The true stress concentration factors, Kf and Kfs, for bending and shear, respectively, are given by

Equations (21) and (22).

Where q and qs are the notch sensitivities for bending and shear, respectively. These can be found from
Figures 6-20 and 6-21 in Shigley given the notch radius and tensile strength of the steel, which is
reported to be 1100 MPa (Budyas 295-296). Referring to the charts,
When plugged into Equations (21) and (22) with Kt and Kts the same as in the first iteration, these give
values of:
The surface condition factor, ka will be the same. The shape factor, kb, can now be calculated as:
Per Shigley Equation 6-20 (Budyas 288). This gives kb = 0.945, close to the initial guess. The yield strength
is estimated again at half the tensile strength, or 550 MPa. Therefore Equation 6-18 from Shigley puts
the overall endurance limit at 458.44 MPa. The Goodman Failure Criterion will be used again, this time
by calculation the alternating and midline Von-Mises Stresses via Equations (24) and (25), respectively,
which are Equations 7-5 and 7-6 from Shigley with terms that are nonzero and simplified (Budyas 368).
√
These equations yield alternating and midline Von-Mises Stresses of 8.574 MPa and 3.400 MPa,
respectively. The Goodman Criterion, with a factor of safety n, expressed in terms of these stresses is: P
a g e | 10
Giving a factor of safety of 45.88, which is more than satisfactory for safety concerns. Since the bearing
at A will have less of a load, and the pulley is held on without diameter change, this result is appropriate
for the whole shaft.
It may be important to consider the effects of thermal expansion, especially if the bearings are tightly
secured axially. An average thermal expansion coefficient, α, for steel is 10.8*10-6/°C. This can simply be
multiplied by the temperature change expected to find the strain related to the elongation to the
member. Assuming a very conservative 50 °C temperature increase, the strain is 5.4*10-4 mm/mm,
which will have a negligible effect on shaft length at any point.
The final consideration is the shaft critical speed that will cause uncontrolled increasing deflections. The
equation to find this speed is given as Equation 7-22 in Shigley (Budyas 383). ( ) √
Where:
ω1 = critical speed
l = length of shaft
g= acceleration due to gravity
E= Modulus of Elasticity
I= second moment of cross sectional area
A= cross sectional area
γ= specific weight
With g= 9.8 m/s2, I as previously defined, A being π/4*d2, and γ being 76.5 kN/m3 for carbon steels,
So the design is well below the critical shaft speed. Since all of the safety concerns are far exceeded, this
shaft meets all of the design requirements. P a g e | 11
Ultra-Flex Coupling (From McMaster-Carr website)
VII. Final Design

Solid models of the final design follow. Unfortunately, McMaster-Carr did not offer a model of their
sheave nor a detailed drawing, so an attempt to recreate it is shown. The coupling also did not come
with a model, and would be very complicated to draw in SolidWorks, so a picture is included to illustrate
what it would look like. It would attach to the left side opposite the sheave. A bill of materials follows
those models. P a g e | 12
4
3
5
1
6
2
Table 1: Bill of Description Model No. Cost
Materials. All Parts
from McMaster-Carr
Part No.
1 5/8” Diameter, 24” 98535A120 $18.00
Long Steel Shaft
2 2x ½” bore Cast Iron 6244K51 $65.68
Mounted Steel Ball
Bearings
3 Quick-Disconnect 6086K111 $11.78
Bushing Style JA, ½”
Bore, 1/8” x 1/16”
Keyway
4 V-Belt Pulley 5.95” 6407A24 $42.70
Outer Diameter
5 Standard Key Stock, 98535A120 $0.97
1/8” x 1/8”, 12” long
6 2x ½” Bore Self- 98430A138 $0.10 ($9.52 per 100)
Locking External
Retaining Rings
7 Ultra-Flex Double- 6183K61 $19.83
Loop Shaft Coupling,
½” to ½” Bore
Total $159.06