4

Keys, Pins, Cotter and Knuckle Joints

Symbols Description and Units

b width of key, mm
d diam eter of the shaft, mm
dp diam eter of the pin, mm
F press ure betw een the hub and the shaft , N (kgf)
F, circu mfere ntial force , N (kgf)
h thick ness of key, mm
I lengt h of key, mm
2 2
p tange ntial press ure per unit length, MN/ m (kgf/ mm )
2
(kgf/ mm2 )
p1 maxi mum press ure wher e the shaft enter s the hub, MN/m
2 2
p2 press ure at the end of key, MN/ m (kgf/ mm )
T Torque, N mm (kgf- mm)
2
(kgf/ mm2 )
ub 1 nomi nal beari ng stress at the dang erous point, MN/m
2
mm2 )
T1 nomi nal shear stress at the dang erous point, MN/ m (kgf/
µ1 coefficient of friction betw een the shaft and the hub
ces of the key
µ2 coefficient of fricti on on both the top and botto m surfa

Equation Eqn. No.

Particular
Square and Rectangular keys: (Fig. 4.l(a )) (Table 4.1)
b = ¼d 4.1
The width of the squar e key
4.2(a )
The width of the recta ngula r key b = ¼d
h =i d 4.2(b )
The height of the recta ngula r key

a) Crushing strength:
p = Pt - Ix tan a 4.3
The tangential press ure per unit length of the
key at any inten nedia te dista nce Ix from the
hub edge (Fig. 4.l (b))

61
62 Keys, Pins, Cotter and Knuckle Joints

Particular Equation Eqn. No.

Pt - P Pt - P2 _ Pt - P2 = f!.2.
where tan a = = l - I I
1X Z O

Torque transmitted by the key can be dl2

T = ½Pidl - - tan a 4.4(a)
expres sed by the equatio n r
The general equation for torgue transmitted 4.4(b)
when p2 =0 and l = lo = 2.25d
O"bth
tan a= pi/lo =
4 .Sd
4.4(c)
b) Strength in shear:

The general expression for torque

transmitted
4.S(a)

Pt
when tan a = T; = 2Ttb
_ d
25 4.S(b)
T
where Tt = lb(0.5d - 0.11 /) 4.S(c)
2) Taper keys: (Table 4.2)
The relation involving the circumferential
force F, and the pressure F between the
shaft and hub (Fig. 4.2)
where µ1 = 0.25, coefficient of friction betwee n
the shaft and hub
The pressur e F between the shaft and hub
F = blp 4.7
where p is the pressure, or compre ssive stress in the key, MN/m2 (kgf/m rn2
)

l2 ..1
lo= 2.25 d
Fig. 4.l(a): Rectangular Key
Fig. 4.l(b): Pressures between key and key seat
 Jo int s 65
Keys, Pins, Co tte r an d Kn uc kle

Particular Equation Eqn. No.

(0. 8D p) 4.l 6(d )

Area of contact of all 'N ' teeth Ac = N (LN ) = 0 .8D L

The torque cap aci ty of spline in

bearing Tb = (0. 8D pL ) (~P) a-b 4.15(e)

stress
= (0. 8D µL) ( ~P) 2a-dc

= 0.8D~La-dc
where a-b = 2a-de, bearing stress
pression
a-de is the aJiowable stress in com

T = !!.....vJTd 4. l 5(f)
Torque capacity 16
L = Dp 4.15(g)
t of the teeth
Assuming only abo ut 25 per cen
of the spline
are in actual contact, the length
s 4.16(b) and
(Equating torque from equation
4.16(t))

Cotter Joint: (Fig. 4.4)

a) Design of the rod: ,r 4. 16(a)
id rod P = -d2 a-,
The tearing resistance of the sol 4
4.16(b)
end to P = d,ta-c
The resistance of cot ter an d rod
crushing 4.16(c)
end through P = (~ti; -di t)a -,
The tearing resistance of the rod
the cotter hole 2 4.16(d)
the P = ,r4(d22 - d 1 )a-c
When the joi nt is in compression
on
resistance of col lar in compressi 4.16(e)
shearing P=1rd1t1T
The resistance of thrust col lar to I

_ [3- P(d2 - di) 1

2 4.16(f)
the col!ar t, -
Equating the bending mo me nt on 2 1rd,a-b
ckness of
to the resistance moment, the thi
the coIJar 4.16(g)
end
The shearing resistance of the rod
66 Keys, Pins, Cotter and Knuckle Joints

.d Compression

Diameter of
rod end
Symbol

di
Proportions
used in practice
1.25d
Rod end -,L--IL1-
1..--
-~'==--i
d2 - -
i.-~--D --4---- ----+l t1
Thickness of 0.25d1
t
cotter
Width of cotter B=b l.25d1 or 5t c Clearance
Diameter of 2.00d1 3mm
D '-=:;
the socket
' 5mm
Diameter of
socket across
1.75d to 2.00d I
I I
:
I
T
D1 - •- ·- ·"'T ·- ·J·- ·- - · ·- -- -- -~---,--- ·- ·- ·- ·- · . .
I
I
I
I
B ' 'I
cotter note ~ ~-+--tm:m :
I

:
Diameter
di
1.5d ,-, I ~;t'=
""'
---
c = 3mm
of the collar
Length 11 and l 0.75d to 1.25d ~ SI--+ -~~~- Soclct end
Thickness of 0.50d
the collar '•
Thickness of 0.50d
l2
socket end
Clearance C 2mmto3 mm
Diameter of -
d
solid rod
Alternatin g load

Fig. 4.4: Cotter Joint

<Tc allowable crushing stress, MN/m2 (kgf/mm2 )

<Tb allowable bending stress, MN/m2 (kgf/mm2 )
u, allowable tensile stress, MN/m2 (kgf/mm2 )
T allowable shear stress, MN/m2 (kgf/mm2 )
r' allowable shear stress parallel with fibre, MN/m2 (kgf/mm2)
Keys. Pins. Cotter and Knuckle Joints 67

--:::=--
Particular - Equation Eqn. No.
-
b)
---
Design of tht! socket:
---------------

The tearing resistance of the socket end p = [rr

- ( D')j - d'j)-(D 1 -d 1)t ] er, 4. I 7(a)
4
through the cotter hole
p = (D _ d, )!ere 4.17(b)
The resistance of cotter and socket end to
crushing
p = 2(D- di)IT' 4.17(c)
The shearing resistance of socket end in
front of cotter
D ~ 2d, 4. l 7(d)
The diameter of the socket end
P = ,rdt2 r' 4. l 7(e)
The shearing resistance of the solid rod from
the socket end
c) Design of cotter:
P = 2btT 4.18(a)
The shearing resistance of the cotter
2
p = ~ tb <Tb 4.18(b)
Equating the maximum bending moment to 3 D
resisting moment
Design of Knuckle Joint: (Fig. 4.5)
1T
P = -d2cr, 4.19(a)
Tearing resistance of the tod 4
P = 2Ad2<r, 4. I 9(b)
The tearing resistance of the two sections
across the fork where d2 = S = width of the square section, mm
= 7!...d2 T X 2 = 7!...d2 r 4.20(a)
The resistance to shearing of the pin p 2 I
4 I

P = di<rr 4.20(b)
The tearing resistance of the square section
I

_ [(1.44d X 2 X
2
<r,)] 2
4.20(c)
Equating the shearing resistance of the pin di - lIT
to the tearing resistance of the square section
the diameter of the pin
P = 2(D - d1)B<r, 4.2l(a)
The tearing resistance of the two sections
across the forked and along the plane
through the pin axis
P = F(D - d1)<r, 4.2 l (b)
The tearing resistance of the section across
the eye and along a plane through the pin
axis
P = Fdi<rc 4.2l(c)
The resistance of the rod end to crushing
P = 2Bd1<rc 4.21 (d)
The resistance of fork end to crushfog
 Keys, Pi,ns, Cotter and Knuckle Join,
68

i
d

Octagonal i
i
-t
section- - i l

Eye end-
i
i
iS
_!
i
Square section i L
!i I BI
' ' EI
"I / p·1n
i - - - !F
----- -1---·+
-!- ---- --- !
~--
_t
·-·-·-· ·-·-· ·-·-·
·- ·- · ·- ·- · · d 1 C
-- --- - ---1- ---- --- U_
I
Taper pin · Forked i
i
solid or split i
-i---c:--r-- --.- end i
dia G= 6mm i
i
L1 ---;----
l ;

-+
i
S - S1 1.2d i
i
F 1.5d i
l i
() d i
C 1.5d ! !
E d/ 2
G 316d to 1/ 4d
B 0.75d
H 0.80d
A 0.60d
1.50d to 2.00d
D 2.00d
L 4.00d
L1 4.80d
Part inverted plan
Fig. 4.5: Knuckle Joint

References
[1] Siegel M. J., Maleev V. L., Hartman, J.B., "Mechanical Design of Machines", 4th edition, Inter-
national Text Book Company, 1965. ·
[2] Vallance A., Doughtie V. L., "Design of Machine Members", 3rd edition, McGraw Hill Book
Company, 1951.

[3] Ghosh A. K., "Practical Machine Design", S. Bhattacharya & Co., Calcutta. 1969.

[4] Bhattacharya S. C., Basu Mallik J. R., "Machine Design", Basu Mallik & Co., Calcutta, 1966.
 -ct'r r,~ r J
?ia ~ I ,~□
d Chamfer or radius
Keyway I· L ·I h;-i
radius in
of key
shaft and hub

Table 4.1 Dimensions of Parallel keys and keyways (All Dimensions in mm)
Forshart Above 6 8 IO 12 17 22 30 38 44 50 58 65 75 85 95 110 130 150 170 200 230 260 290 330 380 400
diameters Upto 8 10 12 17 22 30 38 44 50 58 65 75 85 95 l IO 130 150 170 200 230 260 290 330 380 400 500
Key cross Width b 2 3 4 5 6 8 IO 12 14 16 18 20 22 25 28 32 36 40 45 50 56 63 70 80 90 100
section Height h 2 3 4 5 6 7 8 8 9 IO 11 12 14 14 16 18 20 22 25 28 32 32 36 40 45 50
Keyway
depth in shaft t 1 1.2 1.8 2.5 3.0 3.5 4.0 5.0 5.0 5.5 6.0 7.0 7.5 8.5 9.0 IO 11 12 13 15 17 19 20 22 25 28 31
(nominal) in hub t2 1.0 1.4 1.8 2.3 2.8 3.3 3.3 3.3 3.8 4.3 4.4 4.9 4.9 5.4 6.4 7.4 8.4 9.4 10.4 11.4 12.4 13.4 14.4 15.4 17.4 19.5
Tolerance on t1 + 0.1 +0.2 + 0.3
Keyway depth t2 + 0.1 +0.2 + 0.3
Chamfer Max 0.25 0.35 0.55 0.80 1.30 2.00 2.95
or radius r1
of key Min 0.16 0.25 0.40 0.60 1.00 1.60 2.50
keyway
radius r2 Max 0.16 0.25 0.40 0.60 1.00 1.60 2.50
Length Min 6 6 8 10 14 18 22 28 36 45 50 56 63 70 80 90 100 110 125 140 160 180 200 220 250 280
of key L Max 20 36 45 56 70 90 110 140 160 180 200 220 250 280 320 360 400 400 400 400 400 400 400 400 400 400
Designation: A Parallel Key of width IO mm, height 8 mm, and length 50 mm shall be designated as: Parallel Key IO x 8 x 50 x LS:2048
70 Keys, Pins, Cotter and Knuckle Joints

Basic t aper 1: 1000

\ on this face
b
IT I ', I
~ I. . ____
1- L - I
x 450 Key

.d
r1

Key way
in hub
Assembly Key way
in shaft
~r~
I ~
~ 2

Table 4.2 Taper keys and keyways (All dimensions in mm)

/
Shaft
Key Keyway in Shaft and Hub Length
Diametre, d
Upto& Cross Chamfer Keyway Depth in Toi. on Depth Toi. on Radius Min. Max.
lnclud- Section or width b Shaft t1 t1 in hub t2 r2 Max.
Above
ing Width, Height Radius r1 (D 10) ti
b (h9) h (Min)
6 8 2 2 0.16 2 1.2 +0.05 0.5 0.16 6 20
8 IO 3 3 3 1.8 0.9 8 36
10 12 4 4 4 2.5 1.2 IO 45
12 17 5 5 0.25 5 3.0 1.7 +0.10 0.25 12 56
17 22 6 6 6 3.5 2.1 16 70
22 30 8 7 8 4.0 + 0.1 2.5 20 90
30 38 IO 8 IO 5.0 2.5 25 110
38 44 12 8 12 5.0 2.5 32 140
44 50 14 9 0.40 14 5.5 2.9 40 160
50 58 16 IO 16 6.0 3.4 45 180
58 65 18 II 18 7.0 3.4 50 200
65 75 20 12 20 7.5 3.8 56 220
75 85 22 14 22 8.5 3.8 63 250
85 95 25 14 0.60 25 9.0 4.3 +0.2 0.60 70 280
95 110 28 16 28 10.0 5.3 80 315
I IO 130 32 18 32 11.0 6.2 90 355
130 150 36 20 36 12.0 7.2 100 400
150 170 40 22 1.00 40 13.0 +0.15 8.2 1.00 110 400
170 200 45 25 45 15.0 9.2 125 400
200 230 50 28 50 17.0 IO.I 140 400
230 260 56 32 56 19.0 12. I
260 290 63 33 1.6 63 20.0 12.1 1.60
290 330 70 36 70 22.0 13. l +0.3
330 380 80 40 80 25.0 14. I
380 440 90 45 2.5 90 28.0 16.1 2.50
440 500 100 50 100 31.0 I8.1
-
IS: 2292-1963
 1J
Couplings, Clutches and Brakes

Symbols Description and Units

d diameter of bolt, mm
D diameter of shaft, mm
D1 hub diameter, mm
D2 diameter of the bolt circle, mm
D3 outside diameter or flange, mm
, number of bolts
t thickness of flange, mm
T torque, N mm (kgf mm)

Particular I Equation Eqn. No.

Cast Iron Fia,,,,ge Coupling: (Fig. 13.l(a)) and Pulley Coupling. (Fig. 13.l(b))
1 3
An empirical rule .to determine the i= D + 2 to D + 2 (or) 13.l(a)
approximate number of bolts• 40 80
i = 0.02D + 3 13.l(b)
0.423D 0.5D
The preliminary bolt diameter may be d= _r; +7.5mm(or)d= - - 13.l(c)
determined by the empirical formula vi Vi

b = 0.5D + 25mm
> 0.3D + 1.3d + 7.55 mm
c = 0. ID+ 2.5 mm
f = 1.5d
L t1 = 0.25D + 6.35 mm
b b
ti = 0.30D + 1 .50 mm
t3 = 0.1 OD + 5.00 mm
Fig. 13.l(a): Cast iron flange Fig. 13.l(b): Cast iron pulley a = 0.20D + 5.00 mm
coupling coupling
the nearest larger even number must be selected.

251
 Couplings, Clutches and Brakes
252

Equation Eqn. No.

Particular
D 1 = 1.5D + 25 mm (or) 2D 13. l(d)
The hub diameter
D 2 = D1 + 3.2d (or) 2D + 50mm (or) 3D 13.l(e)
The diameter of the bolt circle
The outside diameter of flange D; = D 1 + 6d (or) 2.5D + 75 (or) 4D 13.l(f)

The hub length

L = 1.2D + 20 mm (or) 1.25D + 20mm (or) 125D to 1.5D 13. l(g)

The flange thickness (Cl Flange coupling) t = 0.35D + 9 mm 13.1(h)

The maximum power capacity based upon P(kW) = ( 1r ) Tn SI Units 13.2(a)

0.5 X 106
friction such that slip occurs between faces of
contact.
- Tn Metnc
P(MHP) = -2n) .umts
. 13.2(b)
( 75000

where T = µFR, torque capacity based on friction, N mm (kgf mm)

F is the axial force caused by bolt loading, N (kgf); µ is the coefficient of friction

R = -I ( D~ - Df), fri ctlon

· rad'ms assuming
· the pressure 1s
. um1orm
.' 1y d'1stn'buted , mm
3 D 02 -D.2I
D0 =Outer diameter of contact, mm; D; =Inner diameter of contact, mm
T = T1rid1D2 13.2(c)
The torque capacity based on shear of bolts
8
The torque capacity based on bearing of bolts T = <TbitdD2
13.2(d)
2
and flange
T7fDit
The torque capacity based on shear of flange T=-- 13.2(e)
2
where Tis the allowable shear stress, MN/m2 (kgf/mm2 )
<Tb is the allowable bearing pressure for the bolt or web
(whichever is weaker) of projected area, MN/m2 (kgf/mm2 )
i = the number of effective bolts, taken as all the bolts if finished bolts are used in reamed
holes and taken as half the total number of bolts, if bolts are set in clearance holes
Muff Coupling
nD3
Torque transmitted by the steel shaft Ts= - T s 13.3(a)
16
Torque transmitted by the CI Muff (Assuming Tc, = Ts)

· Tm; I: (Ir,; D}a ; ;; (Ir,; 0

}, J3.3(b)

where Ta and Ts are allowable shear stresses for cast iron and steel respectively
Hub diameter of Muff Coupling D 1 ~ 1.5D 13.3(c)
 253
couplings, Clutc hes and Brake s

Particular / Equation Eqn. No.

Marine or Sold Flange Coupling (Fig. 13.3)
The number of bolts 13.4(a)
i = 0.01 32D + 2
13.4(b)
The diameter of bolt circle D2 = D + J½d to D + 2.5d
13.4(c )
The averag e diame ter of bolt circle D2= D+2d

Li = 2.25D + 20mm
L = 2.5D + 50mm
L = 0.875D + 3mm
_l
I-- L --j
(a) Ordina ry muff coupli ng (b) Fairbairn's halp-la p coupling

Fig. 13.2: Muff Couplings

Recessed Flange
Spig
flan bi- -- f 4+--4----~-
"'Q c:i
TD D' = locating diamet er
b 1 = Recess depth
Q j l
--- ___l -
-- - ---
b2 = Spigot-depth

1-t -l
Fig. 13.3: Marine or solid Fig. 13.4: Forged end type rigid coupling (Table 13.1)
flange couplings

--- - - L - - ---,

Length of box, L = 4D
Inside diame ter of conical sleeve D 1 = 2D + 12.5mm
Outside diame ter of box D2 = 3D
Length of conical sleeve E = l.5D

Fig. 13.5: Sellers cone coupling

254 Couplings, Clutches and Brakes

Particular Equation Eqn. No.

d = --
D3 )2
If the bolts are made of the same material as ( 2iD2 for solid shafts 13.4(d)
the shaft, the diameter of bolt
I

~ [(d.; D;) (Zi~ )]' for hollow shafts 13.4(e)

0

where D0 = external diameter of hollow shaft, mm

D; = internal diameter of hollow shaft, mm
Thickness of flange t = 0.27D + 5 mm for solid shafts l3.4(t)
I
3
~ 0.29 ( D! ; lY;) for hollow shafts l3.4(g)
0

Diameter of flange D3 = (D2 + I .9d) to (D2 + 3.9d) 13.4(h)

Flexible Couplings (Fig. 13.6 and Table 13.2(a), (b) and (c))

The maximum allowable load rating at kW of power} x {Service} x 100

{ of application factor
100 RPM of coupling P =--- -------
(RPM of application)
13.S(a)

Service factor - Refer Table. 13.3

r1ridf,D2
The torque capacity based on so shear of bolts T = - - - 13.S(b)
.8
The torque capacity based on bearing of pins 13.S(c)
and flange

Assuming that the force is distributed M= Fl 13.5(d)

miformly over the bush of length /, the 2
maximum bending moment
16Fl
The stress due to bending Moment CTb = -- 13.S(e)
,rd3p
F

T Il l lllll~ where dp is the diameter of pin at the neck, mm

d' is the outside diameter of the bush, mm
d' dp
l _L Pb is the bearing pressure on the projected area of the
bronze bushing, (Pb = 0.2 MN/m2)
ttttttttttttttttt
~~~
CTb is the allowable bending stress