KEYS

Shaft keys are small machine member inserted between a shaft and a hub to prevent angular rotation.
Keys require a key seat both in the shaft and the hub. Keys also acts like a fuse, in which it is designed to
fall first before the shaft is damaged completely.

Where: D = shaft diameter

L = length of the key = length of the hub = 1.5D

t = thickness of the key

b>t

size of the key: b x t x L

Note: Hub and the pulley are made of the same material

Power Transmitted by the key:

2πTN
P=
60

Where: P = power transmitted, kW

T = torque or torsional moment

N = speed (rpm)
Torque Transmitted:

T = F ∗r
D
T = F( )
2

Note: TK = T

Torque capacity for one key = total torque transmitted

Design of Keys:

1. Based on torsional stress in the shaft

16 T
SS = (pure torsion of a solid shaft)
π D3

Sfail
From: = Sall
F.S.

0.6 Sy 16 T
=
F.S. π D3

Sy = yield stress based on shaft material

The value 0.6 is estimated due to the reduction of strength in the keyway because of the
torsional effect in the shaft.

(Refer to the statement from Table AT 7, page 576: Design of Machine Elements 4 th Edition by
Virgil Faires)

2. Based on the compressive stress between the key/hub or key/shaft

F
Sc =
A

2T t
Then: F = and A = L substituting;
D 2

4T
Sc =
DtL
 For the design compressive stress:
Sy
Sc =
F.S.

Sy = yield stress based on the weakest material, either from the key, hub, or shaft.

The compressive stress, Sc should always be based on the strength of the weakest member.

3. Based on shearing of the key

F
SS =
A
2T
Then: F = and A = bL substituting;
D
2T
SS =
DbL

For the design shearing stress:

0.6 Sy
SS =
F.S.

Sy = yield stress based on the material of the key

Factor of safety (Design Factors)

F.S. = 1.5 for smooth loading

F.S. = 2.0 – 2.25 for minor shock loading

F.S. = 4.5 for severe shock loading

Example:

A rectangular key was used in a pulley connected to a lineshaft to transmit a power of 130 kW at 1000
rpm. The shearing stress of the shaft and the key is 45 MPa and 25 MPa, respectively. Calculate the
length of the key if the width is one fourth of the shaft diameter.

SOLUTION:

Solving for the torque, T;

2πTN
P=
60

2πT( 1000 rpm)

130,000 W =
60

T = 1241.4086 N − m
Solving for the diameter of the shaft, based on the torsional stress in the shaft;
16 T
SS =
π D3

1000 mm
N 16( 1241.4086 N−m)( )
1m
45 2
=
mm π D3

D = 51.9865 mm

Hence, solving for the length of the key;

2T 1
SS = ; b= D
DbL 4

8T
SS =
D2L

1000 mm
N 8( 1241.4086 N−m)( )
1m
25 =
mm2 ( 51.9865mm) 2L

L = 146.9886 mm

Example:

A key with a size of ¾ x ¾ x 6 inches is used in a 4-in diameter shafting of SAE 1040 grade, cold rolled,
having a yield point of 50 ksi. Calculate the minimum yield point in the key to transmit power of the
shaft. Use a factor of safety of 3 and Sys = 0.5Sy

SOLUTION:

Solving for the torque, based on the torsional stress of the shaft and using the basic shearing stress of
Sys = 0.5Sy :

0.5 Sy 16 T
=
F.S. π D3

lb
0.5 (50,000 2 ) 16 T
in
=
3 π 4 in) 3
(

T = 104,718.7551 lb − in
Solving for the minimum yield point of the key:
0.5 Sykey 2T
=
F.S. DbL

0.5 Sykey 2 ( 104,719.7551 lb−in)

= ( 4 in)(3/4 in)(6 in)
3

Sykey = 69,813.1701 psi

Sykey = 69.8132 ksi

Example:

A cast iron pulley with a diameter of 1300 mm is to be fastened to a 115 mm shaft. The material for the
shaft and the key is SAE 1030 steel annealed. If the dimension of the key used is 30 mm square key and
180 mm long, calculate:

(a) The force at the rim of the pulley that will shear the key.
(b) The force at the rim of the pulley that will crush the cast iron key way. The strength of cast iron
is 1700 kg/cm2 and 6800 kg/cm2 in tension and compression, respectively.

SOLUTION:

(a) Solving for the force at the rim of the pulley that will shear the key:

From the table AT8, Typical Properties of Steel – Various Sizes and Conditions, page 578 of
Design Machine Elements 4th Edition by Virgil Morning Faires
lb
For SAE 1030 steel, annealed: Sy = 49000
in2

lb 1 kg 1 mm 2 kg
Sy = (49000 )( )( ) = 34.5228
in2 2.2 lb 25.4 in mm2

kg kg
SS = 0.6 Sy = 0.6 (34.5228 ) = 20.7137
mm2 mm2
Based on shearing of the key:
F
SS = ; A = bL ;
A

F
Ss =
bL

kg F
20.7137 =(
mm2 30mm)(180mm)

F = 111,853.98 kg

(shearing force experienced by the key)

Hence the force, F’ to shear the key at the pulley rim:

Total torque transmitted by the shaft is equal to the torque transmitted to the key:

T ′ = Tkey

1300 mm 115 mm
F′ ( ) = (111,853.98 kg) ( )
2 2

F ′ = 9,894.7752 kg

(Force at the pulley rim to shear the key)

(b) Solving for the force at the rim of the pulley that will crush the cast iron key way.

Based on the compressive stress between the key/hub or the key/shaft:

F t
Sc = ; A= L
A 2

2F
Sc =
tL

kg 1 cm 2 2F
(6800 2
)( ) =(
cm 10 mm 30mm)( 180mm)

F = 183600 kg

(compressive force experienced by the key)

Hence the force, F’ to compress the key at the pulley rim:

 Total torque transmitted by the shaft is equal to the torque transmitted to the key:

T ′ = Tkey

1300 mm 115 mm
F′ ( ) = (183,600 kg) ( )
2 2

F ′ = 16,241.5385 kg

(Force at the pulley rim to crush the keyway)

Number of Keys Used:

For heavy loads, two or more keys can be employed. Two keys are usually separated by 90 degrees and
each key can are sized to carry 20 percent more than one-half of the total torque. Three keys are usually
separated by 120 degrees and each key can carry 15 percent of the total torque.

Design of 2-keys separated by 90°

Torque Transmitted per key:

Total torque transmitted
TK = ∗ 1.2
No.of keys

T
TK = ∗ 1.2
NK

Where: 𝑁𝐾 = number of keys

1. Based on the compressive stress between the key/hub or key/shaft

4𝑇𝑘 T
From: Sc = and TK = ∗ 1.2 substituting
DtL NK

4T( 1.2)
Sc =
DtLNK
 2. Based on shearing of the key
2TK T
From: Ss = and TK = ∗ 1.2 substituting;
DbL NK

2T( 1.2)
SS =
DbLNK

Design of 2-keys separated by 120°

Torque Transmitted per key:

Total torque transmitted
TK = ∗ 1.15
No.of keys

T
TK = ∗ 1.15
NK

Where: NK = number of keys

1. Based on the compressive stress between the key/hub or key/shaft

4T( 1.15)
SC =
DtLNK

2. Based on shearing of the key

2T( 1.15)
SS =
DbLNK
SPLINE SHAFT

Spline shaft is a shaft with series of permanent keys formed longitudinally around its circumference.
Spline shaft is recommended when high torque capacity is to be transmitted or when axial motion of the
mating parts under load is expected.

Where: D = major diameter

Dm = mean diameter

d = minor or shaft diameter

L = length of spline = length of hub = 1.5D

t = thickness of the spline

b = width of the spline

b>t

size of the spline: b x t x L

Note: Hub and the pulley are made of the same material

Power transmitted by the key:

2πTN
P=
60

Where: P = power transmitted, kW

T = torque or torsional moment

N = speed (rpm)
Torque transmitted per spline:
Total torque transmitted
Ts = ∗ 1.1
No .of splines

T
Ts = ∗ 1.1
Ns

T = F rm
D+d
T = F( )
4

Where: NS = number of splines

rm = mean radius

Design of splines:

1. Based on torsional stress in the shaft

16 T
SS = (pure torsion of a solid shaft)
π d3

Sfail
From: = Sall
F.S.

0.6 Sy 16 T
=
F.S. π d3

Sy = yield stress based on shaft material

2. Based on compressive stress between the key/hub of key/shaft

F
SC =
AC

Where: AC = tL (area under compression)

4TS T
From: F = and Ts = ∗ 1.1 substituting;
D+d Ns

4T( 1.1)
SC = (
D+d) t LNs
 3. Based on shearing of the key

F
SS =
As

Where: As = bL (area under shear)

2Ts T
Then: F = and Ts = ∗ 1.1 substituting;
d Ns

2T( 1.1)
Ss =
dbLNs

For the design shearing stress:

0.6 Sy
Ss =
F.S.

Sy = yield stress based on the material of shaft or spline

Types of Fits:

(D = shaft diameter)

Types of Fits 6 splines 4 splines 10 splines

d = 0.9D d = 0.85D d = 0.91D
b = 0.25D b = 0.241D b = 0.156D
Permanent Fit
t = 0.05D t = 0.075D t = 0.45D
d = 0.85D d = 0.75D d = 0.86D
To slide when not
b = 0.25D b = 0.241D b = 0.156D
under load
t = 0.075D t = 0.125D t = 0.07D
d = 0.80D d = 0.81D
To slide when under
b = 0.25D b = 0.156D
load
t = 0.10D t = 0.095D

Example:

A 12-in spur gear transmits 100 hp at 350 is fastened to a shaft. The shaft is 6-splined permanent fit
shaft, made of SAE 1045 Water Quenched (QW) 197 BHN. The gear is made of AISI 1022 as rolled.
Calculate the spline dimensions if the power is to be transmitted with severe shock loads.

SAE 1045 WQ 197 BHN: Sy = 60,000 psi

AISI 1022 as rolled: Sy = 52,000 psi

SOLUTION:

Torque transmitted:
2πTN
P=
60

550 ft−lb 12−in 2 π T ( 350 rpm)

(100 hp) ( )( )=
1 hp 1 ft 60

T = 18007.2450 in − lb

Based on torsional stress on shaft:

0.6 Sy 16 T
=
F.S. π d3

Factor of safety for heavy shock load = 4.5, from page 282 of Design of Machine Elements 4 th
Edition by Virgil Morning Faires

0.6 (60,000 lb/in2) 16 ( 18,007.2450 in−lb)

=
4.5 π d3

d = 2.2548 − in

From spline specification:

d = 0.9D

2.2548-in = 0.9 D

` D = 2.5053-in

Based on the compressive stress between the key/hub or key/shaft

Sy 4T ( 1.1)
Sc = =(
F.S. D+d) t LNs

60,000 lb/in2 4 ( 18,007.2450 in−lb)( 1.1)

=(
4.5 D+0.9D)(0.05D)( 1.5D)(6)

D = 1.9084 − in

Based on the shearing of the key:

0.6 Sy 2T ( 1.1)
Ss = =
F.S. dbLNs

60,000 lb/in2 2 ( 18,007.2450 in−lb)(1.1)

= ( 0.9D)( 0.25D)(1.5D)(6)
4.5

D = 1.1363 − in
Hence; choose the largest value

D = 2.5053 − in

Summary of answers: d = 2.2548-in

b = 0.6263-in

t = 0.1253-in