KEYS AND COUPLING

Objectives:
After completing this lesson the students should be able to:
1. To describe several type of keys.
2. To specify suitable size key for a given size shaft.
3. To specify suitable materials for keys
4. To design of keys.
5. To describe rigid couplings and flexible couplings
6. To design of couplings
KEYS
Keys - are machine elements weak in shear, the function of which 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
Types of Keys:
1. Square Key - common in general industrial machinery, the width of
the key being equal to its height.
• Where:
t = thickness of key
b = width of key
L = length of key
Types of Keys:
2. Flat Key- used when added stability of the connection is advised, as
in machine tools.
Types of Keys:
3. Gib Head Key - tapered keys provided with gib head to facilitate
removal. In tapered keys, the width is uniform but the height is tapered
by 1/8 inch per foot.
Types of Keys:
4. Kennedy Key - used for heavy duty and consists of two keys. The hub
is bored to fit the shaft and is then rebored off center.

5. Round Key - it has the advantage of less stress concentration at the

key seat. The main disadvantage is the necessity of drilling the hole to
accommodate the pin after assembly of the hub and the shaft.

6. Woodruff Key - requires a key seat formed by a special side-milling

cutter. This key will align itself in the key seat. It has the disadvantage of
weakening the shaft more than by the use of a straight key.
Stress analysis to design the key:
Stresses on Key:
1. Shear stress
2. Compressive, crushing or bearing stress
Stresses on Key:
1. Shear stress
2. Compressive, crushing or bearing stress

For the key in shear:

In terms of transmitted torque, T:
In terms of transmitted torque, T:
In Designing:
𝑠𝑠 = shearing yield strength of the key material
𝑆𝑇𝑆 0.5 𝑜𝑟 0.6 𝑆𝑦
𝑠𝑠 = or
𝑁 𝑁
In Designing:
𝑠𝑠 = shearing yield strength of the key material
𝑆𝑇𝑆 0.5 𝑜𝑟 0.6 𝑆𝑦
𝑠𝑠 = or
𝑁 𝑁

For the values of the factor of safety, N

N = 18 for smooth load
N = 20-2.5 for minor shock loading
N = up to 4.5 for severe shock loading
For key in compression (bearing)
For key in compression (bearing)
For key in compression (bearing)
In Designing:
Design Procedures:
Design Procedures:
1. Solve for the shaft diameter
2. Determine the values of b and t from table AT-19, DOME by Faires
3. Solve for L from equation A and B. (use larger value of L.)
Other techniques in solving for the torque
acting on the key if not specified in problem.
1. Power Rating of Shaft is given
2𝜋𝑇𝑁
P= P = Hp ; T = lb-ft
33,000
𝑇𝑁
P= P = Hp ; T = lb.in
63025
2𝜋𝑇𝑁
P= P = kW ; T = kN.m
60
2𝜋𝑇𝑁
P= 6 P = kW ; T = N.mm
9.55 𝑋 10
Other techniques in solving for the torque
acting on the key if not specified in problem.
2. Allowable strength of the shaft or shaft material will be specified
Let: Strength of the key equal to the strength of the shaft
16𝑇
𝑠𝑘 = 𝑠𝑠 =
𝜋𝐷3
Other techniques in solving for the torque
acting on the key if not specified in problem.
3. If keyway effect is to be considered, then reduce the strength of
shaft by 25%
𝑠𝑘 = 0.75𝑠𝑠
Note:
a) For standard keys: b = 1Τ4 D
𝑡
b) Usual proportion of is 0.625 to 0.70
𝑏
c) 𝐿𝐻 ≥ L where: 𝐿𝐻 = 𝑙𝑒𝑛𝑔𝑡ℎ ℎ𝑢𝑏
𝐿𝐻 = 1.25D to 2.4D L = length of key
Example:
A cast iron pulley is keyed to a 70 mm shaft made of mild steel
and is to transmit 93.25 kW at 185 rpm. A flat key of cold-finished
carbon steel having a yield strength of 4000 kg/cm is used. Since the
drive is expected to be subjected to minor vibration, a safety factor of
1.75 may be used. Determine the length of the key.
 A cast iron pulley is keyed to a 70 mm shaft made of mild steel and is to transmit 93.25 kW at 185 rpm.
A flat key of cold-finished carbon steel having a yield strength of 4000 kg/cm is used. Since the drive is expected
to be subjected to minor vibration, a safety factor of 1.75 may be used. Determine the length of the key.
 A cast iron pulley is keyed to a 70 mm shaft made of mild steel and is to transmit 93.25 kW at 185 rpm.
A flat key of cold-finished carbon steel having a yield strength of 4000 kg/cm is used. Since the drive is expected
to be subjected to minor vibration, a safety factor of 1.75 may be used. Determine the length of the key.
 A cast iron pulley is keyed to a 70 mm shaft made of mild steel and is to transmit 93.25 kW at 185 rpm.
A flat key of cold-finished carbon steel having a yield strength of 4000 kg/cm is used. Since the drive is expected
to be subjected to minor vibration, a safety factor of 1.75 may be used. Determine the length of the key.
 A cast iron pulley is keyed to a 70 mm shaft made of mild steel and is to transmit 93.25 kW at 185 rpm.
A flat key of cold-finished carbon steel having a yield strength of 4000 kg/cm is used. Since the drive is expected
to be subjected to minor vibration, a safety factor of 1.75 may be used. Determine the length of the key.
 A cast iron pulley is keyed to a 70 mm shaft made of mild steel and is to transmit 93.25 kW at 185 rpm.
A flat key of cold-finished carbon steel having a yield strength of 4000 kg/cm is used. Since the drive is expected
to be subjected to minor vibration, a safety factor of 1.75 may be used. Determine the length of the key.
Example:
A 63.5 mm diameter shaft has a key 16 mm x 16 mm. The shaft
material tests 400 MPa at yield point. Let.5,-0.55, The factor of safety
equals 2. The shaft fits into a cast iron hub for which the working stress
in compression is 125 MPa. What length of key in the hub material will
be required to carry the torque of the solid shaft? The key material is
assumed to be amply strong.
A 63.5 mm diameter shaft has a key 16 mm x 16 mm. The shaft material tests 400 MPa at yield point. Let.5,-
0.55, The factor of safety equals 2. The shaft fits into a cast iron hub for which the working stress in
compression is 125 MPa. What length of key in the hub material will be required to carry the torque of the
solid shaft? The key material is assumed to be amply strong.
A 63.5 mm diameter shaft has a key 16 mm x 16 mm. The shaft material tests 400 MPa at yield point. Let.5,-
0.55, The factor of safety equals 2. The shaft fits into a cast iron hub for which the working stress in
compression is 125 MPa. What length of key in the hub material will be required to carry the torque of the
solid shaft? The key material is assumed to be amply strong.
A 63.5 mm diameter shaft has a key 16 mm x 16 mm. The shaft material tests 400 MPa at yield point. Let.5,-
0.55, The factor of safety equals 2. The shaft fits into a cast iron hub for which the working stress in
compression is 125 MPa. What length of key in the hub material will be required to carry the torque of the
solid shaft? The key material is assumed to be amply strong.
COUPLING
Coupling - is a mechanical device for uniting or connecting parts of a
mechanical system.
Purpose of coupling
1. To provide for the connection of shafts of units that are
manufactured separately, such as motor and generator.
2. To provide for misalignment of the shafts or to introduce mechanical
flexibility
3. To reduce the transmission of shock loads from one shaft to another.
4 To introduce protection against overloads 5. To alter the vibration
characteristics of rotating units.
Kinds of Coupling
1. Rigid coupling
2. Flexible coupling
Kinds of Coupling
1. Rigid coupling
2. Flexible coupling
Rigid Couplings
Rigid Couplings - are permanent couplings which by virtue of their
construction have essentially no degree of angular, axial, or rotational
flexibility. They must be used with collinear shafts.
Types of Rigid couplings
1. Flange Coupling - most common type of rigid coupling, it is
composed of two mating halves
2. Compression Coupling - utilizes two split cones which are drawn
together by the bolt in order to produce a wedging action which
tightens the parts of the coupling and the shaft
3. Collar Coupling - consists of a cylindrical collar pressed over the
ends of two collinear shafts being connected
Flexible couplings
Flexible couplings - couplings that can accommodate reasonable
amounts of axial angularity between shafts, a small amount of
eccentricity between parallel shafts, or axial movements of shafts
Types of Flexible Couplings
1. Elastic - material bonded coupling (provide slight amount of torsional
and angular flexibility)
2. Chain Couplings – consists essentially of two chain sprockets connected
with a short continuous length of roller or silent chain. They find
application with angular misalignment as well as with slight eccentricity
of shafts.
3. Old Ham Coupling – can be employed for connecting two parallel shafts
with axial eccentricities.
4. Universal Joint (Hooke's Joint) – is used frequently for shafts with
angular misalignment.
5. Hydraulic Couplings (Fluid Coupling) - employs a fluid to provide angular
flexibility between the input and output shafts.
BASIC INFORMATION AND NOMENCLATURES
OF COUPLINGS:

where:
Ds = Diameter of shaft
d = diameter of bolt
H = diameter of hub
B = bolt circle diameter
L = length of key
tf = thickness of flange
th = thickness of hub
Design Considerations:
- For given dimensions of the elements of the flanged coupling
determine the factor of safety.
Design Considerations:
- For given dimensions of the elements of the flanged coupling
determine the factor of safety.
Step 1. Check the possible cause of failure of each element.
Elements Failure
A. Key shear, compression
B. Bolt shear, compression
C. Flange Hub shears the flange
A. Key: Failure Analysis:
1. Transverse shear: Force acting on parallel to area
A. Key: Failure Analysis:
1. Transverse shear: Force acting on parallel to area
A. Key: Failure Analysis:
1. Transverse shear: Force acting on parallel to area
A. Key: Failure Analysis:
1. Transverse shear: Force acting on parallel to area
A. Key: Failure Analysis:
2. Bearing stress or compressive stress: Force perpendicular to area.
A. Key: Failure Analysis:
2. Bearing stress or compressive stress: Force perpendicular to area.
A. Key: Failure Analysis:
2. Bearing stress or compressive stress: Force perpendicular to area.
A. Key: Failure Analysis:
2. Bearing stress or compressive stress: Force perpendicular to area.
 B. Bolt: Failure Analysis:
1. Transverse Shear: Force acting on parallel area.

Note: Fb = force acting per bolt considered equally

distributed on each bolt.
 B. Bolt: Failure Analysis:
1. Transverse Shear: Force acting on parallel area.

Note: Fb = force acting per bolt considered equally

distributed on each bolt.
B. Bolt: Failure Analysis:
1. Transverse Shear: Force acting on parallel area.
B. Bolt: Failure Analysis:
1. Transverse Shear: Force acting on parallel area.
B. Bolt: Failure Analysis:
2. Bearing or Crushing of bolt: Force perpendicular or area
B. Bolt: Failure Analysis:
2. Bearing or Crushing of bolt: Force perpendicular or area
B. Bolt: Failure Analysis:
2. Bearing or Crushing of bolt: Force perpendicular or area
B. Bolt: Failure Analysis:
2. Bearing or Crushing of bolt: Force perpendicular or area
C. Flange: Failure Analysis
C. Flange: Failure Analysis
1. Hub will shear the flange or hub bores through the flange
C. Flange: Failure Analysis
1. Hub will shear the flange or hub bores through the flange
C. Flange: Failure Analysis
1. Hub will shear the flange or hub bores through the flange
C. Flange: Failure Analysis
1. Hub will shear the flange or hub bores through the flange
Design Considerations:
- For given dimensions of the elements of the flanged coupling
determine the factor of safety.
Step 1. Check the possible cause of failure of each element.
Elements Failure
A. Key shear, compression
B. Bolt shear, compression
C. Flange Hub shears the flange
Design Considerations:
Step 1. Check the possible cause of failure of each element.
Elements Failure
A. Key shear, compression
B. Bolt shear, compression
C. Flange Hub shears the flange

Step 2. Compute the value of each individual safety factor. Choose the
least factor as the factor of safety of the flanged coupling
Design Considerations:
Step 2. Compute the value of each individual safety factor. Choose the
least factor as the factor of safety of the flanged coupling
Design Considerations:
Step 2. Compute the value of each individual safety factor. Choose the
least factor as the factor of safety of the flanged coupling