KEYS

Functions:
 To prevent the relative motion between the shaft and the hub of rotating
element like : gear, pulley, or sprocket.
 To transmit the torque from the shaft to the rotating element or vice-versa.
 Keyway is a slot in a shaft and a hub of the rotating element to
accommodate a key.
 It is inserted between the shaft and the hub of the rotating element so as
to prevent the relative motion between them.

Materials for key:

 Plain carbon steels
 Alloy steels.
TYPES OF KEYS

 Sunk key

 Saddle Key

 Tangent Key

 Kennedy Key

 Round Key & Taper Pins

 Splines
 Provided half in the keyway of the shaft and half in the
keyway of the hub or the rotating element.
Saddle Keys
The saddle key is a tapered key
which completely fits in the
keyway provided in the hub of
rotating element.
The torque is transmitted due to
the friction between the key and
the shaft. Hence, the torque
transmitting capacity of saddle
Flat saddle key :
key is low.
The flat saddle key is a taper key which fits in the keyway
Types of saddle keys provided in the hub of rotating element and its lower surface is
flat. The shaft surface is planed off to accommodate the key
Hollow saddle key :
Due to flat surface contact between the lower surface of the
The hollow saddle key is a key and the shaft, the torque transmitting capacity of the flat
tapered key which fits in the saddle key is more than the torque transmitting capacity of the
keyway provided in the hub of hollow saddle key.
rotating element and it’s lower Applications :
surface is hollow or curved to fit Saddle keys are used for light duty applications.
on the curved surface of the shaft.
used as temporary fastenings in fixing and setting the
eccentrics and cams.
Kennedy keys consist of A round key is a
two tapered square keys straight pin of circular
placed 90 apart. cross-section, fitted
into a common hole
Applications : drilled at the interface
Kennedy keys are used A taper pin is a pin of
of shaft and hub circular cross-section,
in heavy duty industrial
applications. fitted into a common hole
Applications : drilled through the hub
Round keys and taper and shaft, which is
pins are commonly perpendicular to the axis
used for low power of the shaft.
drives.
 Tangent Keys

The tangent keys consist of two

tapered rectangular keys placed
90 apart. Each key withstands
torque in one direction.

Applications :
Tangent keys are used in heavy
duty industrial applications.
 Splines are Multiple keyway which are made integral with the shaft.
 To prevent relative rotary motion but permit the relative axial motion
between the shaft and hub.
 Used in automobile gear boxes and machine tool gear boxes.
 COUPLING

Coupling is the mechanical element used

to connect two shafts of a transmission system and
transmit the torque from one shaft to another.
 Functions of Coupling

 It connects the shafts of two different units such as an

electric motor and machine.

 It introduces mechanical flexibility between two

connected units and tolerates small misalignment
between the connecting shafts.

 It reduces the transmission of vibrations and shocks

between two connected units.
 Requirements of good coupling

 It should transmit the full power from one shaft to another.

 It should keep the shafts in perfect alignment.

 It should absorb the slight misalignment that may be present

between the driver and drive shaft.

 It should be easy to connect and disconnect.

 It should have no projecting parts.

Types of Couplings

 Rigid coupling

 Flexible Coupling
 Rigid Couplings
 Rigid couplings are used to connect two shafts which
are perfectly aligned.

 These couplings are not capable of tolerating any

misalignment between two shafts.

 These couplings are not capable of absorbing shocks

and vibrations.

 These are simple and inexpensive.

Types of rigid couplings

 Muff or sleeve coupling:

Used for line shaft

 Split muff or clamp or compression coupling

Used for line shaft

 Flange coupling
Used for connecting electric motor to pump or
compressor.
 Flexible Couplings

 Flexible couplings are used to connect two shafts

having small amount of lateral or angular
misalignment.

 These couplings are capable of absorbing shocks

and vibrations.

 These couplings are costly.

Types of flexible couplings

 Bushed-pin type flexible coupling

Used for connecting diesel engine to generator.

 Oldham coupling
Used for connecting two eccentric shaft.

 Universal coupling
Used between gear box and differential in automobile.
 A muff or sleeve
coupling, is the simplest
type of rigid coupling
used to connect two
shafts rigidly.

 It consists of a sleeve or
a hollow cylinder,
generally made of cast
iron, fitted over the ends
of the shafts to be
connected and keyed by
means of a sunk key.
 The power is transmitted
from one shaft to
another shaft through
the key and sleeve.
Advantages of muff coupling
1. It is simple in construction,
2. It has no projecting parts.
3. It requires less radial space.
Disadvantages of muff coupling
1. Muff coupling is difficult to assemble and disassemble. It
cannot be removed without moving the shafts in the axial
direction.
2. Though the coupling is simple, it requires very careful
fitting.
3. If the depth of keyway is not exactly same in each shaft,
then the key will be loose in one shaft and bedded on
other shaft. In order to prevent this, many a times, the
key is made in two lengths.

Applications of muff coupling

The muff coupling can be used to connect two line shafts.
Split muff coupling is the
modification of muff coupling.

In split muff coupling, the sleeve is

split into two halves along the
plane passing through the axes of
the shafts.
The two halves of the sleeve
(upper and lower) are clamped by
Advantages:
the bolts, which are 4, 8 or 12 in
1. Easy to assemble and disassemble.
number
2. Easily removed without moving the shafts in
The clamping force due to bolts
the axial direction.
creates the frictional force
3. Higher torque transmitting capacity than the
between the sleeve and the
muff coupling.
shafts, which is responsible for
transmitting the torque.
Disadvantages:
The keys are also provided
1. Because of its shape, the split muff coupling
between the sleeve and the
is difficult to balance dynamically. Hence, it
shafts.
is not suitable for high speed applications.
2. It is complicated in construction.

Applications: Used to connect two line shafts.

A protected type rigid flange
coupling consists of two
flanges :
one keyed to the driving shaft
and other to the driven shaft.
One of the flange has projected
portion and other has a
corresponding recess. This
helps to bring two shafts in line
and maintain the alignment.
The two flanges are coupled
together by means of bolts and
nuts. The number of bolts used
are generally three, four or six.
The two keys are staggered at
right angles along the
circumference of the shafts.
• The flanges are made of cast
iron, cast steel, or steel.
The torque is transmitted from the driving shaft to
the left side flange through the key. It is then
transmitted from the left side flange to the right
side flange through the bolts. Finally, it is
transmitted from the right side flange to the driven
shaft through the key.
Advantages
1. The flange coupling is easy to assemble and
disassemble.
2. It has high torque transmitting capacity.
Disadvantages
1. The flange coupling cannot tolerate misalignment
between driving and driven shafts.
2. It requires more radial space.
Applications
The flange coupling is used for connecting electric
motor to pump or compressor.
Bushed-pin type flexible flange
coupling

• Modified version of the rigid flange

coupling.

• The rubber bushes are inserted

between the coupling belts, known as
pins* and one of the flanges.

• The pins are rigidly fastened by the

nuts to the other flange.

• The number of pins used are

generally three, four, six or eight.

• The torque is transmitted though the

flexible bush, which absorbs the
shock and compensate for the
misalignment.

• A brass bush is provided between pin

and rubber bush to avoid the wear of
pin and to ensure the uniform
distribution of force on pin.
 Advantages:
The torque is transmitted from the 1. Tolerate small amount of lateral or angular
driving shaft to the left side flange
through the key. It is then misalignment.
transmitted from the left side 2. Absorb shocks and vibrations.
flange to the pins through the 3. High torque transmitting capacity.
rubber bushes. From the pin sit is
transmitted to the right side
flange. Finally, it is transmitted
Disadvantages:
from the right side flange to the 1. Requires more radial space.
driven shaft through the key. 2. These couplings are costly.
The two flanges of the coupling are
dissimilar in construction. The
flanges may be made of cost iron or
Applications: used for connecting diesel engine
steel. to generator.
Oldham’s coupling is used for connecting two shafts
whose axes are parallel and are at a small distance apart.

It consists of two identical flanges having rectangular slot or

groove cut on the face along the diameter.

• Flanges are mounted on the

driving shaft & driven shaft.

• The two flanges are coupled by

an intermediate circular disk
which has tongue or rectangular
projection on its both the faces.

• The two rectangular projections

are at right angles to each
other.

• Each tongue or rectangular

projection on the intermediate
circular disk fits into the slot of
the corresponding flange.
The torque in transmitted
from the driving shaft to
the left side flange through
the key. It is then
transmitted to the
intermediate circular disk
through the tongue. From
the intermediate circular
disk it is transmitted to the
right side flange through
the another tongue.
Finally, it is transmitted
from the right side flange
to the driven shaft through
the key.

There is a relative sliding

motion between the flanges
and the intermediate circular
disk,
Advantages:

 Can connect two non-coaxial shafts whose axes are at a small

distance apart.

 Compact and simple in construction.

Disadvantages:

 Because of the relative sliding motion between the flanges and

the intermediate circular disk, there is a power loss due to
friction.

 used for high speed and high torque applications

Applications: used to connecting two eccentric shaft.

 Universal coupling or
Hook’s Joint is used to
connect two non-parallel and
intersecting axes shaft,
having small angle between
two axes.

 Two U-shaped yokes or forks

which are integral with driving
and driven shafts and the cross,
which is the connecting link.

 The arms of the cross are at

right angles. The torque is
transmitted from the driving
shaft to the driven shaft through
the cross.

Advantages:
1. Connect two non parallel
and intersecting axes shaft.
Applications: used between the gear shaft and
2. Simple in construction.
the differential of Automobile.
(Car, Bus, truck etc.)
Disadvantages:
1. Can not be used for high
speed application.
 BRAKE
 Brake is a mechanical device for applying a
force against the friction of the road, slowing or
stopping the motion of a machine or vehicle, or
alternatively it is a device to restrain it from
starting to move again.
 The kinetic energy lost by the moving part is
usually translated to heat by friction.
The capacity of a brake depends upon the following
factors

1. The unit pressure between the braking surfaces,

2. The coefficient of friction between the braking surfaces.
3. The peripheral velocity of the brake drum,
4. The projected area of the friction surfaces, and
5. The ability of the brake to dissipate heat equivalent to the energy
being absorbed.
 The major functional difference between a
clutch and a brake:

 Clutch is used to keep the driving and driven member moving

together.
whereas
 Brakes are used to stop a moving member or to control its
speed.

 In Clutch power is transmitted from rotating to stationary shaft.

whereas
 In Brakes rotating shaft is made standstill or its speed is
decreased by a stationary shaft.
Types of Brakes
Block or Shoe brake

Brakes. (Fig. shows)

a) Single-block brake. The
block is fixed to the operating
lever; force in the direction of
the top arrow applies the
brake.
b) Double-block brake. The
blocks are pivoted on their
levers; force in the direction of
the arrow releases the brake.
c)External Expanding shoe brake. It is used in crane hoists.
Shoes are lined with friction material. The main advantage is that
c)Internal expanding shoe brake with braking action is doubled by
lining. the use of two blocks & both
can be operated by the same
It is used in automobile vehicles (trucks,
force.
buses, cars, motorcycles, scooters etc.)
 Block or Shoe brake
The single-block is the simplest form of
brake.
It consists of a short block fitted to the
contours of a wheel or drum and
pressed against its surface by means of
a lever on a fulcrum, as widely used
on railroad cars.
The block may have the contour lined
with friction-brake material, which gives
long wear and a high coefficient of
friction.
The fulcrum may be located with
respect to the lever in a manner to aid
or retard the braking torque of the
block.
The lever may be operated manually or
by a remotely controlled force.
Friction lining material: Asbestos,
leather, cork, wood
 How Brakes Work
Brake Pedal
 The brake pedal is directly
attached to the master cylinder.
 Pedal pulsation, excessive
pedal travel, a “soft” or “hard”
pedal can be indicators of
serious problems, including a
leak in the hydraulic system,
low fluid levels, or unevenly
worn shoes or pads.
Master Cylinder

 The master cylinder acts as a

holding tank for brake fluid until it is
needed. When the brake pedal is
depressed, the master cylinder
forces fluid to each of the vehicle's
wheels.

 Wear on the master cylinder's

moving parts may allow brake fluid
to leak, causing unreliable stopping
or possible system failure.
Combination Valve
 A vehicle's wheel can lock up if
the front and rear brake systems
are not working together
properly. Comprised of a
metering valve, proportioning
valve, and brake warning light,
the combination valve helps
regulate the amount of pressure
on each set of wheels – making
sure both front and rear brakes
are applied at the same time.
Wheel Cylinder
 The wheel cylinder is a critical
element in the drum brake
assembly. It contains fluid-
activated pistons that push the
shoes against the drums to slow
the wheels.
 The wheel cylinder is also the
source of many brake problems.
If brake fluid leaks from the
wheel cylinder, the vehicle could
experience unreliable stopping,
damage to new brake shoes, or
partial brake system failure. A
sticking wheel cylinder may
cause brake drag, excessive
pedal effort, and reduced braking
efficiency.
Drum Brake Assembly
 A drum brake assembly is used
to bring the rear wheels of most
vehicles to a stop. Fluid pressure
from the master cylinder causes
the wheel cylinder to push the
brake shoes against the brake
drums which are attached to the
vehicle's rear wheels. The
friction between the stationary
shoes and the revolving drums
causes the drums to slow and
stop the rear wheels.
 Worn drums and shoes,
however, can cause unreliable
stopping, excessive pedal effort,
or brake pedal pulsation.

Internal Expanding Brake

INTERNAL EXPANDING SHOE BRAKE.
 Disc Brake Assembly
Because a disc brake assembly
can absorb more heat than a
drum brake assembly, most cars
use disc brakes for their front
brake systems. When the brake
pedal is pushed, brake fluid from
the master cylinder compresses
the brake pads against the rotors
attached to the vehicle's front
wheels. The friction between the
stationary pads and the revolving
Advantage: Excellent Control.
rotors causes the rotors and
wheel to slow and stop. Application: used in vehicle conveyers,
Due to excellent control,
specially used in motor
cycles & racing cars
Disc Brake
This 2-D fig. to draw
in disc brakes
A   band brake Band Brakes
consists of a
flexible band
faced with
friction material
bearing on the
periphery of a
drum which may
rotate in either
direction.
 Band & Block Brakes
 A   band brake consists of a
flexible band faced with friction
material bearing on the periphery of
a drum which may rotate in either
direction.
 The band cross-section lining
material riveted to the band.
Allowance for lining wear is
provided - when the rivets start to
rub on the drum they are drilled out
prior to new linings being riveted to
Advantages:
the band.
These Band & Block Brakes are
 The   actuation force P is applied simple, effective, and economical for
to the band's extremities through an a variety of light duty small vehicles. 
  actuation linkage which provides
the breaking action. Wooden blocks
have high coefficient of friction. Applications:
Such blocks are easily replaced Used in material Handling Equipments.
after they are worn out.
The wagon brake (top) and the band brake
(bottom) are common forms of mechanical
brakes.
 MECHANISMS

 Mechanisms are used to convert between one type of

motion and another. Any machine can be looked on as a
group of interconnected mechanisms which convert one
type of motion to a variety of other motions.
 These changes may be to convert rotary motion to
straight line motion or to convert reciprocal (back and
forth) motion to intermittent motion. They may also
transform a fixed type of motion, for example by
magnifying a linear motion or by slowing down a rotary
motion.
 MOTIONS

 Linear motion is the most basic of all motions. Uninterrupted objects will
continue to move in a straight line indefinitely. Under every day
circumstances gravity and friction conspire to bring objects to rest.
 Linear motion is measured in two parts. Speed, and direction. Together
these make up the velocity.
 Rotary motion is motion in a circle. The starting point for many
mechanisms.
 Measurement: Rotary motion is measured in either angular velocity, the
number of degrees turned in a given time, or in revolutions per minute
(rpm).
 Oscillation is back and forth motion about a pivot point. It is measured in
terms of both the angle of throw (amplitude) and the period of time for one
complete cycle (periodic time) or the number of cycles in a given time
(frequency).Oscillation tends to be an ending point for a mechanism
rather than the starting point, however some mechanisms are available to
convert or transform oscillations.
 Intermittent motion is motion which starts and stops regularly. For example,
in a cinema projector the film needs to be moved on one frame at a time
then held stationary while the light projects it onto the screen. This is usually
done with a Geneva stop as shown here.
 Intermittent motion is usually the end result of a mechanism rather than the
starting point for conversion.
 Irregular motion is motion which has no obvious pattern to its movement. It
is often needed in automata to recreate the movements of living things.
 Irregular motion is usually created using a cam or series of cams
 Irregular motion is not often used as the starting point for a mechanism.