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The specification of performance requirements for shaft is given below in terms of power to be transmitted, and the speed of transmission: Performance specification required=30 Kw*1450 r.p.m. SELECTION OF MATERIAL FOR PART Material selected is medium carbon steel, to British Standard specification BS 970:080M040(H&T), whose mechanical properties are: (a) Tensile yield strength S y = 385 Mpa (b) Ultimate tensile strength Sut = 625 775 Mpa (c) Elongation %=16% (1)
(d) Hardness number=179-229 HB The material is a ductile material, having an elongation % of 16 %>5%. DETERMINATION OF EXTERNAL LOADS CARRIED BY GEAR SHAFT Torque required to transmit power at the speed specified The relationship between power and torque transmitted is given by the equation:
Power = T * watts
Where
N-m
(2)
Where
(3)
(4)
TRANSVERSE LOAD ON GEAR SHAFT ARISING FROM THE TORQUE TRANSMITTED TANGENTIAL FORCE ON GEAR TEETH F REQUIRED TO TRANSMIT TORQUE SPECIFIED As shown in the gear set diagram, the tangential force on the gear teeth, is the gear tooth force operating at the pitch diameter d of the driving gear on the input shaft. The torque transmitted is then given as function of the tangential tooth force and the pitch diameter of the gear as below:
Torque T = F *
2 d Therefore F = T * d 2
Newtons
Substituting for the pitch diameter of the input gear d = 40 mm. and T=197.6 N-m
F = 197.6 *
F = 9880 Newtons
2 Newtons 0.04
(5)
RESULTANT FORCE ON GEAR TOOTH REQUIRED TO TRANSMIT TORQUE SPECIFIED The tangential force F is the component of the resultant gear tooth force that gives rise to the transmitted torque. It acts at the pitch point, along the tangent to the pitch circle diameter of the gear tooth. The resultant gear tooth force is normal to the tooth surface, and therefore inclined to the tangent to pitch circle diameter at an angle equal to the pressure angle of the gear tooth. The resultant force on the gear tooth is given by the equation
Re sul tan t R =
R = F * sec
F cos
R = 10154 Newtons
N (6)
DETERMINE BENDING MOMENT LOADS ON THE INPUT SHAFT LOADING DIAGRAM OF THE INPUT SHAFT-CONSIDERED AS A SIMPLY SUPPORTED BEAM SUBJECT TO TRANSVERSE POINT LOADS The loading diagram is shown at Appendix A and reproduced below:
R1 = R *
35 85
N,
and
R2 = R *
50 85
35 85
N,
and
and
R2 = 10154 *
N
50 85
N,
R2 = 5972
(7)
SHEAR FORCE DIAGRAM The shear force diagram is shown at appendix a. however, the direct shear stress induced by the shear force reaches its maximum value at the centre of the shaft, while the stresses caused by bending and torsion reach their maximum values the surface of the shaft. the effect of the direct shear stress is therefore ignored. BENDING MOMENT DIAGRAM FOR INPUT SHAFT The bending moment diagram for a straight beam with intermediate load and simple supports is then as shown below
M max = M a = R *
N mm
M max = 10154 *
M max = 209052
35 * 50 85
N mm = 209052
N mm
N mm
(8)
4
EXTERNAL LOAD ON THE GEAR SHAFT The external load on the input gear shaft then reduces to combined torsion and bending, where the torsion and bending loads are: T =197.6 N m =197600 N mm (9) M max = 209052 N mm (10) Determination of stresses induced by the external loads STRESSES DUE TO COMBINED TORSION AND BENDING OF SHAFT In this situation, there is a plane stress at the location of maximum bending moment as shown below
32M
d 3
16T d3
Simplifying the loading situation of the input shaft into a static load which remains constant in spite of the rotation of the shaft, determine the significant stress at the location of highest stresses in terms of principal and maximum shear stress arising from the loads on the member Applying maximum shear stress theory of failure
The MAXIMUM SHEAR STRESS theory of failure states: When Yielding occurs in any material, the maximum shear stress at the point of failure equals or exceeds the maximum shear stress when yielding occurs in the tension test specimen. STRESS ELEMENTS IN THE PLANE STRESS SITUATION The plane stress situation is the stress situation in which the stress elements are x , y , and xy , and the stresses on the z-axis are zero, MAXIMUM SHEAR STRESS IN TERMS OF PLANE STRESS ELEMENTS The maximum shear stress is the significant stress in this situation and is given by the expression
x y + xy 2 max = 2
2
(11)
Maximum shear stress in the case of plane stress situation with y = 0 THE GENERAL CASE OF PLANE STRESS SITUATION WITH y = 0 Substituting for y = 0 into the equation for maximum shear stress yields
0 x2 2 2 max = x + xy = x + xy = + xy 2 2 2 4
2 2
max =
1 x2 x 2 + 4 xy 2 + xy 2 = 2 4
(12)
Stresses induced in gear shaft by the external loads SOLID CIRCULAR SHAFT SUBJECT TO BENDING AND TORSION In the case of combined torsion and bending, the stress elements in the plane stress situation are:
x = normal stress due to bending =
y = 0
32 M
d 3
16T d3
MAXIMUM SHEAR STRESS IN ELEMENT IN TERMS EXTERNAL LOADS Substituting for x and xy in equation for maximum shear stress yields the expression for maximum shear stress in terms of load and dimension of element as shown below:
max =
1 1 32M x 2 + 4 xy 2 = 2 2 d 3
16T + 4 3 d
max =
16
M 2 +T2
(13)
SHEAR STRENGTH OF CHOSEN (DUCTILE) MATERIAL The yield strength in shear of ductile materials such steel is predicted to be half the tensile yield strength by the maximum shear stress theory of failure, and the shear yield strength of such materials can therefore be derived from the tensile yield strength Therefore S sy = Where
Sy 2
(14)
COMPARE SIGNIFICANT STRESS WITH STRENGTH: DESIGN EQUATION Design equation then becomes
max =
16
S sy f .s. Sy 2 * f .s. ssy f .s =
16 d3 = 2 * f .s. Sy
M2 +T2 =
OR
Sy 2 * f .s
M 2 +T 2 *
Where
f .s. = factor of safety , and = d , the design or allowable shear stress
(15)
SOLVING DESIGN EQUATION Substituting the TORQUE and BENDING MOMENT loads into design equation T = 197.6 N m (16) M max = 209052 N mm (17)
32 d3 =
( 209052) 2 + (197600) 2 *
f .s. Sy
Substituting for yield strength of chosen material and the factor of safety Factor of safety =2.5 and Tensile yield strength
d3 =
S y = 385 Mpa
32
385
d =26.7
mm.
(18)
SELECT SHAFT SIZE FROM PREFERRED METRIC RANGE Select the shaft size to be used form the nearest size in the range of preferred metric sizes1 (1,1.2,1.6,2,2.5,3,4,5,6,8,10,12,16,20,25,30,35,40,45,50,55,60,65,70,75,80,90,100 mm.) Nearest shaft size selected is 30 mm. REVIEW DESIGN Determine the actual factor of safety resulting from the use of the selected standard shaft size Rewriting the design equation in terms of the factor of safety
f .s. = S sy = Sy 2 * max
M2 +T2
max
But max =
T = 197.6
16
Substituting
N m
M max = 209052
N mm
(16) (17)
And
d = 30 mm
max =
16
303
Substituting
f .s. =
Sy 2
max
Shigley Joseph, Mechanical Engineering Design, First Metric Edition, , McGraw Hill, 1986, page 660 8
APPENDIX A: LOADING, SHEAR FORCE, AND BENDING MOMENT DIAGRAMS LOADING DIAGRAM
R1 =
Rb l
and
R2 =
Ra l
VAB = R1
and
VBc = R2
M AB =
Rbx l
and
M BC =
Ra ( l x) l
0.40C
080M40
0.50C
080M50
3NiCrMo
830M31
H&T
1.5MnNiCrMo
945M38
H&T
2 3
Shigley, Joseph E., Mechanical Engineering Design, pp. 664, McGraw-Hill Inc., 1986 British Standards Institution, BS 970: Part 1: 1983 4 HR-Hot rolled and normalised 5 CD-Cold drawn 6 H&T-Hardened and tempered 10
A 4340 3250
Arbors Armature shafts Axles Ball races Bolts and studs Bushings Cams Camshaft Cant dogs Chain Links Chain Pins Chuck Jaws Chuck screws Clutches Collets Connecting Rods Crankshafts Drift Pins Engine bolts Gears Guide Pins Mandrels Pinions Pins Pistons Pump Shafts Rollers Rolls Lead Screws Set Screws Spindles Stay Bolts Thrust washers Turbine Shafts Turnbuckles U bolts Universal Joint Pins Universal joint bodies Worm Gears
T T T T T T T T T T T
C C C C C
C C
T T
C C N,A
T T T
C C C C C
C C C C C
S,T
N,S,T
S,T
S,T
T T T T T T
C N
C A C
S,T
T T
T T T T S,T T
pp. 10, ASME Handbook, Metals Engineering-Processes, McGraw-Hill Book Company, 1958 11