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Plugging numbers into a long complex formula leads to mistakes and a lack of

understanding of how something is done.


You really need to work out basic shaft design from first principles.
Draw out the shaft and add the loads at the correct positions.
Work out the torque being transmitted and the bending moments at the critical
positions.
Select the material you will use for the shaft and establish is maximum tensile and
shear stress, then choose a suitable factor of safety.
Choose what you consider is the most suitable method to combine the torque and
bending moment with the stress to calculate the shaft diameters.
I generally combine the torque and bending moment into a combined bending
moment
Mcombined = M + Sqrt(M^2 + T^2)
then work from
Bending stress = Mcombined / Z
All of this is basic engineering stuff, no rocket science. If you do it my way you'll
understand what you are doing.
Rule of thumb with ISO keyways, add 10% to shaft diameter without keyway.

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