CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600

069 DEPARTMENT OF MECHANICAL ENGINEERING

ME 8593- DESIGN OF MACHINE ELEMENTS

UNIT–II DESIGN OF SHAFTS

1. Introduction
Shaft is a common machine element which is used to transmit rotary motion or torque. It generally has
circular cross-section and can be solid or hollow. Shafts are supported on the bearings and transmit
torque with the help of gears, belts and pulleys etc. Shafts are generally subjected to bending moment,
torsion and axial force or a combination of these three. So the shafts are designed depending upon the
combination of loads it is subjected to. Spindle stub and axle are some important types of shaft. Small
shaft is called spindle. Shaft integral part of the prime mover is called stub shaft. An axle is a non-
rotating member that carries no torque and is used to support rotating wheels, pulleys etc. And therefore
is subjected to bending moment only.
2. Shaft Materials
Hot-rolled plain carbon steel is the least expensive material used for shafts. These essentially require
machining to remove the scales of hot rolling process. Cold rolled plain carbon steel provides better
yield strength and endurance strength but the cold working induces residual stresses. Surface is smooth
in this case and amount of machining therefore is minimal. It is used for general purpose transmission
shafts. When a shaft is to work under severe loading and corrosive conditions and require more strength,
alloy steels are used, generally having Ni, Cr, Mo and V as alloying elements. Alloy steels are
expensive. Sometimes shafts are heat treated to improve hardness and shock resistance and surface
hardening techniques are also used if high wear resistance is the requirement. As the shafts transmitting
power are subjected to fatigue loading, therefore higher factor of safety of 3 to 4 is used on the basis of
yield strength for static load analysis.
3. Design of Shafts
Shafts are designed on the basis of strength or rigidity or both. Design based on strength is to ensure that
stress at any location of the shaft does not exceed the material yield stress. Design based on rigidity is to
ensure that maximum deflection (because of bending) and maximum twist (due to torsion) of the shaft is
within the allowable limits. Rigidity consideration is also very important in some cases for example
position of a gear mounted on the shaft will change if the shaft gets deflected and if this value is more
than some allowable limit, it may lead to high dynamic loads and noise in the gears.
In designing shafts on the basis of strength, the following cases may be considered:
(a) Shafts subjected to torque
(b) Shafts subjected to bending moment

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ME 8593- DESIGN OF MACHINE ELEMENTS

(c) Shafts subjected to combination of torque and bending moment

(d) Shafts subjected to axial loads in addition to combination of torque and bending moment
3.1 Shafts Subjected to Torque
Maximum shear stress developed in a shaft subjected to torque is given by,

where T = Twisting moment (or torque) acting upon the shaft,

J = Polar moment of inertia of the shaft about the axis of rotation

= for solid shafts with diameter d

= for hollow shafts with do and di as outer and inner diameter.

r = Distance from neutral axis to the outer most fibre = d/2 (or do/2)
So dimensions of the shaft subjected to torque can be determined from above relation for a known value
of allowable shear stress, [τ].
3.2 Shafts Subjected to Bending Moment
Maximum bending stress developed in a shaft is given by,

where M = Bending Moment acting upon the shaft,

I = Moment of inertia of cross-sectional area of the shaft about the axis of rotation

= for solid shafts with diameter d

= for hollow shafts with do and di as outer and inner diameter.

y = Distance from neutral axis to the outer most fibre = d / 2 (or do/2)
So dimensions of the shaft subjected to bending moment can be determined from above relation for a
known value of allowable tensile stress, [t ].
3.3 Shafts Subjected to Combination of Torque and Bending Moment
When the shaft is subjected to combination of torque and bending moment, principal stresses are
calculated and then different theories of failure are used. Bending stress and torsional shear stress can be
calculated using the above relations.

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ME 8593- DESIGN OF MACHINE ELEMENTS

Maximum Shear Stress Theory

Maximum shear stress is given by,

is called equivalent torque, Te, such that

Maximum Principal Stress Theory
Maximum principal stress is given by,

is called equivalent bending moment, Me, such that

A.S.M.E. Code for Shaft Design
According to A.S.M.E. code, the bending and twisting moment are to be multiplied by factors k b and
kt respectively, to account for shock and fatigue in operating condition. Therefore, if the shaft is
subjected to dynamic loading, equivalent torque and equivalent bending moment will become:

and
Table.1 Values of kb and kt for different types of loading
Different Types of Loading kb kt
Gradually applied load 1.5 1.0
Suddenly applied load (minor shock) 1.5-2.0 1.0-1.5
Suddenly applied load 2.0-3.0 1.5-3.0

3.4 Shafts Subjected to Axial Loads in addition to Combination of Torque and Bending Moment

Tensile Stress due to axial load is given by,

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ME 8593- DESIGN OF MACHINE ELEMENTS

where, P = axial load acting on the shaft A = cross-sectional area of the shaft
As nature of the bending stress and this axial stress is same, these can be vectorially added for any
location on the shaft, so as to get the resultant tensile/compressive stress, which can then be used to find
the principal stresses in the shaft.
3.5 Design of Shaft on the basis of Rigidity
3.5.1 Torsional Rigidity

For a shaft subjected twisting moment, the angle of twist is given by,
Where, T = Torqe applied L = Length of the shaft
J = Polar moment of inertia of the shaft about the axis of rotation
G = Modulus of rigidity of the shaft material
Therefore for the known values of T, L and G and allowable value of angle of twist, diameter of the
shaft can be calculated.
3.5.2 Lateral Rigidity

Bending moment acting on any shaft is given by,

Integrating this equation twice with respect to x and applying the boundary conditions, y can be
calculated. y should be ≤ allowable value of deflection, [y].
3.6 A.S.M.E. Code for Shaft Design
According to A.S.M.E. code, the bending and twisting moment are to be multiplied by factors k b and
kt respectively, to account for shock and fatigue in operating condition. Therefore, if the shaft is
subjected to dynamic loading, equivalent torque and equivalent bending moment will become:

and
Table 1 Values of kb and kt for different types of loading
Different Types of Loading kb kt
Gradually applied load 1.5 1.0
Suddenly applied load (minor shock) 1.5-2.0 1.0-1.5
Suddenly applied load 2.0-3.0 1.5-3.0

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ME 8593- DESIGN OF MACHINE ELEMENTS

DESIGN OF KEYS
1. Introduction
Key is a machine element which is used to connect the transmission shaft to rotating machine elements
like pulley, gear, sprocket or flywheel. Keys provide a positive means of transmitting torque between
shaft and hub of the mating element. A slot is machined in the shaft or in the hub or both to
accommodate the key is called keyway. Keyway reduces the strength of the shaft as it results in stress
concentration.
Keys are made of ductile materials. Commonly used materials for a key are hardened and tempered steel
of grades C30, C35, C40, C50 and 55Mn75 etc. Brass and stainless keys are used in corrosive
environment. Factor of safety of 3 to 4 is generally taken on yield strength.
2 . Types of Keys
Common types of keys are:
1. Sunk keys 2. Saddle keys 3. Tangent keys 4. Round keys 5. Splines
2.1 Sunk Keys
A sunk key is a key in which half of the thickness of key fits into the keyway in the shaft and half in the
keyway of the hub. The sunk keys are of the following types:
Rectangular sunk key: It is the simplest type of key and has a rectangular cross-section. A taper of about
1 in 100 is provided on its top side. Rectangular sunk key is shown in Figure.1.

Figure.1 Rectangular Sunk Key

Square sunk key: Rectangular sunk key having equal width and thickness is called square sunk key.
Parallel sunk key: If no taper is provided on the rectangular or square sunk key, it is called parallel sunk
key i.e. it is uniform in width and thickness throughout. It is used where the pulley, gear or other mating
piece is required to slide along the shaft.
Gib-head key: It is a rectangular sunk key with a head at one end known as gib head, which is provided
to facilitate the removal of key. Gib Head key is shown in Figure 2.

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ME 8593- DESIGN OF MACHINE ELEMENTS

Figure .2 Gib Head Key

Feather key: Feather key is a parallel key made as an integral part of the shaft with the help of
machining or using set-screws. It permits axial movement and has a sliding fit in the key way of the
moving piece. Feather keys are shown in Figure 3.

Figure .3 Feather Key

Woodruff key: Woodruff key is a sunk key in the form of a semicircular disc of uniform thickness.
Lower portion of the key fits into the circular keyway of the shaft. It can be used with tapered shafts as it
can tilt and align itself on the shaft. But the extra depth of keyway in the shaft increases stress
concentration and reduces strength of the shaft. Woodruff key is shown in Figure 4.

Figure.4 Woodruff Key

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ME 8593- DESIGN OF MACHINE ELEMENTS

2.2 Saddle Keys

Slot for this type of is provided only in the hub as shown in Figure 15.5. Torque is transmitted by
friction only and cannot therefore transmit high torque and is used only for light applications. The saddle
keys are of two types: Flat Saddle Key and Hollow Saddle Key. In flat saddle key, the bottom surface
touching the shaft is flat and it sits on the flat surface machined on the shaft. Hollow saddle key has a
concave surface at the bottom to match the circular surface of the shaft. Chances of slip in case of the
flat saddle key are relatively lesser and can transmit more power than the hollow saddle key.

Figure.5 Saddle Keys Figure.6 Tangent Keys

2.3 Tangent Keys
Tangent keys are shown in Figure 15.6. These are used to transmit high torque. They may be used as a
single key or a pair at right angles. Single tangent key can transmit torque only in one direction.
2.4 Round Keys
The round keys have a circular cross-section and fit into holes drilled partly in the shaft and partly in the
hub. Slot is drilled after the assembly so the shafts can be properly aligned. These are used for low
torque transmission. Round keys are shown in Figure.7.

Figure .7 Round Key Figure .8 Splines

15.2.5 Splines
A number of keys made as an integral part of the shaft are called splines. Keyways are provided in the
hub. These are used for high torque transmission e.g. in automobile transmission. Splines also permit the
axial movement. Splines are shown in Figure.8.
15.3 Design of Sunk Keys

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ME 8593- DESIGN OF MACHINE ELEMENTS

Figure.9 shows the forces acting on a rectangular key having width w and height h. Let l be the length of
the key. Torque is transmitted from the shaft to the hub through key. Shaft applies a force P on the key
and the key applies an equal force on the hub. Therefore the key is acted upon by two equal forces of
magnitude P, one applied by the shaft (on the lower portion) and the other because of the reaction of hub
(on the upper portion).
As these two forces are not in same plane, they constitute a couple which tries to tilt the key. Therefore
equal and opposite forces P’ also act on the key, which provide a resisting couple that keeps the key in
position.
As the exact location of force P is not known, to simplify the analysis it is assumed that the force P acts
tangential to the shaft. If T is the torque transmitted,

where, d = diameter of the shaft

Figure .9 Forces Acting on Key Figure.10 Failure of Key a. Shear Failure b. Crushing Falure
In the design of key two types of failures are considered, shear failure and crushing failure.
Area resisting shear failure = w l

Shear stress, Crushing Area = l h/2 Crushing stress,

Tables are available which give standard cross-sections for square and rectangular keys corresponding to
different shaft diameters. But in the absence of such data, following relations are generally used:
For Rectangular Key: w = d / 4 and h = d / 6
For Square Key: w = h = d /4
For a known diameter of shaft, w and h can be calculated using these relations and then using the above
strength equations required length of the key is calculated for given values of allowable stresses. Length
is calculated both for shear and crushing and then maximum value out of the two is considered.

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ME 8593- DESIGN OF MACHINE ELEMENTS

DESIGN OF COUPLINGS
1.Introduction
Couplings are used to connect two rotating shafts to transmit torque from one to the other. For example
coupling is used to connect the output shaft of an electric motor to the input shaft of a hydraulic pump.
2. Types of Shafts Couplings
Rigid Couplings
Rigid Couplings are used to connect two shafts which are perfectly aligned. These are simple and
inexpensive.
Rigid Couplings are of following types:
1. Sleeve or Muff Coupling
2. Clamp or Split-muff or Compression Coupling
3. Flange Coupling
Flexible Couplings
Flexible couplings are used to connect two shafts having lateral or angular misalignment. Flexible
elements provided in flexible coupling absorb shocks and vibrations.
Flexible Couplings are of following types:
1. Bushed pin type Coupling
2. Universal Coupling
3. Oldham Coupling
3 Muff Coupling
3.1 Introduction
Assembly of muff coupling is shown in Figure 16.1. Sleeve, a hollow cylinder, is fitted on the ends of
input and output shaft with the help of a sunk key. Torque is transmitted from input shaft to the sleeve
through key and from the sleeve to the output shaft through the key again. It is simple to design and
manufacture but difficult to assemble and dismantle. It requires more axial space and has small radial
dimensions. Sleeve is made of cast iron and for it a larger factor of safety of 6-8 is used on the ultimate
strength. Standard proportions used for sleeve are:
Outer diameter of the sleeve, D = 2d + 13
Length of the sleeve, L = 3.5d
where d is the diameter of the shaft.
So the muff coupling has three main components: shafts, sleeve and key.

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ME 8593- DESIGN OF MACHINE ELEMENTS

Figure.1 Muff Coupling

3.2 Design
3.2.1.Design of Shafts
Shafts are designed on the basis of torsional shear stress induced because of the torque to be transmitted.

Shear stress induced in shaft for transmitting torque, T is given by,

Where T = Twisting moment (or torque) acting upon the shaft,
J = Polar moment of inertia of the shaft about the axis of rotation
r = Distance from neutral axis to the outer most fibre = d/2
So dimensions of the shaft can be determined from above relation for a known value of allowable shear
stress, [τ].
3.2.2. Sleeve Design
As discussed earlier, following relations are used to calculate the dimensions.
D = 2d + 13 L = 3.5d
Then the torsional shear stress in the sleeve is checked considering it as a hollow shaft.

Shear stress,
where, T = Twisting moment (or torque) to be transmitted
J= Polar moment of inertia about the axis of rotation
r = Distance from neutral axis to the outer most fibre = D/2
3.2.3. Design of Key
Cross-section of the key is taken from the table corresponding to the shaft diameter or relations (square
key) or and (for rectangular key) are used to find the cross-section, where w is width and h is the height
of the key.

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ME 8593- DESIGN OF MACHINE ELEMENTS

Length of key in each shaft, .

The keys are then checked in shear and crushing.

Shear stress, Crushing stress

4 .Clamp Coupling
4.1 Introduction
Clamp coupling is also known as split-muff coupling or compression coupling. In this coupling, sleeve
or muff is made in two halves, which are split along the plane passing through the axes of the shafts.
These two halves are clamped together with the help of bolts, which are placed in recesses made in the
sleeve halves. Dynamic balancing of clamp coupling is difficult making it unsuitable for high speed
applications. It is also unsuitable for shock loads. Assembly and dismantling is easier for this coupling.
Figure 2 shows Clamp Coupling assembly.
A small clearance is provided between the two halves of the sleeve along the parting line and the force
due to clamping of bolts creates frictional force between the surface of the shafts and inner surface of
sleeve halves. Torque is transmitted by means of this frictional force and through the key, from the input
shaft to the sleeve and from sleeve to the output shaft. It is not possible to find out the exact percentage
of torque transmitted by friction and by the key. Therefore, for designing the bolts it is assumed that
whole of the torque is transmitted by friction and while designing the key, it is assumed that whole of
the torque is transmitted by it.
Design is similar to the design of muff coupling and an additional calculation is required for designing
the bolts.

Figure.2 Clamp Coupling

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4.2 Design
Design of Clamp Coupling is similar to the design of muff coupling and an additional calculation is
required for designing the bolts.
4.2.1 Design of Shafts
Same as discussed in sleeve coupling.
4.2.2 Sleeve Design
Same as discussed in Sleeve Coupling
4.2.3 Design of Key
Same as discussed in Sleeve Coupling
4.2.4 Design of Bolts
Bolts are designed assuming that whole of the torque is transmitted by friction between sleeve and
shafts.
Let [σt] = permissible tensile stress of bolts dc = core diameter of bolts
n = number of bolts
Clamping force of each bolt,

Figure.3 Forces acting on Bolts

Assuming that half of the bolts apply clamping force on one shaft and half of the bolts on the other.

Clamping force on each shaft,

Frictional Torque, where, m = coefficient of friction between shafts and sleeve.

Above two relations can be used to find the core diameter of the bolts by equating to the total torque
transmitted.

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ME 8593- DESIGN OF MACHINE ELEMENTS

5. Flange Coupling
5.1 Introduction
Flange coupling consists of two flanges keyed to the shafts. The flanges are connected together by
means of bolts arranged on a circle concentric to shaft. Power is transmitted from driving shaft to flange
on driving shaft through key, from flange on driving shaft to the flange on driven shaft through bolts and
then to the driven shaft through key again. Projection is provided on one of the flanges and a
corresponding recess is provided in the other for proper alignment.
Flange coupling is of two types – unprotected and protected. These are shown in Figure.3. If in case
failure of bolts occurs during the operation, the bolts may hit the operator in case of unprotected flange
coupling. To avoid this, protective circumferential flanges are provided in the protected type flange
coupling.
Flange of a protected type flange coupling has three distinct regions – inner hub, flanges and protective
circumferential flanges. Following standard proportions are used in the design of flange coupling:
Outer diameter of hub, D=2d
Pitch circle diameter of bolts, D1 = 3 d
Outer diameter of flange, D2 = 4 d
Length of the hub, L = 1.5 d
Thickness of flange, tf = 0.5 d
Thickness of protective circumferential flange, tp = 0.25 d where d is the diameter of shafts

Figure .4 Flange Coupling

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ME 8593- DESIGN OF MACHINE ELEMENTS

2.Protected type flange coupling.

In a protected type flange coupling, as shown in Fig. The thickness of the protective circumferential
flange (tp) is taken as 0.25 d.
If d is the diameter of the shaft or inner Number of bolts = 6, for d upto 180 mm
diameter of the hub,
Outside diameter of hub, D = 2 d
Length of hub, L = 1.5 d
Pitch circle diameter of bolts, D1 = 3d
Outside diameter of flange, D2 = D1 + (D1 – D)
= 2 D1 – D = 4 d
Thickness of flange, tf = 0.5 d ,
Number of bolts= 3, for d upto 40 mm
Number of bolts = 4, for d upto 100 mm

3. Marine type flange coupling.

The other proportions for the marine type flange
coupling are taken as follows:
Thickness of flange = d / 3
Taper of bolt = 1 in 20 to 1 in 40
Pitch circle diameter of bolts, D1 = 1.6 d
Outside diameter of flange, D2 = 2.2 d

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ME 8593- DESIGN OF MACHINE ELEMENTS

5.2 Design
5.2.1 Design of Shafts
Same as discussed in sleeve coupling.
5.2.2 Design of Hub
Hub is designed considering it as a hollow shaft, with inner diameter equal to diameter of shafts and
outer diameter double of that. It is checked for torsional shear stress.

Shear stress,
Where T = Twisting moment (or torque) to be transmitted
J = Polar moment of inertia about the axis of rotation
r = Distance from neutral axis to the outer most fibre = D/2
5.2.3 Design of Key
In this case two separate keys are used for the two shafts. Key is designed as discussed earlier. In this
case, length of key, (length of the hub)
5.2.4 Design of Flange
The flange is subjected to shear at the junction of the hub as it transmits torque through the bolts. Area
resisting shear where, tf is the thickness of the flange.

If T is the torque to be transmitted, tangential force,

Shear stress,
5.2.5 Design of Bolts
Due to transmission of torque, force acts perpendicular to the bolt axes and the bolts are subjected to
shear and crushing stresses. Let n be the total number of bolts.

Force acting on each bolt, where D1 is the pitch circle diameter of bolts.

Area resisting shear where, dc = core diameter of bolts

Shear stress, Area under crushing., Crushing stress,

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Design for flexible couplings--Bushed-pin Flexible Coupling

A bushed-pin flexible coupling, as shown in Fig. is a modification of the rigid type of flange coupling.

Design procedure bused pin flexible couplings Ref p.no.106 &108

Where A- Dia of shaft B – Out Side Diameter C- Hub dia D – PCD of Bolt E- Hub
Length

F – Bolt Dia G – Flange width n- no of bolts t- clearance

H- Protective Circumferential Flange Thickness db- bush dia

Read the value of A,B,C,D,E,F,G,H,n,t, from DB at design power

1. Calculation of shaft diameter

Let P –power in watts N- speed in rpm T –torque on shaft in Nm

[t] –permissible shear stress

Calculate diameter of shaft (d) select nearest std value

2.Selection of coupling Ref P.No 7.108,109

Maximum rating at 100 rpm =(KW of powerapplication x service factor x100) / RPM of application

Select service factor from pg.no 7.109 and ref p.no7.108 select coupling no.,at the maximum rating

Take the proportions based on coupling no. the value of A,B,C,D,E,F,G,H,n,t

3.Bearing pressure in the rubber bush

Let Ft- tangential force on pitch circle ref p.no-10.6 .

Let p = bearing pressure

If p>[p] change the coupling no. and select new proportions and recalculating bearing pressure.

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4.Check the stresses in the pin

Let pin subjected to bending and shear

Mb- bending moment in pin = load x distance =

Bending stress in the pin =

F – diameter of bolt

5.Design of keys p.no 5.19 & 5.21

Select b and h from DB at diameter of shaft

length of key = hub length =E

Check the stresses in the key

Check for shear stress

Check for crushing stress

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