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DESIGN OF MACHINE MEMBERS – 1

DESIGN OF KEYS
Unit-5
OBJECTIVE
After this presentation you should be able to
• Identify keys and their applications
• Calculate forces on keys
• Design keys
INTRODUCTION
A key is a piece of steel inserted between a
shaft and a component, such as a pulley or a gear
wheel, to transmit rotary motion (torque). Keys and
keyways vary in size according to the diameter of the
shaft on which they are fitted
INTRODUCTION
The key is inserted parallel to the axis of
the shaft and used as temporary fastenings
A keyway is a slot or recess in the shaft
and hub of the pulley to accommodate a key
TYPES OF KEYS
• Sunk keys
• Saddle keys
• Tangent keys
• Round keys
• Splines
TYPES OF SUNK KEYS
• Rectangular sunk key
• Square sunk key
• Parallel sunk key
• Gib-head key
• Feather key
• Woodruff key
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
Let
‘d’ – diameter of the shaft or diameter of the hole in
the hub
‘w’ – width of the key
‘t’ – thickness of the key
SUNK KEYS
For RECTANGULAR SUNK KEY
• Width of key w = d/4
• Thickness of the key t = 2w/3 = d/6
• The key has the taper 1 in 100 on the topside.
For SQUARE SUNK KEY the width is equal to
thickness. w = t = d/4
PARALLEL SUNK KEY contains uniform width and
thickness through out and are taperless
SUNK KEYS
The rectangular sunk key with head at one end
is known as GIB HEAD KEY. The head is provided to
facilitate the removal of key.
Width w = d/4
Thickness at large end t = 2w/3 = d/6
SUNK KEYS
FEATHER KEY is attached either to the pulley or to
the shaft thus permitting one member to slide along
the other. It may be screwed into a recess in the
shaft, have a double head or a central peg, which
causes it to be contained in the pulley and slide in
the keyway or the shaft. Their proportions are similar
to square or rectangular keys.
SUNK KEYS
WOODRUFF KEY is used particularly in machine
tools and in automotive work. It fits into a recess
milled in the shaft by a special cutter. It has the
advantage of being easily adjustable to any taper in
the keyway of the pulley. These keys should never be
used as feather keys.
SADDLE KEYS
Saddle keys are suitable for light duty only. They
tend to work loose and rock on the shaft under heavy
duty.
The saddle keys are of two types
1. Flat saddle keys
2. Hallow saddle keys
SADDLE KEYS
FLAT SADDLE KEY is a taper key which fits in a
keyway in the hub and is flat on the shaft. It is likely
to slip round the shaft under load. Therefore it is
used for comparatively light loads.
HALLOW SADDLE KEYS 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. These
keys hold on by friction, therefore suitable for light
loads.
TANGENT KEYS
TANGENT KEYS are fitted in pair at right angles.
Each key is to withstand torsion in one direction
only. These are used in large heavy duty shafts
ROUND KEYS
These are circular in section and fit into the
holes drilled partly in the shaft and partly in the hub.
Their keyways may be drilled and reamed after
mating parts have been assembled. These are
appropriate for low power drives
SPLINES
Keys are made integral with the shaft which fits in
the keyways broached in the hub. Such keys are
known as SPLINED SHAFTS. These shafts usually
have four, six, ten or sixteen splines. These splined
shafts are relatively stronger than shafts having a
single keyway. By using splined shafts axial
movement as well as positive drive is obtained
FORCES ACTING ON SUNK KEY
When key is used in transmitting torque from a shaft
to rotor or hub the following two types of forces act
on the key
1. The forces produced due to tight fitting of the key
leads to compressive stresses on the key
2. The forces produced due to torque transmitted by
the shaft leads to shearing and compressive
(crushing) stresses in the key
Since the forces are concentrated near the torque
input end the distribution of forces along the length
of the key is not uniform
FORCES ACTING ON SUNK KEY
F1
l
F
F

F1

F1 is the compressive stresses in the key caused by the torque transmitted


by the shaft
F is the shear stresses in the key caused by the torque transmitted by the
shaft
The forces due to fit of the key are neglected in the design of the key and it
is assumed that the distribution of forces along the length of key is uniform
STRENGTH OF THE KEY
Let
T - Torque transmitted by the shaft
F - Tangential force acting at the circumference of
the shaft
d - Diameter of shaft
l - Length of key
w - Width of key
t - Thickness of key
τ - Shear stresses for the material of key
σc - Crushing stresses for the material of key
τ1 - shear stress for the shaft material
STRENGTH OF THE KEY
1.Shearing of the key
The tangential shearing force acting at the
circumference of the shaft

F = Area resisting shearing x Shear stress = l.w.τ

Torque transmitted by the shaft T = F . (d/2)

T = l . w . τ . (d/2) (i)
STRENGTH OF THE KEY
2. Crushing of the key
The tangential crushing force acting at the
circumference of the shaft
F = Area resisting crushing x Crushing stress
F = l . (t/2) .σc
Torque transmitted by the shaft

T = F . (d/2) = l . (t/2) .σc . (d/2)

T = l . (t/2) .σc . (d/2) (ii)


STRENGTH OF THE KEY
The key is equally strong in shearing and crushing, if
l . w . τ . (d/2) = l . (t/2) .σc . (d/2)
Or
(w/t) = σc / 2τ (iii)
The permissible crushing stress for the usual
key material is atleast twice the permissible shearing
stress. Therefore from equation (iii), we have w=t. in
other words, a square key is equally strong in
shearing and crushing
STRENGTH OF THE KEY
In order to find the length of the key to transmit full
power of the shaft, the shearing strength of the shaft
is equal to torsional shear strength of the shaft
From equation (i) we have T = l . w . τ . (d/2)
Torsional strength of the shaft
T = (π/16) . τ1 . d3 (iv)
Equating equation (i) and (iv)
l . w . τ . (d/2) = (π/16) . τ1 . d3
Substituting w= d/4 and the considering the material
is same as the material of the shaft, then τ = τ1
l = 1.571 d
Problem: Design the rectangular key for a shaft of 50 mm
diameter. The shearing and crushing stresses for the key
material are 42MPa and 70 MPa.
Given data:
d = 50mm; τ = 42MPa = 42N/mm2; σc = 70MPa = 70
N/mm2
From the table we find that for a shaft of 50mm diameter
Width of the key w = 16mm; thickness of key t = 10mm
The length of the key is obtained by considering the key in
shearing and crushing.
Let ‘l’ be the length of the key. Considering shearing of the
key
T = l . w . τ . (d/2) = l x 16 x 42 x (50/2) = 16800.l N-mm
Torsional shear strength of the shaft
T= (π/16) . τ . d3 = (π/16) x 42 x 503 = 1.03x106 N-mm
Problem: Design the rectangular key for a shaft of 50 mm
diameter. The shearing and crushing stresses for the key
material are 42MPa and 70 MPa.

Equating both shear strength of the key and torsional


strength of the shaft, we get
l= 61.31 mm
Now considering crushing of the key
T = l . (t/2) .σc . (d/2) = l x (10/2) x 70 x (50/2) = 8750 l N-
mm
Equating torsional shear strength and crushing strength
l = 117.7mm
Taking larger of the two values we have the length of the
key
l = 117.7 mm say 120mm
Problem: A 45mm diameter shaft is made of steel with yield
strength of 400Mpa. A parallel key of size 14mm wide and 9mm
thick made of steel with a yield strength of 340MPa is to be
used. Find the required length of key, if the shaft is loaded to
transmit the maximum permissible torque. Use maximum shear
stress theory and assume a factor of safety of 2
Given data:
d= 45mm; σyt for shaft = 400MPa = 400 N/mm2;
w = 14mm; t = 9mm; σyt for key = 340MPa = 340N/mm2;
F.S = 2
Let l is the length of key.
According to max. shear stress theory, the max shear
stress of the shaft
τmax = σyt /(2 x F.S) = 400/(2 x2) = 100N/mm2
max. shear stress for key
τk = σyt /(2 x F.S) = 340/(2x2) = 85 N/mm2
Problem: A 45mm diameter shaft is made of steel with yield strength
of 400Mpa. A parallel key of size 14mm wide and 9mm thick made of
steel with a yield strength of 340MPa is ti be used. Find the required
length of key, if the shaft is loaded to transmit the maximum
permissible torque. Use maximum shear stress theory and assume a
factor of safety of 2.

Max. torque transmitted by shaft and key


T = (π/16) . τmax . d3 = (π/16) . 100 . 453 = 1.8x106N-mm
Failure of the key due to shearing
1.8x106 = l x w x τk. (d/2)  l= 67.2mm
Failure of the key due to crushing
1.8x106 = l x (t/2) x σck x (d/2)  l = 104.6mm
Taking larger value of the two values
l = 104.6 say 105mm
RULES FOR EFFICIENCY IN JOINING
KEYS
1. Clearances between components should be
minimal, otherwise when the key is fitted the
components being joined could run eccentrically
and cause out of balance forces.
2. Clearances between key and keyway must not
allow malalignment of components, otherwise
unwanted backlash can occur under drive
conditions .
RULES FOR EFFICIENCY IN JOINING
KEYS
3. Where taper keys are concerned, the tapers MUST
correspond to each other.
4. Tapers on shafts and hubs/collars should be
carefully checked for scoring and burring.
Questions
1. What factors determine the CROSS-SECTIONAL size of any
particular key?
2. Why are SADDLE KEYS only suitable for light duty?
3. Give three examples of where components are joined by keys?
4. What special "movement" feature does a feather key allow when
used in gear boxes?
5. On a sheet of paper, sketch two types of feather key showing
clearly their method of location?
6. What is the main advantage of using woodruff keys where
shafts are tapered?
7. Why should woodruff keys never be used as feather keys?
8. Explain the difference between FLAT SADDLE and HOLLOW
SADDLE KEYS?
9. Explain the type of force exerted on keys?
10. List the general rules for efficiency in joining by keys?
ANSWERS
1. Shaft diameter and load (torque) on the secured components.
2. They hold by friction only.
3. i. Gear wheels on shafts ii. Fly wheels iii. Taper locks
4. Allows linear movement of one member of the keyed components.
In a gear box this would normally be the gears or gear clusters.
5. Check the figures in slide no:9
6. They adjust easily to accommodate any taper in the keyway of the
pulley.
7. Any movement would likely jam up because the key would rotate
in its semi circular slot.
8. Flat saddle requires a flat surface machined on the mating shaft.
Hollow saddle requires a radius recess machined on its underside.
Both drive by friction only.
9. Shear force and compressive force
10. Check slide no:28

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