Calculation of Shaft Design

CHAPTER 4
CALCULATION OF SHAFT DESIGN
The data specifications of overload truck are as follow;

Gross weight = 3500 kg
Overall height = 2194 mm
Overall width = 1695 mm
2nd gear ratio = 2.33
Transmission efficiency = 90%
Coefficient of friction = 0.2
Drag coefficient = 0.73
Engine speed = 1800 rpm
Average velocity = 2.78 m/s
Density of air = 1.225 kg/m3
Helical gear diameter = 100 mm
Bevel gear diameter = 80 mm
Helical gears are meshed up with vertical and bevel gears are meshed up with
horizontal to transmit the power into rear wheels. The outer diameter of shaft is 10%
larger than inner diameter of shaft.
4.1 Calculation of Gear Torque from Road Load Performance

The required engine power for over-weight truck can be calculated as
following;
From Equation, 3.34
1
F A = ρ a C d A ⊽2
2
1
¿ ×1.225 ×0.73 × (2.194 × 1.695 ) ×2.782
2
¿ 12.85 N
2
From Equation, 3.35

F RO=F r ×W cos α
¿ 0.2 ×3500 ×9.81
¿ 6867 N
From Equation, 3.36
F G=W sin α
¿ 3500 ×9.81 ×sin 0
¿0 N
From Equation, 3.37
dv
F I =m
dt
d
¿m ( 1)
dt
¿0 N
From Equation, 3.33
F w =F A + F RO + FG + F I
¿ 12.85+6867+ 0+0
¿ 6879.85 N
From Equation, 3.38
The engine power can be calculated as follow,
Fw × ⊽
Pe =¿
ηt
6879.85× 2.78
¿
0.9
¿ 21251.092W
From Equation, 3.16
2 πNT
Power=
60
60× Power
T =¿
2 πN
3
60× 21251.092
¿
2 π ×1800
¿ 112.74 Nm
The torque of shaft or gear torque is the multiply of engine torque and gear ratio.
From Equation, 3.39
T shaft =Gear torque=T e × second gear ratio
¿ 112.74 × 2.33
¿ 262.68 Nm
4.2 Calculation of Forces Exerted on Shaft by Machine Elements

Two kinds of gears are subjected to the shaft and they are helical gear at left
side and bevel gear at right side of the shaft.
For helical gear, D 1=100 mm
From Equations, 3.2
Mt
F t=¿ D1
2
262.68× 2
¿
0.1
¿ 5253.68 N
From Equation, 3.3
F r=F t tanφ
¿ 5253.68 × tan20
¿ 1912.18 N
From Equation, 3.4
F a=F t tan Ψ
¿ 5253.68 × tan 45
¿ 5253.68 N
4
For bevel gear, D 2=80 mm

From Equations, 3.5
Mt
F t=¿ D2
2
262.68× 2
¿
0.08
¿ 6567 N
From Equation, 3.6
F r=F t tanφ
¿ 6567 × tan 20
¿ 2390.19 N
From Equation, 3.7
F a=F t tanφ sinβ
¿ 6567 × tan 20× sin 26
¿ 1047.79 N
4.3 Calculation of Maximum Bending Moment

For vertical load diagram,
∑ M R 1=¿ 0 ¿
1912.18 ×0.25+ R 2 ×1.25−10912.52× 1.4=0
R2=6972.6 N
∑ F y =¿ 0 ¿
R1 +6972.6=1912.18+6567
R1=1506.58 N
For vertical bending moment diagram,

M 1=1912.18 ×0.25−5253.68× 0.05
¿ 215.36 Nm
5
M 2=6567 × 0.15
¿ 985.05 Nm
For horizontal load diagram,
∑ M R 3=¿ 0 ¿
−5253.68 ×0.25−R4 ×1.25+2390.19 ×1.4=0
R4 =1626.27 N
∑ F y =¿ 0 ¿
R3 +1626.27=5253.68+2390.19
R3=6017.6 N
For horizontal bending moment diagram,
M 3=5253.68 ×0.25
¿ 1313.42 Nm
M 4 =2390.19× 0.15−1047.79 × 0.04
¿ 316.62 Nm
For combine bending moment diagram,
M b 1=√ M 12 + M 32
¿ √ 215.362 +1313.422
¿ 1330.96 Nm
Maximum bending moment at left bearing is 1330.96 Nm.
M b 2 = √ M 2 2+ M 4 2
¿ √ 985.052 +316.622
¿ 1034.68 Nm
Maximum bending moment at right bearing is 1034.68 Nm. So, maximum bending
moment is 1330.96 Nm at left bearing. The critical section is at bearing thus without
keyway.
Fr
Ft
6
Ft
250mm 1250mm 150mm Fr
R1 = 1506.58 N R2 = 6972.6 N
V.L.D
Fa
Ft = 6567 N
Fr = 1912.18 N
M2 = 985.05 Nm
V.B.M.D
M1 = 215.36 Nm
Figure 4.1 Vertical load and vertical bending moment diagram
Fr
Ft
Ft
250mm 1250mm 150mm

Fr
Ft = 5253.68 N Fr = 2390.19 N
H.L.D
7
R3 = 6017.6 N R4 = 1626.27 N
H.B.M.D
M4 = 316.62 Nm
M3 = 1313.42 Nm
Mb1 = 1330.96 Nm
Mb2 = 1034.68 Nm
C.B.M.D
Figure 4.2 Horizontal load, horizontal bending moment and combined bending
moment diagram
4.4 Calculation of Shaft Diameter by ASME Code Equation

Aluminum alloy is used as material of this drive shaft. Aluminum alloy,
AA6061 T-6, has 310 MPa of ultimate strength and 270 MPa of yield strength.
Assume outside diameter is 10% larger than inside diameter.
Ultimate strength and yield strength are known and the shaft doesn’t need keyway,
Ss =0.18 × Su
¿ 0.18 ×310
¿ 55.8 MPa
Ss =0.3 × S y
¿ 0.3 ×270
¿ 81 MPa
Choose smaller value Ss ¿ 55.8 MPa
8
From table, 3.2

Assume combined shock and fatigue factor are at steady load condition,
k b=1.5, k t=1.0
L
Assume, <115
k
I
K=
√ A
π
¿
√ 64 o
π 2
4
(
(d 4−d i4 )
2
d o −d i )
( d o2−d i2 )( d o2+ d i2 )
¿
√ 16 ( d o2−d i2 )
do
d o2 ( 1+ K 2 )
¿
√
¿ 0.336 d o
16
( K=
di
=0.9¿
From Equation, 3.31

1
α=
L
1−0.0044 ( )
K
1
¿
1−0.0044 ( 1.25 /0.336 d o )
1
¿
1−( 0.0164 /d o )
do
¿
d o−0.0164
From ASME code Equation for hollow shaft with axial load,
16
d o3 = √¿ ¿
π s s (1− K 4 )
9
16 ×10−6
¿ √¿¿
π ×55.8 × ( 1−0.9 4 )
d o2 ×1188.64 2
√
¿ 2.654 ×10−7 [1996.44+
d o =82.75 mm,
d o−0.0164
] + 69× 103
d i=74.48 mm
Due to standard size of shaft, 2mm increased. Outside diameter of the shaft is
85 mm. Inside diameter of shaft is 77 mm.
4.5 Result Comparison of Normal Load and Over Load

The following table is shown the results for normal weighted truck and over-
weighted truck of power, torque, maximum bending moment and diameter of the
driveshaft.
Table 4.1 Results Comparison

DATA
NAME NORMAL LOAD OVER LOAD
(3000kg) (3500kg)
Engine Power (W) 18220.89 21251.092
Engine Torque (Nm) 96.66 112.74
Gear Torque (Nm) 215.56 262.68
Maximum bending moment (Nm) 1092.19 1330.96
Outside Diameter (mm) 79 85

Inside Diameter (mm) 72 77
10
The following chart is the torque comparison of normal load and overload.
300
262.68
250
NORMAL
LOAD 215.56
200
Torque (Nm)
150
112.74
96.66
100
50
0
Engine Torque Gear Torque
Figure 4.3 Torque comparisons of normal load and over load
The following chart is the diameter comparison of normal load and overload.
11
90
85
85 NORMAL
LOAD
OVERLOAD
Diameter (mm)
80 79
77
75
72
70
65
Outside Diameter Inside Diameter
Figure 4.4 Diameter comparisons of normal load and over load

Calculation of Shaft Design

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CHAPTER 4

CALCULATION OF SHAFT DESIGN

The data specifications of overload truck are as follow;

4.1 Calculation of Gear Torque from Road Load Performance

From Equation, 3.35

4.2 Calculation of Forces Exerted on Shaft by Machine Elements

For bevel gear, D 2=80 mm

4.3 Calculation of Maximum Bending Moment

For vertical bending moment diagram,

250mm 1250mm 150mm Fr

Figure 4.1 Vertical load and vertical bending moment diagram

250mm 1250mm 150mm

4.4 Calculation of Shaft Diameter by ASME Code Equation

From table, 3.2

From Equation, 3.31

4.5 Result Comparison of Normal Load and Over Load

Table 4.1 Results Comparison

Engine Power (W) 18220.89 21251.092

Engine Torque (Nm) 96.66 112.74

Gear Torque (Nm) 215.56 262.68

Maximum bending moment (Nm) 1092.19 1330.96

Outside Diameter (mm) 79 85

Figure 4.3 Torque comparisons of normal load and over load

Figure 4.4 Diameter comparisons of normal load and over load

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