Keys

• Machine element used to prevent relative motion

between parts such as gears and shafts

• A device to transmit torque from shaft to mating gear

or wheel or from gear or pulley to shaft

1
 Types of keys
Keys are generally classified into two types

Sunk keys :
• Require key way in both the shaft and hub

Saddle keys
• Which require a key way in the hub only

2
 Sunk keys
The various types of sunk keys are shown below

(a) Square and rectangular keys

• Strongest and most widely used

• Uniform cross section or they may be slightly

tapered ( 1 in 100 ) on their thickness.

• W = t = d/4 for Square key

• W = d/4, t = d/6 for Rectangular key

3
 Keys

W
W

t
t
Rectangle
Square

4
 Sunk Keys

Hub Shaft
Hub Shaft
Key Key

Fig-1

Square Key Rectangular Key Fig-2

5
 Gib Head Key
• A taper rectangular sunk key fitted with gib head to
facilitate easy withdrawal
• The taper is on the top of the key
Key

Fig-3 Gib Head Key

6
 Feather Key
• Used when relative axial motion is required between the
components while transmitting the torque
key

Fig:4
Feather Keys

7
 Woodruff Key
• Semi-circular in shape and fits a similar shaped key way

• Particularly useful on tapered shafts as it is self-aligning

Key

Fig:5
Woodruff Key

8
Round key:
• Circular pin and does not requires the accurate key way
• Driven into the hole, drilled partly on shaft and partly in
the hub
• Used for light and medium load
Tangent Key:
• Used for heavy duty and are fitted in pair at angles
• Withstand torque in one direction only

Round Key Tangent Key

Fig:6
9
 Saddle Keys

The two forms of saddle keys are:

Hollow saddle key:

• Requires key way in the hub and the under side of

the key is curved to suit the shaft

• Tapered and transmits torque by friction alone

• Therefore it is suitable for light loads

10
 Flat Saddle Key
• Requires a key way in hub and corresponding ‘flat’ on the
shaft
• Used for light loads, but it has a greater driving than saddle
key Key Key

Fig:1 Fig:2
1) Hollow saddle key 2) Flat saddle key

11
 Design of Sunk Keys

The stresses in the key are induced by the following forces:

1. Forces due to fitting of key in a key way

2. Forces that are caused by the torque transmitted

12
 Points to Note

• The keys are failed due to shearing and crushing

• The designer usually confirms to Indian Standard

recommendations on the width and thickness of the
key and required length is calculated by considering the
shear strength and crushing strength of key

• While considering the strength of key, it is customary to

neglect forces due to fit of key in a key way

13
Strength of Key

Fig:3
14
 Strength of Key

Let
T = Torque to be transmitted, N mm
 or f s= shear stress induced in key, N/mm2
σc = compression stress induced
d = diameter of shaft, mm
w = width of key, mm
t = thickness of key, mm
l = length of key, mm

15
Strength of Key (contd..)

Considering shear strength:

T = force x radius of shaft
= (shear stress x shear area) x d/2
d
   w.l  ……(i)
2
Considering crushing strength:
T = (compression stress x area in comp x d/2

t.l.d
T  c  ….(ii)
4
16
Strength of Key (contd..)

• The induced stresses computed by equations

(i) and (ii) should not exceed the permissible value

• Note: (i) For square key, t = w

For steel σc = 2 
(ii) Square steel key is equally strong in shearing
and crushing

17
 Proportions of Rectangular Sunk Key

The usual proportions are given below:

• Width of key, w = d/4

w
• Thickness of key, t = 2/3 w
t = d/6 t

Rectangular key

Fig:4

18
Proportions of Rectangular Sunk Key (Contd..)

where d = diameter of shaft, mm

• The key has a taper 1 in 100 on the top side only

• The required length of key may be obtained by

equating the strength of key to the shaft

19
 Proportions of Rectangular Sunk Key (Contd..)

d3
• Torque transmitted by shaft T 
16
• Resisting torque of key, = wl. . .d / 2
d3
w.l. .d / 2  x
16
But w = d/4; and key is made of same material as the shaft,
Therefore, l =  d= 1.571d
2

20
• It is assumed that the entire torque is
carried by a tangential force located at the
shaft surface and the force along the
length of the key is uniform.

21
 Proportions of Gib Head Key

• A taper rectangular sunk key fitted with gib head to

facilitate easy with draw
• The taper is on the top of the key
• The proportions of gib head key are shown in fig

Proportions of Gib Head Key

22
 Splines
• Number of keys integrated with shaft
• It is a positive drive which permits the axial movement of
hub
• Application in automobile industry

Proportions of a Spline
23
 Splines (contd..)

• Designated by width, height and length followed by

Indian Standard number

• A straight side spline of width 18 mm, thickness 11 mm

and length 112 mm shall be designated as:

Straight side spline 18 x 11 x 112 IS 2610

24
 Splines (contd..)
The proportions of standard spline are shown in fig.
d = 0.75 D
w = 0.25 D
t = 0.125 D

Where, D = major diameter of shaft

d = root diameter of shaft
w = width of spline
t = thickness of spline

25
Dimensions of Keys and Keyways

26
 Problems
1. A 40 mm diameter shaft is subjected to a tangential
force of 20 KN around its circumference. Determine
the sizes of key. The allowable shear stress in key is
60 N/mm2

Solution:

Diameter of shaft, d = 40 mm

Tangential force, F = 20 KN

= 20 x 103 N
27
Solution (contd..)

• For 40 mm diameter shaft, sizes of key;

Width, w = d/4

= 40 / 4 = 10 mm

Thickness, t = d/6 =40/6 = 6.687=7mm

Adopt, t = 8 mm

Consider shear strength of key

F = ( w x l ). t

28
Solution (contd..)

l = F/( w. ‫) ד‬

= 20 x 103/ (10 x 60) =33.3mm

Size of key: Width = 10 mm;

Thickness = 8mm

Length = 34 mm

29
Shaft Couplings

Fig:1

30
 Couplings

• Shaft are usually available up to 7 meters length

• To have greater length ,it is necessary to join two or more

pieces of shafts by means of Couplings

31
 Couplings (contd..)

• Connect the ends of two shafts together

• Transmit power from one shaft to other shaft

• Reduce the vibrations

• Provide mechanical flexibility

• Permit misalignment of shafts

32
 Requirements of Couplings

• It should be easy to connect or disconnect

• It should transmit full power of shaft

• It should hold the shafts in perfect alignment

• It should have no projecting parts

33
 Types of Couplings

• Rigid Couplings

• Flexible Couplings

34
 Rigid Couplings

Used to connect shafts which are perfectly aligned

Axes are Collinear

Fig :1
35
 Types of Rigid couplings

• Sleeve or muff coupling

• Clamp or split muff couplings

• Flange coupling

• Protected type

• Un protected type

• Marine type

36
Details of split muff coupling Fig:4
37
 Flexible Couplings
Used to connect two shafts both lateral and angular
misalignment

Axes are not Collinear

Fig :6
Angular misalignment

38
Flexible Couplings

Axes are not collinear

Fig:7

Lateral misalignment
39
 Flexible Couplings

Axes are not Collinear

Both angular and lateral

misalignment

Fig:8
40
Types of Flexible Couplings

• Bushed pin type

• Universal type

• Old ham coupling

41
 Bushed Pin Type Coupling
It absorbs shocks and permits small amount of angular and
lateral misalignment

Fig:9
Details of bushed pin coupling
42
Bushed Pin Type Coupling (contd..)

Axes are not Collinear

Both angular and lateral

misalignment

Fig:10
43
 Oldham Coupling
Permits small lateral misalignment

Details of oldham coupling

Fig:12
44
Oldham Coupling (contd..)

Axes are not collinear

Fig:13

Lateral misalignment

45
Oldham Coupling

46
Fig:14
Oldham Coupling

Fig:15

Old Ham Coupling

47
 Universal Coupling
It permits small angular misalignment

Details of Universal coupling Fig:16

48
Universal Coupling (contd..)

Axes are not Collinear

Fig:17

Angular misalignment

49
Universal Coupling (contd..)

Universal Coupling
50
 Flange Coupling

• Widely used for heavy power

• Transmit power at low speeds

• Consists of two hubs keyed to two shafts

• The hub extend into flanges whose faces are brought and
held together by series of bolts arranged concentrically
about the shaft so that their axes are parallel to shaft axes

51
 Flange Coupling (contd..)

• To ensure correct alignment ,one of the hubs has a circular

projection which fits corresponding depression in other hub

52
 Flange Coupling (contd..)

• The bolts transmit torque from one flange to the other

flange and then to shaft

53
Marine Type Flange Coupling

Marine type flange coupling

Fig.4
54
 Design of Flange Coupling
• Flange coupling is designed with empirical relations and
these values are checked for the given loaded conditions

Proportions for C.I flange:

Out side diameter of hub D = 2d
Length of hub L = 1.5d
Pitch circle diameter of bolts D p = 3d
Thick ness of flanges tf = 0.5d
Outer diameter of flanges Do = 4d

d = diameter of shaft or inner dia. of hub

55
 Design of Flange Coupling (contd..)

Considering a flange coupling transmit a torque , T

fs = allowable shear stress for shaft ,key and bolts

fc = allowable crushing stress for key and bolts
fs1 = allowable shear stress for flange material
D = outer diameter of hub
Dp = diameter of bolt circle
d = diameter of shaft
d1 = nominal diameter of bolt
n = number of bolts
tf = thickness of flanges
56
 Design of Flange Coupling (contd..)

Design Of Hub

Consider hub as hollow shaft

16 D.T
f s1 
 (D  d )
4 4

Check the value of fs1 with permissible value.

57
 Design of Flange Coupling (contd..)

Design of Flanges

• The flange is at the junction of the hub is under shear

while transmitting torque T
T = shear area x shear stress x radius of hub

T=  D.t f x fs1x D / 2

Check fs1 with value given in problem

58
 Design of Flange Coupling (contd..)
Design of key :

• The key is designed with usual proportions and then

checked for induced stresses in crushing and shearing .
Key proportions may be mentioned
• Width (W) = D/4
• Thickness (t) = D/6
• Fs = 2T / w x l x D and
• Fc = 4T / t x l x D
• The length of key is taken equal to the length of hub .
• l = 1.5D
59
 Design of Flange Coupling (contd..)
Design of bolts:

Let n be the no of bolts used .

Check for shearing
d 2
1
Dp
T= x n x fs x
4 2
Check the value of f s with permissible value .

60
Design of Flange Coupling (contd..)

Design of bolts:
Considering the bolts in crushing:

T = ( d1.t f )n.fc.Dp/2

Check f c with the value given in problem

Number of bolts may be chosen:

n = 3 , for shafts up to 40 mm dia

= 4 , for shafts up to 100 mm dia

= 6 , for shafts up to 180 mm dia

61
 Protected Type Flange Coupling

• Each flange is provided with annular projection which

shelters the bolt heads and nuts

• Prevents the danger to work men who might be near

the coupling

• The proportions of this coupling are similar to that of flange

coupling except thickness of flange

Thickness of flange t f = 0. 25 d

62
Flange Coupling (Protected Type)

Flange coupling (protected type)

Fig.5
63
Unprotected Type Flange Coupling

64
 Muff Coupling

Details of muff coupling

Fig:1
65
 Muff Coupling

• Consists of muff made of cast iron ,whose internal

diameter Same as that of shafts to be connected

• The muff is connected over the ends of the shafts by

means of sunk key

• The power is transmitted from one shaft to other ,and

three elements acts as a single rigid unit

66
 Muff Coupling

Proportions for cast iron sleeve :

Length of sleeve , L = 3.5 d

Diameter of sleeve, D= 2d+13

d Diameter of shaft in mm

67
 Design of Muff Coupling

Design of shaft
16  T
Diameter of shaft d3 max

 
T Torque transmitted, N-mm

 Shear stress for shaft material ,N/mm2

68
 Design of Muff Coupling

Design of muff

Check for shear strength

• Consider the muff as hollow shaft that transmit full
power of shaft.

Tmax   . 1.
 D 4
 d 4

16 D
1 Shear stress for muff ,N/mm2

69
 Design of Muff Coupling

Design for key

• The length of key must be equal to length of sleeve,

L = 3.5 d
• It is made in two portions
3.5 d
Length in each shaft =
2

For sunk key

Width W = d/4
Thick ness t = d/6

70
 Design of Muff Coupling

Check for stresses in key

d
For shear T  w.l .
2

t d
For crushing T  .l. c .
2 2

71
Problem :

• Design a muff coupling to connect two shafts

transmitting 100kw at 200 rpm .The permissible
shearing and crushing stresses for shaft and key
material are 50 N/mm2 and 100 N/mm2
respectively. The material of muff is C.I with a
permissible shear stress of 15 N/mm2. Assume that
the maximum torque transmitted is equal to the
mean torque .

(Hint:  c =2  assume it as square key )

72
 Solution

Given :
Power , P = 100kw =100 x 103 w

Speed , N = 200 rpm.

For shaft & key

Permissible shear stress  = 50 N/mm2

Permissible crushing stress,  c = 100 N/mm2

For muff,
Permissible shear stress 1 = 15 N/mm2

73
Solution (Contd…)

Step1: Torque transmitted by shaft

60  P 60 100 103
T  
2 N 2    200
 4774.648 Nm

74
Solution (Contd…)

Step2: Diameter of shaft

16  T
d 3
 
16  4774648
 3
  50
 79mm

75
Solution (Contd…)

Step 3: Design of muff :

Out side diameter , D = 2d + 13

= 2x79 + 13 = 171mm
Inside diameter , d = 79 mm
Length of muff , L = 3.5 d = 3.5x79 = 276.5mm

76
Solution (Contd…)

Step 4: Check for shear stress of sleeve:

16 D.T
1 
  D4  d 4 
16  171 4774648
  5.1 N
 171  79 
2
4 4 mm

Since shear stress induced less than permissible value,

the design is safe

77
Solution (Contd…)

Step 5: Design of key


Since  c =2 adopt square key which is equally
strong in shear and crushing

t
l
w

78
Solution (Contd…)

Width of key , w = d/4 = 79/4 = 19.75 mm

= 20 mm

Thickness , t = 20 mm

Length of key in each shaft , l = 3.5d /2

= 3.5 x 79
2

=138.5mm = 139 mm

79
Solution (Contd…)

Step 6: Check for induced stresses in Key

Check for shear :

d
T  w.l. .
2
2T 2  4774648
   43.5 N mm 2

w.l.d 20 139  79

Since induced stress is less than permissible value,

The design is safe .

80
Solution (Contd…)

Check for crushing :

t d
T  .l. .
2 2
4T 4  4774648
   87 N mm 2

t.l.d 20 139  79
Since the induced stress is less than permissible value the
design is safe

81