Keys and Couplings

Name : B.
YESWANTH KUMAR REDDY

Department : Mechanical Engineering
Specialization : Design For Manufacturing
College : JNTUA College of Engineering Pulivendula
LECTURE 1
DESIGN OF KEYS AND COUPLINGS
KEYS
JNTUACEP MECH. DEPT 2
BASIREDDY
OBJECTIVE
After this presentation you should
be able to
I d e n t i f y ke y s a n d t h e i r
applications
C a l c u l a t e f o r c e s o n ke y s
D e s i g n ke y s
Applications of couplings
Ty p e s o f c o u p l i n g s
Design of various types of
couplings
BASIREDDY
INTRODUCTION
A ke y i s a p i e c e o f s t e e l i n s e r t e d
b e t w e e n a s h a ft a n d a c o m p o n e n t ,
such as a pulley or a gear wheel, to
transmit ro t a r y motion ( t o rq u e ) .
Ke y s a n d ke y w a y s v a r y i n s i z e
a c c o rd i n g t o t h e d i a m e t e r o f t h e
s h a ft o n w h i c h t h e y a re fi t t e d

BASIREDDY
INTRODUCTION
T h e ke y i s i n s e r t e d p a r a l l e l t o t h e
a x i s o f t h e s h a ft a n d u s e d a s
temA pkeo ryawr y
a yf ai ss tae nsilnogt so r re c e s s i n t h e
s h a ft a n d h u b o f t h e p u l l e y t o
a c c o m m o d a t e a ke y

BASIREDDY
TYPES OF KEYS
S unk ke ys
S ad d le ke y s
Tang e nt ke y s
Ro und ke ys
S p line s

BASIREDDY
TYPES OF SUNK KEYS
Rectangular sunk key
Square sunk key
Parallel sunk key
Gib-head key
Feather key
Woodruff key

BASIREDDY
SUNK KEYS
T h e s u n k ke y s a r e p r o v i d e d h a l f i n
t h e ke y w ay o f t h e s h a f t a n d h a l f i n
t h e ke y w ay o f t h e h u b o r b o s s o f t h e
pulley
Let
d diameter of the shaft or
diameter of the hole in the hub
w w i d t h o f t h e ke y
t t h i c k n e s s o f t h e ke y

BASIREDDY
SUNK KEYS
For RECTANGULAR SUNK KEY
Width of key w = d/4
Thickness of the key t = 2w/3 = d/6
The key has the taper 1 in 100 on the topside.
For SQUARE SUNK KEY the width is equal to
thickness. w = t = d/4
PARALLEL SUNK KEY contains uniform width and
thickness through out and are taperless

BASIREDDY
SUNK KEYS
The rectangular sunk key with head at one end is
known as GIB HEAD KEY. The head is provided to
facilitate the removal of key.
Width w = d/4
Thickness at large end t = 2w/3 = d/6

BASIREDDY
SUNK KEYS
FEATHER KEY is attached either to the pulley or to
the shaft thus permitting one member to slide along
the other. It may be screwed into a recess in the
shaft, have a double head or a central peg, which
causes it to be contained in the pulley and slide in
the keyway or the shaft. Their proportions are similar
to square or rectangular keys.

BASIREDDY
SUNK KEYS
WOODRUFF KEY is used particularly in machine
tools and in automotive work. It fits into a recess
milled in the shaft by a special cutter. It has the
advantage of being easily adjustable to any taper in
the keyway of the pulley. These keys should never be
used as feather keys.

BASIREDDY
SADDLE KEYS
Saddle keys are suitable for light duty only. They tend
to work loose and rock on the shaft under heavy duty.
The saddle keys are of two types
1. Flat saddle keys
2. Hallow saddle keys

BASIREDDY
SADDLE KEYS
FLAT SADDLE KEY is a taper key which fits in a
keyway in the hub and is flat on the shaft. It is likely
to slip round the shaft under load. Therefore it is
used for comparatively light loads.
HALLOW SADDLE KEYS is a taper key which fits in
a keyway in the hub and the bottom of the key is
shaped to fit the curved surface of the shaft. These
keys hold on by friction, therefore suitable for light
loads.

BASIREDDY
TANGENT KEYS
TANGENT KEYS are fitted in pair at right angles.
Each key is to withstand torsion in one direction only.
These are used in large heavy duty shafts

BASIREDDY
ROUND KEYS
These are circular in section and fit into the holes
drilled partly in the shaft and partly in the hub. Their
keyways may be drilled and reamed after mating
parts have been assembled. These are appropriate for
low power drives

BASIREDDY
SPLINES
Keys are made integral with the shaft which fits in
the keyways broached in the hub. Such keys are
known as SPLINED SHAFTS. These shafts usually
have four, six, ten or sixteen splines. These splined
shafts are relatively stronger than shafts having a
single keyway. By using splined shafts axial
movement as well as positive drive is obtained

BASIREDDY
BASIREDDY
FORCES ACTING ON SUNK KEY
When key is used in transmitting torque from a shaft
to rotor or hub the following two types of forces act on
the key
1. The forces produced due to tight fitting of the key
leads to compressive stresses on the key
2. The forces produced due to torque transmitted by
the shaft leads to shearing and compressive
(crushing) stresses in the key
Since the forces are concentrated near the torque
input end the distribution of forces along the length
of the key is not uniform

BASIREDDY
FORCES ACTING ON SUNK KEY
F1
l
F
F
F1
F1 is the compressive stresses in the key caused by the torque transmitted

by the shaft
F is the shear stresses in the key caused by the torque transmitted by the
shaft
The forces due to fit of the key are neglected in the design of the key and it
is assumed that the distribution of forces along the length of key is uniform
BASIREDDY
STRENGTH OF THE KEY
Let
T - Torque transmitted by the shaft
F - Tangential force acting at the circumference of the
shaft
d - Diameter of shaft
l - Length of key
w - Width of key
t - Thickness of key
- Shear stresses for the material of key
c - Crushing stresses for the material of key
1 - shear stress for the shaft material
BASIREDDY
STRENGTH OF THE KEY
1.Shearing of the key
The tangential shearing force acting at the
circumference of the shaft
F = Area resisting shearing x Shear stress = l.w.
Torque transmitted by the shaft T = F . (d/2)
T = l . w . . (d/2) (i)

BASIREDDY
STRENGTH OF THE KEY
2. Crushing of the key
The tangential crushing force acting at the
circumference of the shaft
F = Area resisting crushing x Crushing stress
F = l . (t/2) .c
Torque transmitted by the shaft
T = F . (d/2) = l . (t/2) .c . (d/2)
T = l . (t/2) .c . (d/2) (ii)

BASIREDDY
STRENGTH OF THE KEY
The key is equally strong in shearing and crushing, if
l . w . . (d/2) = l . (t/2) .c . (d/2)
Or
(w/t) = c / 2 (iii)
The permissible crushing stress for the usual key
material is atleast twice the permissible shearing
stress. Therefore from equation (iii), we have w=t. in
other words, a square key is equally strong in
shearing and crushing

BASIREDDY
STRENGTH OF THE KEY
In order to find the length of the key to transmit full
power of the shaft, the shearing strength of the shaft
is equal to torsional shear strength of the shaft
From equation (i) we have T = l . w . . (d/2)
Torsional strength of the shaft
T = (/16) . 1 . d3 (iv)
Equating equation (i) and (iv)
l . w . . (d/2) = (/16) . 1 . d3
Substituting w= d/4 and the considering the material
is same as the material of the shaft, then = 1
l = 1.571 d
BASIREDDY
Problem: Design the rectangular key for a shaft of 50 mm
diameter. The shearing and crushing stresses for the key
material are 42MPa and 70 MPa.
Given data:
d = 50mm; = 42MPa = 42N/mm2; c = 70MPa = 70
N/mm2
From the table we find that for a shaft of 50mm diameter
Width of the key w = 16mm; thickness of key t = 10mm
The length of the key is obtained by considering the key in
shearing and crushing.
Let l be the length of the key. Considering shearing of the
key
T = l . w . . (d/2) = l x 16 x 42 x (50/2) = 16800.l N-mm
Torsional shear strength of the shaft
T= (/16) . . d3 = (/16) x 42 x 503 = 1.03x106 N-mm
BASIREDDY
Problem: Design the rectangular key for a shaft of 50 mm
diameter. The shearing and crushing stresses for the key
material are 42MPa and 70 MPa.
Equating both shear strength of the key and torsional

strength of the shaft, we get
l= 61.31 mm
Now considering crushing of the key
T = l . (t/2) .c . (d/2) = l x (10/2) x 70 x (50/2) = 8750 l N-
mm
Equating torsional shear strength and crushing strength
l = 117.7mm
Taking larger of the two values we have the length of the
key
l = 117.7 mm say 120mm

BASIREDDY
Problem: A 45mm diameter shaft is made of steel with yield
strength of 400Mpa. A parallel key of size 14mm wide and 9mm
thick made of steel with a yield strength of 340MPa 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
Given data:
d= 45mm; yt for shaft = 400MPa = 400 N/mm2;
w = 14mm; t = 9mm; yt for key = 340MPa = 340N/mm2;
F.S = 2
Let l is the length of key.
According to max. shear stress theory, the max shear
stress of the shaft
max = yt /(2 x F.S) = 400/(2 x2) = 100N/mm2
max. shear stress for key
k = yt /(2 x F.S) = 340/(2x2) = 85 N/mm2
BASIREDDY
Problem: A 45mm diameter shaft is made of steel with yield
strength of 400Mpa. A parallel key of size 14mm wide and
9mm thick made of steel with a yield strength of 340MPa is ti
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.
Max. torque transmitted by shaft and key

T = (/16) . max . d3 = (/16) . 100 . 453 = 1.8x106N-mm
Failure of the key due to shearing
1.8x106 = l x w x k. (d/2) l= 67.2mm
Failure of the key due to crushing
1.8x106 = l x (t/2) x ck x (d/2) l = 104.6mm
Taking larger value of the two values
l = 104.6 say 105mm

BASIREDDY
RULES FOR EFFICIENCY IN JOINING
KEYS
1. Clearances between components should be
minimal, otherwise when the key is fitted the
components being joined could run eccentrically
and cause out of balance forces.
2. Clearances between key and keyway must not
allow malalignment of components, otherwise
unwanted backlash can occur under drive
conditions.

BASIREDDY
RULES FOR EFFICIENCY IN JOINING
KEYS
3. Where taper keys are concerned, the tapers MUST
correspond to each other.
4. Tapers on shafts and hubs/collars should be
carefully checked for scoring and burring.

BASIREDDY
Questions on KEYS
1. What factors determine the CROSS-SECTIONAL size of any
particular key?
2. Why are SADDLE KEYS only suitable for light duty?
3. Give three examples of where components are joined by keys?
4. What special "movement" feature does a feather key allow when
used in gear boxes?
5. On a sheet of paper, sketch two types of feather key showing
clearly their method of location?
6. What is the main advantage of using woodruff keys where
shafts are tapered?
7. Why should woodruff keys never be used as feather keys?
8. Explain the difference between FLAT SADDLE and HOLLOW
SADDLE KEYS?
9. Explain the type of force exerted on keys?
10. List the general rules for efficiency in joining by keys?
BASIREDDY
ANSWERS
1. Shaft diameter and load (torque) on the secured components.
2. They hold by friction only.
3. i. Gear wheels on shafts ii. Fly wheels iii. Taper locks
4. Allows linear movement of one member of the keyed
components. In a gear box this would normally be the gears or
gear clusters.
5. Check the figures in slide no:9
6. They adjust easily to accommodate any taper in the keyway of
the pulley.
7. Any movement would likely jam up because the key would
rotate in its semi circular slot.
8. Flat saddle requires a flat surface machined on the mating
shaft. Hollow saddle requires a radius recess machined on its
underside. Both drive by friction only.
9. Shear force and compressive force
10. Check slide no:28
BASIREDDY
COUPLINGS

BASIREDDY
INTRODUCTION TO COUPLINGS
A coupling is a device used to connect two shafts
together at their ends for the purpose of transmitting
power.
The purpose of couplings is to join two pieces of rotating
equipment while permitting some degree of
misalignment or end movement or both.

BASIREDDY
USES OF COUPLINGS
A shaft coupling is used
To provide for the connection of shafts of units that are
manufactured separately such as a motor and generator
and to provide for disconnection for repairs or
alterations.
To provide for misalignment of the shafts or to introduce
mechanical flexibility
To reduce the transmission of shock loads from one
shaft to another
To introduce protection against overloads
To alter the vibration characteristics of rotating units.

BASIREDDY
TYPES OF SHAFT COUPLINGS

BASIREDDY
DESIGN OF SLEEVE OR MUFF
COUPLING
This coupling is made of cast iron
It consists of a hallow cylinder which contains the inner
diameter same as the diameter of the shaft
It is fitted over the ends of the two shafts by means of gib
head key.
The power is transmitted from one shaft to another by
means of sleeve and key
Key way
Muff/Sleeve

BASIREDDY
COUPLING
Let
D Outer Diameter of the sleeve;
d diameter of the shaft;
T Torque transmitted by the coupling;
L length of the sleeve;
c Permissible shear stress for the material of the sleeve.
(cast iron)
The safe value of shear stress for cast iron may be taken
as 14Mpa

BASIREDDY
COUPLING
The outer diameter of the sleeve D = 2d + 13 mm
The length of the sleeve L = 3.5d
The torque transmitted by the hollow shaft is given by
T = (/16) c ((D4 d4)/D) = (/16) c D3 (1-k4)
Where k = d/D
The induced shear stress in the sleeve may be checked

BASIREDDY
COUPLING
DESIGN OF KEY
The length of the coupling key is at least equal to the
length of the sleeve
The coupling key is usually made into two parts so that
the length of the key will be in each shaft.
Length of the key l = L/2 = 3.5d/2
The torque transmitted T = l * w * (d/2)
for shearing of the key
T = l * (t/2) * c* (d/2)
for crushing of the key

BASIREDDY
PROBLEM: Design a muff coupling which is used to connect
two steel shafts transmitting 40 kW at 350 r.p.m. The
material for the shafts and key is plain carbon steel for which
allowable shear and crushing stresses may be taken as 40
MPa and 80 MPa respectively. The material for the muff is
cast iron for which the allowable shear stress may be
assumed
SOLUTION: as 15 MPa.
Given data: P = 40 kW = 40 103 W; N = 350 r.p.m.; s = 40 MPa =
40 N/mm2;
cs = 80 MPa = 80 N/mm2; c = 15 MPa = 15 N/mm2
Let d be the diameter of the shaft, we know that power transmitted
by the shaft is
P= 2NT/60 T = (P * 60)/2N T = (40 103 * 60)/ 2* *350 =
1100 103 N-mm
We also know that torque transmitted T = (/16) s d3 1100 x
103 = (/16) x 40 x d3
d= 52 say 55
DESIGN OF SLEEVE:
we know that D = 2d + 13 mm = (2x55)+13 = 123 say 125 mm
L = 3.5d = 3.5 x 55 = 192.5 say 195 mm
T = (/16) c ((D d )/D) 1100x10 = (/16) c ((1254
4 BASIREDDY
4 3
PROBLEM: Design a muff coupling which is used to connect
two steel shafts transmitting 40 kW at 350 r.p.m. The
material for the shafts and key is plain carbon steel for which
allowable shear and crushing stresses may be taken as 40
MPa and 80 MPa respectively. The material for the muff is
cast iron for which the allowable shear stress may be
DESIGN OF
assumed as KEY:
15 MPa.
From the tables the width of the key for the diameter of shaft d = 55mm is
18mm
W = 18mm
Since the crushing stress for the key material is twice the shearing stress
therefore a square key may be used.
Thickness of key t = w = 18mm
The length of the key in each shaft = l = L/2 = 195/2 = 97.5mm
Now checking the induced shear and crushing stresses in key.
Shearing of the key P = l x w x s x (d/2)
1100x103 = 97.5 x 18 x s x(55/2) s = 22.8N/mm2
Crushing of key P = l x (t/2) x cs x (d/2)
1100x103 = 97.5 x(18/2)x cs x(55/2) cs = 45.6N/mm2
The induced shear and crushing stresses are less than permissible
stresses. Therefore
JNTUACEP MECH. DEPT the design of key is safe.
BASIREDDY
43
CLAMP or COMPRESSION
COUPLING
It is also known as Split muff coupling
The muff is made into two halves and are bolted together
The shaft ends are made to butt each other and a single
key is fitted directly in the keyways of both the shafts.
One half of the muff is fixed from below and the other half
is placed from above
Both the halves are held together by means of studs or
bolts and nuts.
Keyway YESWANTH KUMAR REDDY

BASIREDDY
CLAMP or COMPRESSION
COUPLING
The number of bolts may be two, four or six
The nuts are recessed into the bodies of the muff castings
This coupling may be used for heavy duty and moderate
speeds
The advantage of this coupling is the position of the shafts
need not be changed for assembling or disassembling of
the coupling.
The compression coupling consists of muff, key and
clamping bolts.
The design of muff and key for compression coupling is
same as sleeve coupling and it was discussed in previous
slides

BASIREDDY
DESIGN OF COMPRESSION COUPLING
Let d diameter of the shaft; T torque transmitted by the shaft;
db Root or effective diameter of bolt; n number of bolts
t Permissible tensile stress for bolt material; L Length of muff;
Coefficient of friction between the muff and shaft = 0.3
Diameter of the muff D = 2d + 13mm
Length of the muff L = 3.5d

BASIREDDY
DESIGN OF COMPRESSION COUPLING
DESIGN OF CLAMPING BOLTS

The force exerted by each bolt = (/4)(db)2 t
Force exerted by bolts on each side of shaft = (/4)(db)2 t (n/2)
Let p be the pressure on the shaft and muff surface due to the
force, then for uniform pressure distribution over the surface
p = Force/Projected area = ((/4)(db)2 t (n/2) )/((1/2) L d)
Frictional force between each shaft and muff
F = x pressure x area = x p x (1/2) x ( x d) x L
Substituting the value of p in the above equation
F = x (2/8) x (db)2 x t x n
The torque transmitted by the coupling T = F x (d/2)
T = x (2/16) x (db)2 x t x n x d
The value of d is evaluated from the above equation
BASIREDDY
Design a clamp coupling to transmit 30 kW at 100 r.p.m. The
allowable shear stress for the shaft and key is 40 MPa and the
number of bolts connecting the two halves are six. The
permissible tensile stress for the bolts is 70 MPa. The
coefficient of friction between the muff and the shaft surface
may be taken as 0.3.
Given P = 30kW = 30x103 W; N = 100 r.p.m; n = 6; = 0.3;
= 40MPa = 40N/mm2;t = 70MPa = 70 N/mm2 ;
DESIGN FOR SHAFT
Torque transmitted by the shaft = T = (P x 60)/(2N)
T = 30x103x60/(2 x 100) = 2865x103 N-mm
We also know that the torque transmitted by the shaft
T = (/16) d3 2865x103 = (/16) x 40 x d3
d = 71.4 say 75mm
DESIGN FOR MUFF
The diameter of the muff D = 2d + 13mm = 2x75 +13
= 163 say 165mm
Total length
JNTUACEP MECH.of the muffYESWANTH
DEPT L = 3.5
BASIREDDY
d = 3.5 x 75 = 262.5mm
KUMAR REDDY
48
Design a clamp coupling to transmit 30 kW at 100 r.p.m. The
allowable shear stress for the shaft and key is 40 MPa and the
number of bolts connecting the two halves are six. The
permissible tensile stress for the bolts is 70 MPa. The
coefficient of friction between the muff and the shaft surface
may be taken as 0.3.
DESIGN FOR KEY
From the tables the width and thickness of the key for the
shaft diameter of 75mm are
Width w = 22mm and thickness of key t = 14mm
Length of the key = length of the muff = 262.5mm
DESIGN FOR BOLTS
We know that the torque transmitted
T = x (2/16) x (db)2 x t x n x d
2865x103 = 0.3 x (2/16) x (db)2 x 70 x 6 x 75
(db) = 22.2mm
From the tables we find that the standard core diameter of
the JNTUACEP
bolt for coarse
MECH. DEPT series is 23.32mm
YESWANTH KUMAR REDDY and the nominal diameter
49
BASIREDDY
FLANGE COUPLING
A flange coupling usually applies to a coupling having
two separate cast iron flanges
Each flange is mounted on the shaft end and keyed to it
The faces are turned up at right angles to the axis of
the shaft.
One of the flange has a projected portion and the other
flange has corresponding recess.
Flange coupling is adopted to heavy loads and used on
large shafting
The flange couplings are of three types
1. Unprotected type flange coupling
2. Protected type flange coupling
3. Marine type flange coupling
BASIREDDY
UNPROTECTED TYPE FLANGE COUPLING

BASIREDDY
UNPROTECTED TYPE FLANGE COUPLING
The usual proportions for an unprotected type cast iron

flange couplings are as shown in the figure
Let d diameter of the shaft or inner diameter of the hub
Outside diameter of hub D = 2d
Length of the hub L = 1.5d
Pitch circle diameter of bolts D1 = 3d
Outside diameter of flange D2 = D1 +(D1 D) = 2D1 D = 4d
Thickness of flange tf = 0.5d
Number of bolts n = 3 for d upto 40mm
= 4 for d upto 100mm
= 6 for d upto 180mm

BASIREDDY
PROTECTED TYPE FLANGE COUPLING

BASIREDDY
PROTECTED TYPE FLANGE COUPLING
The protruding bolts and nuts are protected by flanges

on the two halves of the coupling in order to avoid
danger to the workman
The proportions of the coupling are same as for
unprotected type flange coupling except the thickness of
the protective circumferential flange (tp) and it is taken
as 0.25d

BASIREDDY
MARINE TYPE FLANGE COUPLING

BASIREDDY
MARINE TYPE FLANGE COUPLING
In this type the flanges are forged integral with the shafts
The flanges are held together by means of tapered
headless bolts
The number of bolts depends on the diameter of shaft and
it is selected from the following table.
The proportions for marine type flange coupling are
Thickness of flange = d/3
Taper of bolts = 1in 20 to 1 in 40
Pitch circle diameter of bolts D1 = 1.6d
Outside diameter of flange D2 = 2.2d

BASIREDDY
DESIGN OF FLANGE COUPLING
Let d diameter of shaft or inner diameter of hub;

D Outer diameter of hub; n number of bolts;
d1 Nominal or outside diameter of bolts;
D1 Diameter of bolt circle; tf thickness of flange;
s, b,k allowable shear stress for shaft, bolt and key
material
c allowable shear stress for the flange material
cb and ck allowable crushing stress for bolt and key
material
The design of flange coupling includes the design of
hub, key, flange and bolts

BASIREDDY
DESIGN OF HUB:
The hub is designed by considering it as a hollow shaft,
transmitting the same torque as that of solid shaft
T = (/16)c ((D4 d4)/D)
The outer diameter of hub is usually taken as twice the
diameter of shaft. The induced shearing stress in the hub
was checked.
The length of hub (L) is taken as 1.5d
DESIGN OF KEY
The length of the key is equal to the length of the hub.
The key is designed in the same way as in muff coupling
and then induced shearing and crushing stresses were
checked YESWANTH KUMAR REDDY
BASIREDDY
DESIGN OF FLANGE
The flange at the junction of the hub is under shear while
transmitting torque
Torque transmitted = circumference of hub x thickness of
flange x shear stress of flange x radius
of hub
T = D x tf x c x (D/2) = (D2 /2) x tf x c
The thickness of flange usually taken as half the
diameter of shaft. The induced shearing stress in the
flange was checked

BASIREDDY
DESIGN FOR BOLTS

The number of bolts (n) depends on the diameter of the shaft and pitch
circle diameter of bolts (D1) is taken as 3d.
Since the bolts were subjected to shear stress due to the torque
transmitted.
Load on each bolt = (/4) (d1)2
b
Total load on all the bolts = (/4) (d1)2

b n
Torque transmitted T = (/4) (d1)2

b n (D1/2)
The diameter of bolts is obtained from the above equation

The diameter of bolt will be checked for crushing stresses
Area resisting crushing = (n. d1. tf)
Crushing strength of all bolts = n. d1. tf)
cb
Torque T = (n. d1. tf)

cb (D1/2)
From this equation the induced crushing stress in the bolts is checked
BASIREDDY
Design a cast iron flange coupling for a mild steel shaft
transmitting 90 kW at 250 r.p.m. The allowable shear stress in the
shaft is 40 MPa and the angle of twist is not to exceed 1 in a
length of 20 diameters. The allowable shear stress in the coupling
bolts is 30 MPa.
Given :
P = 90kW = 90 103 W ; N = 250r.p.m; s = 40MPa = 40 N/mm2;
= 1 = /180 = 0.0175 rad ; b = 30MPa = 30 N/mm2
Finding the diameter of the shaft (d)
Torque transmitted T = (Px60)/(2N) = (90x103 x 60)/(2xx250)
T = 3440 103 N-mm
Considering strength of the shaft (T/J) = s/(d/2)
{3440x103/(d4/32)} = 40/(d/2) d = 76mm
Considering rigidity of the shaft
(T/J) = C /l
{3440x103/(d4/32)} = (84x103x0.0175/20d) d = 78mm
Taking the larger of the two values we have d= 78 say 80mm
BASIREDDY
bolts is 30 MPa.
DESIGN OF HUB
Outer diameter of the hub D = 2d = 2x80 = 160mm
Length of the hub L = 1.5d = 1.5 x 80 = 120mm
Checking the induced shear stress in the hub by considering
hub as hallow shaft
Torque transmitted T = (/16)
c ((D4 d4)/D)
3440x103 = (/16)
c ((160 80 )/160)
4 4
c = 4.56 Mpa
The induced shear stress is less than shear stress for the
hub material (cast iron) which is usually taken as 14MPa.
The design of hub is safe.

BASIREDDY
bolts is 30 MPa.
DESIGN OF KEY
From the tables for 80mm diameter shaft
Width of the key w = 25mm.
Thickness of key t is 14mm.
Length of the key (l) is taken equal to the length of hub (L)
l = L = 120mm
Assume the key and shaft are made of same material.
Checking the induced shear stress in the key
T = l . w . k . (d/2) 3440x103 = 120 x 25 x k x (80/2)
k = 28.7MPa
The induced shear stress in the key is less than 40MPa. The
design is safe
BASIREDDY
bolts is 30 MPa.
DESIGN OF FLANGE
The thickness of the flange (tf) = 0.5d = 0.5x80 = 40mm
Checking the induced stress
The torque transmitted T = (D2/2) tf
c
3440x103 = (1602/2) 40 c = 2.14MPa

c
The induced shear stress in flange is less than 14MPa. So,

the design is safe

BASIREDDY
bolts is 30 MPa.
DESIGN OF BOLTS
Let d1 be nominal diameter of bolts
For the diamter of the shaft with 80mm let us take number
of bolts n = 4
Pitch circle diameter of the bolts D1 = 3d = 3x80 = 240mm
Since the bolts are under shear stress. The torque
transmitted T = (d12/4) n
b (D1/2)
3440x103 = (d12/4) x 4 x 30 x (240/2) d1 = 17.4mm

Assuming coarse thread the standard nominal diameter of
bolts is 18mm
Outer diameter of the flange = D2 = 4d = 4x80 = 320mm
Thickness of the protective circumferential flange tp = 0.25d
JNTUACEP MECH. DEPT
tYESWANTH
p = 0.25 x 80
KUMAR = 20mm
REDDY
65
BASIREDDY
BUSHED PIN FLEXIBLE COUPLINGS
These flexible couplings are used to join abutting ends of shafts
when they are not in alignment.
This is also known as modified flange coupling.
In this the coupling bolts are known as pins
Rubber and leather bushes are used over the pins
The two halves of the couplings are not similar in construction
A clearance of 5mm is left between the face of the two halves of
the coupling
There is no rigid connection between the two halves and the
drive takes place through the medium of compressible rubber
and leather bushes.
The main modification is to reduce the bearing pressure on the
rubber and leather bushes and it should be less than 0.5N/mm 2
For low bearing pressure the pitch circle diameter and pin size is
increased YESWANTH KUMAR REDDY
BASIREDDY
BUSHED PIN FLEXIBLE COUPLINGS

BASIREDDY
DESIGN OF BUSHED PIN
FLEXIBLE COUPLINGS
Let l = length of bush in flange; d2 = diameter of bush;
Pb = bearing pressure on the bush or pin; n = number of pins
D1 = Diameter of pitch circle of the pins.
The bearing load acting on each pin W = Pb x d2 x l
Total bearing load acting on the bush or pins = W x n
= P b x d2 x l x n
The torque transmitted by the coupling T = W x n x (D1/2)
T = Pb x d2 x l x n x (D1/2)
The threaded portion of the pin in the right hand flange
should be a tapping fit in the coupling hole to avoid
bending stresses.
The threaded length of the pin should be as small as
possible so that the direct shear stress can be taken by the
unthreaded neck. YESWANTH KUMAR REDDY
BASIREDDY
FLEXIBLE COUPLINGS
Direct shear stress due to pure torsion in the coupling halves
= W/((d12)/4)
Since the pin and rubber or leather bush is not rigidly
held in the left hand flange.
The tangential load (W) at the enlarged portion will exert
a bending action on the pin.
The bush portion of the pin acts as a cantilever beam of
length l.
Assuming a uniformly distributed load W acting along the
bush

BASIREDDY
FLEXIBLE COUPLINGS
The maximum bending moment on the pin
M = W ((l/2) + 5mm)
Bending stress = M/Z = {W ((l/2) + 5mm)/ ((d13)/32)}
Since the pin is subjected to bending and shear stresses,
therefore the design must be checked either for the maximum
principal stress or maximum shear stress
Maximum principal stress = (1/2) ( + (2 + 42)1/2)
Maximum shear stress on the pin = (1/2) ((2 + 4)1/2)
The value of maximum principal stress varies from 28 to 42MPa
The design of hub, key and flange are same as in design of flange
coupling

BASIREDDY
OLDHAM COUPLING
It is used to join two shafts which have lateral misalignment
It consists of two flanges A and B with slots and a central
floating part E with two tongues T1 and T2 at right angles
The central floating part is held by means of a pin passing
through the flanges and the floating part

BASIREDDY
OLDHAM COUPLING
The tongue T1 fits into the slot of flange A and allows for
to and fro relative motion of the shafts
The tongue T2 fits into the slot of the flange B and allows
for vertical relative motion of the parts.
The resultant of these two components of motion will
accommodate lateral misalignment of the shaft as they
rotate.

BASIREDDY
UNIVERSAL COUPLING
This is also known as Hookes coupling.
This is used to connect two shafts whose axes intersect at
small angles
The inclination of the shafts may be constant but it varies in
actual practice when the motion is transmitted from one shaft
to another
This is used in automobiles to transmit power from gear box
to the differential unit
One end of the shaft is connected to gear box and the other
end is connected to differential unit
This type of couplings are also used for transmission of power
to different spindles of multiple drilling machine.
It is used as knee joint in milling machine
BASIREDDY
DESIGN OF UNIVERSAL JOINT

BASIREDDY
DESIGN OF UNIVERSAL JOINT
Let d diameter of the shaft; db diameter of the pin;
and 1 allowable shear stress for the material of the shaft
and pin.
The torque transmitted by the shaft T = (/16) x x d3
From the above equation the diameter of the shaft is
obtained.
Since the pin is in double shear, the torque transmitted
T = 2 x (/4) x (dp)2 x
1 x d
From the above equation the diameter of the pin is obtained.

The other dimensions of the universal joint will be taken as
shown in the figure.

BASIREDDY
An universal coupling is used to connect two mild steel shafts
transmitting a torque of 5000 N-m. Assuming that the shafts are
subjected to torsion only, find the diameter of the shafts and pins.
The allowable shear stresses for the shaft and pin may be taken as
60 MPa and 28 MPa respectively.
Given T = 5000 N-m = 5x106 N-mm; = 60MPa = 60N/mm2;
1 = 28MPa = 28N/mm ;
2
DIAMETER OF THE SHAFT (d)

The torque transmitted T = (/16) x x d3
5x106 = /16) x 60 x d3 d = 75mm
DIAMETER OF PINS (dp)
the torque transmitted T = 2 x (/4) x (dp)2 x
1 x d
5x106 = 2 x (/4) x (dp)2 x 28 x 75 dp = 39 say 40mm

BASIREDDY
REFERENCES
Machine design by R.S.Khurmi
and Guptha
A textbook of machine design by
S.Md.Jalaludeen
Machine design by Pandya and
Shah
Design of machine elements by
V.B.Bandari
BASIREDDY
THE END

BASIREDDY

Keys and Couplings

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Keys and Couplings

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YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

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YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

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YESWANTH KUMAR REDDY

F1 is the compressive stresses in the key caused by the torque transmitted

F = Area resisting shearing x Shear stress = l.w.

Torque transmitted by the shaft T = F . (d/2)

YESWANTH KUMAR REDDY

T = F . (d/2) = l . (t/2) .c . (d/2)

T = l . (t/2) .c . (d/2) (ii)

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

Equating both shear strength of the key and torsional

YESWANTH KUMAR REDDY

Max. torque transmitted by shaft and key

YESWANTH KUMAR REDDY

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YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

Keyway YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

DESIGN OF CLAMPING BOLTS

YESWANTH KUMAR REDDY

The usual proportions for an unprotected type cast iron

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

The protruding bolts and nuts are protected by flanges

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

Let d diameter of shaft or inner diameter of hub;

YESWANTH KUMAR REDDY

YESWANTH KUMAR REDDY

DESIGN FOR BOLTS

Total load on all the bolts = (/4) (d1)2

Torque transmitted T = (/4) (d1)2

The diameter of bolts is obtained from the above equation

Torque T = (n. d1. tf)

YESWANTH KUMAR REDDY

3440x103 = (1602/2) 40 c = 2.14MPa

The induced shear stress in flange is less than 14MPa. So,

YESWANTH KUMAR REDDY

3440x103 = (d12/4) x 4 x 30 x (240/2) d1 = 17.4mm