Square head for shaft-hub connection

The advantage of this connection is easy assembly and disassembly. The disadvantage is the
low manufacturing precision and consequent consequences for limited speeds and small
torques.
For a simplified calculation, it is assumed that the joint is without will, and that the torque
causes the contact stress to be half of each function area of the square head. It is possible to
assume a triangular distribution of this stress.
Load distribution will differ from the assumption due to production inaccuracy due to
looseness or prestressing of joints and shaft deformations by from torsion torque. These
deviations can include in the calculation a coefficient max. stress 𝑆" = 1,3 − 2 the lower
value of which applies to short joints 𝑙 ≤ 𝑠 and for high accuracy of manufacturing.

1
Fig. 1 square head for shaft-hub connection

2
Bearing stress:
𝑀. ∗ 𝑠"
𝑝= ≤ 𝜎344
2𝑎 ∗ 𝑙 ∗ 𝑏

p bearing stress [MPa]

MT torque [Nm]
ss coefficient of maximum stress increase []
a length square head load [mm]
l length square head in the hub [mm]
b distance of the resultant of the pressure [mm]

Distance of the resultant of the pressure:

2
𝑏 = 𝑎5 + 𝑎
3

b distance of the resultant of the pressure [mm]

a1 length square head without load [mm]
a length square head load [mm]

Length square head without load:

𝑑8 𝑠
𝑎5 = sin <cos ?5 @
2 𝑑8

a1 length square head without load [mm]

d9 free diameter [mm]
s width square head [mm]

Length square head with load:

𝑑A 𝑠
𝑎 = sin <cos ?5 @ − 𝑎5
2 𝑑A

a length square head with load [mm]

d8 diameter square head [mm]
s width square head [mm]
a1 length square head without load [mm]

Allowable bearing stress:

0,9𝑅EF,G.
𝜎344 = ∗ 𝐶J
𝑆H

σall allowable bearing stress [MPa]

Rp0,2T the minimum yield strength or 0,2% proof strength at calculation temperature [MPa]
SF safety factor []
Cc coefficient of use of joints according to load []

3
Coefficient of use of joints according to load:
load []
Unidirectional load, non-impact load 0,8
Unidirectional load, with a small impact load 0,7
Unidirectional load, with a big impact load 0,6
Alternating load, with a small impact load 0,45
Alternating load, with a big impact load 0,25

Torsion stress in the shaft:

16𝑀.
𝜏" = ≤ 𝜏344
𝜋𝑑 N

τs torsion stress in the shaft [MPa]

MT torque [Nm]
d diameter of the shaft [mm]
τall allowable shear stress [MPa]

Allowable shear stress:

0,4𝑅EF,G.
𝜏344 = ∗ 𝐶J
𝑆H

τall allowable shear stress [MPa]

Rp0,2T the minimum yield strength or 0,2% proof strength at calculation temperature [MPa]
SF safety factor []
Cc coefficient of use of joints according to load []

Torsion stress in the hub:

16𝑀.
𝜏P = 3,962 ≤ 𝜏344
𝜋Q(𝐷PT − 4𝑠 T )/𝐷P W

τh torsion stress in the hub [MPa]

MT torque [Nm]
Dh diameter of the hub [mm]
s width square head [mm]
τall allowable shear stress [MPa]

If the shaft is loaded with the bending moment in the joint, the bending stress must be
checked. If the shaft is loaded with a shear force in the joint, the shear stress must be
checked. The shaft may be load in the joint by axial force. The shaft must be checked for
axial stresses. When calculating the different load types, it is necessary to calculate the
combined stress.

Bending stress in the shaft:

32𝑀X
𝜎X = ≤ 𝜎X344
𝜋𝑑 N

4
σB bending stress in the shaft [MPa]
MB bending moment [Nm]
d diameter of the shaft [mm]
σBall allowable bending stress [MPa]

Allowable bending stress:

0,6𝑅EF,G.
𝜎X344 = ∗ 𝐶J
𝑆H

σBall allowable bending stress [MPa]

Rp0,2T the minimum yield strength or 0,2% proof strength at calculation temperature [MPa]
SF safety factor []
Cc coefficient of use of joints according to load []

Shear stress in the shaft:

4𝐹Z
𝜏"(") = ≤ 𝜏344
𝜋𝑑 G

τs(s) shear stress in the shaft [MPa]

FR shear forces [N]
d diameter of the shaft [mm]
τall allowable shear stress [MPa]

Axial stress in the shaft:

4𝐹[
𝜎[ = ≤ 𝜎[344
𝜋𝑑 G

σA axial stress in the shaft [MPa]

FA axial forces [N]
d diameter of the shaft [mm]
σAall allowable axial stress [MPa]

Allowable axial stress:

0,45𝑅EF,G.
𝜎[344 = ∗ 𝐶J
𝑆H

σAall allowable axial stress [MPa]

Rp0,2T the minimum yield strength or 0,2% proof strength at calculation temperature [MPa]
SF safety factor []
Cc coefficient of use of joints according to load []

Combined stress in the shaft:

G
𝜎]^_"J3 = `(𝐾]X ∗ 𝜎X )G + (𝐾][ ∗ 𝜎[ )G + 4b(𝐾]" ∗ 𝜏" )G + 𝜏"(") c ≤ 𝜎d344

σtresca combined stress in the shaft [MPa]

KtB concentration factor in bending []

5
σB bending stress in the shaft [MPa]
KtA concentration factor in axial []
σA axial stress in the shaft [MPa]
Kts concentration factor in torsion []
τs torsion stress in the shaft [MPa]
τs(s) shear stress in the shaft [MPa]
σCall allowable combined stress [MPa]

Concentration factor in bending:

𝐷−𝑑 𝐷−𝑑 G 𝐷−𝑑 N
𝐾]X = 𝐶5X + 𝐶GX < @ + 𝐶NX < @ + 𝐶TX < @
𝐷 𝐷 𝐷

𝐷−𝑑 𝐷−𝑑
𝐶5X = 0,947 + 1,206f − 0,131
2𝑟 2𝑟

𝐷−𝑑 𝐷−𝑑
𝐶GX = 0,022 − 3,405f + 0,915
2𝑟 2𝑟

𝐷−𝑑 𝐷−𝑑
𝐶NX = 0,869 + 1,777f − 0,555
2𝑟 2𝑟

𝐷−𝑑 𝐷−𝑑
𝐶TX = −0,810 + 0,422f − 0,260
2𝑟 2𝑟

KtB concentration factor in bending []

C1B coefficient []
C2B coefficient []
C3B coefficient []
C4B coefficient []
D diameter of the shaft [mm]
d diameter of the shaft [mm]
r radius [mm]

Concentration factor in axial:

𝐷−𝑑 𝐷−𝑑 G 𝐷−𝑑 N
𝐾][ = 𝐶5[ + 𝐶G[ < @ + 𝐶N[ < @ + 𝐶T[ < @
𝐷 𝐷 𝐷

𝐷−𝑑 𝐷−𝑑
𝐶5[ = 0,926 + 1,157f − 0,099
2𝑟 2𝑟

6
 𝐷−𝑑 𝐷−𝑑
𝐶G[ = 0,012 − 3,036f + 0,961
2𝑟 2𝑟

𝐷−𝑑 𝐷−𝑑
𝐶N[ = −0,302 + 3,977f − 1,744
2𝑟 2𝑟

𝐷−𝑑 𝐷−𝑑
𝐶T[ = 0,365 − 2,098f + 0,878
2𝑟 2𝑟

KtA concentration factor in axial []

C1A coefficient []
C2A coefficient []
C3A coefficient []
C4A coefficient []
D diameter of the shaft [mm]
d diameter of the shaft [mm]
r radius [mm]

Concentration factor in torsion:

i?j i?j G i?j N
𝐾]" = 𝐶5" + 𝐶G" Q i
W + 𝐶N" Q i
W + 𝐶T" Q i
W

𝐷−𝑑 𝐷−𝑑
𝐶5" = 0,905 + 0,783f − 0,075
2𝑟 2𝑟

𝐷−𝑑 𝐷−𝑑
𝐶G" = −0,437 − 1,969f + 0,553
2𝑟 2𝑟

𝐷−𝑑 𝐷−𝑑
𝐶N" = 1,557 + 1,073f − 0,578
2𝑟 2𝑟

𝐷−𝑑 𝐷−𝑑
𝐶T" = −1,061 + 0,171f + 0,086
2𝑟 2𝑟

Kts concentration factor in torsion []

C1s coefficient []
C2s coefficient []
C3s coefficient []
C4s coefficient []
D diameter of the shaft [mm]
d diameter of the shaft [mm]

7
r radius [mm]

Allowable combined stress:

𝑅EF,G.
𝜎d344 = ∗ 𝐶J
𝑆H

σCall allowable combined stress [MPa]

Rp0,2T the minimum yield strength or 0,2% proof strength at calculation temperature [MPa]
SF safety factor []
Cc coefficient according to load []

Literature:
AISC: Specification for structural steel buildings: Allowable Stress design and plastic design
1989
Walter D. Pilkey, Deborah F. Pilkey: Peterson’s stress concentration factors. 2008
Joseph E. Shigley, Charles R. Mischke, Richard G. Budynas: Konstruování strojních součástí
2010.
MET-Calc: Allowable stress.
https://met-calc.com/soubory/clanky/Allowable%20stress%20[EN].pdf
A. Bolek, J. Kochman a kol.: Části a mechanismy strojů I. 1989.
K. Kříž a kol.: Strojní součásti 1. 1984.