CHAPTER 3: Keys and Coupling

KEY
Is a machine member at the interface of a pair mating male and female cross sectioned members to prevent relative angular motion
between these mating.

Square key – is square in section and may or may not be tapered.

Round key – is circular in section and fit into holes drilled partly in the shaft and partly in the hub.
Barth key – is a square key with bottom two corners bevelled.
Gib-head key - is a square or flat and tapered key with a head at one end known as gib head. It is usually provided to facilitate the
removal of key.
Saddle key – is tapered and are either hollow with a radius of curvature slightly smaller than the shaft radius, or flat in which case
they are assembled on a flat on the shaft. It is used without keyway on the shaft.
Flat saddle key – is a taper key which fits in a keyway in the hub and is flat on the shaft.
Hollow saddle key – is a taper key which fits in a keyway in the hub and the bottom of the key is shaped to fit the curved surface of
the shaft.
Woodruff key – is a key which fits into a semi-cylindrical seat on the shaft.
Feather key – is a key that allows the hub to move along the shaft but prevents rotation on the shaft.
Kennedy key – is a tapered square key, with or without gib heads, assembled with the diagonal dimension virtually in a
circumferential direction. It is also called tangential key.
Rollpin – is a key driven or pressed into a hole that is small enough to close the slit, assembled in radial direction.

COMPRESSIVE STRESS OF KEY KEY DIMENSIONS FOR SAME MATERIAL OF

KEY AND SHAFT
2 F 4T
SC = =
hL hLD D
w= L=1.2 D
4
SHEARING STRESS OF KEY

F – force applied T – torque

F 2T
Ss = =
wL wLD h – height (thickness) of key L – length of key

W – width of key

SPLINES
are permanent keys made integral with the shaft and fitting into keyways broached into the mating hub

COMPRESSIVE STRESS OF KEY

F T
SC = =
A N sp hL R m N sp

TOTAL TORQUE TRANSMITTED

SHEARING STRESS OF THE SPLINE T =F Rm

F 2T
Ss = = MEMD-413: Machine Design 1 1
wL N sp wLD N sp
TORQUE CAPACITY
F – force applied T – torque

h – height (thickness) of key L – length of key

T
T C =1.1∙ W – width of key Nsp – number of splines
N sp
Rm – mean radius
COUPLING

Is a mechanical device which is used to connect length of shafts permanently

Rigid coupling – is used to connect two shafts which are perfectly aligned.
Flange coupling - usually applies to a coupling having two separate cast iron flanges. Each flange is mounted on the shaft end and
keyed to it. The faces are turned up at right angle to the axis of the shaft. One of the flanges has a projected portion and the other
flange has a corresponding recess.

Compression coupling utilizes two split cones which are drawn together by the bolts in order to produce a wedging action which
tightens the parts of the coupling and the shafts.

Flexible coupling – is used to connect two shafts having both lateral and angular misalignment.
Oldham coupling – is used to join two shafts which have lateral mis-alignment.
Universal or Hooke’s coupling – is used to connect two shafts whose axes intersect at a small angle. The inclination of the two
shafts may be constant, but in actual practice, it varies when the motion is transmitted from one shaft to another.
FORMULAS IN COUPLINGS SHEARING OF THE BOLTS
POWER TRANSMITTED
T =Ssb A b Rbc n b 8T 4 Fb
P=2 πTN Ssb = =
π Dbc Db nb π Db2
2

TOTAL LOAD TRANSMITTED ON BOLTS

COMPRESSION BETWEEN BOLTS AND THE
2T T
F= = FLANGE
D bc Rbc
2T F
TRANSMITTED FORCE PER BOLT Scb = = b
D bc Db nb t tDb
F PUNCHING SHEAR ON HUB
F b=
nb
2T
Ss =
π D h2 t

P – power transmitted Ss– shear on hub

T – torque Ab – bolt area

N – speed Dh– hub diameter

F – total force transmitted Rbc – bolt circle radius

Fb – force per bolt MEMD-413: Machine Design 1

Dbc – bolt circle diameter 2
Problem Set (Keys and Splines):
1. A keyed sprocket delivers a torque of 778.8 N-m thru the shaft of 54 mm outside diameter. The key thickness is
1.5875 cm and the width is 1.11 cm. Compute the length of the same key. The permissible stress value is 60 MPa for
shear and 90 MPa for tension.
2. A solid steel machine shaft with a safe shearing stress of 7000 psi transmits a torque of 10500 in-lb. A square is used
whose width is equal to one fourth the shaft diameter and whose length is equal to 1 ½ times the shaft diameter. Find
the key dimensions. Determine the crushing stress of the key. Obtain the factor of safety of the key in crushing,
allowing an ultimate shearing stress of 50000 psi and ultimate stress for compression of 60000 psi.
3. What length of a square key is required for a 4-in diameter shaft transmitting 1000 hp at 1000 rpm? The allowable
shear and compressive stresses in the key are 15 ksi and 30 ksi, respectively.
4. A rectangular key was used in a pulley connected to a line shaft with a power of 7.46kW at a speed of 1200 rpm. If the
shearing stress of the shaft and key are 30N/mm 2 and 240N/mm2,respectively, what is the length of the key if the
width is one fourth that of shaft diameter.
5. A shaft for an automobile transmission has 10 splines with the following dimensions: D o = 1.25 in., Di = 1.087 in., and
L = 1.000 in. Determine the safe torque capacity and horsepower at 3600 rpm of this sliding connection for a
compressive stress of 1000 psi.
6. The rear axle of an automobile has one end splined. For this fitting there are ten splines, and D =1.31 in., d = 1.122
in., and L = 1 15/16 in. The minimum shaft diameter is 1 3/16 in. For a compressive stress of 1000 psi, determine the
safe torque capacity of the splined connection, sliding under load.

Problem Set (Couplings):

1. Two shafts are connected by flange coupling. The coupling is secured by 6 bolts, 20 mm in diameter of 150 mm. If
torque of 120 N-m is applied, find the shear stress in the bolts.
2. A turbine is connected to a generator by means of flange coupling that has a bolt circle diameter of 500 mm. The
generator output is 40 MW, 3600 rpm and 90% efficiency. If there are 16 bolts, determine the force acting on each
bolt.
3. A flange bolt coupling is to be designed, using 25-mm diameter bolts at a distance of 152 mm from the center of the
shaft. Allowable stress on the bolt is 103 MPa. If the shaft is to transmit 5800 hp at a speed of 1200 rpm, how many
bolts are needed in the connection?
4. A flange bolt coupling having 180 mm bolt circle and 19 mm thick uses 8 bolts, 16 mm diameter to connect two shafts.
It is used to transmit 60 kW at 1800 rpm. Determine the factor of safety in bearing if yield point in compression is 44.8
MPa
5. A flange coupling is to connect two 57 mm shafts. The hubs of the coupling are each 111 mm in diameter and 92 mm
thick and the flange webs are 19 mm thick. Six 16 mm bolts in a 165 mm diameter circle connect the flanges. The
keyway is 6 mm shorter than the hub’s thickness and key is 14mm x14mm. Coupling is to transmit 45 kW at 160 rpm.
For all parts, yield point value in shear is one half the yield point in tension or compression which is 448 MPa. Find: a.
shear stress in shaft, b. shear stress in key, c. bearing pressure in key and factor of safety based on yield point, d.
shear stress in bolts, e. bearing pressure in coupling.

MEMD-413: Machine Design 1 3