A novel approach for the determination of optimal diameter of shaft with keyway: Analytical and numerical study

• Published in: Mechanics based design of structures and machines 2024-08, Vol.52 (8), p.5610-5636
• Main Authors: Nuraliyev, Mirali, Dundar, Mehmet Akif, Akyildiz, Hamza Kemal, Sahin, Davut Erdem
• Format: Article
• Language: English
• Subjects: finite element method; keyway; Optimal design; shaft; strength analysis
• ISSN: 1539-7734; 1539-7742
• DOI: 10.1080/15397734.2023.2259968

A new analytical methodology has been presented for the determination of the optimal diameter of a shaft with a keyway subjected to a combination of completely reversed bending and steady torsion. To specify the optimal shaft diameter, the lack of a keyway in the shaft has been first assumed and its corresponding diameter has been determined. Then, the optimal diameter of the shaft with a keyway satisfying strength requirements has been specified by establishing a correlation between the diameters of shafts with and without a keyway. The correlation has been defined based on a cross-section design model developed for the shaft with a keyway. Strength analyses have been carried out on the shaft with a keyway by equating its cross-section to the cross-section of a solid shaft, called an equivalent cross-section, by means of the developed cross-section design model. The present methodology has been validated against numerical results attained from the Abaqus finite element code. Comparisons of the present study findings with the results of existing models have revealed that the reported analytical procedure significantly reduces material costs by bringing a material saving of 1.21 kg for per meter length of the shaft. The developed analytical procedure can be used as a benchmark to determine the optimal diameter of the shaft with a keyway subjected to a combined fully reserved bending and steady torsion. The analytical expressions derived have been made available to practical engineering for use in real design applications.