ME3070: Design of Machine Elements

Tutorial 8
Indian Institute of Technology Palakkad

December 1, 2023

1. An AISI 1020 CD steel shaft is to be designed to sup-

port the spur gear and overhanging worm as shown
below. The shaft speed is 300 rpm. The bearing at
A takes pure radial load and the bearing at B can take
axial thrust for rotation of worm in either direction.
The radial loads on the gear and the worm are in the
same plane. The torque transfer between gears and the
shaft takes place through rectangular keys. Design the
shaft by following the steps below.
(a) Draw the diagrams corresponding to bending mo-
ment, torque and axial thrust. (Mark:
3+2+1)

Figure 1: Problem-1
(b) Identify the critical locations and determine the minimum shaft diameter at those locations based
on a factor of safety of 2 for the shaft. Use static yielding and modified Goodman criteria. Maintain
a diameter ratio (D/d) of 1.2 and fillet-radius to smaller diameter ratio (r/d) of 0.05 at each bearing
location. The fatigue stress concentration factors at the keyways are 5.0 for bending and 3 for torsion.
(Mark: 10)
(c) Check for the failure of keys for both the spur gear and the worm. The factor of safety for the key
should be 1.8. Key material is AISI 1006 HR steel. (Mark: 4)

Solution:
Σ𝐹𝑥 = 0; 𝑅 𝐵𝑋 = 22.4 kN
Σ𝐹𝑦 = 0; 𝑅 𝐴 + 𝑅 𝐵 = 6.2 kN
Σ𝑀 𝐴 = 0; 𝑅 𝐵 × 0.45 − 2.4 × 0.1 − 3.8 × 0.525 = 0
=⇒ 𝑅 𝐵 = 4.967 kN & 𝑅 𝐴 = 1.233 kN

1
Part b: Most critical point: Just right of point B.

𝑀 = 285 N-m

𝑇 = 540 N-m
𝐹𝑎𝑥𝑖𝑎𝑙 = 22.4 kN
Static stress concentration factors:

When 𝐷/𝑑 at 𝐵, 𝑟/𝑑 = 0.05 =⇒ 𝐾𝑡 = 2.0 (Axial) ( 𝐴 − 15.7)

𝐾𝑡 = 1.95 (Bending); 𝐾𝑡𝑠 = 1.6 (Torsion) (From 𝐴 − 15.9)

2
Notch sensitivity factor: q depends on fillet radius which we do not know yet.
We will take guess values of 𝐾 𝑓 and 𝐾 𝑓 𝑠 to be same as the static stress concentration factors.
From A-20: AISI 1020 CD Steel:

𝑆𝑢𝑡 = 470 MPa, 𝑆 𝑦 = 390 MPa

(From Eq.6-19):
𝑏
𝐾𝑎 = 𝑎𝑆𝑢𝑡 = 4.51(470) −0.251 = 0.883
𝐾 𝑏 = 0.9 (guess)
𝐾𝑐 = 𝐾 𝑑 = 𝐾𝑒 = 1
=⇒ 𝑆 𝑒 = (0.883)(0.9)(1)(1)(1)(0.5)(470) = 186 MPa
Bending moment is completely reversing. Axial loads and torque are constants.

=⇒ 𝑀𝑎 = 285 N-m; 𝑇𝑎 = 0; 𝐹𝑎 = 0

𝑀𝑚 = 0; 𝑇𝑚 = 540 N-m; 𝐹𝑚 = 22.4 kN

Ignore axial load first:
von-Mises Stresses:
 2   2 ! 1/2
32𝐾 𝑓 𝑀𝑎 16𝐾 𝑓 𝑠𝑇𝑎
𝜎𝑎′ = +3
𝜋𝑑 3 𝜋𝑑 3
 2   2 ! 1/2
32𝐾 𝑓 𝑀𝑚 16𝐾 𝑓 𝑠𝑇𝑚
𝜎𝑚′ = +3
𝜋𝑑 3 𝜋𝑑 3
32𝐾 𝑓 𝑀𝑎 5661
=⇒ 𝜎𝑎′ = =
𝜋𝑑 3 𝜋𝑑 3
√ 16𝐾 𝑓 𝑠𝑇𝑚 7621.57
𝜎𝑚′ = 3 =
𝜋𝑑 3 𝑑3
Modified Goodman criteria:
1 𝜎′ 𝜎′
= 𝑎+ 𝑚
𝑛𝑓 𝑆 𝑒 𝑆𝑢𝑡
1 5661 7621.57
=⇒ = + =⇒ 𝑑 = 45.4 mm
2 186 × 106 𝑑 3 470 × 106 𝑑 3
Since we started in a conservative manner, we can choose the standard size to be 𝑑 = 45 mm (from
Table A-17) and (instead of next value 𝑑 = 50 mm)
Now we do a thorough calculation with this starting dia. d = 45 mm. (at right of b)
For the fillet:
𝑟 = 0.05 × 45 = 2.25 mm
𝑞 = 0.78; 𝑞 𝑠ℎ𝑒𝑎𝑟 = 0.81 (Fig.6 − 20 & 6 − 21)
=⇒ 𝐾 𝑓 |𝑎𝑥𝑖𝑎𝑙 = 1 + 𝑞(𝐾𝑡|𝑎𝑥𝑖𝑎𝑙−1 ) = 1 + 0.78(2 − 1) = 1.78
𝐾 𝑓 |𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = 1 + 0.78(1.95 − 1) = 1.741
𝐾 𝑓 |𝑠ℎ𝑒𝑎𝑟 = 1 + 0.81(1.6 − 1) = 1.486

3
=⇒ 𝐾𝑎 remains the same. =⇒ 𝐾𝑎 = 0.883
  (−0.107)   (−0.107)
𝑑 𝑑
𝐾𝑏 = = = 0.827 (eq.6-20 )
7.62 7.62
𝐾𝑐 = 𝐾 𝑑 = 𝐾𝑒 = 1
=⇒ 𝑆 𝑒 = 171.6 MPa
32𝐾 𝑓 𝑀𝑎
𝜎𝑎|𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = = 55.5 MPa
𝜋𝑑 3
𝜎𝑎|𝑎𝑥𝑖𝑎𝑙 = 𝜏𝑎 = 0
22.4 × 103
𝜎𝑚|𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = 0, 𝜎𝑚|𝑎𝑥𝑖𝑎𝑙 = 𝐾 𝑓 𝑠 = 25.07 MPa
𝜋𝑑 2 /4
16𝑇𝑚
𝜏𝑚 = 𝑘 𝑓 𝑠 = 44.9 MPa
𝜋𝑑 3
𝜎𝑎′ = 55.5 MPa
𝜎𝑚′ = [𝜎𝑚|𝑎𝑥𝑖𝑎𝑙 ) 2 + 3𝜏𝑚2 ]1/2 = 81.2 MPa (eq.6-55, 6-56 )
1
𝑛𝑓 = = 2 (okay)
𝜎𝑎′ 𝜎′
+ 𝑚
𝑆 𝑒 𝑆𝑢𝑡
Static yield:
′
𝜎𝑚𝑎𝑥 = 𝜎𝑎′ + 𝜎𝑚′ = 138.7 MPa
𝑆𝑦
=⇒ 𝑛 𝑦 = ′ = 2.812 (okay)
𝜎𝑚𝑎𝑥
=⇒ 𝑑 = 45 mm at the right of B is okay.
𝐷
At the left of B: = 1.2 =⇒ 𝐷 = 54 mm
𝑑
Again this is not a standard size. Since major part of the shaft will be of diameter D. We should choose
standard value for this.
Let D = 60 mm, =⇒ 𝑑 = 50 mm (Table A-17)
Next critical location is the spur gear, because of key way: D = 60 mm.
Load: 𝑀𝑎 = 123.3 N-m; 𝑀𝑚 = 0
𝑇𝑚 = 540 N-m, 𝑇𝑎 = 0 No axial load.
𝐾 𝑓 = 5.0, 𝐾 𝑓 𝑠 = 3.0

32𝑀𝑎
=⇒ 𝜎𝑎′ = 𝐾 𝑓 = 29.07 MPa
𝜋𝐷 3
√ 𝑇𝑚 × 16
𝜎𝑚′ = 3.𝐾 𝑓 𝑠 . = 66.16 MPa
𝜋𝐷 3
  −1
29.07 66.16
𝑛𝑓 = + = 3.22 (okay)
171.6 470
So, the sizes mentioned above are okay.
Shaft Size: Between bearing A and B: D = 60 mm
For bearing A and bearing B and the remaining: d = 50 mm

4
 Part C: Design of rectangular key.
Material- AISI 1006 HR Steel =⇒ 𝑆 𝑦 = 170MPa, 𝑆 𝑠𝑦 = 0.577𝑆 𝑦 = 98.1 MPa
Key For spur gear:

(From table 7-6:)

Key Size for shaft (dia. = 60 mm)

𝑤 = 60 mm

ℎ = 12 mm
𝑡 = 5.5 mm

Failure due to shearing:

𝑇 = 540 N-m
540
=⇒ 𝐹 = = 18 kN
0.03
𝑆 𝑠𝑦 𝐹
=
𝑛 𝑤𝑎
98.1 × 106 18 × 103
=⇒ =
1.8 16 × 10−3 × 𝑎
=⇒ 𝑎 = 20.64 mm

Failure due to bearing:

𝑆𝑦 𝐹 170 × 106 18 × 103
= =⇒ = =⇒ 𝑎 = 34.65 mm
𝑛 𝑎𝑡 1.8 5.5 × 𝑎
=⇒ Keylength should be larger than 34.65 mm.
Key for worm:
(Table 7-6): Key Size (shaft dia.= 50 mm)
𝑤 = 12 mm, ℎ = 10 mm, 𝑡 = 5 mm

5
 20.64 16
Shearing: 𝑎 = × = 27.52 mm
50/60 12
60 5.5
Bearing: 𝑎 = 34.65 × × = 45.74 mm
50 5
=⇒ Key length 𝑎 ≤ 45.74 mm (for worm)
Since both key should have 𝑎 ≈ 100 mm (width of worm & gear hub)- both are safe.