Unit II-Design of Machine Elements

Session 10
Keys

Contents
10.1 Introduction 123
10.2 Types of Keys 124
10.3 Strength Consideration of Key Joints 125
10.4 Selection of Keys 128
10.5 Illustrative Example 129
Aim 131
Learning Outcomes 131

10.1 Introduction

The machine elements, such as pulleys, gears and other similar devices are
mainly employed to transmit power to or from shafts. Therefore these
machine elements must rigidly be attached to shafts by some means in order
to prevent selective angular or sliding motion between them. More often, the
joints formed with such elements should permit repeated disassembly and
re-assembly. For such joints keys are generally used as fasteners.
A key is a piece of metal fitted between two machine components to prevent
their relative angular motion and in certain cases, the axial motion. For an
example, a key is used to fasten a pulley to a shaft and the key is held in
keyways cut in both components as shown in Fig. 10.1.
Keys are mainly employed to transmit torsional loads to or from shafts. In
many applications the key prevents relative axial motion between mating
parts.

Fig 10.1

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Key joints find extensive application in engineering industry owing to their

simple and reliable design, convenience in use and low cost.
Different types of keys are available and the choice for one depends on
several factors such as power to be transmitted, strength and stability of
joint, tightness of fit and relative cost.
The principal shortcomings of key joints are as follows;

(a) Reduction of strength of mated elements because their cross sections

are weakened by key ways, flats and holes for the positioning of
keys, and considerable stress concentration in these cross sections.
(b) Difficulty in achieving concentricity between mating parts of the
assembly.

10.2 Types of Keys

The main designs of keys and key joints employed in engineering industry
are illustrated in Fig. 10.2. Key joints can be classified as;
1. Unstressed joints:
The keys are not prestressed in the assembly.
Eg: Joints with parallel or woodruff keys.
2. Stressed joints:
The keys are pre-stressed in the assembly.
Eg: Joints with taper keys.

10.2.1 Square Parallel Key

Square parallel key is shown in Fig.10.2.a. The ends of square parallel key
may be either rounded or square. The key is sunk into the shaft to about 0.6
of its height. There is usually a clearance between the top of the key and the
hub. The load is carried by the sides of the key.

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Fig 10.2

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10.2.2 Rectangular Parallel Key

This type of keys are called feather keys as well. The key and the key joint
are shown in Fig. 10.2 b. Feather keys are usually used where the weakening
of the shaft by deep keyways is objectionable and added stability of the joint
is desired.
A feather key allows the hub to move along the length of the shaft but
prevents relative rotation between mating parts. It is frequently used in gear
transmission units.
Feather keys are fastened to the shafts by means of screws. This is done to
avoid excessive friction and wear due to misalignment of an unfastened key.
These are called guide keys. Another type of feather key move along with
the hub to which it is secured and is used for long axial movements.
Keyways for square and feather keys are cut by end mill cutter or side mill
cutter.

10.2.3 Woodruff Keys

Woodruff key and key joint are shown in the Fig. 10.2.c. It is used
particularly in machine tools and also in motor vehicles when the torques
are not too large.
The keyway in the shaft is of circular outline and is cut by a disk milling
cutter having the same width and diameter as the key. The main advantage
of the woodruff key is its stable position in the shaft, since it aligns itself in
the keyway. One such key is used for a short hub, or two in a line for longer
hub. It has the disadvantage of weakening the shaft more than that by the
use of parallel key, because the keyway has greater depth than for ordinary
keys.

Fig. 10.3
Woodruff keys have two main dimensions, the width b and the diameter of
the key d (see Fig. 10.3)

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10.2.4 Taper Key

Taper keys usually have 1:100 taper on the top surface. These keys are
available in two types, with and without gib-head. (Fig. 10.2 d and 10.2e
respectively).
Taper keys with gib-head are used to facilitate their removal when the other
end is not accessible and convenient for frequent disassembly and
reassembly. The projecting head is dangerous for workmen and must be
properly guarded.
In contrast to parallel keys, the working surfaces of taper keys are the top
and bottom. There is clearance at the sides. Taper keys provide a stressed
joint which is capable of transmitting an axial force in addition to the torque.
The magnitude of a torque transmitted by a taper key joint depends on the
friction forces developed on the contact sides. To increase these forces,
considerable pressure should be created on the contact surfaces. They arise
as a result of fitting the key into the keyway, thus straining the joint before
external load is applied. In this case the part fitted onto the shaft carries
considerable radial thrust forces which may shift its axis relative to that of
the shaft by an amount of the fit clearance or may even deform the part. If
the hub is short, there may also be angular misalignment between joined
members. All these factors restrict the use of taper keys at the present time.
They are not employed at all in precision machinery.
The prestressed nature of the taper key assembly provide better rigidity and
stability and hence it can withstand impact loads.
A joint with a sunk taper key is made with keyways in both the shaft and
hub. The keyway in the hub has the same taper as the key. (Fig. 10.2 e)
Joints with flat taper keys have a flat on the shaft and a keyway with a 1:100
taper in the hub. (See Fig.10.2 f). They weaken the shaft less but require
heavier hubs.
Taper keys are used only when accuracy is not of prime consideration.
Diametrically opposite location of two tapered keys enables the mounted
part, wheel or gear, to be adjusted so that, its axis coincides with that of the
shaft.

10.2.5 Saddle Keys

Saddle keys join a plain cylindrical shaft with a hub having a tapered
keyway. The surface of the key contacting the shaft is cylindrical and of the
same radius as the shaft (see Fig. 10.2 g). Saddle keys transmit torque only
by frictional forces, between the shaft and key. The load capacity and the
stability of saddle keys are lower than those of sunk keys. They are used
only for light service and in case where the hub is often adjusted angularly
or axial 1y along the shaft, and when a keyway cannot be provided in the
shaft.

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10.26 Tangential Keys

Tangential key and key joint are shown in fig. 10.2h. These keys differ from
ordinary taper keys in that the tightness between the shaft and hub is
produced in the tangent rather than in the radial direction so that two keys
are required to transmit torque in either direction.
To facilitate assembly each key is made up of two wedges tapered on one
side (taper 1:100) and installed with their tapered sides facing each other.
The smaller ends of the two mating wedges are at opposite sides of the hub
so that the outer working surfaces of the key are parallel. The joint is
tightened by relative axial displacement of the wedge.
By using a single pair of tangential keys loads can be transmitted in only
one direction.
Tangential keys are employed in the heavy engineering industries for
transmitting severe dynamic loads.
When the drive is reversible two pairs of keys are employed. They are
usually located with an angle of 120˚ between them.

10.3 Strength Consideration of Key Joints

According to the stress induced in the keys, various types of keys can be
classified as follows:
i. Square or rectangular feather keys, in which the torque is
transmitted by means of compressive and shear stresses.
ii. Taper key in which the torque is transmitted by means of friction
induced by compressive stresses.
iii. Tangential keys, in which the torque is transmitted by means of
compressive stresses alone.

Fig 10.4
The actual pressure distribution in a parallel key joint is illustrated in fig.
10.4 and it shows that the distribution of the force on the surface of key is
very complicated. In addition, the stresses are not uniform along the key in
the axial direction, they are high near the ends. Because of these

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uncertainties, an exact analysis of the stresses cannot be easily made. For

design purposes it is customary to neglect the forces due to the initial fit of
the key and to assume uniform distribution of force along the entire length
of the key. It further assumed that the entire torque is carried by
circumferential force F acting at the shaft surface.

10.3.1 Square or Rectangular Keys

Fig 10.5
Strength calculations for parallel keys are firstly based on the resistance to
crushing. It is assumed that the pressure is uniformly distributed over the
contact surfaces. Design diagram of pressure distribution is shown in the fig.
10.5.
To simplify matters, it is further assumed that the lever of the force acting
on the key equals 0.5d, where d is the shaft diameter. Then the strength
consideration to resist crushing can be written as;
T  0.5 dlk cr 
Where T -Torque transmitted
L -Working length of the key
K -Depth to which the key extends into the hub
cr  -Allowable crushing stress of the key material
d -Shaft diameter
Since key cross sections have to be standardized, this formula is most
frequently used to find the allowable torque or the working length 1 of the
key being selected to suit the length of the hub. If necessary, the formula can
be used to determine the required length of the key.
The strength consideration in shear over section A-A can be written as;
T  0.5 dh1s 
Where b - Breadth of the key
s - Allowable shear stress

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This consideration has been incorporated in standardizing the cross-section

of the keys. Therefore no such strength calculation for shear is required in
designing.

10.3.2 Woodruff Keys

Strength calculations for woodruff keys are same as for parallel keys.

10.3.3 Taper Keys

Fig 10.6 Fig 10.7

In accurately manufactured joints with sunk or flat tapered keys, the
pressure along the width of the key due to driving in is rectangular as shown
in fig. 10.6. In transmitting a torque the shaft tends to turn with respect to
the hub so that the key is non-uniformly compressed. And as a result the
pressure distribution will approximately be triangular as shown in fig. 10.7.
If the key is not tight, the pressure may not be evenly distributed over the
entire width of the key. Due to all these reasons the strength calculations are
based on a certain pressure distribution over the width of the key
corresponding to optimal tightening. Such a design pressure distribution is
taken to be triangular and extending over the whole width of the key. (See
fig.10.8)

Fig 10.8
The driving in force acting on the key cause’s pressure in the surface of
contact diametrically opposite to the key between the shaft and hub can be
represented by a sickle-shaped diagram. The total force acting normal to the
shaft surface can be shown to be 4 /  times force Q.
The transmitted torque is made up of:

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i. The moment due to non-uniform distribution of pressure over

the width of key - Qa.
ii. The moment of the friction forces between key and the shaft
- Qc.
iii. The moment of the forces of friction between the hub and
shaft.
Thus;
T  Qa + Qc + Nd / 2
We assume that c ~− 0.5d . For the chosen triangular diagram of pressure over
the width of the key,
Q = 0.5b1cr  And
a=b/6
Then the design formula can be written

T
b1
b + 3(1 + 4 / )dcr 
12
10.3.4 Saddle Keys

Fig 10.9
SADDLE KEY JOINT
The strength calculations are based on the assumption that the pressure
distribution over the width of key is rectangular. The transmitted torque is
made up of the moments of friction forces between the shafts & key, and
between the key and hub. (Fig. 10.9).
 4 
T   Q + Q 0.5d
  

10.4 Selection of Keys

The types of keys commonly used in Mechanical Engineering practice,

parallel, woodruff, taper and tangential etc., are standardized according to

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the shaft diameter. Flat and saddle keys are not standardized since they are
required to be machined to match with the exact shaft surface profile.
Firstly, the type of key for a particular application is selected by considering
the factors such as power transmittion requirement, stability and rigidity,
accuracy of fit, physical configuration etc. Based on the shaft diameter, the
cross-sectional dimensions of the key are select from standard charts. In the
case of woodruff keys, full dimensions of the key can be obtained. The
relevant strength calculations as described above are then performed to
determine the working length of the key or the magnitude of the torque
transmission.
If the calculated length of the key is larger than the axial length of the hub, it
is necessary to increase either the length of the hub or the number of keys
(usually not more than two). If two keys are used the total length should be
increased against the design value by about 25 %, because the torque may
be distributed unevenly between them. Two keys may be installed at an
angle of 120˚ on 180˚.
It is a good practice to make keys of a weaker material than that of the shaft
and hub so that the key will fail first in the case of overload.
Owing to difficulties, that may arise in disassembling a key joint in confined
placed by driving out a straight key, shafts are designed so that all the parts
can be removed without removing the keys. For this purpose, the fit
diameters are designed in steps, smaller towards the end of the shafts.
To facilitate shaft manufacture with simple production methods it may be
advisable to have all the keys in a shaft of the same cross section. (For this
diameter steps of the shaft must lie within the range corresponding to the
same size of the key).
If two gears mounted on a shaft transmit torque in opposite direction, it is
good practice to avoid possible misalignment by mounting them on separate
keys. A single key can be used if the torque is in the same direction.
Keys are commonly made of medium carbon steels. Other steels with a
tensile strength of not less than 550MN/m2 also can be used.

10.5 Illustrative Example

A pulley is to be connected to a shaft transmitting a power of 11 KW at 600

rpm, by means of a rectangular key. If the allowable shear stress of the shaft
material and crushing stress of the key are 500105 Nm2 and
800105 N/m2 respectively. Select suitable rectangular key for the joint.
Answer
Given data:
Power to be transmitted p = 11 KW
At rpm n = 600

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Allowable shear stress of the shaft

s  = 500 105 N / m2 ,
Allowable crushing stress of the key
cr  = 800105 N / m2
The torque to be transmitted by the shaft is,

P P 11103  60
T= = =
 n.2 / 60 600  2
= 175 Nm.
Diameter of the shaft:
Diameter of the shaft can be estimated as follows:
T 
=
J d/2
Where;
J - Polar moment of inertia of the crosectional area of the shaft
d 4
= -for the solid shaft
32
d- Diameter of the shaft

So,
32T 32  175
d =
  2     2  500  105
= 0.026m
d  26mm.
So, we adopt the diameter of the shaft, d = 30 mm.
Selection of key:
According to the diameter of the shaft, the standard cross section of the
rectangular key is (with reference to ISO standard).
b  h = 8 7
Where;
b - Breadth of the key in mm.
h - Height of the key in mm.
The minimum required length of the key can be obtained by checking for
the crushing strength.
Let 1 be the minimum required length of the key.
Assuming the projecting height of the key from the shaft (the height of the
portion of the key, in the pulley)
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− 0.4h
t~
Then the area subjected to crushing is
Acr = t 2  1 = 0.4h1
So, using the following expression we obtain 1,
T  0.4  h  1  d / 2  cr 
175
1
30
 10− 3  0.4  7  10− 3  800  105
2
0.052  1
Answers;
Cross section of the key;
b  h = 8  7 mm  mm
Minimum required length of the key
1 = 52 mm
In actual practice, however, length of the key is made equal to length of the
hub.

Aim

To introduce different types of keys and key joints used in engineering

practice.

Learning Outcomes

The student will be able to

1. Describe different type of keys and their applications.
2. Perform strength calculations leading to the design of a key joint.

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