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Topic 3: KEYS AND COUPLING

DEFINITIONS AND USEFUL INFORMATIONS
▪ Key – is a rigid connector between a shaft and the hub of another component such as
pulley, cam, or gear.
▪ Key is a demountable machinery part which, when assembled into keyseats, provides a
positive means for transmitting torque between the shaft and hub.
▪ The most common function of a key is to prevent relative rotation of a shaft and the
member to which it is connected, such as the hub of a gear, pulley, or crank. Its purpose
is to prevent relative rotation between the two parts.
▪ Keyseat is an axially located rectangular groove in a shaft or hub.
▪ Keyway is a groove in the shaft and the mating member to which the key fits.
▪ A key seat must be provided in the shaft and a key-way in the hub of the other part.
▪ Seat screw is frequently used to seat the key firmly in the keyway and to prevent axial
motion of the parts.
Types of Key with Constant Cross Section
1. Square key is the most commonly used in general industrial machinery. The key is sunk half
in the shaft and half in the hub.
2. Flat key is a key used where the weakening of the shaft by the keyway is serious and where
added stability of the connection is desired, as in machine tools.
3. Round key is a key used for fastening cranks, hand wheels, and other parts that do not
transmit heavy torques. Some manufacturers employed this type of key for heavy-duty shafts
over 6 inches because the absence of the sharp corners reduces the stress concentration
below that which would exist had a square key and flat key been used. Keyway for this key
may be drilled and reamed after assembly of the mating parts.
4. Barth key is a square in which the two bottom corners are beveled to ensure that the key will
fit tightly against the top of the keyway when the drive is in either direction, and lessen the
tendency to twist. It does not require a tight fit, and the small clearance permits easy assembly
and removal.
Types of Keys with Variable Cross Section
1. Kennedy keys, also called as tangential keys, are tapered square keys that are assembled
with the diagonal dimension virtually in a circumferential direction. This key is used for heavy-
duty application.
2. Gib-head keys are tapered square or flat keys with head.
3. Pin key is usually a drive fit key, either straight or tapered (taper of ¼ to 3/16 inch per ft);
longitudinally assembled on the shaft, can be sized about ¼ of the shaft diameter and can
transmit heavy power.
4. Woodruff key is a key widely used in the automotive and machine tool industries. It fits into a
semi-cylindrical seat in the shaft.
5. Feather key is a key that allows the hub to move along the shaft but prevents rotation on the
shaft. It is used to permit moving element, say gear, into or out of engagement with its mate,
to engage or disengage, say, a jaw clutch.
6. Saddle key is used for light power; it is tapered and either hollow, with a radius of curvature
slightly smaller than the shaft radius, or flat that is assembled flat on the shaft. 7. Spline fitting
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is composed of a spline shaft formed by milling and mating hub with internal splines formed
by broaching. Splines are actually number of keys integral with the shaft. These splines have
the advantages of greater strength and a self-centering feature.

Figure 3.1. Flat Key

TORQUE TO BE TRANSMITTED
THROUGH THE KEY
1. Transmitted Torque Based on
Shear Stress
▪ Transmitted torque is due
to the load or force, Fn,
that tends to shear the
key on the middle point of
its thickness, in which the
shearing area is the key
length times half the
thickness.
Figure 3.2. Load Analysis on the Key

▪ Transmitted Torque is
given by the following
expression

D Fn D D Ss b L D
T= = Ss As = ( ) Ss (b L) =
2 2 2 2

Where, T = transmitted toruqe, in − lb, kN − m

As = shearing area, in2 , m2
Ss = shear stress, psi, MPa
D = shaft diameter, in, m
L = length of the key, in, m, mm
t = thickness o fthe key, in, m, mm

Figure 3.3. Shearing Area of the Key

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2. Transmitted Torque Based on Compression Stress

▪ Transmitted torque based on compression is due to the bearing force applied on
the bearing area, as shown in figure 3.4 below. Either on the key, hub, or shaft.
Figure 3.4. Bearing Area on the Key

Transmitted Torque,
D D D t sc t L D
T = ( ) F n = ( ) sc A b = ( ) sc ( ) L = Eq. 3.2
2 2 2 2 4

Where, T = Transmitted torque, equal to transmitted torque based on shear, in − lb, kN − m

t = thickness of the key, in, m, mm
sc = compression stress, psi, MPa
Fn = bearing force, which is equal to shearing force, lb, kN

Design Considerations for Keys

1. The shearing stress in eq. 3.1 may be obtained from the shearing yield stress or strength of
the key material.
2. The compression stress in eq. 3.2 is taken according to the weakest of the three parts involved,
the shaft, the key, or the hub.
3. Design factor of safety on the yield strength: Smooth load = 1.5; Minor shock loading = 2 to
2.25; Severe shock loading = 2.25 to 4.
4. Yield stress on shear to be used (for ductile material): sys = syc ; sys = 0.6 sy (Faires); sys =
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0.5 sy (MSST); sys = 0.577 sy (OSST)

Design procedure for Flat and Square Keys

1. To find shaft diameter, change the cross-sectional dimensions b and t of the flat or square key
in accordance with ASA standards, from Table 3.1 below.
2. Solve for L from equation 1 and equation 2, and use the larger value.

Other Information on Keys

▪ Hub length – between 1.25D and 2.4D, where D is the shaft diameter.
▪ If the needed key length is greater than about 2D, use two keys 180o apart or Kennedy keys
▪ If the load is other than smooth, the key should fit tightly, either by use of taper keys or by
clamping the hub onto the shaft and key.
▪ If the key and shaft are of the same material, the length of key required to transmit the full
power capacity of the shaft is determined by equating the shear stress of the key to the
torsional stress of the shaft,
2T 16 T 1 D
= ( ) and b =
b L D π D3 0.75 4

then L = 1.18D or approximately L = 1.2D. The value 0.75 is the estimated weakening effect
of the keyway on the torsional strength of the shaft.
▪ The common material of keys is cold-finished, low-carbon steel (0.2% C or less) or heat-
treated steels.

Sample Problems:
Solutions will be solved in class. Additional Problems will also be solved in class.

1. A 76.2 mm diameter shafting of SAE 1040 grade, cold drawn, having a yield point of 50 ksi
has a key with a dimension of ¾ inch x ¾ inch x 5 inches. Compute the minimum yield point in
the key in order to transmit the torque of the shaft. The factor of safety is 2 and syc = 0.5sy .

2. A key is to be designed for a 12.7 cm shaft that will transmit power of 150 kW at 360 rpm. If the
allowable shear stress for the key is 920 kg/cm2 and the allowable compressive stress is 1200
kg/cm2 , determine the length of the key. Key dimensions: b = 1 ¼ inches = 3.175 mm, and t =
7/8 inches = 2.2225 cm.

3. A rectangular key was used in a pulley connected in a line shaft with a power of 125 kW at a
speed of 900 rpm. If the shearing stress of the shaft is 40 N/mm2 and the key to be 22 N/mm2 ,
determine the length of a rectangular key with width equals to one-fourth of the shaft diameter.
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SHAFT COUPLING
▪ Coupling is a mechanical device for uniting or connecting parts of a mechanical system.
▪ Coupling provides for connection of shafts of units that are manufactured separately, such as
a motor and a generator, and to provide for disconnection for repairs or alterations. It provides
for misalignment of the shafts as to introduce mechanical flexibility.
▪ Coupling reduces the transmission of shack loads from one shaft to another.
▪ Coupling introduces protection against overloading.
▪ Coupling alters the vibration characteristics of rotating units.
Types of Coupling
1. Rigid Coupling is a permanent coupling that by virtue of its construction has essentially no
degree of angular, axial or rotational flexibility and it must be used with collinear shafts.
o It has no flexibility and resilience.
o It is necessary for the shafts that are to be connected to be in good alignment, both
laterally and angularly, in order to avoid excessive loads on the coupling, on the shafts,
or on the shaft bearings.
2. Flexible Coupling is a coupling that allows angularity for the misalignment of the shafts.
Kinds of Rigid Coupling
1. Flanged Coupling is a rigid coupling that consists of two halves of flanges and is connected
to each other by bolts.
2. Collar coupling – is a rigid coupling that consists of cylindrical collar pressed over the ends of
the two collinear shafts being connected, approximately one-half of the collar contacting each
other
Kinds of Flexible Coupling
1. Chain Coupling – is a flexible coupling consists of essentially of two chain sprockets
connected with short continuous length of roller or silent chains.
2. Oldham Coupling – is a flexible coupling that can be employed for connecting two parallel
shafts with axial eccentricities from zero to a reasonable amount.
3. Flexible Disk Coupling - is an all-metal coupling with the intermediate flexible elements being
thin steel disks.
4. Universal Joint – is a flexible coupling used to connect shafts whose axes intersect, that is,
whose angular misalignment is permanent.
5. Hydraulic Coupling – a coupling that employs a fluid to provide angular flexibility between the
input and output shafts.

DESIGN CALCULATIONS FOR FLANGE COUPLING

D = shaft diameter, inches, mm
Dh = hub diameter, inches, mm
Db = bolts circle diameter, inches, mm
d = bolt diameter, inch, mm w = flange thickness, inch, mm
b = width of the key, inch, mm
t = thickness of the key, inch, mm
Lh = Hub length, inches, mm
L = length of key, inches, mm
Do = outside diameter of the coupling, inches, mm
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F = shearing or compressive force on bolts, lb., kN

T = coupling transmitted torque, in-lb., kN-m
P = power transmitted, kW Hp = transmitted Hp
N = Factor of safety on shaft
Nks = Factor of safety on key based on shear
Nkc = Factor of safety on key based on compression
Nbs = Factor of safety on bolts based on shear
Nbc = Factor of safety on bolts based on compression
Nh = Factor of safety on the hub

Figure 3.5. Flange Coupling

DESIGN EQUATIONS
1. Total transmitted force or load on bold:
2T
F=
Db

2. Shearing on each bolt:

F 2T
Fb = =
nb nb Db

3. Shearing Stress on Bolts:

Fb 4 Fb 8T
ssb = = 2 =
Ab π d π nb d2 Db

4. Compressing or bearing stress on bolts or flange:

Fb Fb 2T
scb = = =
Ac d w nb d w Db

5. Shearing Stress on flange with the hub:

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Fch 2T 2T
ssh = = =
Ash (π Dh w)Dh π w D2h

6. Shearing Stress on key:

Fk 2T 2T
ss = = =
Ask (b L)D bLD

7. Compressing or bearing stress on either key, hub, or shaft:

Fk 2T 4T
sc = = t =
Ack ( b) D b t D
2

Sample Problems:
Solutions will be solved in class. Additional Problems will also be solved in class.

1. A flange coupling is to connect two 57 mm shafts. The hubs of the coupling are each 111 mm
in diameter and 92 mm hub length. Six 16-mm bolts in a 165-mm diameter bolts circle connect
the flanges. The key way is 6 mm shorter than the hub length and the key is 14 mm x 14 mm.
Coupling is to transmit 45 kW at 160 rpm. For all parts, yield point value in shear is one-half the
yield point value in tension or compression that is 448 MPa. Find a) the shearing stress of key
and its factor of safety; b) the bearing stress of key and the factor of safety based on yield point;
c) the shearing stress in bolts and factor of safety based on yield point. (Board problem, November
1983)
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Lecture Worksheet 3
(to be provided separately)