10. KEYS AND COUPLINGS ‘Objectives ofthis Chapter ‘After completing tis chapter the student willbe abletor 1. Deserbe several kinds of keys, thoi suitable ‘materials, and élmensions in relation to. given shaft sae 2. Complete the design of keys by considering Stresses and siandard proportions 3. Design other kinds of Keys such as the WoodrutTkey or multiple keyslike spines 4 Be'familiarzed withthe standard couplings used for power transmission: rigid couplings and typer of fesile couplings. 5. Complete ‘the analysis of a flange bolt coupling in terms of stresses and lactors of safety during transmission of power + Defisition of Terms Key machine member used to conmeet to ‘mating parts (usually a shaft 10 8 pulley. gear, ‘coupling, tc) such that relative motions prevened between them, Keyway—a groove athe mating members where the key fits Types of Keys: — @& <= © © Ker PRKEY — sx0biE = 6 © KENNEDY ROUND KEYAS A ‘SHEAR BN PNKeY WoOoRUFF KEY Leama eS Eee @ a Metin esata asseny &. ame “EHS 9 vetanguat key with te smaller dimgasion ‘Paced ina oda decom eave be shu CE "SFE a hey with asquar section oie tne an ae seo a pcre Key wih et or cost removal rom assembly "Pig? key of round section, soypsimes used asa shear in agar sealer te conduct) \ “Ral a tion wound key with att 0 proce lexbiliy along its circumference, when inserted into he | eyway. (abr. cc ding fume pe rg \ mani \ "Sedaka a fat ey with ts botom side tavinga rads | of carvatie slighty les than that of the shat radius. This ‘safrictondependem key and ths, its torque capacity is | sini, peo sq ey tae 90g whose ar ss tae keys aealso known as tngentil kos. Gnatmitl Baar ara) | Tae eo Ae "Woodruff ey —key that fits into a semi-cylindrical seat at \ the shat Sice tps deeper imo the sha tas Test tendency op when he load is appicd Fear ya og Nak tat allows hb © move along the shafi but prevents rotation on the shaft. sme aa tual) a lat key with beveled botom comers, (chante cormonhy 45°) TL es Design or Selection of a Rectangular Key His ~ Key material is usually plain earbon ste (C1010,c1018 or C1020) yay kad = Factorof safety anges fromagto (DME Faires) Fe sheek od ~ Key length is generally referred tothe hub length 128% hoe Deion use msant uasarn ey 5 Compressive sre in key shaft tbe shat dlameter“D"is known, standard key proportions can be taken from 41/9. DAE 12. p Fares per (Casual rectangilar key proportion) + Fora atkey, bee tes + Fora square key bro: bee Key length is referred othe length of hb, The bub ength is usual Wy L25D10.24p, where Disthe shaft diameter If the computed key length Consider using 2 keys 00” oF 180°apart) 13 keys are used, the usual spacing is 120° ‘fmore than 3 keys are required, consider using @ splined_shaft (where the keys are made integral with the shaft) Stress Analysis fora Rectangular Key L F T= torque transmitted Fang fe tht, io Shearing stress in key F és 5 Tp 7 Sea} (eqn.10.1) ip Rye ; length of key width of key thickness okey force applied shearing stss in key compressive stress or bearing sess in key shear design stress normal design srs Note: ‘The required key length is computed from 2488 10.1 and 10.2. Use whichever is lomger! Example t: ‘A rectangular key transmit 100 fp at 200 rpm. The key material is A/S1 C1020, cold drawn (S, = 66 ket), and the shaft diameter where the key is atached tos 25 inches. Use a factor of safety of 2.25 based on S,. Compute the flat key dimensions (b x2 14). Also. ifthe key is square, determine its dimensions (bx b & 1) Solution: TE (as) T> @ (uns) Te 9159 Gj 2) Flatkey:y = From AT AA aa ’ ba] 28th pets SHEARING, 129 wf , ot +B, oth | ain Leb VSN Na, oS COA STON Jeur vow 2(S4819)_, 0 § (4v008) RODCR ats 2h BEARING (compression) EAD ce Se Se "be" Tad w Sea be co) (4) NJ evar key 4 Crs, | vod Lk SCIW) 2S. ABiy chase, longer Le 2 Lye $430 ea" We bxtxle eat ray By Square key: bx bx by = and in uonpresstion SHEAR A 28h Le (0)(0) N 2515) 0-5 (000) uM) 2-25 by =1-15in BEARING se 41513) | (ovooe) W(29(Se) 2-25 ly +215 A square kay "0 equtly tryin Sear 7 ® (x for hun ts egval 40 Le Fr (para (compression) le 2 159 Use bats be + SPLINES Spline ~ pemanent keys tht ae made ners with the oat : wae NAN m)Ne 7=s.000 alm = torque capacity (torque transmited) = force ating on each spline = height ofeach spline = contact length ~ cutsde diameter of spine > inside diameter of spline = rmcandiamete of spline = mean dius of spline WN. ~ umber of spline ‘S. = “compresive stress on each spline, ‘generally, this side pressure is based feodyg;, 09 1000 pi ita sliding is present if nok specified, Ifthe problem doesnt pei the allowable si sbleside pres, the usual design value being used is 1000 psi, 1, Se4 Mascon intense ussamny Tas, soling fer Power Example: : Aled sa ta tke owing spectcaos, apt stern) (0g) Daur paver pec int a 900 4 Consider the set havea toa shear sent of B $3025 ‘90 MPa and use the following mesons Outside diameter=2" [amber of splines = 6 Depth ofeach spline = 025 ‘with ofeach Spine Length ofeach spline = 25 Dm=00-h = g*-0-15" Droz. TSie + Based on Spline T= gaps lo-in “Based on Shatt Devarr = 0D -2h = 2°-2(o26)" Dsz1-Sin or Sas ars omen x Hotes atte Pie 5-100 925 nits T= R052 Ibiy The maxi mum permisine torque ts te Howest Value, 1+ 3084.3 Ib-in Sc (lin) (ag) (92) _ too %, (2-54) @2d0 (0 (4) Paver = 15:6 by © Woodeutt Key ‘A Woodniy key is a key that ts into a semic ‘nlndrical set in the sha Since it goes deeper into the shal it has less tendency to tp when the load is applied. During assembly, the key isto be inserted fist imo, Shaft The pulley is next fied, and itis usually bel place with a threaded: nut into the end of the ‘Woodtru keys come in wo shapes, semi-cylindrical hey with or without aflatened bottom as shown inthe figure below, vette AD rN coe “ wre “> Sines bear ng aren is large 3} 6 loghoal 0 nol ove fb eompration ctete at de Woodeltkey yesible failire uw, fey Searing, ont TagLg (Sb > 176-1947) Example 3: ‘A Woodruff key i to be selected fora shaft diameter of 1.5 inches, which is connected to a pulley. The tomas {rassmited is 7000 Ib — in. Use a yield strength for shear(S,) of key material of 44Ksi. Determine the dimension of dhe ssnallest Woodruff key (and its standard key mmber) that ts allowed and the resuling factor of safety of the key selected ‘The factor of safety shonld not be less than 1.5. 11From Table 40-4 For shat} diameter of 1-5 mthe ff. an the pascible bays be weed Key £09 ote. i KEY 840 0-24U Key 812 0: 350 Trying 4# 800: (Sve hear sess Fac of aks at ee Reghirad) ae goo 2 eames oS Bg 2 abt ei +1 gg < BoU23-$ pst hoa Btne Ths, aa oer tapos ae sys, Pe 4.24 21-55 - NOT OR Soe ee Nee 35023-4ps taper to “Trying #810 gree the dition ie ony ratio Sab pat pear] pear Net (Sie: oF AS ee Pee | Neha ede NOT DEE + SETSCREWS elt #817 Set screws are also used to prevent relative motior ‘between a shaft and the hub 2 /.34 baveg of pulley, gear, or sprocket nero (2226) Teme tela hbo and is cesta © E rea: py Nr4.U8 74-5 5 “Ok Hp riting of ¢ standard ec dice A, Moe Wood raf Hay A812 pae] 50 Ref: Machinery's Handbook 25° ed p. 1394 132set sre diameter equi, n omspower tse by shaft sft ameter. in = salt pe Examples: ‘Compute how many 3/-inch diameter set screws ered raat Shp ata edo 100 ps Paty For each set sorw), fe ee n) p= L0auhp ie For no- of seh axeus ravired Pr Pod ah Necw = 7 ag helscxa o- of sch Sorets = 1.43 WL * COUPLINGS Necrws = Coupling ~ a machine member used for connecting shafts direcly by means of detachable fasteners. The shafis may be collinear ot with permissible misalignments. ‘Types of Coupling: 1. Rigid Couplings ~ coupling used with collinear shafis where axial, rotational and angular flexibility is not permitted. The anged-bott coupling isthe most common example. M6 Noctis sgn. tem aztat ASAIN 2 (Pie Couns — comings sa son ‘usaliznmen angblaraxil-oesottinga. i sent ‘These couplings include the Roller Chas coupling, ‘Modes coupling, Fesoin coupling, Flexible dik ‘coupling. Gear isp= coupling and Unsial joins Flouble couplings are wally ned fr more scretive machines (0 avotd direct trasmiesion of tremendous Shock fom the driving tothe driven machines be Oldham covptng ccm pccs ernst Sig ‘kdhamcouping mtg present (Geto meant) gation sh sample ofa Fle Conlin: Oldham Comping FLANGE COUPLING‘Torque capacity of coupling: [ZMe = 9) [eer renege Where: T~ torque capacity of coupling Fe bolle dneter face n cach bot ber ote Shea design ates of ols trainee D> shah diameter Dy ~ hub diameter Ly = hublength te = web thickness Ty = length of key Note: Stress considerations on the above assembly may include he Tllowing > Shearing stress inthe bots > Bearing stress inthe bots, > Shearing sires inthe key > Bearing stress inthe key > Shearing stress in the shaft > Shearing stress in the flange web Example §: ‘A flange coupling isto comect two S7mm dismetez shalls. The hubs of the coupling are each 1L1-mm in diameter, 22mm thick and the flange webs are 19 mm thick Six16 mum diameter bolts in a 65mm diameter bolt circle connect the flanges. The keyway is Som and the key is Lamm ‘4mm, The coupling isto transmit 5KW at 160. Forall parts the yield point value in shear is one-half the ‘yield point value in tension and compression which is 448 MPs, Find the following stresses and factors of safety based (@) shear in the key, (b) bearing inthe key, (c) shear in bolts, (4) bearing inthe bolts; (¢) shear in shaft; (9) shear in hub Ds 2 51m ty = Summ Dn « fam bu = tk 214mm Ly 24ime Powers 45 kW wt {ama ne 0 rpm db = tyne Sys = 0-5 ( 408) Dy < 165mm =724MPa Noob Sad = a eR Te gy rSb5u.25 Non 8) Shearing in key, N =? 2 (tasseSu-25) re aC CIC Toyo” 8 - gg 12.21, : za wro N= 56 Fp TT wo wey 134by Bearing inkey, =? pele : “he “hen * Te _ A autsun 29) GAED (0 een 4adg Mia nee N= 1.20 MPay ©) Shearing in bolt, W =? Re | og =F Ihe Beate * any ie % (ayy (u) $= 1U.98 may = Sys, 2 Ne a eae N=¢-304 4) Bearing in bol, N = ? te Sorat < Tete _ 2 C1GsSu5¢-25) [105 te) (4a) (4) Sebdt * 17-85 Mfay wot. 55, ©) Shearing in sha, N = ? AUT i sou 4, . Su ussite 26) apm (sN® Sg= 13-80Mm 8 _ 224 Mi Noose ayant * 79. Fue N= 2.0% Shearing in hub, N =? Deiimm Shear area at hub: A; = Dy ty ssf = Boe © 1 (to tS 28) [nt ear MCN TC) Semb = 1.903 MR, > Sus, 224 Nee La Neg. 1B5Example 2 sa minimum weld size is required for the joint toaded as shown? Use Sug = 90 MPa. Sy, é S Qe two filet welis f= 6OKN be? ee Syq Th om N= 10 Nlemt te Dome ids of Sam be 4 teem RO ge Clue) piel welds AARP 00> Example 3: Recommend the weld size required for the given tee joint consisting of two identical fillet welds if the ‘Shear design stress of the welds is 70 MPa Solution: Combine. Shear an From 3 ganeery St Ga Wore: p00, Ss? Sy *eetmm) b 4 Normal, Stress 202-2004 _BASAEN.BY- *% Mutioe Dian? 1°58 © me cso 5) (100 met 7] ge Mee 3 Sulptihcing, VAs TLE = 0 vim oA SU Tyee ke Stan Pan can ee a Example 4: Wat uniform weld size is necessary for the thee fillet ‘elds in a joint loaded as shown? Use an allowable shear hess of 90 MPa for the welds, Dimensions are in mm. Solution: Fou teNTROND LOCRTON G2 209 yee agen) Come) zn 4 OGM) BELT ats vaso one qo petone 88FOR RADIAL Distances Soq = W884 cout eas 1479 = EBS pm ree KB mm FoR 7 (Radial Vislong of Hast Stressed web 2 1.0m +, T0lmm 4 aymm Point from the Cortoid ne et 0: 207 C2 LCS + (125 -91.25" mor = tomm For rillel Welds C= 150-25mm k=1. o4mm 3 10 eam SHEAR STRESS ~Divect Shear Stress sec: etl FEL = E [rage (20 415007 Ss ie = Twishing Shear Sess Sse TA where: Se? Tee 2 M50 -% T= SSO0OW (Ha6m-®) FF Msu-2S JesZLatAacdiprte Jee ae leas $sni*] + [ase 4 (2509 OF 500] Jez ord 7s* Ssh CS3000n (UES <1 asym) 1s. 25 = @0223254 gh GATE FOR "jemi SHER® STRESS Gse5 2 SSeq 7 Sm? Sid From se [BY ETHIER) 89 OO ETANNULAR FILLET WELDS UNDER BENDING Where: = applied bending moment on the weld tensile stress on the weld at point 1 ~ tensile stress onthe most stressed point of weld (Maximum tensile stess et point A) ‘Relationship of S, and $ S Fain =F + $,=Ssing| Also, for filler weld leg of the weld (nominal weld size) = throat thickness of weld Where: = be0s45° or 6 =0707b AX Mudine Dosen? _t*Soma0n104 _BASAIAL RY Taking moment summation athe center ofthe ane mM, =) b aM | ar G-sno) where dF = S, (dA) Then, sabstnuing the expression fom sbove Ait = 5G (rnd) » Sano a (rn) Then, wom Oe “+ equation (1) M= ser or a) Din [As presente in textbooks since ¢ = 0.7075 pare = wRo707e) variant of equation (1) (maximum normal stress a the most stressed portion ofthe annular filled weld) Note Above formula is purely bending stress (5). Ifthe pint has combined stresses due to other loads that are simultaneously applied, use the maximum shear stess ormula (since wes are generally ductile and its failure is ‘mast likely duet shear), r 2 sme Example 5: ‘Consider the joint being loaded as shown, The ‘75mm dia, 200 mm long, axle is being held by @ $ mm ‘annular fillet weld tothe fixed member. For each of the following cases compute the maximum permissible load indicated, Use a design stress of Syq = 60MPa and Sq 90 MPa a F=0T=0M b F=2,7=0M=0 © F=0r=2.M=0 4 Ifthe loads that are simultaneously applied have the following magnitudes, is the weld size used sill strong enough? F = 15KN,T = 1kN—mM = 0SkN—mSs taeqaoennd Hen OF y= fd beM Tm ae 4 “bh ace PE TCrsmpeCseanay "WON met ; Le bn b Be F leads to cheow shea M leads ty norma! shess “pe f £53 20-0010F Sez t rdt a Gaal e one sete AM. , MOG 5 S25 otter T 7 MDE TCIS)* (scope sing SWuFT-souve: % Mine Dion2_1*Sem207.2024_nasann.ey 5, T=: Weld is under pure torsion, 4 Combined loads as given: Is the wel sate? ‘mim anlar filet weld P= 15KN.T=1kN~m,M=05kN—m 7 tyr ) Ma FLV 1S KN Cogn) Mas 0-dknm Me = 0-Si ten we Mp Mee MAA Mt, = (0-6 $0.3) Kner My = 0-8 Kalen Ts 1 ktm Frt6 un For Normal Stress 4 (0000 fren) S= TDM * Ar (Sem (Scants) $ > 54.95 wa For Shear Stress Te, 2 ate aah S84 7S ay Ce (SeoslE") "TE San 97.08 Ro oO3000 Ae HCI)? CS Ssae Seu 2 1.0Ma for Sse Se + J50* +58 = VOnoIMay ECE MR Sse = 92.00MPa Tor Str seewx [a (SF G8 mea? * 44.04 mPa, ng, Semon & Std Wecan say that the weld Is SAFE to bhandle Hu specified load combination nals