The document discusses different types of keys and couplings used to connect transmission shafts to rotating machine elements like gears. It describes saddle keys, sunk keys, and flat rectangular keys. It also explains box or muff couplings, clamp couplings, and rigid flange couplings. Design procedures are provided for determining the dimensions of keys and couplings components based on the power transmitted, shaft dimensions, material properties, and safety factors. Examples are included to demonstrate how to design a square key and select the dimensions of a flat key based on given application parameters.
The document discusses different types of keys and couplings used to connect transmission shafts to rotating machine elements like gears. It describes saddle keys, sunk keys, and flat rectangular keys. It also explains box or muff couplings, clamp couplings, and rigid flange couplings. Design procedures are provided for determining the dimensions of keys and couplings components based on the power transmitted, shaft dimensions, material properties, and safety factors. Examples are included to demonstrate how to design a square key and select the dimensions of a flat key based on given application parameters.
The document discusses different types of keys and couplings used to connect transmission shafts to rotating machine elements like gears. It describes saddle keys, sunk keys, and flat rectangular keys. It also explains box or muff couplings, clamp couplings, and rigid flange couplings. Design procedures are provided for determining the dimensions of keys and couplings components based on the power transmitted, shaft dimensions, material properties, and safety factors. Examples are included to demonstrate how to design a square key and select the dimensions of a flat key based on given application parameters.
Ratna Kumar Annabattula Department of Mechanical Engineering IIT Madras Key Design ! Key is used to connect a transmission shaft to a rotating machine element such as a gear, hub, pulley, etc.. ! Primary function is to transmit torque from shaft to the hub of mating element ! Secondary function is to prevent relative rotation between the joining machine elements ! Types of Keys ! Saddle key ! Fits in the keyway of hub only; no keyway on the shaft ! Torque is transmitted only through friction between key, shaft and hub only ! Used for light duty application ! Sunk key ! Fits half in the keyway of hub and remaining half in the keyway of shaft ! Torque transmission is through shear resistance of the key ! Suitable for heavy duty application ! Positive drive ! Flat and Rectangular keys (more stable) Source: V. B. Bhandari, Design of Machine Elements Example Problem ! It is required to design a square key for xing a gear on a shaft of 25 mm diameter. 15 kW power at 720 r.p.m. is transmitted from the shaft to the gear. The key is made of steel 50C4 (Syt = 460 MPa) and the factor of safety is 3. The yield strength in compression can be assumed to be equal to the yield strength in tension. Determine the dimensions of the key. Example Problem ! The standard cross section for a at key, which is tted on a 50 mm diameter shaft, is 16 x 10 mm. The key is transmitting 475 N-m torque from the shaft to the hub and is made of commercial steel (Syt=Syc=230 MPa). Determine the length of the key, if the factor of safety is 3. Rigid Couplings ! Box or Muff or Sleeve Coupling ! Clamped Coupling ! Rigid Flange Coupling Box or Muff Coupling ! Coupling are checked for shear of the pins and crushing of sleeves and shaft by pin ! For shaft: M t /J = s /r ! s =M t r/J = 16 Mt/d 3 ! sleeve = Tr/J; J = (D 4 -d 4 )/32; r = D/2 ! The key/pin must have equal depth in shaft and muff to avoid bending ! muff - made of cast iron and key - plain carbon steel ! Outer diameter of the muff d 0 = 2d+13 mm ! Length of the muff l = 3.5 d ! Width of key b=d/4 ! Thickness of key h = d/4 ! Mean diameter of the pin d p = 0.2 - 0.3 d ! Taper of the pin = 1:20 to 1:30 ! Edge distance e = 0.75 d Design Procedure for Muff Coupling ! Calculate the diameter of each shaft by following equations M t = 60 10 6 (kW) 2n and = 16M t d 3 ! Calculate the dimensions of the sleeve by following empirical equations D = (2d + 13) mm and L = 3.5d Also check the torsional shear stress induced in the sleeve by the following equation = M t r J , J = (D 4 d 4 ) 32 , r = D 2 ! Determine the standard cross section of the at sunk key. The length of the key in each shaft is half of the sleeve length. Therefore l=L/2 = 2M t dbl , c = 4M t dhl Exercise ! Design a muff coupling for the following data ! The yield strength of plain carbon steel is 400 MPa ! Ultimate tensile strength of cast iron is 200 MPa ! Power to be transmitted is 25 kW ! Shafts rotates at 360 rpm ! Factor of safety for key and shaft material is 4 ! Factor of safety for muff is 6 Clamp Coupling ! For sleeve halves: ! D = 2.5d ! L = 3.5 d ! For clamping bolts: ! d 1 = 0.20d+10 mm for d < 55mm ! d 1 = 0.15d+15 mm for d > 55 mm Clamp or Split Muff Coupling ! In Clamp Coupling, torque is transmitted by means of friction between sleeve halves and shaft surface and partly by shear resistance of keys ! Not suitable for shock loads Exercise ! Design a clamp coupling for the following data ! The yield strength of plain carbon steel in tension is 400 MPa and in compression it is 150% of tensile strength ! Ultimate tensile strength of cast iron is 200 MPa ! Power to be transmitted is 50 kW ! Shafts rotates at 120 rpm ! Factor of safety for key, bolts and shaft material is 5 ! Number of bolts is 8 ! Coefcient of friction between sleeve and shaft is 0.3 Flange Coupling Unprotected Flange Coupling Protected Flange Coupling Proportions d h = Outer diameter of hub = 2d l h = Length of hub (key) = 1.5 d D = PCD of bolts = 3d t = Thickness of ange = 0.5d t 1 = Thickness of protecting rim = 0.25d d r = Dia of spigot and recess = 1.5d D 0 = OD of ange = (4d+2t 1 ) N = (3,4,6) for (d<40, 40<d<100,100<d<180) Flange Coupling ! Consists of two anges - one keyed to the driving shaft and other to the driven shaft ! Two anges are connected together by means of four or six bolts ! Power is transmitted ! from the driving shaft to the left ange through key ! left ange to right ange through bolts ! right ange to right shaft through key ! Provision for spigot (on left ange) and recess (on right ange) for easy alignment ! Two type - protected and unprotected Design Procedure for Flange Coupling ! Calculate shaft diameter by usual method adopted in muff and clamp coupling (We have M t and d now) ! Dimensions of ange (from standard proportions). Torsional shear stress in the hub can be calculated by assuming it to be a hollow shaft subjected to torsional moment M t, ! = M t r/J, where J = "(d h 4 -d 4 )/32 and r = d h /2 ! Flange at the junction of hub is under shear while transmitting moment Mt ! area under shear = ("d h )t; Shear force = ("d h t) ! ! Resisting torque Mt = ("d h t !)(d h /2) ! Diameter of bolts ! Number of bolts N = 3 for d < 40 mm; N = 4 for 40 < d < 100 mm; and N = 6 for 100 < d <=180 mm Design Procedure for Flange Coupling ! Bolts are subjected to direct shear and not to torsional shear. ! M t = P * N * D/2 ! Direct shear stress in a bolt is given by ! = P/(("/4)d 1 2 ) ! ! = 8M t /"DNd 1 2 ! Compressive stress in each bolt is given by crushing area (d 1 t) times the crush stress ! Mt = Nd 1 t" c D/2 ! Dimensions of Keys ! l = l h ! ! = 2M t /(dbl) ! " c = 4M t /(dhl) Example Design a rigid ange coupling tow shafts for the following conditions ! Input shaft transmits 37.5 kW at 180 rpm to output shaft through coupling ! Service factor for the application is 1.5 (i.e., design torque is 1.5 times the rate torque) ! S yt for shafts = 380 MPa and a F.S. of 2.5 ! For Keys and bolts S yt = 400 MPa, S yc = 150% of S yt and F.S. = 2.5 ! For ange (Grey C.I.) S ut = 200 MPa and F.S. = 6 and ultimate shear strength is one-half of ultimate tensile strength