UNIT 2

UNIT ---- II
DESIGN OF SHAFTS
&
COUPLINGS

DESIGN OF SHAFTS & COUPLINGS

Design Of Solid Shaft Based On Strength, Rigidity And

Critical Speed
Design Of Keys, Key Ways & Splines
Design Of Rigid Coupling
Design Of Flexible Coupling
Design Of Crank Shaft

SHAFT:
A shaft is a rotating machine element which is used to
transmit power from one place to another.

The power is delivered to the shaft by some tangential

force and the resultant torque (or twisting moment) set up
within the shaft permits the power to be transferred to

various machines linked up to the shaft.

In order to transfer the power from one shaft to another,
the various members such as pulleys, gears etc., are
mounted on it.

SHAFT:
These members along with the forces exerted upon them
causes the shaft to bending.

In other words, we may say that a shaft is used for the

transmission of torque and bending moment. The various
members are mounted on the shaft by means of keys or

splines.
Notes:
1. The shafts are usually cylindrical, but may be square or cross-shaped

in section. They are solid in cross-section but sometimes hollow shafts

are also used.

2. An axle, though similar in shape to the shaft, is a

stationary machine element and is used for the transmission
of bending moment only. It simply acts as a support for some

rotating body such as hoisting drum, a car wheel or a rope

sheave.
3. A spindle is a short shaft that imparts motion either to a

cutting tool (e.g. drill press spindles) or to a work piece (e.g.

lathe spindles).

Material Used for Shafts:

The material used for shafts should have the following properties :
1. It should have high strength.
2. It should have good machinability.

3. It should have low notch sensitivity factor.

4. It should have good heat treatment properties.
5. It should have high wear resistant properties.

Materials:
The material used for ordinary shafts is carbon steel of grades 40 C
8, 45 C 8, 50 C 4 and 50 C 12.
When a shaft of high strength is required, then an alloy steel such

as nickel, nickel-chromium or chrome-vanadium steel is used.

Manufacturing of Shafts
Shafts are generally manufactured by hot rolling and finished to size by cold
drawing or turning and grinding. The cold rolled shafts are stronger than hot
rolled shafts but with higher residual stresses. The residual stresses may cause
distortion of the shaft when it is machined, especially when slots or keyways are cut.
Shafts of larger diameter are usually forged and turned to size in a lathe.
Types of Shafts
The following two types of shafts are important from the subject point of view :
1. Transmission shafts. These shafts transmit power between the source and
the machines absorbing power. The counter shafts, line shafts, over head shafts
and all factory shafts are transmission shafts. Since these shafts carry machine
parts such as pulleys, gears etc., therefore they are subjected to bending in addition

to twisting.
2. Machine shafts. These shafts form an integral part of the machine itself.
The crank shaft is an example of machine shaft.

Stresses in Shafts:
The following stresses are induced in the shafts :
1. Shear stresses due to the transmission of torque

(i.e. due to Torsional load).

2. Bending stresses (tensile or compressive), due to the
forces acting upon machine elements like gears, pulleys
etc. as well as due to the weight of the shaft itself.
3. Stresses due to combined Torsional and bending
loads.

Design of Shafts:
The shafts may be designed on the basis of
1. Strength, and 2. Rigidity and stiffness.

In designing shafts on the basis of strength, the following

cases may be considered :
(a) Shafts subjected to twisting moment or torque only,

(b) Shafts subjected to bending moment only,

(c) Shafts subjected to combined twisting and bending
moments, and

(d) Shafts subjected to axial loads in addition to

combined Torsional and bending loads.

The term shaft usually refers to a component of

circular cross-section that rotates and transmits power
from a driving device, such as a motor or engine,
through a machine.
Shafts can carry gears, pulleys and sprockets to
transmit rotary motion and power via mating gears, belts
and chains.
Alternatively, a shaft may simply connect to another
via a coupling.
A shaft can be stationary and support a rotating
member, such as the short shafts that support the nondriven wheels of automobiles often referred to as
spindles.

Case 1 : Shafts Subjected to Twisting Moment Only

When the shaft is subjected to a twisting moment (or torque) only, then the diameter
of the shaft may be obtained by using the torsion equation.

1. Find the diameter of a solid steel shaft to transmit 20 kW at 200 r.p.m. The ultimate

shear stress for the steel may be taken as 360 MPa and a factor of safety as 8. If a hollow
shaft is to be used in place of the solid shaft, find the inside and outside diameter when
the ratio of inside to outside diameters is 0.5.

Solution. Given : P = 20 kW = 20 103 W ; N = 200 r.p.m. ; u = 360 MPa = 360 N/mm2 ;

F.S. = 8 ; k = di / do = 0.5
2. A line shaft rotating at 200 r.p.m. is to transmit 20 kW. The shaft may be
assumed to be made of mild steel with an allowable shear stress of 42 MPa.
Determine the diameter of the shaft, neglecting the bending moment on the

shaft.
Solution. Given : N = 200 r.p.m. ; P = 20 kW = 20 103 W; = 42 MPa = 42 N/mm2
3. A solid shaft is transmitting 1 MW at 240 r.p.m. Determine the diameter of
the shaft if the maximum torque transmitted exceeds the mean torque by 20%.
Take the maximum allowable shear stress as 60 MPa.
Solution. Given : P = 1 MW = 1 106 W ; N = 240 r.p.m. ; Tmax = 1.2 Tmean ; = 60
MPa = 60 N/mm2

Case 2 : Shafts Subjected to Bending Moment Only

When the shaft is subjected to a bending moment only, then the maximum stress (tensile or
compressive) is given by the bending equation.

Case 3 : Shafts Subjected to Combined Twisting Moment and Bending Moment

When the shaft is subjected to combined twisting moment and bending moment,
then the shaft must be designed on the basis of the two moments simultaneously. Various
theories have been suggested to account for the elastic failure of the materials when they
are subjected to various types of combined stresses. The following two theories are
important from the subject point of view :
1. Maximum shear stress theory or Guest's theory. It is used for ductile materials such
as mild steel.
2. Maximum normal stress theory or Rankines theory. It is used for brittle materials
such as cast iron.
Let
= Shear stress induced due to twisting moment, and
b = Bending stress (tensile or compressive) induced due to bending moment.
According to maximum shear stress theory, the maximum shear stress in the shaft,

PROBLEM: 4: A solid circular shaft is subjected to a bending moment

of 3000 N-m and a torque of 10 000 N-m. The shaft is made of 45 C 8
steel having ultimate tensile stress of 700 MPa and a ultimate shear
stress of 500 MPa. Assuming a factor of safety as 6, determine the

diameter of the shaft.

5. A shaft supported at the ends in ball bearings carries a straight tooth spur gear at
its mid span and is to transmit 7.5 kW at 300 r.p.m. The pitch circle diameter of the
gear is 150 mm. The distances between the centre line of bearings and gear are 100
mm each. If the shaft is made of steel and the allowable shear stress is 45 MPa,

determine the diameter of the shaft. Show in a sketch how the gear will be mounted
on the shaft; also indicate the ends where the bearings will be mounted? The
pressure angle of the gear may be taken as 20.
Solution. Given : P = 7.5 kW = 7500 W; N = 300 r.p.m. ; D = 150 mm = 0.15 m ;
L = 200 mm = 0.2 m ; = 45 MPa = 45 N/mm2 ; = 20

6. A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter pulley

is mounted at a distance of 300 mm to the right of left hand bearing and this drives
a pulley directly below it with the help of belt having maximum tension of 2.25 kN.
Another pulley 400 mm diameter is placed 200 mm to the left of right hand bearing
and is driven with the help of electric motor and belt, which is placed horizontally to
the right. The angle of contact for both the pulleys is 180 and = 0.24. Determine
the suitable diameter for a solid shaft, allowing working stress of 63 MPa in tension
and 42 MPa in shear for the material of shaft. Assume that the torque on one pulley
is equal to that on the other pulley.

6:A shaft is supported on bearings A& B , 800 mm between centres. A 20o

straight tooth spur gear having 600 mm pitch diameter, is located 200 mm
to the right of the left hand bearing A and a 700 mm diameter pulley is
mounted 250mm onwards the left of the bearing B. The gear ids driven by
a pinion with a downward tangential force while the pulley drives a
horizontal belt having 180o angle of warp. the pulley also serves as a
flywheel and weighs 2000 N. The maximum belt tension is 3000 N and the

tension ratio is 3:1. Determine the maximum bending moment and the
necessary shaft diameter if the allowable shear stress of the material is 40
MPa.

Problem :7: A steel solid shaft transmitting 15 kW at 200 r.p.m. is supported on

two bearings 750 mm apart and has two gears keyed to it. The pinion having 30
teeth of 5 mm module is located 100 mm to the left of the right hand bearing and
delivers power horizontally to the right. The gear having 100 teeth of 5 mm
module is located

150 mm to the right of the left hand bearing and receives

power in a vertical direction from below. Using an allowable stress of 54 MPa in

shear, determine the diameter of the shaft.

Shafts Subjected to Fluctuating Loads

The shafts are subjected to fluctuating torque

and bending moments.

In order to design such shafts like line shafts and
counter shafts, the combined shock and fatigue

factors must be taken into account for the

computed twisting moment (T ) and bending
moment (M ).

Thus for a shaft subjected to combined bending

and torsion, the equivalent twisting moment,

A mild steel shaft transmits 20 kW at 200 r.p.m. It carries a central load of 900 N
and is simply supported between the bearings 2.5 metres apart. Determine the size
of the shaft, if the allowable shear stress is 42 MPa and the maximum tensile or
compressive stress is not to exceed 56 MPa. What size of the shaft will be
required, if it is subjected to gradually applied loads?
Solution. Given : P = 20 kW = 20 103 W ; N = 200 r.p.m. ; W = 900 N ; L = 2.5 m ;
= 42 MPa = 42 N/mm2 ; b = 56 MPa = 56 N/mm2

P:1: A mild steel shaft transmits 20 kW at 200 r.p.m. It carries a central load of 900
N and is simply supported between the bearings 2.5 metres apart. Determine the
size of the shaft, if the allowable shear stress is 42 MPa and the maximum tensile
or compressive stress is not to exceed 56 MPa. What size of the shaft will be
required, if it is subjected to gradually applied loads?
Solution. Given : P = 20 kW = 20 103 W ; N = 200 r.p.m. ; W = 900 N ; L = 2.5 m ;
= 42 MPa = 42 N/mm2 ; b = 56 MPa = 56 N/mm2 Take K m = 1.5, K t = 1

P-2:Fig. shows a shaft carrying a pulley A and a gear B and supported in two
bearings C and D. The shaft transmits 20 kW at 150 r.p.m. The tangential force Ft
on the gear B acts vertically upwards as shown. The pulley delivers the power
through a belt to another pulley of equal diameter vertically below the pulley A.
The ratio of tensions T1/ T2 is equal to 2.5. The gear and the pulley weigh 900 N
and 2700 N respectively. The permissible shear stress for the material of the shaft
may be taken as 63 MPa. Assuming the weight of the shaft to be negligible in
comparison with the other loads, determine its diameter. Take shock and fatigue
factors for bending and torsion as 2 and 1.5 respectively.

Solution. Given : P = 20 kW = 20 103 W ; N = 150 r.p.m. ; T1/T2 = 2.5 ; WB =

900 N ; WA = 2700 N ; = 63 MPa = 63 N/mm2 ; Km = 2 ; Kt = 1.5 ; DB = 750
mm or RB = 375 mm ; DA = 1250 mm or RA = 625 mm.

P : 3: A hoisting drum 0.5 m in diameter is keyed to a shaft which is supported in

two bearings and driven through a 12 : 1 reduction ratio by an electric motor.

Determine the power of the driving motor, if the maximum load of 8 kN is hoisted at
a speed of 50 m/min and the efficiency of the drive is 80%. Also determine the
torque on the drum shaft and the speed of the motor in r.p.m. Determine also the
diameter of the shaft made of machinery steel, the working stresses of which are
115 MPa in tension and 50 MPa in shear. The drive gear whose diameter is 450
mm is mounted at the end of the shaft such that it overhangs the nearest bearing
by 150 mm. The combined shock and fatigue factors for bending and torsion may
be taken as 2 and 1.5 respectively.
Solution. Given : D = 0.5 m or R = 0.25 m ; Reduction ratio = 12 : 1 ; W = 8 kN = 8000 N
; v = 50 m/min ; = 80% = 0.8 ; t = 115 MPa = 115 N/mm2 ; = 50 MPa = 50 N/mm2 ;

D1 = 450 mm or R1 = 225 mm = 0.225 m ; Overhang = 150 mm = 0.15 m ; Km = 2 ; Kt =

1.5

Shafts Subjected to Axial Load in addition to Combined

Torsion and Bending Loads

Problem:1: A hollow shaft of 0.5 m outside diameter and

0.3 m inside diameter is used to drive a propeller of a
marine vessel. The shaft is mounted on bearings 6 metre
apart and it transmits 5600 kW at 150 r.p.m. The maximum
axial propeller thrust is 500 kN and the shaft weighs 70 kN.
Determine
1.The maximum shear stress developed in the shaft, and
2.The angular twist between the bearings.

Design of Shafts on the basis of Rigidity

1. A steel spindle transmits 4 kW at 800 r.p.m. The angular deflection should not
exceed 0.25 per metre of the spindle. If the modulus of rigidity for the material of the
spindle is 84 GPa, find the diameter of the spindle and the shear stress induced in
the spindle.
2. Compare the weight, strength and stiffness of a hollow shaft of the same external
diameter as that of solid shaft. The inside diameter of the hollow shaft being half the
external diameter. Both the shafts have the same material and length.

ASSIGNMENTS

1.) A shaft is supported by two bearings placed 1 m apart. A

600 mm diameter pulley is mounted at a distance of 300 mm
to the right of left hand bearing and this drives a pulley
directly below it with the help of belt having maximum tension
of 2.25 kN. Another pulley 400 mm diameter is placed 200
mm to the left of right hand bearing and is driven with the
help of electric motor and belt, which is placed horizontally
to the right. The angle of contact for both the pulleys is 180
and = 0.24. Determine the suitable diameter for a solid
shaft, allowing working stress of 63 MPa in tension and 42
MPa in shear for the material of shaft. Assume that the
torque on one pulley is equal to that on the other pulley.

2). A steel solid shaft transmitting 15 kW at 200 r.p.m. is

supported on two bearings 750 mm apart and

has two

gears keyed to it. The pinion having 30 teeth of 5 mm

module is located 100 mm to the left of the right hand
bearing and delivers power horizontally to the right. The
gear having 100 teeth of 5 mm module is located 150 mm
to the right of the left hand bearing and receives power in a
vertical direction from below. Using an allowable stress of
54 MPa in shear, determine the diameter of the shaft.

3). A shaft is supported on bearings A& B , 800 mm between centers. A 20o

straight tooth spur gear having 600 mm pitch diameter, is located 200 mm to
the right of the left hand bearing A and a 700 mm diameter pulley is
mounted 250mm onwards the left of the bearing B. The gear is driven by a

pinion with a downward tangential force while the pulley drives a horizontal
belt having 180o angle of warp. the pulley also serves as a flywheel and
weighs 2000 N. The maximum belt tension is 3000 N and the tension ratio is
3:1. Determine the maximum bending moment and the necessary shaft
diameter if the allowable shear stress of the material is 40 MPa.
4. Compare the weight, strength and stiffness of a hollow shaft of the same
external diameter as that of solid shaft. The inside diameter of the hollow
shaft being half the external diameter. Both the shafts have the same
material and length.