Mechanical Keys Theory

Introduction To Mechanical Key:
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.,
• keys are used to prevent relative rotation but sometimes may allow sliding
movement along the shaft if required.
• Keys are temporary fastening and are always made of mild steel because they are
subjected to shearing and compressive stresses caused by the torque they
transmit.
• A keyway is the groove cut in the shaft or hub to accommodate a key. Keyways
can be milled horizontally or vertically.
Functions of Key:
a) To transmit torque from shaft to hub of the mating element such as the pulley,
gear, etc.
b)To prevent relative motion between the shaft & mating machine element
Types Of Keys:
There is a large variety of machine keys and they may be classified under four
broad headings:
 Sunk keys,
 Flat keys,
 Saddle keys
 Pins or round keys
Sunk keys may be further classified into the following categories:
(a) Rectangular sunk keys
Rectangular sunk keys are shown in figure- They are the simplest form of machine
keys and may be either straight or slightly tapered on one side. The parallel side is
usually fitted into the shaft.
(b) Gib head sunk keys
The gib head keys are ordinary sunk keys tapered on top with a raised head on
one side so that its removal is easy.
(c) Feather keys
A feather key is used when one component slides over another. The key may be
fastened either to the hub or the shaft and the keyway usually has a sliding fit.
(d) Woodruff keys
A woodruff key is a form of sunk key where the key shape is that of a
truncated disc, as shown in the figure-. It is usually used for shafts less than
about 60 mm diameter and the keyway is cut in the shaft using a milling
cutter. It is widely used in machine tools and automobiles due to the extra
advantage derived from the extra depth. Steel keys are widely used in
securing machine parts such as gears and pulleys.
Saddles keys are sub-classified as :
1. Hollow saddle key

2. Flat saddle key
A flat key, as shown in figure- is used for light load because they depend entirely
on friction for the grip. The sides of these keys are parallel but the top is slightly
tapered for a tight fit. Theses keys have about half the thickness of sunk keys.
A saddle key, shown in figure- is very similar to a flat key except that the bottom
side is concave to fit the shaft surface. These keys also have friction grip and
therefore cannot be used for heavy loads. A simple pin can be used as a key to
transmit large torques. Very little stress concentration occurs in the shaft in these
cases.
Round Keys are sub-classified as,
1. Parallel pin
2. Taper pin
Lewis keys, shown in figure- are expensive but offer excellent service.
They may be used as a single or double key. When they are used as a single key
the positioning depends on the direction of rotation of the shaft.
Spline shaft and hub:

A spline shaft is used when the hub is required to slide along the shaft. These
shafts are used mostly for sliding gear applications as in the automotive gearbox
and propeller shaft of aircraft.
• By this means the power transmitted is equally divided amongst the number of
keys giving
• A spline shaft in which are cut equiangular longitudinal groove, the metal between
these grooves forming splines or feathers of uniform depth. great strength and
security against total failure than by using a single key.
Design Consideration of key :
1) Power to be transmitted.
2) Tightness of fit
3) Stability of connection
4) Cost
5) Crushing failure of key:
6) shearing failure of key
7) The material of key, shaft should be the same but the key should be weaker
than the shaft.
Application Of Mechanical Keys :

1) Sunk Key: used for heavy-duty application
a) Rectangular sunk key: for preventing rotation of gears and pulleys on the
shaft
b) Gib headed key: used where the key to be removed frequently.
c) feather key: Machine tool
2) Saddle key: for light-duty or low power transmission
3) Round key: Used for low Power drive
4) Splines: Where providing axial movement between the shaft and mounted
member
Keyway Design :
Effect of Keyway on strength of shaft:
 The keyway is a slot machined either on the shaft or in the hub to

accommodate the key. It is cut by a vertical or horizontal milling cutter.
 A little consideration will show that the keyway cut into the shaft reduces the
load-carrying capacity of the shaft.
 This is due to the stress concentration near the corners of the keyway and
reduction in the cross-sectional area of the shaft. It other words, the
torsional strength of the shaft is reduced.

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Introduction To Mechanical Key:

Sunk keys may be further classified into the following categories:

(a) Rectangular sunk keys

(b) Gib head sunk keys

(d) Woodruff keys

Saddles keys are sub-classified as :

1. Hollow saddle key

Round Keys are sub-classified as,

Spline shaft and hub:

Application Of Mechanical Keys :

 The keyway is a slot machined either on the shaft or in the hub to

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