE ELEMENTS

Nivish George
 Shafts
Transmission shaft usually refers to a rotating machine element,
circular in cross-section, which supports transmission elements like
gears, pulleys and sprockets and transmits power

Categories of transmission shafts

• Axle
• Spindle
• Countershaft
• Jackshaft
• Line shaft

Department of Mechanical Engineering 2

 Design of shafts on strength basis
Shaft subjected to pure axial tensile load
1
32𝑀 1 3 (Eqn. 3.4b) with K=0 for
𝑑0 = solid shafts
𝜋𝜎𝑑 1 − 𝐾 4
Shaft subjected to pure torsional load 1
16𝑇 1 3 (Eqn. 3.4a) with K=0 for
𝑑0 = solid shafts
𝜋𝜏 1 − 𝐾 4
Combined torsion and bending (maximum normal stress theory)
1
16 1 3
𝑑= 2
𝑀+ 𝑀 +𝑇 × 2 (Eqn. 3.5a)
𝜋𝜎𝑚𝑎𝑥 1 − 𝐾4
Combined torsion and bending (maximum shear
1
stress theory)
16 1 3
𝑑= 𝑀2 + 𝑇 2 × 4
(Eqn. 3.5b)
𝜋𝜏 1−𝐾
Department of Mechanical Engineering 3
 Design of shafts on Rigidity basis
Torsional rigidity: Ability to resist twist under the action of
an external torque
Lateral rigidity: Ability to resist deflection under the action
of external forces

Rigidity 𝑑𝑖
𝐾=
• Torsional rigidity 𝑑𝑜
1 584𝑇𝐿
584𝑇𝐿 4 𝜃=
𝑑= (𝑑04 − 𝑑𝑖4 )𝐺
𝐺𝜃 (Eqn. 3.2) (Eqn. 3.2)

• Lateral rigidity

Department of Mechanical Engineering 4

 Design of shafts on strength basis (Fluctuating load)

Shaft subjected to pure axial tensile load

1
32𝐶𝑚 𝑀 3
𝑑0 =
𝜋𝜎𝑏
Shaft subjected to pure torsional load 1
16𝐶𝑡 𝑇 3
𝑑0 =
𝜋𝜏
Combined torsion and bending (maximum normal stress theory)
1
16 1 3
𝑑0 = 2
𝐶𝑚 𝑀 + 𝐶𝑚 𝑀 + 𝐶𝑡 𝑇 2 ×
𝜋𝜎𝑚𝑎𝑥 1 − 𝐾 4 (Eqn. 3.6a)
Combined torsion and bending (maximum shear stress theory)
1
16 1 3
𝑑0 = 𝐶𝑚 𝑀 2 + 𝐶𝑡 𝑇 2 × (Eqn. 3.6b)
𝜋𝜏 1 − 𝐾4
Department of Mechanical Engineering 5
 Problem 6.1
The layout of a transmission shaft carrying two pulleys B and C are
supported on bearings A and D is shown in Figure. Power is supplied to
the shaft by means of a vertical belt on the pulley B, which is then
transmitted to the pulley C carrying a horizontal belt. The maximum
tension in the belt on the pulley B is 2.5 kN. The angle of wrap for both
pulleys is 1800 and the coefficient of friction is 0.24. The shaft is made
of plain carbon steel 30C8 (Syt=400 N/mm2) and the factor of safety is 3.
Determine the shaft diameter on strength basis.

Department of Mechanical Engineering 6

Problem 6.1

Department of Mechanical Engineering 7

 Problem 6.2
The layout of a shaft carrying two pulleys 1 and 2, and supported on two
bearings A and B is shown in Figure. The shaft transmit 7.5kW power at
360 rpm from the pulley 1 to the pulley 2. The diameters of pulleys 1 and
2 are 250 mm and 500 mm, respectively. The masses of the pulleys 1 and
2 are 10 kg and 30 kg, respectively. The belt tensions act vertically
downward and the ratio of belt tensions on the tight side to slack side for
each pulley is 2.5:1. The shaft is made of plain carbon steel 40C8 (Syt =
380N/mm2) and the factor of safety is 3. Estimate suitable diameter of
shaft. If the permissible angle of twist is 0.50 per metre length , calculate
the shaft diameter on the basis of torsional rigidity. Assume G=79300
N/mm2.

Department of Mechanical Engineering 8

Problem 6.2

Department of Mechanical Engineering 9

 Problem 6.3
A layout of an intermediate shaft of a gear box supporting two spur
gears B and C is shown in Figure. The shaft is mounted on two
bearings A and D. The pitch circle diameters of gears B and C are 900
and 600 mm, respectively. The material of the shaft is steel FeE 580
(Sut = 770 and Syt = 580 N/mm2). The factors Cm and Ct are 1.5 and
2.0, respectively. Determine the shaft diameter using the A.S.M.E
code. Assume that the gears are connected to the shaft by means of
keys.

Department of Mechanical Engineering 10

Problem 6.3

Department of Mechanical Engineering 11

 Problem 6.4
A hollow transmission shaft, having inside diameter of 0.6 times the
outside diameter is made of plain carbon steel 40C8 (Syt=380N/mm2) and
the factor of safety is 3. A belt pulley 1000mm in diameter, is mounted on
the shaft which overhangs the left hand bearing by 250 mm. The belts are
vertical and transmit power to the machine shaft below the pulley. The
tension on the tight side and slack sides of the belt are 3kN and 500 N.
The angle of wrap of the belt on the pulley is 1800. Calculate the outside
and inside diameters of the shaft.

Department of Mechanical Engineering 12

Problem 6.3

Department of Mechanical Engineering 13

 Problem 6.5
A solid shaft of diameter d is used in power transmission. Due to
modification of the existing system, it is required to replace the solid shaft
by a hollow shaft of the same material and equally strong in torsion.
Further, the weight of the hollow shaft per metre length should be half of
the solid shaft. Determine the outer diameter of the hollow shaft in terms
of d

Department of Mechanical Engineering 14

 Couplings
A coupling can be defined as a mechanical device that
permanently joints two rotating shafts to each other

Types
• Oldham coupling

• Hooke’s coupling

• Rigid or flexible coupling

Department of Mechanical Engineering 15

 Rigid Coupling

𝐷: 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 𝐿: 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 ℎ𝑢𝑏 = 1.25 𝑡𝑜 1.5𝐷(𝐸𝑞𝑛 13.1𝑔)

𝐷1 : 𝐻𝑢𝑏 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 2𝐷 (𝐸𝑞𝑛 13.1𝑑)
𝐷2 : 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑏𝑜𝑙𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 = 3𝐷 (𝐸𝑞𝑛 13.1𝑒)
𝐷3 : 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝐹𝑙𝑎𝑛𝑔𝑒 = 4𝐷 (𝐸𝑞𝑛 13.1𝑓)
𝑡: 𝐹𝑙𝑎𝑛𝑔𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.35𝐷 + 9 𝑚𝑚(𝐸𝑞𝑛 13.1ℎ)
𝑡3 : 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑝𝑟𝑜𝑡𝑒𝑐𝑡𝑖𝑛𝑔 𝑟𝑖𝑚 = 0.10𝐷 + 5 𝑚𝑚(𝑃𝑔. 251)
1 3
𝑖: 𝑁𝑜. 𝑜𝑓 𝑏𝑜𝑙𝑡𝑠 = 𝐷 + 2 𝑡𝑜 𝐷 + 2 𝑜𝑟 0.02𝐷 + 3 (𝐸𝑞𝑛 13.1𝑎 𝑎𝑛𝑑 13.1𝑏))
40 80
Department of Mechanical Engineering 16
Design Procedure: Rigid Flange Coupling
• Obtain the shaft diameter. Standard shaft sizes can be selected
from Table 3.5a, Page 57
• Find the dimensions of flanges by empirical relations on Pg 251
and Pg 252
• The inner and outer diameters of the hub are D and D1.
𝑇𝑟
𝜏=
𝐽
𝜋 𝐷14 − 𝐷4
𝐽=
32
𝐷1
𝑟=
2
• Shear force on flange = 𝜋𝐷1 𝑡 × 𝜏
𝐷
• Resistive torque = Shear force × 1
2
1
𝑇 = 𝜋𝐷12 𝑡𝜏 (Eqn. 13.2e)
2
Department of Mechanical Engineering 17
Design Procedure: Rigid Flange Coupling
• Decide the number of bolts based on empirical relationship
1 3
𝑖: 𝑁𝑜. 𝑜𝑓 𝑏𝑜𝑙𝑡𝑠 = 𝐷 + 2 𝑡𝑜 𝐷 + 2 𝑜𝑟 0.02𝐷 + 3 (𝐸𝑞𝑛 13.1𝑎 𝑎𝑛𝑑 13.1𝑏))
40 80
• Determine the diameter of the bolts from Eqn. 13.2c
𝜏𝜋𝑖𝑑2 𝐷2
𝑇=
8
• Compressive stress in the bolt from Eqn 13.2d
𝜎𝑏 𝑖𝑡𝑑𝐷2
𝑇=
2
• Dimensions of keys (Page 61)
1
1. The width of the square key , 𝑏 = 4 𝑑 Page 61 Eq. 4.1
1
2. The width of the rectangular key, 𝑏 = 𝑑 Page 61 Eq. 4.2 a
4
1
3. The height of the rectangular key, h = 𝑑 Page 61 Eq. 4.2 b
6
4. Refer table 4.1, data book page 69
2𝑇 4𝑇
• Check for shear and compressive stresses 𝜏 = , 𝜎𝑐 =
𝐷𝑏𝐿 𝐷ℎ𝐿
Department of Mechanical Engineering 18
Design Procedure: Rigid Flange Coupling
Forces acting on key

Department of Mechanical Engineering 19

 Problem 6.6
A rigid coupling is used to transmit 20 kW power at 720 rpm.
There are four bolts and the pitch circle diameter of the bolts is
125 mm. The bolts are made of steel 45C8 (Syt = 380 N/mm2)
and the factor of safety is 3. Determine the diameter of the
bolts.
Assume that the bolts are finger tight in reamed and ground
holes.

Department of Mechanical Engineering 20

 Problem 6.7
It is required to design a rigid type of flange coupling to
connect two shafts. The input shaft transmits 37.5 kW power
at 180 rpm to the output shaft through the coupling. The
service factor for the application is 1.5, i.e. the design torque is
1.5 times of the rated torque. Select suitable materials for
various parts of the coupling and design the coupling and
specify the dimensions of its components

Department of Mechanical Engineering 21

 Flexible Coupling

• Can tolerate 0.5 mm of

lateral or axial
misalignment and 1.50 of
angular misalignment
• Absorbs vibrations
• Used for transmitting
high torques

Department of Mechanical Engineering 22

Flexible Coupling: Animation

Department of Mechanical Engineering 23

 Problem 6.8
It is required to design a bushed pin type flexible coupling to
connect the output shaft of an electric motor to the shaft of a
centrifugal pump. The motor delivers 20 kW power at 720 rpm. The
starting torque of the motor can be assumed to be 150% of the
rated torque. Design the coupling and specify the dimensions of its
components.

Department of Mechanical Engineering 24

Problem 6.8

Department of Mechanical Engineering 25