CHAPTER 04 Shaft, Keys & coupling

Introduction, Application , Numerical

etc.

SHAFT

In machinery, the general term shaft refers to a member, usually

of circular cross-section, which supports gears, sprockets, wheels,
rotors, etc.
Transmission shaft refers to rotating machine element, which
support gear, pulley, and sprocket, and transmit power.
Shaft are usually cylindrical, may be square or cross-shaped in
section.
The shaft is always stepped with maximum diameter in the middle
& minimum at end to mount the bearing
Fillet provided to avoid stress concentration due to abrupt change in
cross section

SHAFT
q

An axle is a non-rotating member that used to supports rotating

member wheels, pulleys which is fitted o housing by bearing and
carries no torque.

A spindle is a short rotating shaft. Used in al machine tools,

Terms such as line shaft, head shaft, transmission shaft,
countershaft, are names associated with special usage.
q

Counter shaft secondary shaft, driven by the main shaft

Jackshaft Intermediate shaft between two shaft, function

same as countershaft

Line shaft Consist no. of shaft, connected in axial direction by

coupling, used in group drive

A good practice for Material selection

Start with an inexpensive, low or medium carbon steel for the first
time through the design calculations.
Applications requiring greater strength often specify alloy steels,
Nickel, chromium corrosion applications call for brass, stainless,
Ti, or others.
The cost of the material and its processing must be weighed
against the need for smaller shaft diameters.
Manufacturing of Shafts
For low production, turning is the usual primary shaping process.
An economic viewpoint may require removing the least material.
High production may permit a volume conservative shaping
method (hot or cold forming, Forging)
Shoulder
It allows precise positioning
Support to minimize deflection.
In cases where the loads are small, positioning is not very
important, shoulders can be eliminated.

ELEMENTS ATTACHED TO A SHAFT

Shoulders provide axial positioning location, & allow for larger center shaft diameter
where bending stress is highest.

SHAFT DESIGN FOR STRESS

It is not necessary to evaluate the stresses in a shaft at every
point; a few potentially critical locations will suffice. Critical
locations will usually be on the outer surface.
Possible Critical Locations, axial locations where:
The bending moment is large and/or
The torque is present, and/or
Stress concentrations exist.
Stresses due to
Shear stress (Transmission torque)
Bending stress (machine element)
Combined Torsional & Bending loads

STRESS DUE TO TORSION

Stress should not exceed yield point due to twisting moment
Diameter of shaft obtained by Torsion equation

T
J

Where,
T = Twisting moment
J = Polar moment of inertia = ( / 32) x d4
= Torsional shear stress
r = Distance from NA to outer most fiber = d / 2

r
T

( / 32) x d4

d/2

T = ( / 16) x x d3
Torque can be obtained by Power formula

SUM 1
A

line shaft at 200rpm is to transmit 20kw. Shaft is

made of up mild steel of shear stress 42MPa. Determine
the diameter of shaft by torsion formula

Solution
Calculate T = torque
Power = (2 NT / 60 )
Calculate d = Shaft Dia

STRESS DUE TO BENDING MOMENT

Stress should not exceed yield point due to twisting moment
Diameter of shaft obtained by pure bending equation

b
y

Where,
M = Bending moment
I = Moment of inertia = ( / 64) x d4
b = Bending stress

( / 64) x d4

y = Distance from NA to outer most fiber = d / 2

= d/ 2b

M = ( / 32) x b x d3

STRESS DUE TO COMBINED TORSION & BENDING

MOMENT

When shaft subject to two moment simultaneously various theories

are suggested for elastic failure of the material

Maximum shear stress theory or Guests Theory Ductile Material

Maximum normal stress theory or Ranking's Theory Brittle material

qMaximum shear stress theory or Guests Theory

- Max shear stress at shaft

!max = (1 / 2) x [(b)2 + 4(!)2]1/2

!max = (1 / 2) x [(32M / d3 )2 + 4 (16T/

!max = (16 /

d3)2]1/2

d3) x [ M2 +

T2 ]1/2

[ M2 + T2 ]1/2 = Equivalent twisting moment = Denoted by Te

qMaximum normal stress theory or Ranking's Theory

b(max) = (1 / 2) b + {(1 / 2) x [(b)2 +

4(!)2]1/2}
Putting b & ! In above equation

M = ( / 32) x b x d3
T = ( / 16) x x d3
We get,

b(max) = (32 /

d3) x { (1/2) M + [M2 + T2 ]1/2

{(1/2) M +[ (M2 + T2) ] } = Equivalent Bending moment

= Denoted by Me

STRESS DUE TO AXIAL, COMBINED TO TORSION &

BENDING LOAD
Shaft

is subjected to axial load (tensile or compressive)

P = F / A = F / [( / 4) x d2]
Resultant Stress

32 M 4 F
x =
+
3
d
d2

CH-18

Static or Quasi-Static Loading on

Shaft

LEC 29

Normal stress

Shear stress

Slide 13

The stress at an element located

on the surface of a solid round
shaft of diameter d subjected to
bending, axial loading, and
twisting is

32 M 4 F
x =
+
3
d
d2
16T
xy = 3
d
2

Non-zero principal
stresses

12

x + y x y
2
A , B =

+ xy

2 2

keys

A key is the piece inserted in an axial direction between a shaft and

hub of the mounted machine element such as pulley or gear etc.
A key is used for temporary fastening, Key joint consist of shaft, hub,
and key
The shaft and rotating machine element must have akeyway, also
known as akey seat, which is a slot or pocket the key fits in. The
whole system is called akeyed joint
2 basic function of key

Primary function is to transmit the torque from shaft to the hub of

mating element and vice versa
Secondary function is to prevent rotational motion between the shaft and
the hub like gear or pulley.

Slot machined on the shaft & hub called keyway, usually cut by
milling cutter
Drawback keyway result in stress concentration in the shaft & part
becomes weak
Material usually plain carbon steel to withstand shear and
compressive stresses
Types of keys are
Saddle key & sunk key
Square key & flat key
Key with & without Gib head
Special types

Square & rectangular key

The sunk keys are provided half in the keyway of the shaft and
half in the keyway of the hub or boss of the pulley.
1. Rectangular sunk key
-
Also called flat key
-
More stability than square key
-
Used in machine tool
2. Square sunk key
- Used in general industrial machinery
The only difference between a rectangular sunk key and a square
sunk key is that its width and thickness are equal, i.e. b = h
Selecting key without stress analysis Thumb Rule
Square, b = h = (d / 4), l = 1.5 d
Rectangular b = d / 4, h = (2b / 3) = (d / 6), l = 1.5 d
Where, d = Diameter of shaft (mm)
b = Width of key (mm)
h = Height of key
(mm)
l = Length of key (mm)

Design of Keys stress analysis to determine required

length
1. Forces ( P ) due to the torque transmitted by the shaft.
2. Forces ( P ) due to fit of the key in its keyway, as in a tight fitting straight key
driven in place.

Force (P) = Mt / (d/2)

Where Mt = Transmitted torque
d = diameter of shaft
P = force on key

Failure of key in shear: occurs at Plane AB

Strength of a Sunk Key

Considering shearing of the
key, the tangential shearing
force acting at the
circumference of the shaft:

P = Area resisting shearing Shear stress

Plane AB

2 Mt
=
dxbxl
bxl
P

Where, d = Diameter of shaft (mm)

b = Width of key (mm)
h = Height of key(mm)
l = Length of key (mm)

Failure of key in Compressive

Crushing between shaft and key : Considering crushing of the key, the
tangential crushing force acting at the circumference of the shaft:
P = Area resisting crushing Crushing stress

P
Surface AC

P
(h/2) x l

Square Key h = b

c =

4 Mt
bxlxd

2 Mt
(h/2) x l x
d

4 Mt
hxlxd

 The

permissible crushing stress for the usual key

material is at least twice the permissible shearing stress

2 Mt
=
dxbxl

From

c =

4 Mt
dxbxl

above equation, We get

c = 2
Sum 1
required to design a square key for fixing gear on a shaft of 25mm diameter.
The shaft transmitting 15kw power at 720rpm to the gear. Ultimate tensile
stress is 460MPa, factor of safety 3. Determine the dimensions of the key.
Solution :
1. find out permissible stress
2. Find out torque (Mt) by power formula
3. Calculate b = h = (d / 4)
4. Calculate l by shearing
5. Check the crushing stress by putting above value

Coupling

All manufacturing plants have at least 2 things in common. These

are:
Electric motors and.
Couplings - There are many different types, sizes and styles.
All couplings;
1. Connect 2 shafts together 2. Require safety guards.
Most couplings;
1. Do more than 1 function at a time.
2. Connect 2 shafts together.
3. Allow for minor misalignment.
4. Allow for axial movement.

 Two

major classification

Solid couplings (also called rigid or sleeve couplings)

Flexible couplings

q Rigid

coupling : It is used to connect two shafts which are

perfectly aligned.
Types of rigid coupling are

Sleeve or muff coupling.

Clamp or split-muff or compression coupling,
Flange coupling

q Flexible

coupling : It is used to connect two shafts having both

lateral and angular misalignment.
Types of flexible coupling are

Bushed pin type coupling,

Universal coupling, and
Oldham coupling

Muff Coupling

Also called sleeve or box coupling

It is the simplest type of rigid coupling, made of cast iron.
It consist of hollow cylinder or sleeve, shaft (input & output) & key
Sleeve inner diameter is the same as that of the shaft diameter.
It is fitted over the ends of the two shafts by means of a sunk key, the
power is transmitted from one shaft to the other shaft by means of a
key and a sleeve.
Simple in design & manufacture.

Design procedure
1. Calculated the diameter of shaft (d) : Shaft subjected to pure Torsional
moment,

16 Mt
d3

2. Usually defined on shop floor. Empirical relationship were developed

by engineer on the basis their past experience then check for
shearing
D = 2d + 13
L = 3.5d
Where, D = Outer diameter of the sleeve
L = axial length of sleeve

Mt x r
= J
3. Determine the dimension of key
l = L / 2 each shaft
4. Check shear & compressive stress in the key

2 Mt
=
dxbxl

c =

4 Mt
dxbxl

J=
D
=r 2

(D4 d4)

32

SUM 1

Design muff coupling to connect two steel shaft transmitting

25kw power at 360rpm. The shaft and key are made of plain
carbon steel of ultimate yield stress 400MPa. Factor of safety for
shaft & key 4. the sleeve made of grey cast iron, ultimate yield
stress 200MPa. Factor of safety for shaft & key 6.
Solution :
Find out permissible stress
Diameter of shaft
Dimensions of sleeve
Dimensions of key
Key for stresses in key

CLAMP COUPLING

Second type of rigid coupling, Also called split muff coupling or

compression coupling
In this, sleeve is made of two halves, which are split along a plane
passing trough axes of shaft
The two halves of the sleeve are clamped together by means of bolts
No. of bolts can be four or eight
It is easy to assemble & dismantle

Design procedure
1. Calculated the diameter of shaft (d) : Shaft subjected to pure Torsional
moment,

Mt x r
= J
2. Usually defined on shop floor. Empirical relationship were developed
by engineer on the basis their past experience
D = 2.5 d

L = 3.5 d

Where, D = Outer diameter of the sleeve

L = axial length of sleeve

3. Determine the dimension of key

l = L / 2 each shaft
4. Check shear & compressive stress in the key

2 Mt
dxbxl

c =

4 Mt
dxbxl

Calculate the diameter of clamping bolts by using, (d1)

1.

By empirical,
when d < 55 mm ------- d = diameter of shaft
d1 = 0.2d + 10 mm
d > 55 mm
d1 = 0.15d + 15 mm

4. Clamping force (P1) : Each bolt

P1 = ( / 4) d12 x !t
2. Clamping force (N) : Each Shaft (half bolts)
N = (P1 x n) / 2
where n = Total no. of bolts
3. Frictional force : between sleeve halves & shaft
Mt =

f x d x P1 x n
2

P1 =

2 x Mt
fxdxn

FLANGE COUPLING