SHAFT DESIGN FOR STRESS

It is not necessary to evaluate the stresses in a shaft at every point, only at the critical points.
Critical locations usually will be on the outer surface at axial locations where the bending
moment is large, where the torque is present and where stress concentrations exist.
The bending moment can be determined by bending moment and shear force diagrams. Torque
is relatively constant at steady state operation. The shear stress due to the torsion will be
greatest on outer surfaces.
Shaft Stresses
The fluctuating stresses due to bending and torsion are given by:

Where Mm and Ma are the midrange and alternating bending moments, Tm and Ta are the
midrange and alternating torques, and Kf and Kfs are the fatigue stress concentration factors
for bending and torsion, respectively.
Using DE- Gerber criteria

Note: For a rotating shaft with constant bending and torsion, the bending stress is completely
reversed and the torsion is steady. Mm and Ta are equal to 0, which drops out some of the
terms.
It is always necessary to consider the possibility of static failure in the first load cycle as the
Gerber criteria does not guard against yielding. A von Mises stress is calculated for this
purpose.

To check for yielding, this von Mises maximum stress is compared to the yield strength:

Steps to carry out shaft design

Step 1: Given UTS, yield strength, r/d ratio; determine stress concentration factors for both
bending and torsion

Step 2: After obtaining stress concentration factors (Kt & Kts) determine fatigue stress
concentration factors for both bending and torsion. Use notch sensitivity equation

Obtain the values of q for bending and torsion from the notch sensitivity charts given below.
After obtaining q values, calculate Kf and Kfs

Step 3: Estimate endurance limit

Step 4: Endurance Limit Modifying factors // (This step is optional)

The factors are:

Surface factor

Sut = minimum tensile strength

a and b are determined from the table below:

Size factor

For axial loading there is no size effect, so kb = 1

Loading factor

Temperature modification factor

Can ignore this factor if part operates at room temperature as in your case
Reliability factor

Za can be obtained from the table below

Step 5: Determine the endurance limit at the critical point

Ignore Kf and Kd
Step 6: You have obtained all the variables you need so go back to DE Gerber criteria and
solve for the diameter.

GOOD LUCK