UNIT 2: Design of Shafts, Keys and Couplings (08 hrs)

Shaft design on the basis of

strength
 torsional rigidity
lateral rigidity
A.S.M.E. code
Hollow shaft
 Design of keys (square and rectangular key) and splines.
Design of Flange Coupling and Flexible Bushed Pin Coupling.
 TRANSMISSION SHAFTS
The term ‘transmission shaft’ usually refers to a rotating machine element,
circular in cross section, which supports transmission elements like gears,
pulleys and sprockets and transmits power. Types of Shaft
(i) Axle
(ii)Spindle
(iii)Countershaft
(iv) Jackshaft
(v) Line shaft
• Ordinary transmission shafts are made of medium carbon steels with a carbon
content from 0.15 to 0.40 per cent such as 30C8 or 40C8.
• These steels are commonly called machinery steels.
• Common grades of alloy steels used for making transmission shafts are
16Mn5Cr4, 40Cr4Mo2, 16Ni3Cr2, 35Ni5Cr2, 40Ni6Cr4Mo2 and 40Ni10Cr3Mo6.
SHAFT DESIGN ON STRENGTH BASIS

Transmission shafts are subjected to axial tensile force,

bending moment or torsional moment or their combinations.
Case I In this case, the shaft is subjected to a
combination of axial force, bending moment and
torsional moment.

Case II In this case, the shaft is subjected to a

combination of bending and torsional moments
without any axial force.
 Since the shaft is subjected to bending and torsional moments
without any axial force,

The permissible value of maximum principal

stress is given by,
(i) Maximum Principal Stress Theory
Experimental investigations suggest that
maximum principal stress theory gives good
predictions for brittle materials. Shafts are made of
ductile material like steel and therefore, this theory
is not applicable to shaft design
Equivalent bending moment  M b
 M M
2
b
2
t
The equivalent bending moment is defined as the bending moment, which
when acting alone, will produce the same bending stresses (tensile and
compressive) in the shaft as under the combined action of bending moment
(Mb) and torsional moment (Mt).
(ii) Maximum Shear Stress Theory The permissible value of maximum shear stress
is given by,

The maximum shear stress theory is applicable

to ductile materials. Since the shafts are made of
ductile materials, it is more logical to apply this
theory to shaft design rather than designing the
shaft on the basis of principal stress theory.
Equivalent Torsional moment  M  M b
2
b
2
t
The equivalent bending moment is defined as the bending moment, which when
acting alone, will produce the same bending stresses (tensile and compressive) in the
shaft as under the combined action of bending moment (Mb) and torsional moment
(Mt).
 SHAFT DESIGN ON TORSIONAL RIGIDITY BASIS
In some applications, the shafts are designed on the basis of either torsional
rigidity or lateral rigidity. A transmission shaft is said to be rigid on the basis
of torsional rigidity, if it does not twist too much under the action of an
external torque. Similarly,
The transmission shaft is said to be rigid on the basis of lateral rigidity, if it does
not deflect too much under the action of external forces and bending
moment.
In certain applications, like machine tool spindles, it is necessary to design the
shaft on the basis of torsional rigidity, i.e., on the basis of permissible angle of
twist per metre length of shaft. The angle of twist is given by(in radians),
The permissible angle of
twist for machine tool applications is 0.25° per
metre length. For line shafts, 3° per metre length is
the limiting value. Modulus of rigidity for steel is
79 300 N/mm2 or approximately 80 kN/mm2.
 ASME CODE FOR SHAFT DESIGN
According to this code, the permissible shear stress τmax. for the shaft without
keyways is taken as 30% of yield strength in tension or 18% of the ultimate
tensile strength of the material, whichever is minimum. Therefore,

If keyways are present, the above values are to be reduced by 25 per cent.
According to the ASME code, the bending and torsional moments are to be multiplied by factors
kb and kt respectively, to account for shock and fatigue in operating condition. The ASME code is
based on maximum shear stress theory of failure.
kb = combined shock and fatigue factor applied
to bending moment
kt = combined shock and fatigue factor applied
to torsional moment
 Design of 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.
• There are different ways to classify
the keys. Some of them are as
follows:
(i) Saddle key and sunk key
(ii) Square key and flat key
(iii) Taper key and parallel key
(iv) Key with and without Gib-head
• A sunk key is a key in which half the thickness of the key fits into the
keyway on the shaft and the remaining half in the keyway on the hub.
Feather Key Woodruff Keys

Saddle Keys
• Effect of Keyway on strength of shaft:
• The keyway is a slot machined either on the shaft or in the hub to
accommodate the key. It is cut by a vertical or horizontal milling
cutter.
• A little consideration will show that the keyway cut into the shaft
reduces the load-carrying capacity of the shaft.
• This is due to the stress concentration near the corners of the keyway
and reduction in the cross-sectional area of the shaft. It other words,
the torsional strength of the shaft is reduced.
• The following relation for the weakening effect of the keyway is based
on the experimental results by
• H.F. Moore. e = 1-0.2(w/d)-1.1(h/d)
• where e = Shaft strength factor.
w = Width of the keyway,
d = Diameter of shaft, and
h = Depth of keyway =Thickness of key (t )/2
It is usually assumed that the strength of the keyed shaft is 75% of the
solid shaft, which is somewhat higher than the value obtained by the
above relation.
 Design of Square Keys
Although there are many types of keys, only square and flat keys are extensively used in
practice
A square key is a particular type of flat key, in which the height is equal to the width of
the cross-section. The forces acting on a flat key, with width as b and height as h, are
shown in Fig.
The shear stress t in the plane AB is given
by, The failure due to compressive stress will
occur on surfaces AC or DB. The crushing
area between shaft and key is shown in
Fig. It is assumed that,
h = height of key (mm)
The compressive stress σc in the key is
given by,
Therefore, the compressive stress induced in a
square key due to the transmitted torque is
twice the shear stress.
It is required to design a square key for fixing a gear on a shaft of 25
mm diameter. The shaft is transmitting 15 kW power at 720 rpm to the
gear. The key is made of steel 50C4 (Syt = 460 N/mm2) and the factor of
safety is 3. For key material, the yield strength in compression can be
assumed to be equal to the yield strength in tension. Determine the
dimensions of the key.
Given: P = 15kw
n = 720 rpm
Syt = 460 N/mm2
(fs) = 3 ,
d = 25 mm
The standard cross-section for a flat key, which is fitted on a 50 mm diameter shaft,
is 16 x 10 mm. The key is transmitting 475 N-m torque from the shaft to the hub.
The key is made of commercial steel (Syt = Syc = 230 N/mm2). Determine the length
of the key, if the factor of safety is 3.
 SPLINES
• Splines are keys which are made integral with the shaft. They are used when
there is a relative axial motion between the shaft and the hub. The gear shifting
mechanism in automobile gearboxes requires such type of construction. Splines
are cut on the shaft by milling and on the hub by broaching. A splined
connection, with straight splines, is shown in Fig. The following notations are
used:
D = major diameter of splines (mm) The area A is given by,
d = minor diameter of splines (mm) A=0.5 x (D-d)l x n
l = length of hub (mm)
Rm =(D+d)/4
n = number of splines

The torque transmitting capacity

of spline is given by,
Mt = pm A Rm
The permissible pressure on the splines is
Mt = transmitted torque (N-mm) limited to 6.5 N/mm2.
pm = permissible pressure on spline ( N/mm2 )
A = total area of splines (mm2)
Rm = mean radius of splines (mm)
A standard splined connection 8 X 52 x 60 mm is used for the gear and the shaft
assembly of a gearbox. The splines transmit 20 kW power at 300 rpm. The
dimensions of the splines are as follows:
Major diameter = 60 mm
Minor diameter = 52 mm
Number of splines = 8
Permissible normal pressure on splines is 6.5 N/mm2. The coefficient of friction is
0.06.
Calculate:
(i) The length of hub of the gear
(ii) The force required for shifting the gear
Given kW = 20 n = 300 rpm pm = 6.5 N/mm2
For splines, D = 60 mm d = 52 mm n = 8
m = 0.06
Step I Torque transmitted by the shaft
 Coupling

• A coupling can be defined as a mechanical device that permanently

joins two rotating shafts to each other.
 Design of Rigid coupling

The standard proportions for various dimensions of the flange

(i) dh = outside diameter of hub dh = 2d No. of Bolts(N) Shaft Dia.(mm)
(ii) lh = length of hub or effective length of key lh = 1.5 d 3 40
(iii) D = pitch circle diameter of bolts D = 3d 4 40-100
(iv) t = thickness of flanges t = 0.5 d 6 100-180
(v) t1 = thickness of protecting rim t1 = 0.25 d
(vi) dr = diameter of spigot and recess dr = 1.5 d
(vii) D0 = outside diameter of flange
D0 = (4d + 2t1)
• The analysis of rigid coupling can be done by two different ways
Case I Bolts Fitted in Reamed and Ground Holes
• No clearance and the bolts are finger tight.
• Power is transmitted by means of shear resistance of the bolts.
Case II Bolts Fitted in Large Clearance Holes
• Bolts are tightened with a preload
• Power is transmitted by means of friction between the two flanges.
Case I: Shear Resistance of bolt Case II: Bolts Fitted in Large
Clearance Holes

Ro = outer radius of the flange (Do /2) (mm)

Ri = radius of the recess (dr /2) (mm)
Assume that,
Pi = initial tension in each bolt (N)
μm = coeffi cient of friction between flanges
Rf = friction radius

Mt = μm Pi N Rf
 DESIGN PROCEDURE FOR RIGID
FLANGE COUPLING
(i) Shaft Diameter The flange at the junction of the hub
is under shear while transmitting the
torsional moment Mt.

(ii) Dimensions of Flanges

dh = 2d lh = 1.5d D = 3d t = 0.5d
t1 = 0.25d dr = 1.5d D0 = (4d + 2t1)
The torsional shear stress in the hub
(iii) Diameter of Bolts Decide the number of bolts
using the following guidelines: (iv) Dimensions of Keys
N = 3 for d < 40 mm
N = 4 for 40 < =d < 100 mm Determine the standard cross-section
N = 6 for 100 <= d < 180 mm of flat key from Table.The length of
where t is the permissible shear stress for the bolt the key in each shaft is lh. Therefore,
material. l = lh
The compressive stress in the bolt can be determined by
referring to Fig. 9.35 again.(From ppt 54) Check
It is required to design a rigid type of flange coupling to connect two shafts. The
input shaft transmits 37.5 kW power at 180 rpm to the output shaft through the
coupling. The service factor for the application is 1.5, i.e., the design torque is 1.5
times of the rated torque. Select suitable materials for various parts of the
coupling, design the coupling and specify the dimensions of its components.
• Solution
Given kW = 37.5 n = 180 rpm
design torque = 1.5 ( rated torque)
Step I Selection of materials
(i) The shafts are subjected to torsional shear (iii) Flanges have complex shape and the
stress. On the basis of strength, plain carbon easiest
steel of grade 40C8 (Syt = 380 N/mm2) is method to make the flanges is casting. Grey
used for the shaft. The factor of safety for cast iron FG 200 (Sut = 200 N/mm2) is
the shafts is assumed to be 2.5. selected as the material for the flanges from
manufacturing considerations. It is assumed
(ii) The keys and bolts are subjected to shear that ultimate shear strength is one half of the
and compressive stresses. On the basis of ultimate tensile strength. The factor of safety
strength criterion, plain carbon steel of grade for the flanges is assumed as 6, since the
30C8 (Syt = 400 N/mm2) is selected for the permissible stress is based on the ultimate
keys and the bolts. It is assumed that the strength and not on the yield strength.
compressive yield strength is 150% of the
tensile yield strength. The factor of safety
for the keys and the bolts is taken as 2.5.