KEYS

KEY IS A MECHANICAL ELEMENT USED ON

SHAFT TO SECURE THE ROTETING ELEMENT
LIKE GEARS , PULLEYS,SPROKETS etc. AND
PREVENT THE RELATIVE MOTION BETWEEN
TWO.

TYPES OF KEYS
Sunk keys
Sadle keys
Tangent key
Kennedy key
Round key And Taper pins
Splines

SUNK KEY
Rectangular key
Square key
Parallel key
Gib head key
Feather key
Woodruff key

SQUARE KEY

RECTANGULAR KEY

KEYS
Gib head key

Woodruff key

Design of sunk keys

1. DIRECT SHEAR STRESS
2. CRUSHING OR COMPRESSIVE STRESS

Direct shear stress

Direct shear stress induced in the
key is given by
= shear force / resisting area =F/wl
Torque acting on key= ForceRadius
=Pressure AreaD/2
T=Shear stressWLD/2
Shear stress=(T2)/(WLD)

Crushing stress in key

Crushing stress induceed

=Compressive force /resisting area
=F/(hl)2
Torque acting on key=Force Radius
T=PressureareaD/2
T=(h/2)L(D/2)Compressive
stress
Compressive stress=4T/(hLD)

MANUFACTURING OF KEY BODY

. A key manufacturing method, comprising:

1. key body manufacturing procedure comprising a first

process to feed material,
2. second process to mold said material into a predetermined shape through pressure die casting to form a
crude key body,
3. third process to cut the side edge of said crude
key body,
4.fourth process to mill said crude key body into
thickness, curvature and length according to predetermined specifications,
5.fifth process to mill a bitting on said crude
key body,
6. sixth process to number and classify the
key body thus formed according to the shape of bitting;
7. Then surface polishing is done by deburring machine.

DEBURRING MACHINE
A deburring machine is a piece of equipment that removes
or treats the burr, when a higher consistency and quality of finish is
needed, for higher volumes of manufactured parts. There are many
different types of deburring machines, which employ a host of
methods for removal and treatment of burrs. Typical deburring
machine processes include vibratory deburring, robotic deburring,
and blast deburring. These process typically involve the use high
barcol abrasives, which abrade the burr. Complete burr removal is
achievable but not normally required. Blast and vibratory deburring
machines are best suited for higher volumes of manufactured parts,
whereas robotic deburring machines are still somewhat limited to
certain production volumes and parts-handling constraints.

KEY SETTING

Keyseating
Keyseatingis the creation of the slots in
the mating items. Keyseating can be
done on a variety of different machines
including a keyseater, a vertical slotting
machine, a broacher, either a vertical or
horizontal mill, or with a chisel and file.

Broachingprimarily used to cut square cornered

internal keyways. The specific broach, bushing and
guide are used for each given keyway crosssection, which makes this process more expensive
than most of the alternatives. However, it can
produce the most accurate keyway out of all the
processes. There are three main steps in broaching
a keyway: First, the workpiece is set on the
arbor pressand the bushing is placed in the
opening of the workpiece. Next, the broach is
inserted and pushed through, cutting the keyway.
Finally,shimsare placed between the bushing and
the broach to achieve the correct depth necessary
for the key
.[6]

Modern keyseating machine

Keyseaters, also known askeyseating machinesandkeyway cutters, are
specialized machines designed to cut keyways. They are very similar to
vertical shapers; the difference is that thecutting toolon a keyseater enters
the workpiece from the bottom and cuts on the down-stroke, while the tool on
a shaper enters the workpiece from the top and cuts downward. Another
difference is a keyseater has a guiding system above the workpiece to
minimize deflection, which results in a closer tolerance cut. The process
starts by clamping the workpiece to the table with afixtureorvise. The
workpiece is properly located and then the reciprocating arm is started.
Some models have a stationary table so the cutter is fed horizontally into the
workpiece, while others have a movable table that feeds the workpiece into a
fixed cutter. These machines can cut other straight sided features other than
keyways (see the picture). They can also produceblindslots, which are slots
that do not extend through the whole workpiece.[7][8]

Milling
Parallel, tapered, and Woodruff keyways can be
produced on amilling machine.End millsor slotting
cutters are used for parallel and tapered keyways,
while aWoodruff cutteris used for Woodruff
keyways.[9]
For internal keyways that are not too long, the
keyways can be milled if a radius is acceptable.

Chiseling
One of the earliest forms of keyseating
was done bychiseling. The keyway is
roughed out using a chisel and thenfiled
to size; the key is tried frequently to
avoid over filing. This technique is long,
tedious, and rarely used anymore.[10]