Total Runout - Long Shaft

[Cup909]

I'm looking to measure the total runout of a very long shaft along the entire length. A 1" diameter shaft, 5' long, with datums 3" from each end, and a total runout requirement of .005".

The traditional method would be to put the datums on Vee-blocks and roll it then drag the dial indicator up and down the shaft. A shaft of this length/diameter/support is going to sag more than the total runout. So how do you measure the total runout using traditional hand tools?

My strategy is as follows; First, constrain the diameter through measurement using snap/mic/etc. Then spin the shaft on rollers taking circular readings along the length of the shaft. A bend in the shaft will show up as circular runout at that spot. TLDR; total runout is circular runout as long as the form (diameter) of the part is constrained.

Does this strategy make sense?

 

[3DDave]

The sag continuously varies and the total runout zone doesn't. Because of the sag it immediately fails the requirement.

The only hope is in noting that the simply supported beam formula allows an angle at the supports, which isn't allowed by the callout; the datum feature simulators/true geometric counterpart simulators are supposed to clamp onto the datum features and hold them rigidly.

Look for a formula where the ends are fixed against rotation.

I'm not too hopeful as making such a clamping device without adding to the measurement error will be difficult. If the clamps are not aligned it could be just as bad and produce weird readings.

 

[drawoh]

The deflection I calculate (screenshot below) for a 1" round, 5ft long at 54" datums (3" from either end), is a deflection of 0.147", so a significant amount and well out of tolerance to just ignore. That will be lessened slightly by the 3" cantilever on either end, but not near enough to counter the runout.

Are you working to ASME Y14.5? Read up on flexible components. You need to specify how your part will be fixtured to control flexibility.

Is your shaft going to run at high speed? Will it be safe? I have not done a lot of power shaft design. You need a certain diameter to transmit the torque, but this not the only control on diameter. Perhaps you should work out vibration modes. If your shaft is stiff enough, you can measure run-out.