SILVER OAK GROUP OF INSTITUTES

DEPARTMENT OF MECHANICAL ENGINEERING

MDID QUESTION BANK SOLUTION
Unit 3 - Shaft, Keys and Couplings
26 Explain functions and classification of shaft. Explain Shaft, Axle, Spindle, Machine shaft, Counter shaft,
and line-shaft with their examples.
Solution: A shaft is a rotating machine element which is used to transmit power from
one place to another.
Torque (or twisting moment) set up within the shaft permits the power to be
transferred.
To transfer power from one shaft to another, various members like pulleys, gears
etc., are mounted on it (shaft). Various members are mounted on the shaft by
means of keys or splines.
These members exert forces and causes the shaft to bend (bending). Thus a shaft is
used for the transmission of torque and bending moment. The shafts are usually
cylindrical, but may be square or cross-shaped in section. They are solid in cross-
section but sometimes hollow shafts are also used.
1. Transmission shafts.

These shafts transmit power between the

source and the machines absorbing
power.
The counter shafts, line shafts, overhead
shafts and all factory shafts are
transmission shafts.
Since these shafts carry machine parts
such as pulleys, gears etc., therefore they
are subjected to bending in addition to
twisting.
2. Machine shafts.
These shafts form an integral part of the
machine itself.
The crank shaft is an example of machine shaft
27
Explain ASME design code for shaft.
In 1927, the American Society of mechanical engineers, (ASME) established a code for the design
of transmission shafting. This code is widely used for the design of shafts based on maximum shear
stress theory.

We know: Equivalent twisting moment (Te) is given by

for solid shafts

when shock and fatigue factors are given.

But sometimes instead of shear stress the strength is given in the numerical. Like yield strength and
ultimate tensile strength for steel from the design data. In such case shear stress has to be found
out in following manner:
(1) Allowable shear stress as per ASME code (without keyway)
For commercial steel shafts:

For steel purchased under specifications:

 (2) Allowable shear stress as per ASME code (with keyways)
If the keyways are present, these values are reduced by 25% to account of keyway effect.
For commercial steel shafts:

For steel purchased under specifications:

NUMERICAL ON ASME CODE OF SHAFT DESIGN:

A belt driven C.I pulley of 0.9 m diameter overhangs the bearing by 0.2 m. The pulley is driven from the
bottom by a belt. The angles of lap and tension on tight side are 180 degree and 2600 N respectively.
The weight of pulley is 600 N. Assume co-efficient of friction 0.25. Shaft is made up of 30C8. Syt=400
MPa, Sut =500 MPa Determine the shaft diameter according to ASME code. Take Ks=1.0, Kb=1.5
Solution:

D = 0.9 m = 900mm
R = 0.45 m = 450mm
L = 0.2m = 200mm
= 1800 = 180 X(/180)= radians
W = 600N
F1 = 2600N
= 0.25
Syt = 400 N/mm2
Sut = 500N/mm2
Kt = 1.0
Kb = 1.5
Step 1: Find allowable shear stress:

Shear
stress = 67.5 N/mm2
Step 2: Calculate Torque on shaft:

= 637.2 X 103 Nmm

Step 3: Calculate Bending moment
 = 2600 + 1184 + 600 = 4384 N

= 4384 x 200 = 876 X 103 Nmm

Step 4: Equilavent Torque

so d = ________________ mm

28 Design a shaft to transmit power from an electric motor to a lathe head stock through a pulley by
means of belt drive. The pulley weighs 200 N and is located at 300 mm from centre of bearing. The
diameter of pulley is 200 mm and maximum power transmitted is 1 kW at 120 rpm. The angle of lap of
belt is 180 and coefficient of friction between belt and pulley is 0.3. The shock and fatigue factors
for bending and twisting are 1.5 and 2.0 respectively. The allowable shear stress for shaft is 35 MPa.

Also (T1 T2) = e =

Solving both equations we get

29 A steel spindle transmits 4kW at 800r.p.m. The angular deflection should not exceed 0.25 degree per
metre of spindle. If modulus of rigidity of spindle is 84 GPa. Find the diameter of spindle & shear stress
induced in the spindle.

30 Which out of solid shaft and hollow shaft is more advantageous and why?
Advantages of hollow shaft:
(1) Stiffness of solid shaft is more than that of solid shaft with same weight.
(2) Strength of hollow shaft is more than that of solid shaft with same weight
(3) Natural frequency hollow shaft is higher than that of solid shaft with same weight.
Disadvantages of hollow shaft compared to solid shaft:
(1) Hollow shaft is costlier than solid shaft
(2) Diameter of hollow shaft is more than that of solid shaft and it requires more
space.
Compare the weight, strength and rigidity of a hollow shaft of same external diameter as that of
solid shaft, Both the shaft are made of same material. Assume that the diameter ratio for the hollow
shaft as 0.6.
31 Explain different types of keys used in shaft coupling. Discuss factors to be considered while
selecting type of key What is keyway? How is its effect considered in shaft design?
The different types of keys are
1. Sunk keys, The sunk keys are provided half in the keyway of the shaft and half in the keyway
of the hub or boss of the pulley. Application: Muff Coupling
2. Saddle keys, Aflat saddle key is a taper key which fits in a keyway in the hub. Appli: Fixing
eccentric cam
3. Tangent keys, The tangent keys are fitted in pair at right angles. These are used in large
heavy duty shafts
4. Round keys, are circular in section and fit into holes drilled partly in the shaft and partly in
the hub. Round keys are usually considered to be most appropriate for low power drives.
5. Splines: keys are made integral with the shaft which fits in the keyways broached in the
hub. Such shafts are known as splined shafts. Used in automobile transmission and sliding
gear transmissions.
Factors to be considered while selecting keys are:
(a) Heavy duty or low duty shafts
(b) Amount of power to be transmitted
(c) Whether how much is the strength required
(d) Whether multiple keys are required or not
Keyway and Effect of Keyway:
Keyway cut into the shaft reduces the load carrying capacity of the shaft. This is due to the
stress concentration near the corners of the keyway and reduction in the cross-sectional area
of the shaft. It other words, the torsional strength of the shaft is reduced.
32 What are the different types of sunk key? Explain each with application.
Different types of sunk keys are;
(a) Rectangular sunk key: It is rectangular in cross section with taper. Used in couplings.
(b) Square sunk key: It is square in cross section used in couplings
(c) Parallel sunk key: They are square or rectangular in crosssection and used in Muff and
Split muff coupling
(d) Gib head key: It is a rectangular sunk key with a head at one end known as gib head. It is
usually provided to facilitate the removal of key.
(e) Feather keys: A key attached to one member of a pair and which permits relative axial
movement is known as feather key. It is a special type of parallel key which transmits a turning
moment and also permits axial movement.
(f) Woodruff Key: The woodruff key is an easily adjustable key. It is a piece from a cylindrical
disc having segmental cross-section in front view
Derive strength equations of sunk key based on shear and compression failures.
Numerical: A 45mm diameter shaft is made of steel with yield strength of 400. A parallel key of size
14 mm wide and 9 mm thick made of steel with a yield strength of 340 MPa is to be used. Find the
required length of key, if the shaft is loaded to transmit the max. permissible torque. Use max. shear
stress theory. assume F.O.S. = 2
33 Differentiate between flexible coupling and rigid coupling? State the different applications of
coupling?
34 Explain the design procedure of (a) Flange coupling (b) Bush Pin type flexible coupling.
Design procedure of Flange coupling:

(a) Design of Shaft

Find shaft dia (d) from

(b) Design of Hub (according to hollow shaft)

(c) Check shear stress (c) of cast iron i.e shear stress of muff.

K = d/D
(d) Design of key
Length of key = Length of Hub = 1.5d

(e) Design for flange

Check shear stress for flange (c) from

(f) Design of Bolts

D1 = 3d
Next put d1 in formulae of crushing stress and check crushing stress
Design of Bush Pin Type of Coupling:
Bushed Pin Type Flexible Coupling

(A) Design of Shaft:

Find shaft dia (d) from

(B) Design of key (Rectangular sunk key)

(C) Dimensions of Hub

(D) Dimensions of Flange

(E) Dimensions of Pin

For n = 3 if diameter (d) less than 30mm

n = 4 if upto 75mm
n = 6 if upto 110 mm and so on

d2 = Outer dia of rubber bush

d2 = d1 + 2 ( thickness of brass bush + thickness of rubber bush)
d2 = d1 + 16mm
 Outer dia of flange: D2 = (2D1 - D)
35 What is the difference between split muff and muff coupling?
In Muff coupling the sleeve is used which doesnt have bolts but in Split muff coupling, the
muff is made in two halves and are bolted together.
Design a split muff clamp coupling to transmit 30 KW power at 100 rpm, using the following data.
Number of bolts = 4, allowable shear stress for shaft and key = 40 MPa, allowable tensile stress for
the bolts = 70 MPa. Take co-efficient of friction = 0.3