Keys, Pins, Splines and Couplings

Keys

A key is a machine member employed at the interface of a pair of mating male and female
circular- sectioned members to prevent relative angular motions between these mating parts. The
key fits into mating grooves in the shaft and mating member called keyway.

Figure:

b = width of key
t = thickness of key
L = length of key
D = shaft diameter
F = crushing/shearing force acting on the key
T = torque to be transmitted
P = power to be transmitted
n = number of revolution per unit time

From the diagram, the torque being transmitted by the pulley or gear and the crushing/shearing
force developed in the key is given by equation;

T = ½ F D or F = 2 T / D

Shear stress in the key;

2T/ D Ss b L D 2T
Ss = F / As = or, T or, L =
bL 2 b D Ss

Compression in the key;

2T/D Ss t L D 4T
S c = F / Ac = or, T or, L=
t/2 x L 4 t D Sc

The usual material for keys is cold finished, low carbon steels (0.2 % C or less) although
heat-treated alloy steels are used where needed.
In design, the design stresses in the foregoing equations are based on the yield strength of
the material involved. The allowable stress in compression is taken according to the weakest of the
three parts involved; the shaft, the key or the hub. The suggested margins of safety based on yield
strength are;
1.5 - for smooth load, 2.0 – 2.25 – for minor shock
4.5 – for severe shock and reversing loads.
Typical hub lengths fall between 1.25 D and 2.4 D, where D is the outside shaft diameter.
If the needed key length is greater than about 2 D, consider using 2 keys, 180° apart.

1
Example1.

A cast steel gear (SAE 0030) with a pitch diameter of 36 in is to transmit 75 hp at 210 rpm
to a rock crusher and is keyed to a 3 in shaft (SAE 1045, as rolled) by means of a square key made
of SAE 1020 cold drawn steel. What should be the length of the square key to be used?

Solution:

Key: SAE 1020 cold drawn steel Sy = 66,000 psi

Shaft: SAE 1045 as rolled steel Sy = 59,000 psi
Gear: SAE 0030 cast steel Sy = 43,750 psi @ 25 % more of 35 ksi

From AT-19, Faires-594, the standard cross-sectional dimensions of the square key for a 3 in
diameter shaft is;
b x b = ¾ in x ¾ in

The driven machine is a rock crusher; so we can assume that the load on the key will be
accompanied with severe shock. Consider a safety factor of N = 4.

Based on shear;

2T
L= , where;
b D Ss

T = 63,000 x 75 hp / 210 rpm = 22,500 in-lb

Ss = Sys / N = 0.6 x 66,000 psi / 4 = 9,900 psi
b = ¾ in
D = 3 in

then, L = 2.02 in

Based on compression,

4T
L= , where;
t D Sc
Sc = 43,750 / 4
= 10,937 psi (The weakest element is the hub of the gear)
t = ¾ in
D = 3 in
T = 22,500 in-lb

then, L = 3.657 in

Use: L = 3 ¾ in

2
Example 2:

A cast steel, SAE 080 N&T, pulley is keyed to a 65 mm diameter shaft by means of a
standard flat key with a length of 90 mm, made of cold drawn SAE 1015. The shaft is made of
cold drawn SAE 1045. If the shaft is virtually under pure tension and turns 420 rpm, what safe
horsepower can the assembly transmit? The load is steady.

Solution:

Pulley: SAE 080 N&T Sy = 50,000 psi @25 % more

Key: SAE 1015 cold drawn Sy = 63,000 psi
Shaft: SAE 1045 cold drawn Su = 100,00 psi Sy = 85,000 psi

For steady load: N = 1.5

The torque being transmitted is;

P hp x 746 watt/hp
T=   16,961 hp, N - mm
2 n 2  x 420 rpm / 60 s

For the shaft, using ASME Code,

16 K s T
Ssd = , where; Ks = 1.0 for steady load
 D3
Ssd = 0.18 x Su x 0.75 = 93 MPa ( with key way)
= 0.30 x Sy x 0.75 = 131.9 MPa or N/mm2
Ssd = 93 MPa (use the lower value)
D = 65 mm
then, hp = 295.6 horsepower

For the key: Standard size is 5/8 in x 7/16 in

For shear:
S bLD
T s , where; Ss = 0.6 x 63,000 psi x 6.895 x 10-3 / 1.5 = 173.75 MPa
2
L = 90 mm b = 5/8 in x 25.4 mm/in = 15.875 mm

then, hp = 475.6 horsepower

For compression,

Ss t L D
T , where; Sc = 50,000 psi x 6.895 x 10-3 / 1.5 = 229.83 MPa
4
t = 7/16 x 25.4 = 11.11 mm

then, hp = 304.9 horsepower

Then, maximum safe is, hp = 295.6 horsepower

3
Example3.

A 1 11/16 shaft rotating at 200 rpm carries a cast iron gear keyed to it by a ¼ x 1 ¼ in
Woodruff key, shaft material is cold finished SAE 1045. The power is transmitted with mild
shock. What horsepower maybe safely transmitted by the key if it is made of cold drawn SAE
1118? How many keys are needed to give a capacity of 20 hp?

Solution:

Shaft: Cold finished SAE 1045: Sy = 85,000 psi

Key: Cold drawn SAE 1118: Sy = 75,000 psi
Gear: Cast iron – It is generally strong against compression.

For a load accompanied with mild shock: Consider N = 2.25

From Table 10.1 (Faires-282), Woodruff key with dimensions of ¼ x 1 ¼ in;

As = 0.296 in2 A = ¼ in B = 1 ¼ in

Computing the torque as a function of horsepower delivered;

T = 63,000 hp / n = 63,000 x hp / 200 rpm = 315 hp, in-lb

Based on shear:

F 2T
Ss = = , where; Ss = 0.6 Sy / N = 0.6 x 75,000 / 2.25 = 20,000 psi
As As D
As = 0.296 in2 D = 1 11/16 in T = 315hp

Then, hp = 15.86

Based on compression:

F 2 T/D
Sc = = , where; Sc = 75,000 / 2.25 = 33,333 psi
Ac A/2 B
B = 1 ¼ in A = ¼ in T = 315hp D = 1 11/16 in

Then, hp = 13.9

For a capacity of 20 hp, number of keys required is 20 / 13.9 or Nkey = 2 keys.

4
Example 4.

A 20 in lever is keyed to a 1 7/8 shaft (cold finished SAE 1141) by a radial taper pin whose
mean diameter is 0.5 in. Pin material is C1095, OQT 800 F. The load on the lever is repeatedly
reversed, N=2 based on endurance strength. What is the safe lever load P? (a) for the shaft (b) for
the pin key (c) for the assembly

Figure:
Solution:

(a) Shaft: SAE 1141 : Sn = 50,000 psi

Stress concentration factor: ave = 1.45 (AT-13)

Load factor: 0.60 (Sys = 0.6 Sy or Sns = 0.6 Sn)
Size factor: 0.85

Endurance strength, Sn = 50,000 psi x 0.6 x 0.85 x 1/1.45

= 17,586 psi

Stress: torsion with T = P x L = 20 P, in-lb

T T T T
Ss =    ,
Z I/c  D 3
dD 3
 D d D2
3
 
16 12 x D/2 16 6

where; d = mean pin hole diameter = 0.5 in

D = 1 7/8 in = 1.875 in

20 P
then, 17,586 / 2 = , then; P = 440 lb
 1.875 0.5 x 1.875 2
3

16 6

(b) For the pin: C1095, OQT 800 F: Su = 176,000 psi then; Sn’ = 0.5 Su = 88,000 psi

Based on shear: Sn = 88,000 x 0.6 x 1.0 = 52,800 psi

Design stress; Ss = Sn / 2 = 52,800 / 2 = 26,400 psi

F T/D 20 P
Ss =   = 26,400 psi, then; P = 486 lb
As  d 2
 0.5 2 1.875
4 4

(c) For the assembly, P = 440 lb

5
Splines

Splines are permanent keys made integral with the shaft and fitting into keyways broached
into the mating hub. They are used where maximum torque capacity is desired or where axial
motion of the mating parts under load is expected. The contour of the sides of the splines may be
either straight or involute, both of which are standardized.

Figure:

D = outside diameter of spline, in

d = root diameter of spline, in
Dm = average diameter of spline
rm = mean radius of the spline, in
= ¼ (D + d)
h = depth of spline, in
= ½ (D – d)

Torque capacity of the spline is;

T = s A rm = s h L rm Ns , in-lb where; s = side pressure in the spline, psi

L = contact length, in
Ns = number of splines

Example1:

The transmission gears of an automobile are carried on a 2¼ in. , SAE 10 spline shaft and
slide when under load. The hub length of each gear is 15/8 in. Determine the total horsepower that
can be transmitted at 3000 rpm with 800 psi permissible pressure on the splines.

Solution:

T = s A rm = s h L rm Nt , where;

From Table 10.2 / Faires-287, SAE 10 spline shaft:

D = 2¼ in.
d = 0.180 D = 0.81 x 2.25 = 1.8225 in.
rm = ¼ (2.25 + 1.8225) = 1.0181in.
h = 0.095 D = .095 x 2.25 = 0.21375 in.
Ns = 10 splines
L = 1 5/8 = 1.625 in

then, T = 800 psi x 0.21375 x 1.625 x 1.0181x 10 = 2829 in – lbs.

and, Hp = T n / 63,000 = 2829 x 3000 rpm / 63,000

= 135 hp

6
Couplings

A coupling is a mechanical device for uniting or connecting parts of a mechanical system.

They are employed for a permanent or semi-permanent connection between shafts or for
disconnection of machine components to permit one member to run while the other is stationary.

Types of Couplings

1. Rigid Couplings – permanent couplings which by virtue of their construction

have essentially no degree of angular, axial, or rotational flexibility, thus, they must be
used with collinear shafts.

Flange Coupling – This is the most common type of coupling and has the advantage of
simplicity of construction and low cost, but the connected shafts must be accurately
aligned to prevent severe benching stresses and excessive wear in the bearings.

Compression Coupling – This type is used in cases where a large flange is objectionable.
Torque is transmitted by keys between the shafts and the cones and by friction between the
cones and the outer sleeve.

Collar Coupling – consists of a cylindrical collar pressed over the ends of the two
collinear shafts being connected, approximately one-half of the collar contacting each
shaft. Usually one or more radial pins completely through each shaft the collar or set
screws may be used to ensure that there is no undesired radial movement.

2. Flexible Couplings – they are used in installations where reasonable amounts of axial
angularity between shafts or a small amount of eccentricity between parallel shafts, or axial
movements between shafts are expected.

Chain Coupling – consists essentially of two chain sprockets connected with a short
continuous length of roller or silent chain.

Olohan Coupling – employed for connecting two parallel shafts with axial eccentricities
from zero to a reasonable amount.

Hooke’s Joint or Universal Joints – are used for connecting shafts with angular
misalignments. The driving shaft rotates at a constant speed and the driven shaft rotates at
a continuously varying angular velocity, the variation increasing with angular
misalignment of the shafts.

7
Example1:

A plain flange coupling for a 3 in. shaft has the following dimensions: bore = 3 in.; hub
diameter = 5 ⅜ in.; hub length = 3 ¾ in.; flange diameter = 10 in.; flange thickness = 1 1/16 in.; bolt
diameter = ¾ in.; bolt circle diameter = 8 ¼ in.; number of bolts = 6; key size = ¾ in. square. The
coupling is made of annealed cast steel, 0.3% c; the bolts made of SAE 1010 cold drawn steel, and
the key made of SAE 1020 cold drawn steel. This coupling is rated 50 HP at 100 rpm. What is the
factor of safety for this coupling?

Figure:
DH = diameter of hub
DS = diameter of shaft
d = diameter of bolt
DBC = bolt center diameter
h = thickness of flange
t = thickness of web

Solution:

Coupling : annealed cast steel, 0.3% C : Sy = 37,500 psi (25 % more)

Bolts : SAE 1010 cold drawn steel : Sy = 55,000 psi
Key : SAE 1020 cold drawn steel : Sy = 66,000 psi

Torque to be transmitted, T = 63,000 x 50 hp / 100 rpm = 31,500 in-lbs

Coupling:
T 31,500 in - lb
Fb =  = 1,272.7 lbs
D BC n b 8.25 in x 6 bolts
2 2
Shear in the bolts: Ss = F / Ab = 1,272.7 / П/4(.75)² = 2,880.8 psi

Compression in the flange: Sc = Fb / Ac = 1,272.7 / ¾ x 1 1/16 = 1,597.7 psi

Key:
F = T / r = 31,500 / 1.5 = 21,000 lb

Shear in the key: Ss = F / bL = 21,000 / (0.75 x 3.75) = 7,466.7 psi

Compression in the key: Sc = 2 F / t L = 2 x 21,000 / 0.75 x 3.75 = 14,933.3 psi

Factor of Safety

Coupling
Shear in bolts: N = 0.6 x 55,000 / 2,880.8 = 11.45
Compression in flange: N = 37,500 / 1,597.7 = 23.5
Key
Shear: N = 0.6 x 66,000 / 7,466.7 = 5.3
Compression: N = 37,500 / 14,933.3 = 2.5

For this coupling: N = 2.5 (Based on yield strength)

8
Example2:

A flange coupling is to transmit 250 hp at 500 rpm. The outside diameter of the flange is
190 mm. The bore diameter is 90 mm. The annular areas of contact between the flanges have
diameters of 190 mm. and 90 mm. There are to be six bolts to be used on a bolt circle with a
diameter of 150 mm. The coefficient of friction between the flanges is 0.15. The bolts are to be
made of steel with Sy = 290 MPA. Assuming that 65.75% of the total torque to be transmitted is to
be transmitted by friction, what should be the diameter of the bolts to be used using a factor of
safety of 2.5 based on maximum shear stress?

Solution:

Torque to be transmitted: T = 9,550 x 250 x .746 x 10³ / 500 = 3,562,150 N-mm

Torque to be transmitted by the bolts: Tb = (1- 0.6575) x 3,562,150 = 1,220,036 N-mm

Torque to be transmitted by friction: Tc = 0.6575 x 3,562,150 = 2,342,114 N-mm

Tc = f N Rf where: f = coefficient of friction

2,342,114 = 0.15 x N x 72.98 N = normal force between flanges
N = 213,450 Newtons Rf = friction radius (equal pressure theory)
2  R 3  R 3i  2  95 3  45 3 
=  2o   
3  R o  R i2  3  95 2  45 2 
= 72.98 mm

The normal force N on the flanges is to be provided by the bolts which are to be tightened to
induce an initial tension, Fi = N / nb

Fί = 213,950 / 6 = 35,658 N

For the coupling bolts: combined shear and axial stress

2
s Fi 4 x 35,658 45401
ssd = s    , where; s =
2
  , d = bolt diameter
s
s  2  d 2
d 2
d
4

Tb = Fb x ½ Dbc nb = 1,220,036 = Fb x ½ 150 x 6 bolts

then; Fb = 2711 N

Ss = F / Ab = 2711 / π d2

ssd = 0.5 Su / N = 0.5 x 290 / 2.5 = 58,000 MPa

Substitute the values in the above equation, then

d = 19.8 mm Use: d = 22.225 mm (STD from English table)