Chapter Six: Design of Key
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Chapter Six
Design of Keys
Introduction:
- A key is a piece of mild steel inserted between the shaft and hub.
- A key connects the shaft and hub to prevent relative motion between them.
- A key always inserted parallel to the axis of the shaft.
- A key subjected to crushing and shearing stresses.
Properties of Standard Parallel Keys:
Shaft diameter Key cross-section Shaft diameter Key cross-section
(mm) up to Thickness (mm) upto Thickness
Width (mm) Width (mm)
and including (mm) and including (mm)
6 2 2 85 25 14
8 3 3 95 28 16
10 4 4 110 32 18
12 5 5 130 36 20
17 6 6 150 40 22
22 8 7 170 45 25
30 10 8 200 50 28
38 12 8 230 56 32
44 14 9 260 63 32
50 16 10 290 70 36
58 18 11 330 80 40
65 20 12 380 90 45
75 22 14 440 100 50
Chapter Six: Design of Key
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Strength of a Sunk Key
A key connecting the shaft and hub is shown in the figure below:
Let: 𝑇 = Torque (N.m)
𝐹 = Tangential force (N).
𝑑 = Diameter of shaft (m).
𝐿 = Length of key (m).
𝑤 = Width of key (m).
𝑡 = Thickness of key (m).
𝜏 𝑎𝑛𝑑 𝜎𝐶 = Shear and crushing stresses (N/m2).
The shearing stress of the key equal to:
𝐹 𝐹
𝜏= = , 𝑇ℎ𝑒𝑛, 𝐹 = 𝑤×𝐿×𝜏
𝐴𝑆 𝑤 × 𝐿
And the torque equal to:
𝑑 𝑑
𝑇=𝐹× =𝑤×𝐿×𝜏×
2 2
And, the crushing stress of the key equal to:
𝐹 𝐹 𝑡
𝜎𝐶 = =𝑡 , 𝑇ℎ𝑒𝑛, 𝐹= × 𝐿 × 𝜎𝐶
𝐴𝐶 2
2×𝐿
And the torque equal to:
𝑑 𝑡 𝑑
𝑇=𝐹× = × 𝐿 × 𝜎𝐶 ×
2 2 2
Chapter Six: Design of Key
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The key is equally strong in shearing and crushing if:
𝑑 𝑡 𝑑
𝑤×𝐿×𝜏× = × 𝐿 × 𝜎𝐶 ×
2 2 2
Or:
𝑤 𝜎𝐶
=
𝑡 2𝜏
Note: The permissible crushing stress for the usual key material is at least twice the
permissible shearing stress. Therefore, from above relation we have (w = t).
Then the square key is equally strong in shearing and crushing.
Length of Key
In order to find the length of the key to transmit full power of the shaft:
- The shearing strength of the key is equal to the torsional shear strength of the
shaft.
- The shearing strength of key equal to:
𝑑
𝑇 = 𝑤×𝐿×𝜏×
2
- The torsional shear strength of the shaft equal to:
𝜋
𝑇= × 𝜏𝑆 × 𝑑 3
16
- Then:
𝑑 𝜋
𝑤×𝐿×𝜏× = × 𝜏𝑆 × 𝑑 3
2 16
- Or:
𝜋 𝜏𝑆 𝑑
𝐿= × × 𝑑, (𝑇𝑎𝑘𝑖𝑛𝑔 𝑤 = )
2 𝜏 4
- When the key material is same as that of the shaft material, then:
𝜋
𝐿= ×𝑑
2
Chapter Six: Design of Key
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Example (1): Design the rectangular key for a shaft of (50 mm) diameter. The
shearing and crushing stresses for the key material are (42 and 70
MPa).
Solution: Given: d = 50 mm
𝜏 = 42 MPa = 42 N/mm2
𝜎𝐶 = 70 MPa = 70 N/mm2
From table e find that for a shaft of (50 mm) diameter:
𝑤 = 16 mm Ans.
𝑡 = 10 mm Ans.
Now, to obtain the length of the key by considering the key in shearing and crushing.
Or:
If the key under shearing, then the torque equal to:
𝑑 50
𝑇 = 𝐿 × 𝑤 × 𝜏 × = 𝐿 × 16 × 42 × = 16800 𝐿 𝑁. 𝑚𝑚 (1)
2 2
And the torque transmitted of the shaft is:
𝜋 𝜋
𝑇= × 𝜏 × 𝑑3 = × 42 × 503 = 1030835.089 𝑁. 𝑚𝑚 (2)
16 16
Then from equation (1) and (2):
16800 𝐿 = 103085.089, 𝐿 = 61.36 𝑚𝑚
Now for crushing case:
𝑡 𝑑 10 50
𝑇=𝐿× × 𝜎𝐶 × = 𝐿 × × 70 × = 8750𝐿 𝑁. 𝑚𝑚 (3)
2 2 2 2
Then from equation (2) and (3):
8750𝐿 = 1030835.089 , 𝐿 = 117.81 𝑚𝑚
Then, taking larger of the two values:
𝐿 = 117.81 𝑚𝑚 𝑠𝑎𝑦 118 𝑚𝑚 𝐴𝑛𝑠.
Chapter Six: Design of Key
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Example (2): A (45 mm) diameter shaft is made of steel with a yield strength of (400
MPa). A parallel key of size (14 mm) wide and (9 mm) thick made of
steel with a yield strength of (340 MPa) is to be used. Find the required
length of key, if the shaft is loaded to transmit the maximum
permissible torque. Use maximum shear stress theory and assume a
factor of safety of (2).
Solution: Given: d = 45 mm
𝜎𝑦𝑡 = 400 MPa = 400 N/mm2 [for shaft]
𝑤 = 14 mm
𝑡 = 9 mm
𝜎𝑦𝑡 = 340 MPa = 340 N/mm2 [for key]
𝐹. 𝑆 = 2
According to maximum shear stress theory,
maximum shear stress for the shaft:
𝜎𝑦𝑡 400
𝜏𝑚𝑎𝑥 = = = 100 𝑁/𝑚𝑚2
2 × 𝐹. 𝑆 2 × 2
And maximum shear stress for the key:
𝜎𝑦𝑡 340
𝜏𝑘 = = = 85 𝑁/𝑚𝑚2
2 × 𝐹. 𝑆 2 × 2
The maximum torque transmitted by the shaft and key:
𝜋 𝜋
𝑇= × 𝜏𝑚𝑎𝑥 × 𝑑 3 = × 100 × 453 = 1789235.2 𝑁. 𝑚𝑚
16 16
Consider the failure of key due to shearing, then the maximum torque transmitted:
𝑑 45
𝑇 = 𝐿 × 𝑤 × 𝜏𝑘 × , 𝑜𝑟 1789235.2 = 𝐿 × 14 × 85 ×
2 2
Then:
𝐿 = 66.825 𝑚𝑚
Now, consider the failure of key due to crushing, the maximum torque transmitted by
the shaft and key:
𝑡 𝑑 𝜎𝑦𝑡
𝑇=𝐿× × 𝜎𝑐𝑘 × , 𝑡𝑎𝑘𝑖𝑛𝑔 (𝜎𝑐𝑘 = )
2 2 𝐹. 𝑆
Then:
9 340 45
1789235.2 = 𝐿 × × × , 𝑡ℎ𝑒𝑛 𝐿 = 103.95 𝑚𝑚
2 2 2
Taking the larger of the two values:
𝐿 = 103.95 𝑚𝑚 𝑠𝑎𝑦 104 𝑚𝑚 𝐴𝑛𝑠.
Chapter Six: Design of Key
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Example (3): A shaft (80 mm) diameter transmits power at maximum shear stress of
(63 MPa). Find the length of a (20 mm) wide key required to mount a
pulley on the shaft so that the stress in the key does not exceed (42
MPa).
Solution: Given: d = 80 mm
𝜏𝑠 = 63 MPa = 63 N/mm2
𝐿=?
𝑤 = 20 mm
𝜏𝑘 = 42 MPa = 42 N/mm2
According to maximum shear stress theory,
The maximum torque transmitted by the shaft and key:
𝜋 𝜋
𝑇= × 𝜏𝑚𝑎𝑥 × 𝑑 3 = × 63 × 803 = 6333450.8𝑁. 𝑚𝑚
16 16
Consider the failure of key due to shearing, then the maximum torque transmitted:
𝑑 80
𝑇 = 𝐿 × 𝑤 × 𝜏𝑘 × , 𝑜𝑟 6333450.8 = 𝐿 × 20 × 42 ×
2 2
Then:
𝐿 = 188.5 𝑚𝑚 𝐴𝑛𝑠.
Chapter Six: Design of Key
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Effect of Keyways
- The keyway reduces the load carrying capacity of the shaft, due to:
- Stress concentration near the corners of the keyway.
- Reduction in the cross-section area of the shaft.
- Then, the torsional strength of the shaft is reduced.
The following relation for the weakening of the keyway is based on the experimental
results by H.F. Moore:
𝑤 ℎ
𝑒 = 1 − 0.2 ( ) − 1.1 ( )
𝑑 𝑑
Where:
𝑒 = Shaft strength factor. The ratio of strength of shaft with and without key way.
𝑤 = Width of the keyway.
𝑑 = Diameter of shaft
𝑡
ℎ = Depth of keyway = 2
Usually:
- Assumed the strength of the keyed shaft is 75% of the solid shaft.
- Somewhat higher than the value obtained by the above relation.
Chapter Six: Design of Key
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Example (4): A (15 kW), (960 r.p.m.) motor has a mild steel shaft of (40 mm)
diameter and the extension being (75 mm). the permissible shear and
crushing stresses for the mild steel key are (56 MPa) and (112 MPa).
Desing the keyway in the motor shaft extension. Check the shear
strength of the key against the normal strength of the shaft.
Solution: Given: 𝑃 = 15 kW = 15000 W
𝑁 = 960 r.p.m.
𝑑 = 40 mm = 0.04 m
𝐿 = 75 mm = 0.075 m
𝜏 = 56 MPa = 56000000 N/m2
𝜎𝑐 = 112 MPa = 112000000 N/m2
The torque transmitted by the motor:
30 × 𝑃 30 × 15000
𝑇= = = 149.208 𝑁. 𝑚
𝜋×𝑁 𝜋 × 960
Considering the key is shearing, then the torque transmitted:
𝑑
𝑇 =𝐿×𝑤×𝜏×
2
Or:
0.04
149.208 = 0.075 × 𝑤 × 56000000 ×
2
Then:
𝑤 = 0.0017763 𝑚 = 1.7763 𝑚𝑚
But, the length of the keyway is too small. The width of keyway should be at least
(d/4), then:
𝑑 0.04
𝑤= = = 0.01 𝑚 = 10 𝑚𝑚 𝐴𝑛𝑠.
4 4
Since (𝜎𝑐 = 2𝜏), therefore a square key of 𝑤 = 10 𝑚𝑚 and 𝑡 = 10 𝑚𝑚 is adopted.
According to H.F. Moore, the shaft strength factor:
𝑤 ℎ 10 5
𝑒 = 1 − 0.2 ( ) − 1.1 ( ) = 1 − 0.2 ( ) − 1.1 ( ) = 0.8125
𝑑 𝑑 40 40
The strength of the shaft with keyway:
𝜋 𝜋
𝑇= × 𝜏 × 𝑑3 × 𝑒 = × 56000000 × 0.043 × 0.8125 = 571.770 𝑁. 𝑚
16 16
And, shear strength of the key:
𝑑 0.04
𝑇 = 𝐿 × 𝑤 × 𝜏 × = 0.075 × 0.01 × 56000000 × = 840 𝑁. 𝑚
2 2
Then, the shear strength of the key to the shear strength of the shaft equal to:
𝑆ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑘𝑒𝑦 840
= = 1.469 𝐴𝑛𝑠.
𝑁𝑜𝑟𝑚𝑎𝑙 𝑠ℎ𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 571.77