Facts on Design Safety

Design safety norms keep on changing for better or worse long before we know
what is happening. We cannot vouch which one is safer to use. There are many
safety norms involved in designing a product. The design concept must be based
on a guaranteed Six Sigma approach. Six Sigma signifies less than 3.4
insignificant defects per million parts produced. The Six Sigma approach in
designing was discovered by W. Edward Deming (six basic concepts) and
introduced by Motorola.
The usual practice of design engineers working on concepts is based on past
experiences with product safety practices. New situations can arise which have
nothing to do with their past experiences. The various issues on certain safety
factors on unknown parameters have to be carefully investigated
Keys
A key is a square, rectangular, circular or semi-circular piece of mild steel or wrought iron,
which is inserted in a recessed shaft or hub called key ways. When the key is in position, it
prevents relative rotary motion between the mating parts. Sometimes, a key also prevents
axial motion in the two parts.

Positio
n of Key and Keyway in a Hub and Shaft

Key Assembly
Types of Keys

The keys can be classified as per the shape and purpose for which they are used. Following
are the types of keys:
(a)

Sunk keys

(b)

Saddle keys

(c)

Tangent keys

(d)

Serrated shaft and Splines

(e)

Round keys or Taper pins

Classification of Keys

Keys are classified into three types as follows:

(a)

Taper keys

(c)

Special keys

(b)

Parallel or Feather keys

Taper Keys. A taper Key is of rectangular cross section having uniform width and tapering
thickness. The taper keys are used to transmit only the turning moment between the shaft and
the hub without any relative rotational and axial motion between them. The examples of
tapered keys are
(a)

Taper sunk key

(c)

Flat key

(b)

Saddle key

(d)

Gib head key

Parallel or Feather Keys. A parallel key or feather key is also of rectangular cross section of
uniform width and thickness throughout. Parallel keys are used to transmit the turning
moment between the shaft and the hub along with the provision to allow a small sliding axial
motion between them wherever required. The examples of the parallel keys are:
(a)

Parallel sunk key

(b)

Peg key

(c)

Single head key

(e)

Spline shaft.

(d)

Double head key

Special Keys. The woodruff key, cone key and pin key are the special purpose keys used for
specific applications.
Sunk Keys

A key that engages a slot formed in both pulley and shaft is known as sunk keys. The sunk
keys are of following types:
(a)

Rectangular key

(c)

Gib head key

(e)

Feather key

(b)

Square key
(d)

Woodruff key

Rectangular Key. This type of key is rectangular in cross section and is very commonly
used. The dimensions of this type of key are as follows:
Width of the key W

=D/4

Thickness of the key T = D / 6

Where D is the diameter of the shaft.
A taper of 1 in 100 on the thickness and parallel in width is given to the key. The taper is
given on the upper surface of the key, i.e. the hub side. The recess in the hub is also given the
same taper. The thickness of the key is measured at the large end.
Key

Gib Head Key. This key can be rectangular or square in cross section having a head at the
large end. The head makes it easier to remove the key from the hub and shaft. The slot for gib
head key must have an open end to permit assembly. For this reason it is placed at the end of
a shaft. The dimensions of a gib head key are given in image below.

Gib Head Key

Woodruff Key. A woodruff key shown in image below is segmental in shape and is an easily
adjustable sunk key. The key fits into a semicircular key way cut into the shaft. The top of the
key fits into a plain rectangular keyway in the hub. This key has the advantage of aligning
itself with the taper of the hub and will not easily turn over, because of its extra depth in the
shaft. Woodruff key largely used in automobile work and machine tools. The dimensions of

the woodruff key are standardized. The dimensions of a woodruff key for d and 22 shaft
are shown in image below. A woodruff key is designated as :
Woodruff key 5 X 9 IS: 2294
Where 5mm is the width and 9mm is the height of the key. IS: 2294 is BIS code for woodruff
key.
Woodruff Key Dimensions of Woodruff Key

Feather Key. The feather key is attached to the shaft or the hub and permits relative axial
movement. Image below shows a feather key with a double gib head, a feather key secured to
the shaft with the help of two set screws, a feather key attached to the hub with the help of
one set screw and a peg feather key. The peg of the key fits into the slot provided in the hub.

Saddle Keys. They are tapered keys and are of two types:

Flat saddle key

Hollow saddle key

Flat Saddle Key. It is a tapered key which fits in the key way of the hub and the flat surface
on the shaft. It has got the tendency to slip round the shaft, that is why, it is suitable for light
duty. Image below shows the proportions of a flat saddle key.
Flat Saddle Key

Hollow Saddle Key. This is also a tapered key fitting into the key way of the hub and the
bottom of the key is curved so as to fit the curved surface of the shaft. It is suitable for light
duty work. Image below shows the proportions of a hollow saddle key.

Hollow Saddle Key

Tangent Keys

These types of keys are used for heavy duty. The key is placed tangential to the shaft. These
keys can withstand torsion on one side. If it is required to be used in a reversible unit then
two keys at 90 or 120 are used. The key can have two wedge shaped pieces or a single
rectangular or square piece as shown in image below.
Tangent Keys
Serrated Shafts and Splines

To prevent the key working loose, to reduce the working stresses and to give a greater
bearing surface, it is now a standard practice to design shafts with keys machined integrally
with the main body. The splines or serrations are milled or hobbed to size and shape and then
heat treated. The slots or serrations are finished by broaching. The serrated or splined shafts
are generally used in automobiles. In case of splined shaft, the number of splines can be four,
six or even more. Image below shows an assembly of a serrated shaft used in a scooter kick
with the view of a splined shaft and hub.

Round Key or Taper Pin

A round or taper pin is commonly used for fastening a collar and pulley to shaft as shown in
image below. The hole for the pin is drilled and reamed with the parts assembled. In some
instances the pin is expected to shear before other parts of the assembly are damaged. So it
also acts as a safety device.

Cotters
A cotter is a flat, wedge shaped piece of steel, used to connect rigidly, two parts which are
subjected to axial forces only. The cotters have a uniform thickness throughout the length and
taper on one or both side. The taper varies from 1 in 8 to 1 in 48. The cotters having large
tapers need a locking device.
Length of the cotter L

= 3.5d to 4d

Breadth of the cotter B

= d to 1.32d

Thickness of the cotter T

= 0.15d to 0.25d

The cotter joints are subjected to axial forces such as tensile or compressive forces. The joints
differ from key joints which are used to join shafts subjected to torsional stresses only.

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Front Wheel Suspension System

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Engine Valve

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BMW ///M Engine Under Test

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Mechanical Art

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Mechanical engg
WOODRUF KEYS are semicircular shaped, such that, when installed, leave a protruding tab.
The keyway in the shaft is a semi-circular pocket, the mating part, a longitudinal slot. They
are used to improve the concentricity of the shaft and the mating part, which is critical for
high speed operation. The main advantage of the Woodruff key is that it eliminates milling a
keyway near shaft shoulders, which already have stress concentrations.

High-Efficiency Belt Drives

Belt drives are frequently used in motor systems and offer advantages such as providing
flexibility with positioning of the motor, allowing speed adjustments with the use of pulleys
with differing diamaters, low maintenance requirements, decreased noise levels, and high
efficiency. However, the efficiency of belt drives differ based on their type and condition.
V-type belts are most commonly used and offer efficiencies between 93 to 98%. However,
their efficiency drops by about 4% by age and by an additional 510% with poor
maintenance.
Wedge or cogged belts can maintain efficiencies that are around 2% higher than ordinary Vbelts
Synchronous/flat/ribbed belts offer efficiencies between 96 to 99%, and require less
maintenance. Advancements with these kinds of belts have widened their application
possibilities, and it is worth exploring the potential to switch over to these.

The articulate or jointed arm robot (or sometime called Anthropomorphic arms) closely
resembles the human arm. The mechanical structure has at least three rotary joints which
forms a polar coordinate system. The Figure shown an articulate robot with 6 degree of
freedom. The basic three rotary joints able Arm swap, shoulder swivel and elbow rotations.
Additional 3 revolute joints (Roll, Yaw, Pitch) and one prismatic joint allow the robot to point
in many directions, and then reach out some radial distance.
Application area:
Arc welding

Spot welding
Assembly
cleaning/spraying
Cutting
Deburring
Die casting
Gluing/sealing
Grinding/polishing
Injection moulding
Machine tending
Material handling
Packing
Palletizing
Picking
Pre-machining
Press brake tending

Date of Issue: 8th August, 2013

August, 2013

Date of Submission: 14th

1. Represent the periodic motion given in figure 1 by harmonic motion

Figure 1
2. Find the sum of harmonic motion of equal amplitude but of slightly different frequencies.
Discuss the beat phenomenon that results from this sum.
3. Split up the harmonic motion 8 sin (t + /4) into two harmonic motions one of which has
amplitude of 10 and phase difference zero.
4. A steel shaft 6 cm diameter and 50 cm long fixed at one end carries a flywheel of weight of
1000 kgf and radius of gyration 30cm at its free end. Find the frequency of free longitudinal
transverse and torsional vibration E= 2 x 106 kgf/ cm2, C = 3.8 x 106 kgf/ cm2.
5. A shock absorber is to be designed so that its overshoot is 10% of the initial displacement
when released. Determine the damping factor. If the damping factor is reduced to one half
this values, what will be the overshoot?

6. A simple U tube manometer filled with liquid is ahown in figure 2. Calculate the frequency
of resulting motion if the minimum length of a manometer tube is 0.15m.

7.
(a)
(b)
(c)

Figure2
A gun barrel having mass 560kg is designed with the following data: Initial recoil velocity 36
m/sec, recoil distance on firing 1.5 m
Calculate:
Spring constant
Damping coefficient
Time required for the barrel to return to a position 0.12 m from its initial position

8. A vibratory system is defined by the following parameters:

m = 3kg, k = 100 N/m, C = 3 N- sec/m. Determine
a. The damping factor
b. The natural frequency of the damped vibration
c. The logarithmic decrement
d. The ratio of two consecutive amplitudes
The number of cycles after which the original amplitude is reduced to 20 percent.
Note: On the last date of submission of your assignment, a minor test of 20 marks will
be conducted
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Design of Machine Elements - I Assignmnet No I

Assignments No I
Topic-Basic Machine Design, Design of Shaft, Keys & Coupling

Date of Issue: 8th August, 2013

August, 2013

Date of Submission: 14th

1. Explain the different stages in the design of machine elements.

2. A armature shaft of a 40 kW, 720 rpm electric motor, mounted on two bearings A and B as
shown in figure. Total magnetic pull on the armature is 7 kN and it can be assumed to be
uniformly distributed over a length of 700 mm midway between the bearings. The shaft is
made of steel with a ultimate tensile strength of 770 N/mm 2 and yield strength of 580 N/mm2.
Determine the diameter of shaft if Km =1.5 and Kt=1.0, assume that the pulley is keyed to the
shaft.

3. The problem is shown in the given figure. A pulley drive is transmitting power to a pinion,
which in turn is transmitting power to some other machine element. Pulley and pinion
diameters are 400mm and 200mm respectively. Shaft has to be designed for minor to heavy
shock

ASME code for shaft design is suitable in this case as no other specifications are provided. In
absence of any data for material property, the allowable shear for commercial steel
shaft may be taken as 40 MPa, where keyway is present in the shaft. For the given
condition of shock, let us consider Km = 2.0 and Kt = 1.5.
4. What is key? How are the keys classified? Draw neat sketches of different types of keys and
state their applications.
5. Discuss the function of couplings and effect of key way cut into shaft. Explain the difference
between rigid and flexible coupling.
6. Design a cast iron protective flange coupling to connect two shafts in order to transmit 7.5
kW at 720 rpm. The following permissible stresses may be used:
Permissible shear stress for shaft, bolt and key material = 33 MPa
Permissible crushing stress for bolt and key material = 60MPa
Permissible shear stress for the cat iron = 15 MPa
7. Design a bushed pin type flexible coupling for connecting a motor shaft to a pump
shaft for the following service conditions:
Power to be transmitted = 40 kW; speed of the motor shaft = 1000 r.p.m.; diameter of the
motor shaft = 50 mm; diameter of the pump shaft = 45 mm. The bearing pressure in the
rubber bush and allowable stress in the pins are to be limited to 0.45 N/mm2 and 25 MPa
respectively.