Keys and Keyways

Keys and Keyways

A key is a piece of mild steel inserted in

the axial direction between the shaft and
hub or boss of the pulley to connect
these together in order to prevent relative
motion between them but allow sliding
movement along the shaft if required.
It is always inserted parallel to the axis of
the shaft
A keyway is a slot or recess (grove) cut
out in a shaft and hub of the pulley to
accommodate a key. Keyways may be
milled vertically, horizontally & sometimes
recessed.
Keys and Keyways
Keys and Keyways
Key parts description
Descriptive parts of a key

Key fits between bushing and shaft to lock them

together radially
Keys

General types of Keys

Sunk keys Saddle keys Tangent keys Round Keys Splines

Rectangular Hollow
Square Flat
Parallel
Gib head
Feather
Woodruff
Keys
Keys

Rectangular sunk key

Keys
Gib head key

The usual proportions of the gib head key are: Width, w

= d / 4 ; and thickness at large end, t = 2w / 3 = d / 6
Keys

Feather key

They are a special type of parallel keys that transmit a turning movement and
also permits axial movement. They may be fastened (screwed) to the hub or
shaft as shown above or may be double gib head key.
Keys

Woodruff key
Keys

Saddle keys
Splines

Slines
Design of splines

(i) Considering bearing failure

Torque transmitted, Mt =
where P or Pb = bearing pressure
L = Length of the spline
n = Number of splines
h = Height of the spline

(ii) Considering bending failure

Bending stress, σb =
where F = tangential force acting on the spline

(iii) Considering shear failure

Shear stress, τ =
where F = tangential force acting on the spline
Keys

Forces acting on a sunk key

Forces due Forces due

to torque to fit of
transmitted + key in
by shaft keyway
Keys
Strength of a Sunk Key

A key connecting the shaft and hub is presented in the previous slide.
Let T = Torque transmitted by the shaft
F = Tangential force acting at the circumference of the shaft,
d = Diameter of shaft,
l = Length of key,
w = Width of key.
t = Thickness of key, and
τ and σc = Shear and crushing stresses for the material of key.
A little consideration will show that due to the power transmitted by the shaft,
the key may fail due to shearing or crushing.
Considering shearing of the key, the tangential shearing force acting at the
circumference of the shaft,
F = Area resisting shearing × Shear stress = l × w × τ
Hence, torque transmitted by the shaft,
T = F x = l × w × τ × …………………………………………………………….. (1)
Considering crushing of the key, the tangential crushing force acting at the
circumference of the key,
F = Area resisting crushing × Crushing stress = l × × σc
Keys
Strength of a Sunk Key

Torque transmitted by the shaft,,

T = F x = l × × σc × …………………………………………………………….. (2)
The key is equally strong in shearing and crushing, if
l × w × τ × = l × × σc × OR = ………………………………… (3)
The permissible crushing stress for the usual key material is at least twice the
permissible shearing stress. Therefore from equation (3), we have w = t. In
other words, a square key is equally strong in shearing and crushing.

In order to find the length of the key to transmit full power of the shaft, the
shearing strength of the key is equal to the torsional shear strength of the shaft.
We know that the shearing strength of key, T = l x w x τ x ………….…. (4)
and torsional shear strength of the shaft, T = x τ1 × d3 …………………… (5)
Taking τ1 = Shear stress for the shaft material, equating equation (4) and (5),
l = × = × (Taking w = d/4) l = 1.571 d × ……………… (6)
When T = , l = 1.571 d
Proportions of standard parallel, tapered and gib head keys
(IS : 2292, 2293-1974)

Table 1
Metric keys and keyways

Table 2
Metric keys and keyways

Table 3
Pinning

Pinning
With the element in position on the shaft, a hole can be drilled
through both the hub and the shaft, and a pin can be inserted in
the hole as shown below.

The straight, solid, cylindrical pin is subjected to shear over two

cross sections. If there is a force, F, on each end of the pin at the
shaft/hub interface, and if the shaft diameter is D, then
Torque (T) = 2F(D/2) = FD or F = T/D.
Pinning

With the symbol d representing the pin diameter, the shear

stress in the pin is:
Td = =

Letting the shear stress equal the design stress in shear as

before, solving for d gives the required pin diameter

d=

Sometimes the diameter of the pin is purposely made small to

ensure that the pin will break if a moderate overload is
encountered, in order to protect critical parts of a mechanism.
Such a pin is called a shear pin.
Effect of keyways

A little consideration will show that the keyway cut into

the shaft reduces the load carrying capacity of the shaft.
This is due to the stress concentration near the corners of
the keyway and reduction in the cross-sectional area of
the shaft. In other words, the torsional strength of the
shaft is reduced. The following relation for the weakening
effect of the keyway is based on the experimental results
by H.F. Moore.

e = 1 – 0.2 () – 1.1 ()
e = Shaft strength factor. It is the ratio of the strength of the
shaft with keyway to the strength of the same shaft without
keyway,
w = Width of keyway,
d = Diameter of shaft, and
h = Depth of keyway =
Effect of keyways

It is usually assumed that the strength of the keyed shaft is

75% of the solid shaft, which is somewhat higher than the
value obtained by the above relation.
In case the keyway is too long and the key is of sliding type,
then the angle of twist is increased in the ratio kθ as given by
the following relation :
kθ = 1 + 0.4 () + 0.7 ()
where kθ = Reduction factor for angular twist.
Example 1
Design the rectangular key for a shaft of 50 mm diameter. The shearing and
crushing stresses for the key material are 42 MPa and 70 MPa.

Given : d = 50 mm ; τ = 42 MPa = 42 N/mm2 ; σ c = 70 MPa = 70 N/mm2

From the table for rectangular keys, for a 50 mm shaft,
the width of key (w) = 16mm and the thickness of key (t) = 10mm

The length (L) of key is obtained by considering the key in shearing and
crushing.
A. Considering the shearing strength (or torque transmitted) of the key,
T = l x w x τ x = l x 16 x 42 x =16,800L (N-mm) …………(i)
and torsional shearing strength (or torque transmitted) of the shaft,
T = x τ × d3 = x 42 × (50)3 = 1.03 Mega N-mm ………..(ii)
Equating shearing strength of key to shearing strength of shaft,
16,800L = 1.03 X 106 Therefore, L = 61.3 mm

B. Considering the crushing of the key,

T = l × × σc × = l × × 70 ×
Equating equ (ii) and (iii), L = 1.03 X 10 6 / 8750 = 117.7 mm
Taking larger of the two lengths, the preferred length of key is 117.7 mm, and
from standard, the length will be taken as 120 mm
Example 2
Determine the dimensions of a rectangular sunk key made up of mild steel
for a 80 mm diameter mild steel shaft to transmit torque of 135Nm. Assume
τ = 50N/mm2 and σc = 120N/mm2

Given: Diameter of shaft (d) = 80mm; Torque to be transmitted, M t= 135Nm

Shear stress, τ = 50N/mm2; Crushing stress, σc = 120N/mm2

To find the dimensions of the rectangular sunk key, from table 1 to 3 for shaft
diameter=80mm,
Width of the key, b =22mm
Height of the key, h = 14mm
From table 3, Length of the key, L = 63 to 250mm. However, from proportions
of keys, L = 1.5d = 1.5 x 80 = 120mm
(i) Check for shear strength of key: From M t =
τ = 1.278 N/mm2 which is less than the allowable strength, hence the
dimensions are in safe limit.
(ii) Check for crushing: M t =
35 x 103 =
= 4.02 N/mm2 which is less than the allowable strength, hence the dimensions
are in safe limit.
Example 3

A 45 mm diameter shaft is made of steel with a yield strength of 400

MPa. A parallel key of size 14 mm wide and 9 mm thick made of steel
with a yield strength of 340 Mpa is to be used. Find the required length
of key, if the shaft is loaded to transmit the maximum permissible
torque. Use maximum shear stress theory and assume a factor of safety
of 2.

Given : d = 45 mm ; σyt for shaft = 400 MPa = 400 N/mm2 ; w = 14mm; t =

9mm ; σyt for key = 340 Mpa = 340 N/mm 2 ; F.S = 2, Let L = lenght of key

The maximum shear stress for the shaft,

T max = = =100 N/mm2

The maximum shear stress for the key,

T k = = =85 N/mm2
the maximum torque transmitted by shaft and key,

T = x τmax × d3 = x 100 × (45)3 = 1.8 M N/mm

First of all, consider the failure of key due to shearing. The maximum torque
transmitted ( T ),
1.8 x 106 = l x w x τk x = l x 14 x 85 x =26,775 L (N/mm)
l = 1.8 x 106 /26,775 =

Now considering the failure of key due to crushing. We know that the maximum
torque transmitted by the shaft and key (T ),
1.8 x 106 = l x σck × = l x x x =17,213 L

l = 1.8 x 106 /17,213 =104.6 mm (Taking σck = )

Taking the larger of the two values, we have

l = 104.6 say 105 mm

Example 4

The propeller of a marine engine has 40mm diameter hub, which is

fastened to a shaft of 32mm diameter by using brass pin. If the
overload occurs at the propeller, the pin will shear thus avoiding
damage to the rest of the mechanism. Determine the diameter of the
shear pin which will fail at a torque of 100N-m with ultimate shear
strength of 320Mpa.

Given : Hub diameter = 40 mm ; shaft

diameter =32mm; Torque, Mt = 100N-m
= 100 X 103 N-mm; Shear stress,
T=320Mpa =320N/mm2

To find the diameter of the pin, the pin placed between a hub and shaft will
be in double shear and the area that resist the shear of the pin will lie
along the surface of the shaft.
Mt = 2 X Area of shearing X T X (M t = F X )
100 X 103 = 2 X
d = 3.53 mm
Example 5

A square key of 10 X 10 X 75mm dimension is required to transmit

1100N-m torque from a 60mm diameter solid shaft. Determine
whether the length is sufficient or not if the permissible shear stress
and crushing stress intensities limited to 60 and 170Mpa respectively.

Given : Width of the key, b = 10 mm; Height of the key, h =10 mm; Length of
the key, L = 75mm; Torque to be transmitted, M t = 1100N-m; Diameter of
shaft, d = 60mm; Permissible shear stress, T = 60Mpa = 60 N/mm 2 ;
Permissible crushing stress, = 170Mpa = 170N/mm2

(i) Check for shear strength of key: From M t =

1100 x 103 = = 48.89 N/mm2 which is less than the permissible value of 60MPa.
Hence, the length is in safe limit.
(ii) Check for crushing: M t =
1100 x 103 =
= 97.78 N/mm2 which is less than the permissible value. Hence, the dimensions
are in safe limit.
Example 6

Design a taper key for a shaft of diameter 100 mm transmitting 60KW

at 300rpm. The allowable compressive stress may be taken as
175N/mm2.

Given : Diameter od shaft, d =100 mm; Power to be transmitted, P = 60kW;

speed, N = 300rpm; Allowable compressive stress, = 175N/mm 2

To find the dimension of taper key:

(i) From standard key table, for shaft diameter of 100 mm, the cross section of
the key is as follows:
Width of key, b = 28mm
Height of key, h = 16mm
Power (P) = , therefore 60 X 103 =
= 1909.85N-m
For taper key, torque to be transmitted, Mt = 0.5μ1bLd
Assume μ1 = 0.25
1909.85 X 103 = 0.5 X 0.25 X 28 X L X 100 X 175
L = 31.18mm
From standard table, the minimum length of the key for that diameter of shaft
is 80mm. However, in practice L=1.25d
D= 1.25 X 100 = 125 mm
Assume the taper key has a standard slope of 1:100
Width of key, b = 28mm
Height of key, h = 16mm
Length of key, L = 125mm
Taper = 1:100
Example 7

A 40 KW power at 300rpm is transmitted from 50 mm diameter shaft

by means of Kennedy keys. The keys are made of C50 steel having
yield of 390N/mm2 and the factor of safety of 3. Design the key.

Given: Power to be transmitted, P = 40 KW

Speed. N = 300 rpm
Shaft diameter, d = 50mm
Yield strength, = 390 N/mm2
Key type: Kennedy key

Allowable yield strength = = =130 N/mm 2

Allowable shear strength, T = 0.5 = 0.5 X 130 = 65N/mm 2

Average torque, Mt = =
= 1273.24N-m
Kennedy Key is similar to flat square key. But in this case, a pair of keys is
mounted between shaft and hub as shown in the diagram. The standard
proportion of the key is
Width of key, b = d/4 =50/4 = 12.5 mm
Thickness of key, h=b=12.5 mm
Since there are two keys, the torque to be transmitted by each key is one half
of the total torque. Mt1 = Mt/2 = 1272.24/2 = 636.62N-m

Tangential Force, F = = = 25464.8N

Shear failure will occur in plane AC. The area A resisting shear is:
Area, A = AC X L = .b.L
Shear stress, T = =

65 = Therefore, L = 22..16mm

We should adopt the length of key at least equal to the shaft diameter,
L = d = 50 mm
Checking for crushing:
= 130N/mm2
Assuming that the ductile material, the crushing strength is equal to the tensile
strength, i.e = = 130N/mm2
For none ductile materials, = 57.62N/mm2

Which is less than the allowable strength. Hence it is safe.

Results:
Width of key, b = 12.5 mm
Thickness of key, h=12.5 mm
Length of key, L = 50 mm
Class work

A heat treated steel shaft of tensile yield strength of 350 MPa and has
a diameter of 50 mm. The shaft rotates at 1000 rpm and transmits
100 kW through a gear. Select an appropriate key for the gear.

Remember: Torque transmitted (T or ) = Power / ()

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