SHAFT DESIGN AND ANALYSIS

MODULE 9| ABE 154 | PREPARED BY: ENGR. CFM

MODULE TOPICS
1. Introduction
2. Shaft Material and Layout
3. Design for Stress
4. ASME Code and PAES Procedure on
Designing Shaft
What is a Shaft and what is an Axle?
SHAFT AND AXLE
A shaft is a rotating member, usually of circular cross section, used to transmit power
or motion. It provides the axis of rotation, or oscillation, of elements such as gears,
pulleys, flywheels, cranks, sprockets, and the like and controls the geometry of their
motion.

An axle is a nonrotating member that carries no torque and is used to support rotating
wheels, pulleys, and the like.

a. The automotive axle is not a true axle; the term is a carry-over from the horse-and-
buggy era, when the wheels rotated on nonrotating members.

b. A non-rotating axle can readily be designed and analyzed as a static beam, and will
not warrant the special attention given in this chapter to the rotating shafts which
are subject to fatigue loading.
Let us take a recap on the Mechanical Properties of
Materials
MECHANICAL PROPERTIES OF MATERIALS
1. Elasticity 8. Toughness
2. Plasticity 9. Resilience
3. Strength
10. Creep
4. Ductility
11. Fatigue
5. Brittleness
12. Hardness
6. Malleability
13. Machinability
7. Stiffness
ELASTICITY
 Theability of a material to deform reversibly
under stress and return to its original shape
when the stress is removed.
PLASTICITY
 Theability of a material to undergo
permanent deformation or changes in
shape without rupturing or breaking.

Not regain its original shape

STRENGTH
 The ability of a material to withstand an applied
force without breaking or yielding.
1. Tensile Strength: This is the maximum stress a material can endure while being stretched or pulled
2. Shear Strength: Shear strength refers to a material's ability to withstand forces that act parallel to its
surface. It's the maximum stress that a material can endure without tearing or rupturing when being
subjected to shear forces.
3. Compressive Strength: This is the maximum stress a material can withstand when it is subjected to a
compressive (pushing or squashing) force. It is the opposite of tensile strength.
4.Torsional Strength: Torsional strength, also known as torque strength, is the maximum amount of
twisting or torsional stress that a material can withstand before failure. It is relevant in applications where
components are subjected to twisting or torsional loads.
DUCTILITY
 The extent to which a material can deform
plastically (stretch) before fracture or
breakage. (TENSILE Force)
BRITTLENESS
 Thetendency of a material to fracture or break
without significant deformation.

It breaks without deformation

MALLEABILITY
 The ability of a material to withstand
deformation under compressive
stress, typically leading to thin sheets
or foils.
STIFFNESS
 The resistance of a material to deformation or
deflection when subjected to an applied force.
It is a measure of how much a material will
deflect under an applied load.
TOUGHNESS
 The ability of a material to
absorb energy and deform
plastically before fracturing or
breaking. This is a combination
of strength and ductility.
HARDNESS
 Theresistance of a material to
deformation, scratching, or
abrasion.
RESILIENCE
 The ability of a material to absorb and store
elastic potential energy when deformed and
then release that energy upon unloading.
CREEP
 Thegradual (slow and permanent)
deformation of a material over time when
subjected to a constant load or stress at
elevated temperatures.
FATIGUE
 The failure of a material under cyclic loading
conditions, especially relevant in situations where
repeated stress is applied.
MACHINABILITY
 Theease with which a material
can be machined or shaped
using various manufacturing
processes.
TOPICS TO COVER IN SHAFT
MODULE TOPICS
1. Introduction
2. Shaft Material and Layout
3. Design for Stress
4. ASME Code and PAES Procedure on
Designing Shaft (PAES 305:2000)
ACRONYMS
 AISI – AMERICAN IRON AND STEEL INSTITUTE
 SAE – SOCIETY OF AUTOMOTIVE ENGINEERS
 ASME – AMERICAN SOCIETY OF MECHANICAL
ENGINEERS
 PAES – PHILIPPINE AGRICULTURAL ENGINEERING
STANDARDS
 ANSI – AMERICAN NATIONAL STANDARDS INSTITUTE
SHAFT MATERIAL
DEFLECTION IN SHAFT
4 TYPES OF STEEL
1. CARBON STEEL
2. ALLOY STEEL
3. STAINLESS STEEL
4. TOOL STEEL
CARBON STEELS
 CARBON STEELS CONTAIN TRACE AMOUNTS OF ALLOYING
ELEMENTS AND ACCOUNT FOR 90% OF TOTAL STEEL PRODUCTION.
 IT CAN BE CATEGORIZED INTO 3 GROUPS:
1. LOW CARBON STEELS/MILD STEELS CONTAIN UP TO 0.3% CARBON
2. MEDIUM CARBON STEELS CONTAIN 0.3-0.6% CARBON
3. HIGH CARBON STEELS CONTAIN MORE THAN 0.6%
ALLOY STEELS
 ALLOY STEELS CONTAIN ALLOYING ELEMENTS SUCH AS MANGANESE,
SILICON, NICKEL, TITANIUM, COPPER, CHROMIUM, AND ALUMINUM
IN VARYING PROPORTIONS IN ORDER TO MANIPULATE THE STEELS’
PROPERTIES SUCH AS HARDENABILITY, CORROSION RESISTANCE,
STRENGTH, WELDABILITY, OR DUCTILITY.
 APPLICATINS FOR ALLOY STEELS INCLUDE PIPELINES, AUTOPARTS,
TRANSFORMERS, POWER GENERATORS, AND ELECTRIC MOTORS
STEEL NUMBERING SYSTEMS
 IT HAS 4-DIGIT CODE NUMBERS IDENTIFYING THE BASE CARBON AND
ALLOY STEELS; HOWEVER, THERE ARE SELECTION OF ALLOY THAT HAVE
5-DIGIT CODE, INSTEAD.
 FIRST DIGIT – TYPE OF STEEL (SEE TABLE)
 2ND DIGIT – (SOMETIMES BUT NOT ALWAYS) INDICATES THE
CONCENTRATION OF THE MAJOR ELEMENT IN PERCENTILES (EX: 1
EQUALS 1%)
 3RD AND 4TH DIGITS – CARBON CONCENTRATION TO 0.01% ONWARDS
 EXAMPLE: SAE 5130
AISI AND SAE CODE DESIGNATION
AISI-SAE DESIGNATION TYPE
1XXX CARBON STEELS
2XXX NICKEL STEELS
3XXX NICKEL-CHROMIUM STEELS
4XXX MOLYBDENUM STEELS
5XXX CHROMIUM STEELS
6XXX CHROMIUM-VANADIUM STEELS
7XXX TUNGSTEN-CHROMIUM STEELS
8XXX NICKEL-CHROMIUM-MOLYBDENUM STEELS
9XXX SILICON-MANGANESE STEELS AND VARIOUS
OTHER SAE GRADES
CHOOSING A SHAFT
A good practice is to start with an
inexpensive, low or medium carbon steel
for the first time through the design
calculations.
If strength considerations turn out to
dominate over deflection, then a higher
strength material should be tried, allowing
the shaft sizes to be reduced until excess
deflection becomes an issue
COST OF MATERIAL AND ITS PROCESSING
SURFACE HARDENING THE SHAFT
Shafts usually don’t need to be
surface hardened unless they serve
as the actual journal of a bearing
surface. Typical material choices
for surface hardening include
carburizing grades of ANSI 1020,
4320, 4820, and 8620.
MACHINING COLD DRAWN SHAFT
Cold drawn steel is usually
used for diameters under
about 3 inches. The nominal
diameter of the bar can be left
unmachined in areas that do
not require fitting of
components. Hot rolled steel
should be machined all over.
CONCENTRICITY FACTOR
For large shafts requiring much
material removal, the residual
stresses may tend to cause
warping. If concentricity is
important, it may be necessary
to rough machine, then heat treat
to remove residual stresses and
increase the strength, then finish
machine to the final dimensions.
PRODUCTION OF SHAFT
• For low production, turning is the usual primary shaping
process, this is an economic viewpoint may require removing
the least material.
• High production may permit a volume conservative shaping
method (hot or cold forming, casting), and minimum material
in the shaft can become a design goal.
SHAFT LAYOUT
TYPICAL GEOMETRY OF SHAFT
SHAFT CONFIGURATION
MODULE TOPICS
1. Introduction
2. Shaft Material and Layout
3. ASME Code and PAES Procedure on
Designing Shaft
4. Design for Stress
PAES 305:2000  Engineering Materials – Shafts for
Agricultural Machines – Specifications and Applications
 Shafts are rotating members, usually of circular cross section used to transmit
power or motion. It provides the axis of rotation, or oscillation, of elements such as
gears, pulleys, flywheels, cranks, sprockets, and the like and controls the geometry
of their motion.
 Standard shafts for agricultural machines are usually of steel designation 1020
(cold rolled). For special purposes, stainless steel shafts usually of steel designation
304 or 316 shall be used.
 In order to provide support for the shaft and for shaft alignment, bearings should
be used. Bearings should be mounted on adequate supports so that accurate
alignment may be maintained. Misalignment may cause shaft or bearing failure.
 Standards on the use of keys and keyways are specified in PAES 304:2000.