Chapter-1

Design of Shaft and its Components(Keys and Couplings)

By

Dr. [Link] Santhosh

Assistant Professor
Faculty of Mechanical Engineering
JiT, Jimma University

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 A classification of mechanical components
Mechanical
components

Transformation of Support of
mechanical power mechanically
generated loads

• Welded joints
Dissipation Transmission Storage • Fasteners and Non-
permanent joints
• Brakes • Springs
• clutches • Flywheels

Fluid to Rotational to Rotational to Rotational

Rotational to linear
Linear
• Gears
• Power screws • Hydraulic
•
• Pulleys, Belts and chains
Pneumatic
• Shafts
• Keys, Couplings, Splines
Design of Shaft

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• The primary function of shafts
is to transmit power through the
components mounted on them,
such as gears, pulleys, couplings,
wheels, and flywheels.

The resulting internal resistance created in the shaft is called

torsional shear stress. The resultant of the resisting stresses
existing on any cross sectional plane of the shaft constitutes an
internal resisting torque. In addition to creating torsional shear
stresses, external torque loads will cause a shaft to twist by an
amount referred to as the angle of twist.
 Locating shaft elements
• Function:
– To accurately position mounted elements axially on
the shaft.
• Common locating elements:
– Washer and Nut
– Spacers
– Shaft shoulders
– Set screws
– Pins
– Retaining rings (snap rings)
 Material Used for Shafts
• The material used for shafts should have the
following properties :
1. It should have high strength.
2. It should have good machinability.
3. It should have low notch sensitivity factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties

The material used for ordinary shafts is carbon steel of

grades 40 C 8, 45 C 8, 50 C 4 and 50 C 12.
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 Shaft materials
 Shafts are commonly made from low carbon, CD or HR steel,
such as ANSI 1020–1050 steels.
 Fatigue properties don’t usually benefit much from high alloy
content and heat treatment.
 Cold drawn steel typical for d < 76mm.
 HR steel common for larger sizes. Should be machined all over.
 Low production quantities
◦ Lathe machining is typical
◦ Minimum material removal is the design goal
 High production quantities
◦ Forming or casting is common
◦ Minimum material is the design goal
 Design of Shafts

• The shafts may be designed on the basis of

1. Strength, and 2. Rigidity and stiffness.
In designing shafts on the basis of strength, the following
cases may be considered :
(a) Shafts subjected to twisting moment or torque only,
(b) Shafts subjected to bending moment only,
(c) Shafts subjected to combined twisting and bending
moments, and
(d) Shafts subjected to axial loads in addition to combined
torsional and bending loads.

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• Basic Formulas (Refer Board)
• Problem 1
A factory line shaft is 4.5m long and its to
transmit 75KW at 200rpm. The allowable stress
in shear is 49 Mpas and the maximum
allowable twist 1 degree in a length of 20
Diameter. Determine the required shaft
diameter?

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• Problem 2
A solid shaft is to transmit 100KW at 120 rpm.
Find the shaft diameter if the design shear stress
is 80 N/mm^2. If the shaft is made of hollow
with internal diameter is 0.6 times the outside ,
find the % of saving in material?

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• Problem 3
Determine the required standard diameter of a
uniform circular shaft carrying 2 pulleys of weight
2kN each. The shaft 750mm long is supported at
the ends and carries 2 pulleys at 250mm and
500mm from the left end. Pull on the right pulley is
10kN vertically downwards. The shaft transmits a
torque of 3kN-m between the pulleys. Assume K b
=Kt =1.5 and allowable shear stress of 70N/mm^2
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• Problem 4
A transmission shaft is supported on two bearings
450mm apart. Two pulleys C and D are located on the
shaft at distances of 100mm and 300mm respectively to
the right of the left hand bearing. Power is transmitted
from pulley C to D. The diameter and weight of pulley C
are 200mm and 600N and those of pulley D are 300mm
and 750N respectively. Ratio of belt tensions is 2 for both
pulleys. Power to be transmitted by the shaft is 25KW at
300rpm. The drive from C is vertically downwards while
from D the drive is upward at an angle of 45 deg. To the
horizontal. The shaft is made of C45 steel. Assume shear
stress= 47.5 N/mm^2. Using Kb = 1.5 and Kt = 1.2, design
the shaft.
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Case (i) Considering vertical loads

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Case (ii) Considering horizontal loads

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Resultant Bending Moment

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• Problem 5
A machine shaft is supported in bearings having their
centres 750mm apart and transmits 200KW at 600rpm.
A gear of 200mm diameter and 20 deg. tooth profile is
located 250mm to the right of left hand bearing and a
450mm diameter pulley is mounted at 200mm to the
right of right hand bearing. The gear is driven by a
pinion with a downward tangential force while the
pulley drives a horizontal belt having 180 deg. angle of
contact. The pulley weighs 1000N and has tension ratio
of 3. Take Yield stress = 380 Mpa, Factor of Safety = 2.
Calculate the required shaft diameter?

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Keys and Pins :
 A key is a rectangular sectioned mild steel piece of required length used
to secure firmly (without any relative motion) elements like gears
pulleys, couplings etc., on a shaft and transmit power.
 The key is inserted into the key ways milled for this purpose half in the
shaft and the other half in the hub or boss with an interference fit.
 Keys are always inserted parallel to the axis of the shaft and used as a
temporary connection.

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 A pin is a circular sectioned mild steel piece of required length used
to connect a hub and a shaft in the transverse direction and transmit
power.

 Keys are majorly classified as sunk key, taper key, woodruff key and
feather key.

Sunk Key

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 Tapper Key
is used when hub
(gear) is required
to be installed
over shaft first
without key

Saddle key - Flat

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Saddle key - Hollow

Gib Head Key

is preferred when ease of
extraction is required.

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Woodruff Key
is used for lightly loaded
cases;
it offers ease of assembly

A spline shaft is rotating shaft with a number of integral keys .

This facilitates both sliding as well as rotary motion of the connected member say a gear

Spline Shaft

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Forces acting on a key :
 Torque transmitted by the shaft results in tangential force F at the key
surfaces as shown in figure below.
P x 60000
T  N mm
2n

 This force causes on the key

considerable amount of crushing
and shear stresses.
 Tangential force the key must resist,

F = T/(d/2) 30
 From the figure it may be seen that the tangential force ‘F’ force will
cause a shearing stress on the key and a crushing stress on the
key way.
 Now, the Shear Stress induced on the key may be obtained as:

Shear force T /  d/ 2 2T

   
Area resisting shear L W d  L W
y / 2
Taking the allowble shear stress as     and rearranging the term s,
FoS
and assuming that the shaft and key are made of same material, we can get
2T
the length of key required to transmit the torque T as L =
sh  d  W
Similarly, crushing stress induced on the key way,

crushing force T /  d/ 2 4 T
Crushing   
area resisting crushing force H d LH
L
2 31
 y
and taking the allowble Crushing stress as  C  
FoS
and rearranging the terms, we get the
4T
Length of key way required to transmit the torque T as L 
 C   d  H
If the key has to have equal strength in compression as well as shear, then
the condition to be satisfied will be Length of key = Length of key way
2T 4 T y 
i.e.,  But    or C
sh  d  W C sh  d  H 2 2

2T 4 T 1 1
Thus     H  W
sh  d  W 2sh  d  H W H

Thus a square key is equally strong in both shear and compression.

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Effect of Keyway :
 Keyway cut into the shaft introduces stress concentration which will
weaken the shaft; this leads to reduced effective area available to
transfer torque; this makes the shaft to have reduced strength.
 This makes the allowable strength of a shaft with keyway to be reduced
to 75% (say) of its strength without keyway.
 Any necessity to increase the length of the key, will lead to increase in
angle of twist especially when a sliding fit is given for the key.
Additional role of a key :
 In addition to the role connecting a machine element with a shaft, it is
also used as a safety device, namely a mechanical fuse.
 Since keys are inexpensive and can be replace quickly they are designed
in such a way that the key fails first, safeguarding the shaft at the
sudden over loads.
 To enable the key to fail first, it is made of relatively low strength
materials such as low carbon steel. 33
 While transmitting the torque the key should not slip; hence the key is
given a tight fit in its slot; but tight fit will add additional stress; in
order to avoid this some times the key is given a clearance fit and
secured firmly on the hub or shaft using a set screw.
 Generally a key is designed for shear strength and checked for crushing
stress.

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Couplings :
 A coupling is a device which connects two machine members such as a
pump and motor, two shafts or pipe lines, etc.
 Need for a coupling arises from the following requirements :
1. To connect two or more number of shafts to construct a single long
transmission shaft.
 Shafts are generally made to a length 7m maximum to satisfy the
transport requirements; in order to make shafts of greater
length couplings are used.

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2. To connect two machines ( a driver and a driven) such a pump and a
motor to transmit power.
 Some times machines manufacture by different
manufacturers at different places need to be connected as
single member.

A Coupling

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3. To provide allowance for inevitable misalignment errors in shafts
assembly or to provide a mechanical flexibility.

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4. To reduce transmission of shock loads from driver shaft to the driven
shaft and vice-versa.

5. To introduce over load protection.

6. To alter the vibrating characteristics of rotating parts of driving and
driven machinery.

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Classification of Couplings:

They can be broadly classified into two category:

1. Permanent connections (couplings) and

2. Temporary connections (clutches).

 Permanent couplings are those used to connect two shafts which will
not be disconnected or disconnected often.

 Only when some maintenance is required, the pump and motor will be
disconnected for servicing.

 Semi permanent couplings are those which are disconnected and

connected back often.

 Temporary couplings are those which are disconnected frequently; i.e.,

will be connected only when required.
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 1
Permanent couplings can be classified based on shaft alignment also.
I Collinear shaft couplings or Rigid couplings :
1. Sleeve coupling or Muff coupling
2. Clamp coupling of Split muff coupling
3. Rigid Flange coupling. 1
4. Gear coupling.
2

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II Non-Collinear shaft couplings or Flexible couplings :
 Because the shafts are non collinear (with slightly larger misalignments),
they are provided with resilient or soft materials to absorb the
resulting vibration or shake or deformations.
A. Flexible couplings with resilient parts :
1. Bushed pin type flexible couplings
2. Disc type flexible couplings
3. Leather link type flexible couplings

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II Non-Collinear shaft couplings or Flexible couplings :
B. Couplings with kinematic flexibility:
1. Oldham’s coupling (for lateral misalignment)
2. Universal coupling (for angular or large misalignment)

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Some important requirements of a good coupling :
 It must transmit the full torque of the shaft.
 It must keep the two shafts in proper alignment.
 It must be easy to assemble and disassemble.
 Projecting parts such as bolt heads, nuts, key heads should be
protected by suitable flanges, rims or cover parts.

Unprotected and Protected type rigid flange couplings :

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Shaft alignment can be achieved by using a spigot and recess joint.

Protected type rigid flange coupling

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Un-protected type Rigid Flange Coupling :
 Design the shaft to transmit the given power / torque.

 Selectan appropriate coupling corresponding to the calculated shaft

diameter and check for the different possible failures.

d – shaft dia
D2 – Bolt PCD,
n – no. of bolts
d1 – Bolt dia,
d2 – Bolt hole dia
b – thickness of flange
[ts] – allowable shear stress
[sb] – allowable bearing stress
Mt – Torque transmitted 45
Step-1 Determination of shaft diameter.
P x 60000
Torque transmited by the shaft, Mt  Nm
2N
16Mt x103
 Diameter of shaft required, d  3 mm
 s
Step-2 Select a rigid flange coupling corresponding to the shaft
diameter calculated in Step-1. (using DDB P 7.107)

Step-3 Check for the shear stress induced at hub-flange junction.

Tangential (or shear force) acting at hub periphery = Mt / ( D / 2 )

Area resisting this shear force =   D  b

 Shear stress induced at the junction of hub and flange

Shear force Mt / ( D / 2 ) 2  Mt
 hub   
Shear area  Db   D2  b 46
Step-3 Check for the shear stress induced in the bolt.
The number of bolts used is found to be a function of the shaft diameter.

Let ‘n’ be the number of bolts used at a pitch circle dia say ‘D2’

The bolts are subjected to a shear stress due to the torque transmitted.

If ‘d2’ is taken as bolt diameter, then

Torque transmitted Mt 2M
Tangential load on all bolts, Fbolt   
(bolt PCD/2)  D2 / 2 D2
2Mt
Tangential load on one bolt, 
n  D2 2Mt
Shear load on bolt n  D2
 Shear stress induced in the bolt  bolt  
shear area of bolt   2 
 d2 
8  Mt 4 

n  D2    d22
Now, Shear stress induced on the bolt,  bolt   s  47
Step-3 Check for the bearing stress induced in the bolt hole.
The bolt may be subjected to a bearing
stress in the bolt hole due the tangential
force acting on it. It has to be checked.

Area resisting the bearing stress of ' n ' bolts Bearing stress

in the bolt hole  d2 x t flange x n

T / (D2 / 2 )
 Bearing stress induced in the bolt,  bolt 
n x d2 x b
 y 
This b   b   
 FoS 

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Bushed Pin Type Protected Flexible Flange Coupling :

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Some important considerations in bushed pin type flexible couplings :
 Rigid couplings are used where perfect alignment of shaft axis is
possible and there is no or negligibly small shock loads or vibration
only are expected.
 Flexible couplings are used where some amount of misalignment is to
be allowed and some small amount of shock load and vibration are
to be tolerated.
 Misalignments up to 10 to 20 can be accepted for bushed pin type
flexible flange coupling; by way of flexing itself the rubber bush
used becomes capable of talking such misalignments.
 When the shock and vibration are seen a little more and misalignment
is above 10 to 20 , disk type and leather link type of flexible coupling
are used.
 Either cast iron-CI or mild steel-MS is used for making the couplings,
due to their easiness in machining and lower costs; for the resilient
material rubber is being used. 50
 In rigid flange coupling, the two flanges are identical in shape and size
but for the spigot on one flange and a recess on the other.
 In the case of rigid couplings the torque is transmitted through the
bolts which are made of steel, capable of withstanding higher stresses;
hence their overall sizes are relatively smaller.
 They are also preferred for higher torque ranges.

Flexible flange coupling

Rigid flange coupling

 Whereas in flexible flange coupling the flange connected to the input

shaft will have larger thickness and larger bolt holes to accommodate
rubber bushes in addition to bolts and the other flange will have
smaller holes to accommodate the bolt (or pin). 51
 When the input shaft flange rotates it exerts a pressure load on the
bushes; the same pressure load causes a bending and a shear load on
the bolt (or the pin).

Pressure Load acting on the bush

 Rubber bushes are available as a standard component; up to an inner

diameter of 25mm the thickness of bush is 6mm and when the inner dia
is more than 25mm the bush thickness becomes 9mm.
 To withstand the torque load, the allowable crushing or bearing
strength of commercially available rubber bush is generally 1N/mm2
only; hence thickness the flange to accommodate the bush length will
be more than the other. 52
Design of Bushed Pin Type Protected Flexible Flange Coupling :
Step-1 Determination of shaft diameter.
P x 60000
Torque transmited by the shaft, Mt  Nm
2N
16Mt x103
 Diameter of shaft required, A  3 mm
 s
Step-2 Select a rigid flange coupling corresponding to the shaft
diameter calculated in Step-1. (using DDB P 7.107)

Step-3 Check for the shear stress induced at hub-flange junction.

Tangential (or shear force) acting at hub periphery = Mt / ( C/ 2)

Area resisting this shear force =   C  G  H 

 Shear stress induced at the junction of hub and flange

Shear force Mt / ( C/ 2) 2  Mt
 hub   
Shear area   C  G  H    C 2  G  H  53
Step-3 Check for the shear stress induced in the bolt.
The number of bolts used is found to be a function of the shaft diameter.

Let ‘n’ be the number of bolts used at a pitch circle dia say ‘D’

The bolts are subjected to a shear stress due to the torque transmitted.

If ‘ F ’ is taken as bolt diameter, then

Torque transmitted Mt 2M
Tangential load on all bolts, Fbolt   
(bolt PCD/2)  D / 2 D
2  Mt
Tangential load on one bolt, 
n D 2Mt
Shear load on one bolt
 Shear stress induced in the bolt  bolt   n D
shear area of bolt   2
 F 
4 
8  Mt
i.e.,  bolt  2
This shear stress,  bolt   s 
n D   F
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Step-4 Check for the bearing stress induced in the bolt hole.

The bolt may be subjected to a bearing

stress in the bolt hole due the tangential
force acting on it. It has to be checked.

Bearing stress

 2 
Area resisting the bearing stress by one bolt in bolt hole  db x  G  F  x n
 3 
Mt /  D2 / 2
Bearing Load (tangential load) on one bolt, Ft =
n
Ft
 Bearing stress induced in one bolt hole,  bolt 
 2 
db x  G  F  x n
 3 
 y 
This b   b  
 
 FoS 
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Step-5 Check for the bending stress induced in the bolt (pin).
1 2 
Bending moment arm, t   G  F 
2 3 
Bending Load (tangential load)
Mt /  D2 / 2 Ft
on one bolt, Ft =
n
Bending moment
Mb = Bendinf load x Bending moment arm
 1 2 
= Ft x  t   G  F  
 2 3  G
Mb y
Bending stress induced in the bolt (or pin)  b =
I
F F 4
Bolt is circular in section.  y  and I 
2 64
 1 2  F
Ft x  t   G  F  
 2 3  2
Thus,  b = 4
  b 
F
64 56
Step-6 Check for the shear and crushing stresses induced in key.

Assuming that the shaft and key are made of same material,
2  Mt
Shear stress induced in key,  =   s 
W L A
Similarly, crushing stress induced on the key way,

crushing force Mt /  A/ 2
Crushing  
area resisting crushing force T
L
2
4  Mt
i.e,  b   b 
T  L A

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Example Design of protected bushed pin type flexible flange coupling :
Design a flexible flange coupling (Bush Type) to transmit 5 KW at
750 rpm with a service factor of 1.2. For shaft,bolt and key
permissible shear stress in 50 N/mm2. For cast iron shear stress is 15
N/mm2 and bearing stress for bush is 2 N/mm2. For key crushing
stress is 100 N/mm2.

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Bending moment arm

Ft

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64
A cast iron protected bushed pin type flexible flange coupling is
required to transmit a power of 10 hp at 720rpm from an electric
motor to a centrifugal pump. Allowable shear strength of CI my be
taken as 10 N/mm2 that of shaft, key and bolt (pin) material as 90
MPa . The bush is made of rubber having 1.2 N/mm2 as working
stress maximum.

Suggest a suitable standard bushed pin type flexible flange

coupling and check it for different possible modes of failure.

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