DESIGN OF KEYS

KEYS
• A key can be defined as a
machine element which is
used to connect the
transmission shaft to rotating
machine elements like
pulleys, gears, sprockets or
flywheels.
• It is always inserted parallel to
the axis of the shaft in the
provided key-way.
Fig.: Key-joint
Functions of the Keys
There are two basic functions of the key:
1. The primary function of the key is to transmit
the torque from the shaft to the hub of mating
element and vice versa.

2. The secondary function of the key is to prevent

relative rotational motion between the shaft
and the joined machine element like gear or
pulley.
Types of key
Saddle Keys
• This type of key fits in the
keyway of the hub only;
there is no keyway on the
shaft.
• There are two types of
saddle key,
– Hollow saddle key
– Flat saddle key Fig.: (a) hollow saddle key
(b) Flat saddle key
• In both types of saddle key, friction between shaft,
key and hub prevents relative motion between the
shaft and the hub.
• The power is transmitted by means of friction.
• Saddle keys are suitable for light duty or low power
transmission as compared with the sunk keys.
• Saddle key requires keyway only on the hub.
Therefore, cost of saddle key joint is less than that of
sunk key joint.
Sunk Keys
• The sunk keys are placed in such a way that its half portion is
in the keyway of the shaft and half is in the keyway of hub or
boss of the rotating element.
• The sunk keys are of the following type
1. Rectangular sunk key
2. Square sunk key
3. Parallel sunk key
4. Gib-head key
5. Feather key
6. Woodruff key
 Sunk Keys
• In sunk key, power is transmitted due to shear resistance of
the key. The relative motion between the shaft and the hub is
also prevented by the shear resistance of the key.
• They are suitable for heavy duty application, since there is no
possibility of the key to slip around the shaft. It is a positive
drive.
• Sunk keys with square or rectangular cross-section are widely
used in practice.
• Sunk key with rectangular cross-section is also called flat key.
Rectangular key
The usual proportions of
rectangular sunk are as show in
figure,
𝑑
Width of key, 𝑏 =
4
Height or thickness of key,
2 𝑑
𝑕 = 𝑏=
3 6
Length of the key, 𝑙 = 1.5𝑑
Where, 𝑑 is diameter of shaft in mm.
 Square key
A square key is similar to
rectangular key, only the
difference is that in its
cross-section width and
height are equal.

𝑑
𝑏=𝑕= 𝑎𝑛𝑑 𝑙 = 1.5𝑑
4

Standard dimensions of square and rectangular sunk keys are given in following table-
Parallel key: A parallel key is a sunk key which is
uniform in width as well as height throughout
the length of the key.

Taper key: A taper key is uniform in width but

tapered in height. The standard taper is 1 in 100.
Gib-head key
• It is a rectangular sunk key with a head at one
of the end called as Gib-head. The head is
provided to facilitate the easy removal of the
key.
Feather key
• A feather key is a parallel
key, which is fixed either to
the shaft or to the hub and
which permits the relative
axial movement between
them.
• There is a clearance fit
between the key and the
keyway in the hub.
Therefore, the hub is free to
slide over the key.
• The feather key transmits the torque and at
the same time permits some axial movement
of the hub.
• They are used where the parts mounted on
the shaft are required to slide along the shaft
such as clutches or gear shifting devices.
• It is an alternative to splined connection.
Woodruff key
• A woodruff key is a sunk key, in the form of an almost semi-
circular disk of uniform thickness.
• The keyway in the shaft is in the form of a semi-circular recess
with the same curvature as that of the key. The keyway is the
hub is made in usual manner.
 Design of Square and Flat keys
For the purpose of analysis flat key is
considered:
• The forces acting on a flat key, with
width as 𝑏 and height 𝑕 are shown
in figure.
• The exact location of force 𝑃 on
surface AC is unknown. In order to
simplify the analysis, it is assumed
that the force 𝑃 is tangential to the
shaft diameter.
 𝑀𝑡 2𝑀𝑡
Therefore, 𝑃 = = ................(a)
𝑑/2 𝑑
Where, 𝑀𝑡 = transmitted torque
𝑑 = shaft diameter
𝑃 = force on key

• The design of square or flat key is based on two

criteria
– Failure due to shear stress
– Failure due to compressive stress
 Shear Failure Crushing Failure
• The shear failure will occur in • The crushing failure will occur in
plane AB and it is given by, surfaces AC or DB.
𝑃 ℎ
𝜏= ……..(b) • It is assumed that, AC ≅ BD ≅
𝑏𝑙 2
𝑃 2𝑃
From (a) and (b) 𝜎𝑐 = = ……..(c)
ℎ/2 𝑙 ℎ𝑙
2𝑀𝑡 From (a) and (c)
𝜏= …..(1)
𝑑𝑏𝑙 4𝑀𝑡
𝜎𝑐 = ……(2)
𝑑ℎ𝑙
• Equation (1) and equation (2) are stress equations of flat
key.
• For square key, 𝑕 = 𝑏
Substituting above relationship in (1) and (2). We get,
2𝑀𝑡 4𝑀𝑡
𝜏= and 𝜎𝑐 =
𝑑𝑏𝑙 𝑑𝑏𝑙
• From above relationship it can be concluded that the
compressive stress induced in a square key due to
transmitted torque is twice of shear stress.
 Design of Kennedy key
• The Kennedy key consists of
two square keys.
• In this case, the hub is bored
off the center and the two keys
force the hub and the shaft to a
concentric position.
• It is used for heavy duty
application.
Analysis
• The design of Kennedy key is
based on two criteria
– Failure due to shear stress
– Failure due to compressive stress
• The forces acting on one of the
two Kennedy keys are shown.
• Since there are two keys, the
torque transmitted by each key is
one half of the total torque i.e.
𝑀𝑡
.
2
• It is assumed that the force P acts
tangential to the shaft diameter,
therefore
𝑀𝑡 𝑑
=𝑃
2 2
𝑀𝑡
Or 𝑃= ……….(a)
𝑑
• The failure due to shear stress will occur
in plane AC.
𝐴𝐶 = 𝐴𝐵2 + 𝐵𝐶 2 = 𝑏 2 + 𝑏 2 = 2𝑏

• The shear stress is given by,

𝑃 𝑀𝑡
𝜏= = …………..(1)
2𝑏𝑙 2𝑑𝑏𝑙
 1 1 𝑏
• 𝑂𝐵 = 𝐴𝐶 = 2𝑏 =
2 2 2

• The compressive stress is given by,

𝑃 𝑃
𝜎𝑐 = =
𝑂𝐵 × 𝑙 ( 𝑏 ) × 𝑙
2
2𝑀𝑡
Hence, 𝜎𝑐 = ……(2)
𝑑𝑏𝑙

Where 𝑙 is the length of the key.

 SPLINES
• Splines are keys, which are made integral with shaft.
• They are used when there is relative axial motion between the shaft
and the hub.
• Splines are cut on the shaft by milling and on the hub by broaching.
 Notations

𝐷 = 𝑚𝑎𝑗𝑜𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑠𝑝𝑙𝑖𝑛𝑒𝑠

𝑑 = 𝑚𝑖𝑛𝑜𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑠𝑝𝑙𝑖𝑛𝑒𝑠
𝑙 = 𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑕𝑢𝑏
𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑝𝑙𝑖𝑛𝑒𝑠
𝑀𝑡 = 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑡𝑜𝑟𝑞𝑢𝑒
𝑝𝑚 = 𝑝𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑜𝑛 𝑠𝑝𝑙𝑖𝑛𝑒𝑠
1
𝐴 = 𝑡𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠𝑝𝑙𝑖𝑛𝑒𝑠 = 𝐷 − 𝑑 𝑙𝑛
2
𝐷+𝑑 Fig.: Splines (a) Shaft (b) Hub
𝑅𝑚 = 𝑚𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑠𝑝𝑙𝑖𝑛𝑒𝑠 =
4
• The torque transmitting capacity
of splines is given by,

𝑀𝑡 = 𝑝𝑚 𝐴 𝑅𝑚

1
Or 𝑀𝑡 = 𝑝𝑚 ln(𝐷2 − 𝑑2 )
8

• The permissible pressure on the Fig.: Splines (a) Shaft (b) Hub
splines is limited to 6.5 𝑁/𝑚𝑚2 .