Shafts, Keys and

Couplings
Slides by Ramkumar

BITS Pilani
Pilani|Dubai|Goa|Hyderabad
Shafts, Keys and Couplings

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Counter Shaft Axle Spindle

Line shaft

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 Material

Transmission shaft
•Medium C-Steel | High C Steel
0.15 to 0.40 C % | 0.45 to 0.6%
•Alloy Steel
Commercial shafts
•Low carbon steels

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 Design of Shaft

Strength (E) Rigidity (G)

Static (Syt) Fatigue (Se)/ ASME CODE

based design

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Ex 1 The layout of a shaft carrying two pulley 1 and 2 and supported on
two bearing A and B is as shown in Fig. The shaft transmits 7.5 kW
power at 360 rpm from pulley 1 to the pulley 2. The dia pulley 1 & 2
are 250 & 500 mm respectively. Mass of pulley 1 & 2 are 10 and 30
kg respectively. The belt tension act vertically downward and the
ratio of belt tensions on the tight side to slack side for each pulley is
2.5:1. The shaft is made of plain carbon steel 40C8 (Syt = 380
N/mm2) and the factor of safety is 3. Estimate suitable diameter of
shaft.
If the permissible angle of twist is 0.50 per meter length, calculate
shaft dia on the basis of torsional rigidity. Assume G= 79300 N/mm2

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
Ex 2 The transmission shaft supporting a spur gear B and the pulley D is as
shown. The shaft is mounted on two bearing A and C. The dia of pulley is
450mm and pitch circle dia of the gear is 300 mm. the pulley transmits 20
kW power at 500 rpm to the gear. P1 and P2 are belt tensions in the tight
and loose sides, while pt and pr are tangential and radial components of
gear tooth force. Assume
P1= 3P2 and Pr= Pt tan(20o)
The gear and pulley are keyed to the shaft. The material of the shaft is steel
50C4(Sut=700 and Syt= 460 N/mm2). The factors kb and kt of the ASME code
are 1.5 each. Determine the shaft diameter using the ASME code.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
 Keys
• A key is the piece inserted in an axial direction between a shaft
and hub of the mounted machine element such as pulley or gear Classification of keys
etc., to prevent relative rotation….
• may allow sliding movement along the shaft if required.
• Keys are temporary fastening and are always made of mild steel
Saddle keys
because they are subjected to shearing and compressive stresses Hollow saddle key
caused by the torque they transmit. Flat saddle key

Sunk keys
• a keyway is the groove cut in the shaft or hub to accommodate a
Feather keys
key. Key ways can be milled horizontally or vertically .
Woodruff key
(adjustable key)

Square and Flat Key

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 Hollow & Flat saddle key
this key has curved underside so that it can be placed on the curved
surface of the shaft. The keyway is cut in the mating piece (hub) only.
Saddle key are taper keys and are sunk into the hub only. Taper prevents
axial movement along the shaft
Saddle key is suitable for light duty, since they rely on a friction drive alone
and are liable to slip on the shaft under load

Hollow saddle key Flat saddle key

Gib-head Taper Key

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 Sunk keys

Sunk keys are sunk in the shaft and the hub. These keys are suitable for
heavy duty since they rely on positive drive.
This is the standard form of the key may be either of rectangular or
square cross-section. The key is sunk in the shaft to a depth of half its
nominal thickness when measured at the side.
» Rectangular cross-section
let d = diameter of the shaft
width of the key b= d/4
nominal thickness h = (2/3)b = (1/6)d
» Square cross-section:
b= h=d/4
l= 1.5 d l= length of key

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Fig. 9.18 (a) Square Key (b) Flat Key

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 Feather keys
It is a key attached to one member of a
pair
It is a particular kind of parallel key that
permits axial moment
A feather key is secured either to the
shaft or to the hub, the key being a
sliding fit in the keyway of the machine
element on which it moves.
Feather key is a particular type of sunk
key with uniform width and height.

Feather Key

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 Woodruff keys

• It is an adjustable sunk key

in the form of a semi-circular
disc of uniform thickness.
• The key fits into a semi-
circular keyway in the shaft
and the top of the key fits
into a plain rectangular key
way in the hub of the wheel.
• Woodruff key can be used in
tapered shaft
• Used in feed gear box of
lathe, other machine tools
and in automobiles

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 Design of square and flat key

Square and flat keys are extensively used.

Flat key: The torque is transmitted by
force P acting on AC. Reaction force is
acting on DB.
Force p is tangential to the shaft dia
P= Mt/ (d/2) = 2 Mt/d (a)
d= dia of shaft, Mt = torque
Design of square or flat is based on 2
criteria, failure due to
Shear stress and compressive stress.
Forces Acting on Key Shear failure will occur in plane AB.
The shear stress ‫ ح‬in the plane AB is
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‫ = ح‬P/ area of plane AB = P/bl (b)
b = width of key, L = length of key
From (a) and (b)
‫ =ح‬2Mt/dbl
The failure due to compressive stress will
occur on surface AC or DB. The crushing area
is as shown
AC=DB= h/2 , h= height of the key
The compressive stress бc = P/ area of
surface AC
= P/(h/2)l= 2P/hl (c)
From (a) and (c)
Бc = 4 Mt/dhl
For square key h=b

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Splines
“Axial keys” machined into a shaft
Transmit torque from shaft to another machine element
The gear shifting mechanism in automobile require this type
of construction.
D= major dia of splines, d = minor dia of splines
l = length of hub, n= no. of splines
Mt =pm A Rm
Pm = permissible pressure on splines
A= total area of splines, A = ½ (D-d)*l* n
R= mean radius of splines, R = 1  D + d  = D + d
2 2  4
Sub above values,
Mt = 1/8 pm * l*n * (D2-d2)

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Types of Spline Profiles
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 Couplings
Coupling is a device used to connect two shafts together at their
ends for the purpose of transmitting power
Coupling
Motor
Pump

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 Uses of coupling Misalignments in shaft
• To provide connection of
shafts of units made separately
• To allow misalignment of the
shafts or to introduce
mechanical flexibility.
• To reduce the transmission of
shock loads
• To introduce protection against
overloads.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 Types of coupling
Rigid
Flexible
Universal

Flexible coupling Oldham Coupling

Rigid coupling

Universal coupling

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Rigid Coupling
• Rigid couplings are used when precise shaft alignment is required
• Simple in design and are more rugged
• Generally able to transmit more power than flexible couplings
• Shaft misalignments cannot be compensated
• Does not reduce shock or vibration across it from one shaft to the other
• suitable for low speeds, accurately aligned shafts

Flexible Coupling
• A flexible coupling permits with in certain limits, Allow radial, angular and
axial misalignment.
• Pins (Bolts) covered by rubber washer or bush is used connect flanges with
nuts.
• The rubber washers or bushes act as a shock absorbers and insulators.

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

 Muff Coupling

It is type of rigid coupling

Consists of hollow cylinder which is fitted over end of i/p & o/p shaft by a sunk key.
Adv:
Simple, Sleeve is smooth so, safety to the operator, cheaper.
Dis adv:
Difficult to assemble or dismantle, cannot tolerate misalignment, cannot absorb
shocks and vibration
Design:
Diameter of the shaft found out by usual method – sleeve dimensionis:
D= (2d+13),
L=3.5 d
D= outer dia of sleeve, L= axial length of sleeve, d= dia of shaft
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
Clamp /Split Muff /compression Coupling

Adv:
Easy to assemble or dismantle
Dis adv:
Difficulty in dynamic balancing. Not used for
high speed.
Unsuitable for shock loads

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Rigid Flange coupling

Unprotected type flange protected type flange coupling

coupling

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Proportions of Rigid Coupling

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Torsional shear stress in the hub of flange coulpling by considering
as hollow shaft

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Shear Resistance of Bolts

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Flexible coupling

Resisting Forces in Rubber Bushes

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956