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Chapter 11
Parallel Key Calculation According to DIN 6892
11.1 General
11.2 Scope of DIN 6892
11.3 Types of Parallel Keys
11.4 Surface Pressure
11.5 Permitted Surface Pressure
11.6 Application factor
11.7 Load Factor
11.8 Load Distribution Factor
11.9 Friction Factor
11.10 Load Direction Changing Factor
11.11 Load Peak Frequency Factor
11.12 Support Factor
11.13 Hardness Influence Factor
11.14 Inputs for Calculation Method B
11.15 Some Additional Information On Method C
11.16 Automatic Dimensioning Functions (Calculator Button)
11.17 Material Selection
11.18 Selection and Geometry of Parallel Keys
11.19 Input of Individual Parallel Keys
11.20 How to Change the Unit of Measurement
11.21 The Button ‘Redo’ and ‘Undo’
11.22 Message Window
11.23 Quick Info: Tooltip
11.24 Calculation Results
11.25 Documentation: Calculation Report
11.26 How to Save the Calculation
11.27 The Button ‘Options’
11.28 Calculation Example: Parallel Key According to DIN 6892

11.1 General

A parallel key is a positive shaft-hub-connection. The torque is transmitted from the shaft to the hub via the parallel key. The main purpose of the
parallel key is to transmit static and qu asi-static torques. The parallel key can be used with limitations also for swelling and alternating torques. In
case a good assembly and disassembly of the shaft-hub-connection are required or necessary (e.g., replacement or repair), then a parallel key
may be used. A shearing off of the parallel key does not happen very often and occurs only in the event of overloading. The fretting corrosion due
to rotating bending and/or torsional oscillation has been proven in numerous endurance tests and is usually the crucial factor which leads to the
failure of the shaft-hub-connection.

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Method B

The dimensioning takes place due to a detailed consideration of the occurring surface pressures. In addition, the proof of strength for the shaft is
carried out according to the nominal stress concept.

Method C

It is a rough calculation of the surface pressure and resulting estimation of the shaft stress.

11.2 Scope of DIN 6892

The calculation is based on DIN 6892. The DIN standard specifies the following scope:

• For parallel keys whose parts are made of metallic materials

• Geometry and parallel key lengths according to DIN 6885
• DIN 743 has to be considered for the shaft strength, hub design and hub wall thickness must also be considered
• Mainly for parallel keys used in mechanical engineering for the temperature range of C to C

11.3 Types of Parallel Keys

The geometry of the parallel keys can be selected according to DIN 6885-1, DIN 6885-2 and DIN 6885-3. This geometry selection includes the
standard lengths of parallel keys. The supporting length is determined from the standard length and the chosen parallel key type. There are
various types of parallel keys - t he types A to J are ava ilable.

Figure 11.3: Parallel key types A to D

Figure 11.4: Parallel key types E to J

The supporting length for the different types of parallel keys is calculated as follows:

• The following applies for round-ended parallel keys (type A, E, C)

• The following applies for straight-ended parallel keys (type B, D, F, G, H, J)

• This applies for combined parallel keys (AB)

is the supporting length

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is the support factor

is the hardness factor

11.6 Application factor

The application factor is determined for the calculation of the equivalent torque (similar to the gear calculation according to DIN 3990)
with the following table:

Application Factors According to DIN 3990-1: 1987-12

Working Characteristics Working Characteristics of the Driven Machine

of the Driving Machine Uniform Light Shocks Moderate Shocks Heavy Shocks

Uniform 1,0 1,25 1,5 1,75

Light Shocks 1,1 1,35 1,6 1,85

Moderate Shocks 1,25 1,5 1,75 2,0

Heavy Shocks 1,5 1,75 2,0 2,25 or higher

11.6.1 Working Characteristics of the Driving Machine

Uniform: e.g., electric motor, steam or gas turbine (small, rarely occurring starting torques)
Light Shocks: e.g., electric motor, steam or gas turbine (large, freque ntly occurring starting torques)

Moderate Shocks: e.g., multiple cylinder internal combustion engines

Heavy Shocks: e.g., single cylinder internal combustion engines

11.6.2 Working Characteristics of the Driven Machines

Uniform: Steady load current generator, uniformly loaded conveyor belt or platform conveyor, worm conveyor, light lifts, packing machinery, feed
drives for machine tools, ventilators, light-weight centrifuges, cen trifugal pumps, agitators and mixers for light liquids or un iform density materials,
shears, presses, stamping machines, vertical gear, running gear

Light Shocks: Non-uniformly (i.e. with piece or batched components) loaded conveyor belts or platform conveyors, machine-tool main drives,
heavy lifts, crane slewing gear, industrial and mine ventilators, heavy centrifuges, centrifugal pu mps, agitators and mixers for viscous liquids or
substances of non-uniform de nsity, multi-cylinder piston pumps, distribution pumps, extruders (gen eral), calendars, rotating kilns, rolling mill
stands, continuous zinc and aluminium strip mills, wire and bar mills

Moderate Shocks: Rubber extruders, continuously operating mixers for rubber and plastics, ball mills (light), wood-working machines (gang
saws, lathes), billet rolling mills, lifting gear, single cylinder piston pumps

Heavy Shocks: Excavators (bucket wheel drives), bucket chain drives, sieve drives, power shovels, ball mills (heavy), rubber kneaders, crushers
(stone, ore), foundry machines, he avy distribution pumps, rotary drills, brick presses, de-ba rking mills, peeling machines, cold strip c, e, briquette
presses, breaker mills

11.7 Load Factor

Due to deviation in form and position of a single parallel key, an unbalanced or uneven carrying of two parallel keys, that are arranged evenly
around the circumference, occurs. Thus, the reduced load capacity of the parallel key is considered by the load factor . In practice, not more
than two parallel keys are used because of the load distribution that is difficult to determine.

• One parallel key ( ):

• Two parallel keys ( ): for the determination of the equivalent surface pressure, for the determination of the maximum
surface pressure

Compared to the calculation of the equivalent surface pressure, a higher load part can be estimated for the determination of the maximum
surface pressure because a torque occurring in several load peaks leads to a higher load part by deformation on the parallel key and keyway
ground. Using these load parts, ductile materials with pronounced yield point a s well as sufficient manufacturing accuracy are required. For brittle
materials (e.g., gray cast iron), there is no established knowledge about the load capacity using two parallel keys.

11.8 Load Distribution Factor

The load distribution factor takes an uneven load distribution into consideration along the keyway length as well as the ratio of load in and
output. For using two parallel keys, the unbalanced carrying is considered by the following assumption:

• One parallel key:

• Two parallel keys:

The factor is dependent upon the kind of load in and output position. Regardless of the torque flow direction, three cases are distinguished.

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Figure 11.6: Kind of load application

For a stepped hub, it means (see above figure):

Small outer diameter of stepped hub

Large outer diameter of stepped hub

Distance between the axial cutting planes through N and W

Width of the hub with within the carrying part of the parallel key, i.e.,

is the outer diameter of the hub or the outer diameter of the alternative cylinder with equal torsional stiffness. The alternative outer diameter is
calculated as follows:

Depending on , the factor is determined by using the figures 3, 4 and 5 in DIN 6892. These diagrams are integrated into the calculation
module and are valid for a specific ratio . For other ratios , the values are determined from two diagrams by
interpolation.

11.9 Friction Factor

For an interference fit, part of the torque is transmitted by friction. The friction factor considers that. But it is taken into consideration only for
the calculation of the maximum effective surface pressure . For a dynamic load, an interference fit stops the occurrence of fretting corrosion.
A clearance fit or interference fit adversely affects the shaft strength. For the determination of the friction factor, a minimum friction torque
of the interference fit is assumed. According to DIN 7190, this can be obtained for a hole without keyway. The joint pressure, that is reduced due
to the parallel key in comparison to the hole without keyway, is considered by the factor . Thus, the friction torque, effective for the power
transmission, is decreased. As a first approximation, can be specified for a parallel key.

With the maximum load peak torque , occurring during the entire operation time, it applies:

For the load peak torque is transmitted by friction. In this case, the surface pressure, occurring in the parallel key, is not relevant.
A check of the maximum surface pressure is not necessary according to DIN 6892. However, it is integrated into the calculation.

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Figure 11.7: Friction factor

Please note: For brittle materials (e.g., gray cast iron), no interference fit is allowed.

11.10 Load Direction Changing Factor

Parallel key connections are on ly conditionally usable during changing the direction of torque. However, the rating life is limited if it comes to
constant slipping between shaft and hub and thus to a deflection of the parallel key connection. There are two different cases:

Case 1: One-sided load of the parallel key during alternating load direction. The maximum torques in reverse direction (against the main load
direction) do not exceed the effective part of the minimum friction torque.

Case 2: Alternating load of the parallel key during alternating load direction. The maximum torques exceed the effective part of the minimum
friction torque in both directions.

In case 2, the changes of load direction factor is dependent upon the frequency of changes of load direction for the parallel key. It can be
determined according to DIN 6892, figure 6. Two cases are distinguished:

• For alternating torques with a slow torque increase (e.g., reversing operation for carriages)
• For alternating torques with a fast torque increase (e.g., high-dynamic servo drives using in robots for industrial environments)

Load direction changes, that occur due to special cases, have to be considered as well.

11.11 Load Peak Frequency Factor

Load peaks occur when the torque clearly exceeds the equivalent torque . Special cases may occur due to starting impacts, short-circuit
torques, emergency breaking torques, abrupt blockings etc. The frequency of the load peaks has to be estimated during the entire operating
time. For a single load peak, depending on the ductility of the material, the 1,3 to 1,5 times the permanent surface pressure is allowed. The
progress of for ductile and brittle materials over the frequency is shown in figure 5 according to DIN 6892.

Figure 11.8: Load peak frequency factor

11.12 Support Factor

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Using the support factor , a supporting effect can be considered that occurs for compressive stress components. From experience, the
supporting effect for hubs is larger due to the higher stressed material volume than for shafts and parallel keys (see table: support and hardness
factors for different materials).

11.13 Hardness Influence Factor

The hardness influence factor is determined from the ratio of surface strength to core strength for case-hardened components. By the
hardness influence factor, an increasing of the permissible surface pressure is considered (see table: support and hardness factors for different
materials).

Support and Hardness Influence Factors for Different Materials

Component Material
Parallel key Structural steel according to DIN EN 10 025 1,0 1,0
Bright steel according to DIN 1652-4 1,0 1,0
Heat-treated steel according to DIN EN 10 083-1 and 10 083-2 1,0 1,0
Case-hardened steel according to DIN 17210 1,0 1,15

Shaft Structural steel according to DIN EN 10 025 1,2 1,0

Heat-treated steel according to DIN EN 10 083-1 and 10 083-2 1,2 1,0
Case-hardened steel according to DIN 17 210 1,2 1,15
Gray cast iron with lamellar graphite according to DIN 1693-1 and 1693-2 1,2 1,0
Steel casting according to DIN 1681 1,2 1,0
Gray cast iron with lamellar graphite according to DIN 1691 1,0 -
Hub Structural steel according to DIN EN 10 025 1,5 1,0
Heat-treated steel according to DIN EN 10 083-1 and 10 083-2 1,5 1,0
Case-hardened steel according to DIN EN 17 210 1,5 1,15
Gray cast iron with spheroidal graphite according to DIN 1693-1 and 1693-2 1,5 1,0
Steel casting according to DIN 1681 1,5 1,0
Gray cast iron with lamellar graphite according to DIN 1691 2,0 -

11.14 Inputs for Calculation Method B

The calculation method B provides a more precise way to determine the surface pressure. The strength of the shaft is verified according to the
nominal stress concept. Select method B from the listbox. The calculation method B requires some additional inputs. Click the button ‘Input data
method B’.

Figure 11.9: Button ‘Input method B’

A new window is opened.

Figure 11.10: Inputs for method B

The following input can be defined:

• Kind of load:
• No alternating torque - load in only one direction
• Alternating torque with a slow torque increase
• Alternating torque with a fast torque increase

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• Changes of load direction

• Maximum reverse torque
• Small outer diameter of stepped hub
• Large outer diameter of stepped hub
• Width of hub with within
• Axial distance between load in and output position
• Chamfer on the shaft keyway edge
• Chamfer on the hub keyway edge

11.15 Some Additional Information On Method C

The calculation method C according to DIN 6892 is suitable only for a rough calculation of parallel keys. The method is based on the following
simplifications:

• Constant surface pressure over the keyway length and height of keyway wall
• No consideration of chamfers or radii for the determination of supporting surfaces

Limitations:

• ; a length going beyond it does not make a considerable contribution for the torque transmission.
• Number of parallel keys
• For an inversion of the torque direction, method C cannot be used. The method B has to be applied.

11.16 Automatic Dimensioning Functions (Calculator Button)

The button for the dimensioning functions is marked by a calculator symbol and is located next to the input fields. If you click on the dimensioning
buttons, you get a suggestion for an appropriate input value. The calculation of the value is carried out so that the given minimum safety is
fulfilled. The default value for the minimum safety is set to ‘1.2’. Clicking the button ‘Options’ allows you to ch ange this value. The following
dimensioning functions (calculator button) provide you with optimal support:

Automatic dimensioning of the shaft diameter

Automatic dimensioning of the nominal torque

Automatic dimensioning of the maximum load peak torque

Automatic dimension of the standard length

Automatic dimensioning of the supporting length

11.17 Material Selection

Clicking the button ‘Material’ opens the mate rial database. In case there is no material that will fulfill the design requirements, then simply define
your individual material.

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Figure 11.11: Material selection

You will find the entry ‘User-defined’ in the listbox. If you select this option, the input fields will be enabled, so that you can enter your own input
values or add a comment. Please select the material from the list. You will get detailed information on the material. The two cursor keys ‘Up’ and
‘Down’ of your keyboard allows you to navigate through the material database, so you can compare the different material properties with each
other. That applies for shaft, hub and parallel key.

Figure 11.12: Own material

11.18 Selection and Geometry of Parallel Keys

Click the button ‘Parallel key’ in order to select p arallel keys quickly and easily.

Figure 11.13: Button ‘Parallel key’

The geometry database will be opended. The database allows you to select a parallel key.

Figure 11.14: Selection dialog for parallel key geometry

The database provides the parallel key selection according to DIN 6885 sheet 1 to 3. The parallel key forms A to J as well as the parallel key size,
including the lengths, can be selected. Clicking the button ‘OK’ confirms yur inputs and leads you back to the the main mask.

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11.19 Input of Individual Parallel Keys

The geometry database offers the possibility to calculate individual parallel keys. You can define the geometry of parallel keys as you wish and
different from the DIN standard. The parallel key forms from A to J are also available. In order to define your individual parallel key, click the
button ‘Parallel key’ to open the p arallel key database. Enable the op tion ‘Own input’ and choose the suitable dimensions from the list or enter
your own values directly into the input field.

Figure 11.15: Own input

11.19.1 Supporting Length of Individual Parallel Keys

It is possible to define a sup porting length for your individual parallel key. Select ‘User d efined input’ from the listbox and e nter your own value for
the supporting length.

Figure 11.16: Own input

You can specify different supporting length for the shaft and hub. Place a checkmark in order to enable the input field and enter a value for the
supporting length.

Figure 11.17: Supporting length for shaft and hub

11.20 How to Change the Unit of Measurement

Use this function if you want to ch ange the unit of measurement quickly. Just a right-click on the input field whe re you want to change t he unit.
The context menu c ontains all available units. The two arrows mark the current setting. As soon as yo u select a unit, the current field value will be
converted automatically into the chosen unit of measurement.

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Figure 11.18: Change measurement unit

11.21 The Button ‘Redo’ and ‘Undo’

The button ‘Undo’ allows you to reset your input to an older state. The button ‘Redo’ reverses the undo.

Figure 11.19: Button ‘Redo’ and ‘Undo’

11.22 Message Window

The calculation module provides a message window. This message window displays detailed information, helpful hints or warnings about
problems. One of the main benefits of the program is that the software provides suggestions for correcting errors during the data input. If you
check the message window carefully for any errors or warnings and follow the hints, you are able to find a solution to quickly resolve calculation
problems.

Figure 11.20: Message window

11.23 Quick Info: Tooltip

The quick info feature gives you additional information about all input fields and buttons. Move the mouse pointer to an input field or a button, then
you will get some additional information. This information will be displayed in the quick info line.

Figure 11.21: The quick info

11.24 Calculation Results

All important calculation results, such as the safeties for the operation load or at the maximum load for all three components (shaft, hub and
parallel key) or the equivalent pre ssure will be calculated during every input and will be displayed in the resu lt panel. A recalculation occurs after
every datathe
complete input. Any
input. changes thatuse
Alternatively, arethe
made
Tabtokey
thetouser
jumpinterface taketoeffect
from field fieldimmediately. Press the Enter
or click the ‘Calculate’ key
button or move
after every to the next
input. Yourinput field
entries tobe
will
also confirmed and the calculation results will displayed automatically. If the result exceeds certain values, the result will be marked red.

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Figure 11.25: Button ‘Save’

Before you can save the calculation to your computer, you need to activate the checkbox ‘Enable save data local’ in the project manager and the
option ‘Local’ in the calculation module. A standard Windows dialog for saving files will appear. Now you will be able to save the calculation to
your computer.

Figure 11.26: Windows dialog for saving the file

In case you do not activate the option in order to save your files locally, then a new window is opened and you can save the calculation to the
eAssistant server. Please enter a na me into the input field ‘Filename’ and click o n the button ‘Save’. Then click on the button ‘Refresh’ in the
project manager. Your saved calculation file is displayed in the window ‘Files’.

Figure 11.27: Save the calculation

11.27 The Button ‘Options’

Click the button ‘Options’ in order to change the default settings.

Figure 11.28: Button ‘Options’

The button ‘Options’ allows you to define the minimum safeties. Additionally, there is the possibility to enter the number of decimal places for the
output of the numerical values in the report.

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Figure 11.29: Options

11.28 Calculation Example: Parallel Key According to DIN 6892

11.28.1 Start the Calculation Module

Please login with your username and your password. Select the module ‘Parallel key’ through the tree structure of the project manager by double-
clicking on the module or clicking on the button ‘New calculation’.

11.28.2 Calculation Example

A strength calculation for the following shaft-hub-connection is required (see also DIN 6892, Example E.2). Enter the following values into the
input fields:

Shaft diameter = 60 mm

Application factor = 1.75

Outer diameter = 120 mm
hub

Calculation =B
method

Operation = 1.950 Nm
nominal torque

Min. frictional = 1.250 Nm

torque

Max. load peak = 3.900 Nm

torque

Load peaks = 500

Material shaft = C45 hardened and tempered

Material hub = 34CrNiMo6 hardened and tempered

Parallel key = DIN 6885.1 AB 18 x 11 x 100

Material parallel = 34CrNiMo6 hardened and tempered

key

Standard length = 100 mm

parallel key

Number of =1
parallel keys

Inputs Method B:

Kind of load = Alternating torque with a slow torque increase

Changes of load =
direction

Max. reverse = 3900 Nm

torque

Small outer = 120 mm

diameter

Large outer = 120 mm

diameter

Width of hub = 91 mm
within

Axial distance = 45.5 mm

Chamfer/radius = 1.0 mm
on shaft keyway
edge

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Chamfer/radius = 1.0 mm
on shaft keyway
edge

11.28.3 Start the Calculation

Please start to enter the values into the input field. All important calculation results will be calculated during every input and will be displayed in
the result panel. A recalculation occurs after every data input. During the inpu t of the values it can happ en that the results will be marked in red.
Nevertheless, please continue to input the data as usual. For the load peaks , please select the entry ‘User defined input’ from the listbox.

Enter the the value ‘500’ into the adjacent input field.

Figure 11.30: Input of the values

11.28.4 Calculation Method B

The direction of the torque is reversed and a rough calculation according to Method C is not possible. It is recommended to use the calculation
method B. Select the calculation method B from the listbox and click the button ‘Inp ut data method B‘.

Figure 11.31: Calculation method B

Clicking this button opens the window ‘Input data method B’ and allows you to enter the other input values.

Figure 11.32: Calculation method B

Please note: If, at a later time, you need to change certain values, then click the button ‘Input data method B’ an d the input mask will open again.

Input Values for Shaft and Hub

Specify the material for the shaft and the hub. The material for the shaft is ‘C45 hardened and tempered’. The required material for the hub is
‘34CrNiMo6 hardened and tempered’. Both materials can be selected from the listbox.

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Selection of Material

Select the material ‘34CrNiMo6 hardened and tempered’ from the listbox. If you need further information on the material, click the button ‘Material’
to open the material database.

Figure 11.37: Material for parallel key

Supporting Length and Number of Parallel Keys

The supporting length is determined automatically from the selected standard length. You can use the listbox to select the number of parallel
keys. For our calculation example we specify one parallel key.

Figure 11.38: Supporting length and number of parallel key

11.28.5 Calculation Results

All important calculation results, such as the safeties for the operation load or at the maximum load for all three components (shaft, hub and
parallel key) or the equivalent pre ssure will be calculated during every input and will be displayed in the resu lt panel. A recalculation occurs after
every data input. Any changes that are made to the user interface take effect immediately. You will get the results for the equivalent pressure and
for the pressure at load peak as well as the safety at operation load and the safety at peak load.

Figure 11.39: Calculation results

In our calculation example the safeties for the shaft, the hub and the parallel key are marked red. That means the minimum safeties are not
fulfilled. In addition, you get also an appropriate message in the message window. The parallel key is not suitable for our calculation example.

Figure 11.40: Message window

Minimum Safety: Dimensioning of the Shaft Diameter

Use the automatic dimensioning function (calculator button) in order to determine the shaft diameter. With just one click, the progra m
automatically determines the shaft diameter so that the required minimum safety of ‘1.2’ will be fulfilled. In order to do so, please click the
calculator button next to the input field of the shaft diameter.

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Figure 11.41: Dimensioning button for the shaft diameter

Now the new shaft diameter is determined.

Figure 11.42: New shaft diameter

The shaft diameter is now = 111.88 mm. With this diameter the minimum safety of ‘1.2’ is achieved and the parallel key is suitable for this
application. The safety can even be increased by selecting another material.

Figure 11.43: Calculation result

Due to ‘Parallel
button the new dimensioning, the shaft
key’ and the larger diameter
parallel key isisdisplayed
significantly larger now. A new size of the parallel key was determined automatically. Click the
automatically.

Figure 11.44: New parallel key

11.28.6 Documentation: Calculation Report

Use the button ‘Report’ to generate the calculation report very fast. This rep ort contains the calculation method, all input v alues as well as the
detailed results.

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Figure 11.45: Button ‘Report’

The calculation report contains a table of contents. You can navigate through the report via the table of contents that provides links to the input
values, results and figures. The report is available in HTML and PDF format. Calculation reports, saved in HTML format, can be opened in a web
browser or in Word for Windows.

Figure 11.46: Calculation report

You may also print or save the calculation report:

• To save the report in the HTML format, please select ‘File’ ‘Save as’ from your browser menu bar. Select the file type ‘Webpage
complete’, then just click on the bu tton ‘Save’.
• If you click on the symbol ‘Print’, then you can print the report very easily.
• If you click on the symbol ‘PDF’, then the report appears in the PDF format. If you right-click on the PDF symbol, you should see the ‘Save
Target As’ option. Click on that option and you will see the dialog bo x for saving the report.

11.28.7 How to Save the Calculation

When the calculation is finished, yo u can save it to your co mputer or to the eAssistant server. Click on the button ‘Save’.

Figure 11.47: Button ‘Save’

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Before you can save the calculation to your computer, you need to activate the checkbox ‘Enable save data local’ in the project manager and the
option ‘Local’ in the calculation module. A standard Windows dialog for saving files will appear. Now you will be able to save the calculation to
your computer.

Figure 11.48: Windows dialog for saving the file

In case you do not activate the option in order to save your files locally, then a new window is opened and you can save the calculation to the
eAssistant server. Please enter a na me into the input field ‘Filename’ and click o n the button ‘Save’. Then click on the button ‘Refresh’ in the
project manager. Your saved calculation file is displayed in the window ‘Files’.

Figure 11.49: Save the calculation

Our manual is improved continually. Of course we are always interested in your opinion, so we would like to know what you think. We
appreciate your feedback and we are looking for ideas, suggestions or criticism. If you have anything to say or if you have any
questions, please let us know by phone +49 (0) 531 129 399-0 or email eAssistant@gwj.de .

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