Chapter 11 Keys and Couplings

ENTC 463 Mechanical Design Applications II

Keys and Couplings

Keys
Machine elements placed at the interface between a shaft and the hub of a gear, sprocket, or sheave to transmit torque

Couplings
Machine elements used to connect two shafts to transmit power

Keys
Types of Keys
Parallel keys
Square keys Rectangular keys

Tapered Keys and Gib Head Keys Pin Keys Woodruff Keys

Parallel Keys

Taper, Gib Head, and Pin Keys

Woodruff Keys

Parallel Keys
Parallel to the axis of shaft Square keys
Preferred size: 3/32 to 1

Rectangular keys
Preferred size: 1 and up

Parallel Keys

Materials for Keys

AISI 1020 Cold Drawn AISI 1040, AISI 1045 Heat treated steel Consider fatigue, shock/impact loading (elongation > 10% needed)

Forces and Stresses on Keys

Failure due to shear (shear stress) Failure due to compression (bearing stress)

Failure Due to Shear

Design Parameter: Length L

T F= D2 A = WL (shear area) 0.5S y 2T F = = < A DWL N 4TN L> S y DW

Failure Due to Compression

LH Ac = 2 Sy F T 4T = = < = Ac (D 2 )(LH 2 ) DLH N 4TN L> S y DH

4TN Shear failure: L > S y DW

Fore square key, W = H For rectangular key, W > H, calculate L based on compression

Key Example
Design a key for a shaft (D = 1.0) rotating at 350 rpm and transmitting 4.0 hp

ENTC 463
HW#11 Key, Spline, and Coupling Due 4/1/2008 Chapter 11 1, 3, 5 (for the application in problem 3)

Next Thursday 4/3/2008 Meet @ Thompson 009B

Allen to Hagan 2:20 to 3:00 PM Higginbotham to Winniford 3:00 to 3:35 PM

ENTC 463 Mechanical Design Applications II

Splines
Splines Concept: multiple parallel keys SAE specifications: 4, 6, 10, 16 splines Torque capacity rating

Straight Splines
SAE Standard
Torque capacity is based on the limit of 1000 psi bearing stress
D d T = 1000 N + 2 h 2 2 N : number of splines L ???
T is per inch spline length

Straight Splines
Keys : F T = = A (D 2 )(H 2 )L Splines : T = (Da 2)(h 2)L

Da : average diameter ( Da = (D + d ) 2) T D + d D d N L 4 2

Since = 1000 psi and L = 1.0" D + d D d T = 1000 N 4 2

(11-10)

Straight Splines
=
D + d D d T = 1000 N 4 2
T < Sy D + d D d N L 4 2 D + d D d T < SyN L 4 2

Torque capacity of the spline: D = 1.0, d=0.85, N=4 (4 splines), L=1.0, Sy=30 ksi

SAE Spline Standard

Known shaft diameter, D, and number of splines Decide type of fit (A, B, or C) Determine other geometry parameters (W, h, d) form the Table 11-4. Compute torque capacity from Table 11-5.

SAE Spline Standard

T = 139 D 2 D = T 139

SAE Spline Standard

Example: N=4, A Fit
h = 0.075 D, d = 0.85 D

(4) D + 0.85D D 0.85D T = 1000

4 2 1.85 D 0.15 D 2 = 4000 = 138.75 D 4 2

D=1.0, Sy = 30 ksi
T = 139(1.0 ) (30) = 4170 lb - in
2

Example
Select a spline and determine the diameter of the shaft for power transmission of 20 hp at 400 rpm.

Other Methods to Connect Elements to Shaft

Pinning

Double shear : F=

(2T D ) = 4T < S 2T T F = = = ys (D 2 ) D 2 A 2 d 2 4 d 2 D

4T d> DS ys

Design pin to fail before others fail

Other Methods to Connect Elements to Shaft

Set screw Taper shaft and screw

Other Methods to Connect Elements to Shaft

Press fit Polygon Hub to shaft connection Molding (plastic gears)

Coupling

Couplings
Objective
Connecting two shafts together at their ends for power transmission Rigid coupling: connecting two shafts with no relative motion of shafts can occur Flexible coupling: also called compliant coupling, can handle misalignment such as axial, angular, parallel, and torsional alignment

Couplings
Rigid coupling
T 2T = (D 2 ) D F 2T < S ys = = 2 A DN d 4 F=

d=

8T DNS ys

N : number of bolts

Types of Flexible Couplings

See samples in the power transmission lab

Types of Flexible Couplings

Exam #2 Review

Flexible machine elements

Belt
V-belt selection (size) Power rating Layout (dimension)
Sheave diameter Length Center distance

Chain
Chain number (size) Power rating Layout (dimension)
Sprockets Length Center distance

Lubrication method

Flexible machine elements

Wire rope
Diameter Material Operating height Sheave
Diameter Material

Evaluation
Tension Bending Fatigue Bearing (sheave)

Example problems
Design a belt system (v-belt) to transmit 20 hp from 1170 rpm to 400 rpm. The input and output of a chain system is 870 rpm and 250 rpm. Select chain and design layout to transmit 25 hp. Select a wire rope and pulley to lift 4000 lb load with the pulley installed at 60 ft off ground.

Gears
Gears types
Spur gear Helical gear Bevel gear Worm and wormgear

Geometry
Diametrial pitch, pd Diameter or # of teeth Face width

Gears Consideration
Forces
Tangential Radial Axial

Stresses (number)
Bending stress Contact stress

Power Torque Force Stress Strength/Stress Force Torque Power

Material selection
Allowable stress number

Gear Examples
Design helical/bevel pinion (rotating at 1200 rpm) and gear (400 rpm) and select gear material to transmit 20 hp. Estimate the power transmission capacity of a gray cast iron Class 30 pinion (D=2) rotating at 1200 rpm. A wormgear set has a single thread worm and a reduction ratio of 30. Design the worm and wormgear dimension and select material to transmit input power of 15 hp with higher than 85% efficiency.

Rolling Contact Bearings

Ball bearing Load life relationship
L2 P = 1 L1 P2
k

Radial load only (P=VR) Radial load and thrust load (P=XVR+YT)

Rolling Contact Bearings

Mean effective load under varying loads
(Fi )k N i Fm = i N i C L = 106 F m
k 1 k

Bearing Example
The radial load acting on a 6315 bearing is 1200 lb. After 100,000 rev., Determine the remaining life of the bearing.

Bearings
Plain Surface Bearing
Boundary Lubricated Bearing
Geometry diameter, length, clearance Material selection

Hydrodynamic Lubricated Bearing

Geometry diameter, length, clearance Lubricant viscosity, film thickness, operating temperature Pressure (load/projected area) Power loss

Bearing Examples
Determine the size and material of a boundary lubrication for a radial load of 200 lb on 0.5 diameter shaft rotating at 300 rpm. Design a hydrodynamic lubrication bearing for an application of: 1200 lb radial load, 1.5 shaft diameter, and 1200 rpm shaft speed. Specify lubricant, operating temperature, power loss.

Bearing
Plain Surface Bearing (cont.)
Hydrostatic bearing
Lifting force (load) capacity Flow rate Power and power loss Operating pressure Pad geometry Lubricant and operating temperature

Bearing Examples
To lift 3500 lb load with a 0.5 hp pump that can deliver lubricant at a max. pressure of 500 psi, determine the pad geometry and the lubricant to be used.

Key, Spline and Coupling

Parallel keys
Square and rectangular keys Select width and height based on shaft diameter Calculate length based on material strength

Spline
Determine torque capacity based on shaft diameter and material

Coupling
Rigid coupling Flexible coupling (torque rating)

Key Examples
Design a key and select key material for a shaft (D = 1.5) rotating at 1200 rpm and transmitting 12 hp.