Key and Coupling Solutions

SECTION 8 KEYS AND COUPLINGS
1

FLAT AND SQUARE KEYS
DESIGN PROBLEMS
521. A 2-in. shaft, of cold-drawn AISI 1137, has a pulley keyed to it. (a) Compute the length of square
key and the length of flat key such that a key made of cold-drawn C1020 has the same yield
strength as the shaft does in pure torsion. (b) The same as (a), except that the key material is
AISI 2317, OQT 1000 F. (c) Would you discard either of these keys? Explain.

Solution:
For AISI 1137 shaft, Table AT 8, sy = 93 ksi
Yield Strength of Shaft
s
ys
= 0.6s
y
= 0.6(93) = 55.8 ksi
( )( )( )
kips in
D s
T
ys
= = = 65 87
16
2 8 55
16
3
3
.
.

(a) Key Material, cold-drawn, C1020, Table AT 7
s
y
= 66 ksi
s
ys
= 0.6sy = 0.6(66) = 39.6 ksi
Table AT 19, use b = in , t = 3/8 in.
For square key, b = t = in.
By shear, s
s
= s
ys

( )
( )( )
in
bD s
T
L
s
43 4
2 2 1 6 39
65 87 2 2
.
.
.
= = =
By compression, s
c
= s
y
. Key has lowest yield strength.
( )
( )( )
in
tD s
T
L
c
32 5
2 2 1 66
65 87 4 4
.
.
= = =
Use L = 5.32 in

For Flat key, b = in , t = 3/8 in.
By shear, s
s
= s
ys

( )
( )( )
in
bD s
T
L
s
43 4
2 2 1 6 39
65 87 2 2
.
.
.
= = =
By compression, s
c
= s
y
( )
( )( )
in
tD s
T
L
c
09 7
2 8 3 66
65 87 4 4
.
.
= = =
Use L = 7.09 in
(b) Key Material, AISI 2317, QOT 1000 F. Table AT 8
s
y
= 71 ksi
s
ys
= 0.6sy = 0.6(71) = 42.6 ksi
Table AT 19, use b = in , t = 3/8 in.
For square key, b = t = in.
By shear, s
s
= s
ys

( )
( )( )
in
bD s
T
L
s
12 4
2 2 1 6 42
65 87 2 2
.
.
.
= = =
By compression, s
c
= s
y
2

( )
( )( )
in
tD s
T
L
c
94 4
2 2 1 71
65 87 4 4
.
.
= = =
Use L = 4.94 in

For Flat key, b = in , t = 3/8 in.
By shear, s
s
= s
ys

( )
( )( )
in
bD s
T
L
s
12 4
2 2 1 6 42
65 87 2 2
.
.
.
= = =
By compression, s
c
= s
y
( )
( )( )
in
tD s
T
L
c
59 6
2 8 3 71
65 87 4 4
.
.
= = =
Use L = 6.59 in

(c) Either of the above is not to be discarded since they are designed based on yield strength with
the same factor of safety.

522. A cast-iron pulley transmits 65.5 hp at 1750 rpm. The 1045 as-rolled shaft to which it is to be
keyed is 1 in. in diameter; key material, cold-drawn 1020. Compute the length of flat key and
of square key needed.
Solution:
For shaft: 1045 as-rolled, Table AT 7, s
y
= 59 ksi
For key: Cold-drawn 1020, s
y
= 66 ksi
D = 1 in = 1.75 in
hp = 65.5 hp, n = 1750 rpm

( )
kips in lb in
n
hp
T = = = = 358 2 2358
1750
5 65 000 63 000 63
.
. , ,

Table AT 19, use b = 3/8 in, t = 1/4 in for D = 1 in
Assume smooth load, N = 1.5

For Flat key, b = 3/8 in, t = 1/4 in.
By shear,
s
ys
= 0.6sy = 0.6(66) = 39.6 ksi
ksi
N
s
s
ys
s
4 26
5 1
6 39
.
.
.
= = =
( )
( )( )
in
bD s
T
L
s
272 0
75 1 8 3 4 26
358 2 2 2
.
. .
.
= = =
By compression, use s
y
of shaft the lowest. Pulley has the highest compressive strength (Cast iron).
ksi
N
s
s
y
c
3 39
5 1
59
.
.
= = =
( )
( )( )
in
tD s
T
L
c
549 0
75 1 4 1 3 39
358 2 4 4
.
. .
.
= = =
Use L = 0.549 in - answer

3

For Square key, b = 3/8 in, t = 3/8 in.
By shear, s
s
= s
ys

s
ys
= 0.6s
y
= 0.6(66) = 39.6 ksi
ksi
N
s
s
ys
s
4 26
5 1
6 39
.
.
.
= = =
( )
( )( )
in
bD s
T
L
s
272 0
75 1 8 3 4 26
358 2 2 2
.
. .
.
= = =
y
of shaft the lowest. Pulley has the highest compressive strength (Cast iron).
ksi
N
s
s
y
c
3 39
5 1
59
.
.
= = =
( )
( )( )
in
tD s
T
L
c
366 0
75 1 8 3 3 39
358 2 4 4
.
. .
.
= = =
Use L = 0.366 in - answer

523. A 3 -in. shaft transmits with medium shock 85 hp at 100 rpm. Power is received through a
sprocket (annealed nodular iron 60-45-10) keyed to the shaft of cold-rolled AISI 1040 (10%
work), with a key of cold-finished B1113. What should be the length of (a) a square key? (b) a
flat key?

Solution:
For sprocket, annealed nodular iron, 60-45-10, Table AT 6, s
y
= 55 ksi
For shaft, cold-rolled AISI 1040 (10% work), Table AT 10, s
y
= 85 ksi
For key, cold-finished B1113, Table AT 7, s
y
= 72 ksi

D = 3 in = 3.25 in
hp = 85 hp
n = 100 rpm

( )
kips in lb in
n
hp
T = = = = 55 53 550 53
100
85 000 63 000 63
. ,
, ,

Table AT 19, use b = in, t = 1/2 in for D = 3 in
For medium shock, N = 2.25
(a) Square key,
b = in, t = in.
By shear,
s
ys
= 0.6s
y
= 0.6(72) = 43.2 ksi
ksi
N
s
s
ys
s
2 19
25 2
2 43
.
.
.
= = =
( )
( )( )
in
bD s
T
L
s
29 2
25 3 4 3 2 19
55 53 2 2
.
. .
.
= = =
y
of sprocket the lowest.
ksi
N
s
s
y
c
4 24
25 2
55
.
.
= = =
( )
( )( )
in
tD s
T
L
c
60 3
25 3 4 3 4 24
55 53 4 4
.
. .
.
= = =
4

Use L = 3.60 in. - answer
(b) Flat key,
b = in, t = in.
By shear, s
s
= s
ys

s
ys
= 0.6s
y
= 0.6(72) = 43.2 ksi
ksi
N
s
s
ys
s
2 19
25 2
2 43
.
.
.
= = =
( )
( )( )
in
bD s
T
L
s
29 2
25 3 4 3 2 19
55 53 2 2
.
. .
.
= = =
y
of sprocket the lowest.
ksi
N
s
s
y
c
4 24
25 2
55
.
.
= = =
( )
( )( )
in
tD s
T
L
c
40 5
25 3 2 1 4 24
55 53 4 4
.
. .
.
= = =

524. A cast-steel gear (SAE 0030), with a pitch diameter of 36 in., is transmitting 75 hp at 210 rpm to
a rock crusher, and is keyed to a 3-in. shaft (AISI 1045, as rolled); the key is made of AISI C1020,
cold drawn. For a design factor of 4 based on yield strength, what should be the length of (a) a
square key, (b) flat key? (c) Would either of these keys be satisfactory?
Solution:
For cast-steel gear (SAE 0030), Table AT 6, s
y
= 35 ksi
For shaft, AISI 1045, as rolled, Table AT 7, s
y
= 59 ksi
For key, AISI C1020, cold-drawn, Table AT 7, s
y
= 66 ksi

D = 3 in
hp = 75 hp
n = 210 rpm

( )
kips in lb in
n
hp
T = = = = 5 22 500 22
210
75 000 63 000 63
. ,
, ,

Table AT 19, use b = in, t = 1/2 in for D = 3 in
Design factor, N = 4
(a) Square key,
b = in, t = in.
By shear,
s
ys
= 0.6s
y
= 0.6(66) = 39.6 ksi
ksi
N
s
s
ys
s
9 9
4
6 39
.
.
= = =
( )
( )( )
in
bD s
T
L
s
02 2
3 4 3 9 9
5 22 2 2
.
.
.
= = =
y
of cast-steel gear the lowest.
ksi
N
s
s
y
c
75 8
4
35
. = = =
5

( )
( )( )
in
tD s
T
L
c
57 4
3 4 3 75 8
5 22 4 4
.
.
.
= = =
(b) Flat key,
b = in, t = in.
By shear, s
s
= s
ys

s
ys
= 0.6s
y
= 0.6(66) = 39.6 ksi
ksi
N
s
s
ys
s
9 9
4
6 39
.
.
= = =
( )
( )( )
in
bD s
T
L
s
02 2
3 4 3 9 9
5 22 2 2
.
.
.
= = =
y
of cast-steel gear the lowest.
ksi
N
s
s
y
c
75 8
4
35
. = = =
( )
( )( )
in
tD s
T
L
c
86 6
3 2 1 75 8
5 22 4 4
.
.
.
= = =

525. An electric motor delivers 50 hp at 1160 rpm to a 1 5/8 in. shaft (AISI 13B45, OQT 1100 F). Keyed
to this shaft is a cast-steel (SAE 080, N & T) pulley whose hub is 2 in. long. The loading may be
classified as mild shock. Decide upon a key for this pulley (material), investigating both flat and
square keys.
Solution:
hp = 50 hp
n = 1160 rpm
D = 1 5/8 in = 1.625 in
Shaft material AISI 13B45, OQT 1100 F, Table AT 10, s
y
= 112 ksi
Pulley material SAE 080, N & T, Table AT 6, s
y
= 40 ksi
L = 2 in
N = 2.0 to 2.25 for mild shock
From Table AT 19 for D = 1 5/8 in
b = 3/8 in, t = in
( )
kips in lb in
n
hp
T = = = = 716 2 716 2
1160
50 000 63 000 63
. ,
, ,

For flat key: b = 3/8 in, t = in
Check for compression:
( )
( )( )( )
ksi
LtD
T
s
c
37 13
625 1 4 1 2
716 2 4 4
.
.
.
= = =
Based on pulley material, 25 2 99 2
37 13
40
. .
.
> = = =
c
y
s
s
N
Therefore safe in compression.
Determine the yield stress on the key
( )
( )( )( )
ksi
LbD
T
s
s
457 4
625 1 8 3 2
716 2 2 2
.
.
.
= = =
6

25 2. = N
s y ys
Ns s s = = 6 0.
( )( ) 457 4 25 2 6 0 . . . =
y
s
ksi s
y
7 16. =
Min. ( )( ) ksi s
y
30 25 2 37 13 = = . . - Minimum yield strength of key material required.
Select SAE 003, Table AT 6, s
y
= 35 ksi Answer.

For square key: b = t = 3/8 in
Check for compression:
( )
( )( )( )
ksi
LtD
T
s
c
914 8
625 1 8 3 2
716 2 4 4
.
.
.
= = =
Based on pulley material, 25 2 49 4
914 8
40
. .
.
> = = =
c
y
s
s
N
Therefore safe in compression.
Determine the yield stress on the key
( )
( )( )( )
ksi
LbD
T
s
s
457 4
625 1 8 3 2
716 2 2 2
.
.
.
= = =
25 2. = N
s y ys
Ns s s = = 6 0.
( )( ) 457 4 25 2 6 0 . . . =
y
s
ksi s
y
7 16. =
Min. ( )( ) ksi s
y
20 25 2 914 8 = = . . - Minimum yield strength of key material required.
Select SAE 003, Table AT 6, s
y
= 35 ksi Answer.

CHECK PROBLEMS
526. A cast-steel (SAE 080, N & T) pulley, attached to a 2-in. shaft, is transmitting 40 hp at 200 rpm,
and is keyed by a standard square key, 3 in. long, made of SAE 1015, cold drawn; shaft material,
C1144, OQT 1000 F. (a) What is the factor of safety of the key? (b) The same as (a) except a flat
key is used.
Solution:
Pulley, Cast steel, SAE 080, N & T, Table AT 6, s
y
= 40 ksi
Key, SAE 1015, cold drawn, Table AT 7, s
y
= 63 ksi
Shaft, C1144, OQT 1000 F, s
y
= 83 ksi
hp = 40 hp
N = 200 rpm
D = 2 in
L = 3 in

( )
kips in lb in
n
hp
T = = = = 6 12 600 12
200
40 000 63 000 63
. ,
, ,

Table AT 19, D = 2 in
b = in, t = 3/8 in

7

a) Square key, b = in, t = in
By shear:
( )
( )( )( )
ksi
LbD
T
s
s
4 8
2 2 1 3
6 12 2 2
.
.
= = =
( )
50 4
4 8
63 6 0
6 0
.
.
.
.
= = = =
s
y
s
ys
s
s
s
s
N < 6.21
By compression:
( )
( )( )( )
ksi
LtD
T
s
c
8 16
2 2 1 3
6 12 4 4
.
.
= = =
( )
38 2
8 16
40
.
.
= = =
c
y
s
pulley s
N < 6.21
Answer N = 2.38

b) Flat key, b = in, t = 3/8 in
By shear:
( )
( )( )( )
ksi
LbD
T
s
s
4 8
2 2 1 3
6 12 2 2
.
.
= = =
( )
50 4
4 8
63 6 0
6 0
.
.
.
.
= = = =
s
y
s
ys
s
s
s
s
N < 6.21
By compression:
( )
( )( )( )
ksi
LtD
T
s
c
4 22
2 8 3 3
6 12 4 4
.
.
= = =
( )
78 1
4 22
40
.
.
= = =
c
y
s
pulley s
N < 6.21
Answer N = 1.78

527. A cast-steel (SAE 080, N & T) pulley is keyed to a 2 1/2-in. shaft by means of a standard square
key, 3 -in. long, made of cold-drawn SAE 1015. The shaft is made of cold-drawn AISI 1045. If
the shaft is in virtually pure torsion, and turns at 420 rpm, what horsepower could the assembly
safely transmit (steady loading)?

Solution:
y
= 40 ksi
y
= 63 ksi
Shaft, AISI 1045, cold drawn, Table AT 7, s
y
= 85 ksi
N = 420 rpm
L = 3 in = 3.5 in
D = 2 in
b = 5/8 in, t = 7/16 in
Square Key, b = t = 5/8 in
N = 1.5 for steady loading (smooth)
For shaft:
8

( )
( )( )( )
( )
kips in
N
D s
D s
T
y
s
= = = = 31 104
16 5 1
5 2 85 6 0
16
6 0
16
3 3
3
.
.
. .
.

Key:

By shear:
2
LbD s
T
s
=
( )
ksi
N
s
N
s
s
y ys
s
2 25
5 1
63 6 0
6 0
.
.
.
.
= = = =
( )( )( )( )
kips in T = = 9 68
2
5 2 8 5 5 3 2 25
.
. . .
< 104.31 in-kips
By compression:
4
LtD s
T
c
=
( )
ksi
N
pulley s
s
y
c
67 26
5 1
40
.
.
= = =
( )( )( )( )
kips in T = = 46 36
4
5 2 8 5 5 3 67 26
.
. . .
< 104.31 in-kips
Use kips in kips in T = = 460 36 46 36 , .
( )
hp
Tn
hp 243
000 63
420 460 36
000 63
= = =
,
,
,

528. The same as 527, except that the diameter is 3 in. and the length of the key is 5 in.

Solution:
y
= 40 ksi
y
= 63 ksi
Shaft, AISI 1045, cold drawn, Table AT 7, s
y
= 85 ksi
N = 420 rpm
L = 5 in
D = 3 in
b = 3/4 in, t = 1/2 in
Square Key, b = t = 3/4 in
N = 1.5 for steady loading (smooth)
For shaft:
( )
( )( )( )
( )
kips in
N
D s
D s
T
y
s
= = = = 25 180
16 5 1
3 85 6 0
16
6 0
16
3 3
3
.
.
.
.

Key:
By shear:
2
LbD s
T
s
=
9

( )
ksi
N
s
N
s
s
y ys
s
2 25
5 1
63 6 0
6 0
.
.
.
.
= = = =
( )( )( )( )
kips in T = = 75 141
2
3 4 3 5 2 25
.
.
< 180.25 in-kips
By compression:
4
LtD s
T
c
=
( )
ksi
N
pulley s
s
y
c
67 26
5 1
40
.
.
= = =
( )( )( )( )
kips in T = = 75
4
3 4 3 5 67 26.
< 180.25 in-kips

Use kips in kips in T = = 000 75 75 ,
( )
hp
Tn
hp 500
000 63
420 000 75
000 63
= = =
,
,
,

MISCELLANEOUS KEYS
529. Two assemblies, one with one feather keys, are shown, with the assumed positions of the
normal forces N. Each assembly is transmitting a torque T. Derive an equation for each case
giving the axial force needed to slide the hub along the shaft (f = coefficient of friction). Does
either have an advantage in this respect?

Solution:
a)
2
ND
T =
D
T
N
2
=
Axial force =
D
fT
fN F
2
= =
b) ND
ND
T = =
2
2

D
T
N =
Axial force =
D
fT
fN F = =
Assembly (b) is stronger than assembly (a) which has an axial force half that of assembly (b).
10

530. A 1 11/16-in. shaft rotating at 200 rpm, carries a cast-iron gear keyed to it by a x 1 -in.
Woodruff key; shaft material is cold-finished SAE 1045. The power is transmitted with mild
shock. What horsepower may be safely transmitted by the key, (a) if it is made of cold-drawn
SAE 1118? (b) if it is made of SAE 2317, OQT 1000 F? (c) How many keys of each material are
needed to give a capacity of 25 hp? Specify a choice.
Solution:
Only shear is used.
D = 1 11/16 in
n = 200 rpm
Woodruff key = x 1 in
N = 2 for mild shock

Shear force for key
s s
A s
D
T
F = =
2

2
D A s
T
s s
=
Table 10.1, x 1 in Woodruff Key is Key No. 810
Shear area, A
s
= 0.296 sq. in.
(a) Key, cold-drawn 1118, Table AT 7, s
y
= 75 ksi
( )
ksi
N
s
N
s
s
y ys
s
5 22
2
75 6 0
6 0
.
.
.
= = = = < 24.06 ksi
( )( )
lb in kips in T = =
|
\
|
= 5620 62 5
2
16
11
1 296 0 5 22
.
. .

( )( )
hp
Tn
hp 84 17
000 63
200 5620
000 63
.
, ,
= = =
(b) Key, SAE 2317, OQT 1000F, Table AT 7, s
y
= 79 ksi
( )
ksi
N
s
N
s
s
y ys
s
7 23
2
79 6 0
6 0
.
.
.
= = = = < 24.06 ksi
( )( )
lb in kips in T = =
|
\
|
= 5920 92 5
2
16
11
1 296 0 7 23
.
. .

( )( )
hp
Tn
hp 79 18
000 63
200 5920
000 63
.
, ,
= = =
(c) Number of keys for (a) = 25 / 17.84 = 1.4 or 2 keys
Number of keys for (b) = 25 / 18.79 = 1.33 or 2 keys
Select (b) which is stronger.

531. A 3/16 x 1-in. Woodruff key is used in a 1 3/16-in. shaft (cold-drawn SAE 1045). (a) If the key is
made of the same material, will it be weaker or stronger than the shaft in pure torsion? (b) If the
key is made of SAE 4130, WQT 1100 F, will it be weaker or stronger? For the purposes here, the
weakening of the shaft by the keyway is ignored.

11

Solution:
Woodruff key, 3/16 x 1 in.
D = 1 3/16 in
Shaft: Cold drawn, SAE 1045 (Table AT 8) s
y
= 85 ksi
2
D A s
T
s s
=
Table 10.1, 3/16 x 1 in., Woodruff key is Key no. 608.
Shear area = A
s
= 0.178 sq. in.
(a) Key material = Shaft Material
In yield: For key
( )( )
kips in
D A s
D A s
T
s y
s s
=
|
\
|
= = = 39 5
2
16
3
1 178 0 85 6 0
2
6 0
2
.
. .
.

For shaft:
( )( )
kips in
D s
D s
T
y
s
=
|
\
|
= = = 77 16
16
16
3
1 85 6 0
16
6 0
16
3
3
3
.
.
.

Therefore the key is weaker.
(b) Key material = SAE 4130, WQT 1100, Table AT 7, s
y
= 114 ksi
In yield: For key
( )( )
kips in
D A s
D A s
T
s y
s s
=
|
\
|
= = = 23 7
2
16
3
1 178 0 114 6 0
2
6 0
2
.
. .
.

For shaft:
( )( )
kips in
D s
D s
T
y
s
=
|
\
|
= = = 77 16
16
16
3
1 85 6 0
16
6 0
16
3
3
3
.
.
.

Therefore the key is weaker.

532. A 2-in. shaft (cold-finished SAE 1137) is connected to a hub by a 3/8-in. radial taper pin made of
4150, OQT 1000 F. (a) What horsepower at 1800 rpm would be transmitted when the pin is
about to be sheared off? (b) For this horsepower, what peak torsional stress may be repeated in
the shaft? Is the shaft safe from fatigue at this stress?

Solution:
D = 2 in
d = 3/8 in
n = 1800 rpm
(a) For pin material , 4150, OQT 1000 F, Table AT9, su = 193.5 ksi
( ) ( )
|
|
\
|
=
|
|
\
|
= =
2 4
2 2
2 2
d
s
d
s A s F
s s s s

D d s
D d
s
FD
T
s s
2
2
4
1
2 2 2
= |
\
|
|
|
\
|
= =
( ) ksi s s s
u us s
1 145 5 193 75 0 75 0 . . . . = = = =
12

( )( ) ( ) lb in kips in T = =
|
\
|
= 050 32 05 32 2
8
3
1 145
4
1
2
, . .
( )( )
hp
Tn
hp 7 915
000 63
1800 050 32
000 63
.
,
,
,
= = =
(b) For shaft, cold-finished, SAE 1137, Table AT 8, s
u
= 103 ksi
ksi
s
s s
u
n ns
96 30
2
103
6 0
2
6 0 6 0 . . . . = |
\
|
= |
\
|
= =

But,
( )
( )
ksi ksi psi
D
T
s
s
96 30 4 20 404 20
2
050 32 16 16
3 3
. . ,
,
< = = = =

52 1
4 20
96 30
.
.
.
= = =
s
ns
s
s
N > 1.5, therefore safe from fatigue at this stress.

533. A 20-in. lever is keyed to a 1 7/8-in. shaft (cold-finished SAE 1141) by a radial taper pin whose
mean diameter is 0.5 in.; pin material, C1095, OQT 800 F. The load on the lever is repeatedly
reversed; N = 2 on endurance strength. What is the safe lever load (a) for the shaft, (b) for the
pin key (shear only), (c) for the combination?
Solution:
T = FL where F = safe lever load.
L = 20 in
D = 1 7/8 in = 1.875 in
Shaft Material, cold finished, SAE 1141, Table AT 10.
ksi s
y
90 =
8 1. =
n
y
s
s

ksi s
n
50
8 1
90
= =
.

Pin Material, C1095, OQT 800 F, Table AT 9.
ksi s
u
176 =
( ) ksi s s
u n
88 176 5 0 5 0 = = = . .
(a) For the shaft.
( )
ksi
N
s
s
y
s
15
2
50 6 0
6 0
= = =
.
.

( )( )
lbs in kips in
D s
T
s
= = = = 414 19 414 19
16
875 1 15
16
3 3
, .
.

FL T =
( ) 20 414 19 F = ,
lb F 7 970. =
(b) For the pin.
( )
ksi
N
s
s
y
s
4 26
2
88 6 0
6 0
.
.
.
= = =
13

( )
3
2
4
4
2
2
d
T
d d
T
A
d T
s
s
s
= = =
( )( )
lbs in kips in
d s
T
s
= = = = 2592 592 2
4
5 0 4 26
4
3 3
.
. .

FL T =
( ) 20 2592 F =
lb F 6 129. =
(c) For the combination.
Use lb F 6 129. =

534. A lever is keyed to a 2 -in. shaft made of SAE 1035, as rolled, by a radial taper pin, made of SAE
1020, as rolled. A load of 200 lb. is applied to the lever 22 in. from the center of the shaft. (a)
What size pin should be used for N = 3 based on the yield strength in shear? (b) Let the hub
diameter be 5 in. and assume that the part of the pin in the hub is uniformly loaded cantilever
beam. Compute the bending stress and comment on the bending strength (especially if the
loading varies).
Solution:
Shaft material, SAE 1035, as rolled, Table AT 7, s
y
= 55 ksi
Pin material, SAE 1020, as rolled, Table AT 7, s
y
= 48 ksi
F = 200 lb, L = 22 in, N = 3
D = 2 in, D
h
= 5 in
T = FL = (200)(22) = 4400 in-lb = 4.4 in-kips
(a) For the pin:
( )
ksi
N
s
s
y
s
6 9
3
48 6 0
6 0
.
.
.
= = =
( )
3
2
4
4
2
2
d
T
d d
T
A
d T
s
s
s
= = =
( )
3
4 4 4
6 9
d
.
. =
in d 836 0. =
Use in in d 875 0
8
7
. = =
(b) For the bending stress.
As cantilever beam let
( ) D D L
h
=
2
1

( ) in L 25 1 5 2 5
2
1
. . = =
From Table AT 2.
2 2
2
FL wL
M = =
Where F is the uniform load.
14

( )
lb
D D
T
D
T
F
h m
2347
5 2 5
4400 4 4 2
2 =
+
=
+
= =
.

lb F 1174 =
( )( )
lb
FL
M 734
2
25 1 1174
2
= = =
.

Bending stress
( )
( )
ksi psi
d
M
s
b
16 11 160 11
875 0
734 32 32
3 3
. ,
.
= = = =

If the loading varies and factor of safety of 3.
( ) ksi Ns s
b n
48 33 16 11 3 . . = = =
Pin material, SAE 1020, as rolled, Table AT 7, s
y
= 48 ksi, s
u
= 65 ksu.
( ) ksi s s
u n
5 32 65 5 0 5 0 . . . = = =

The bending stress is nearly safe as the load varies.

535. A sprocket, transmitting 10 hp at 100 rpm, is attached to a 1 7/16 in. shaft as shown in Fig.
10.15, p. 290., Text; E = 3-1/2 in. What should be the minimum shear pin diameter if the
computed stress is 85% of the breaking stress mentioned in the Text?
Solution:
hp = 10 hp, n = 100 rpm, D = 1 7/16 in = 1.4375 in, E = 3 in = 3.5 in
( )
lb in
n
hp
T = = = 6300
100
10 000 63 000 63 , ,

lb
E
T
F 1800
5 3
6300
= = =
.

From text, Page 290. Breaking stress = 50,000 psi
( ) psi s
s
500 42 000 50 85 0 , , . = =
2
4
d
F
s
s
=
( )
2
1800 4
500 42
d
= ,
in d 2322 0. = use in.

536. A gear is attached to a 2-in. shaft somewhat as shown in Fig. 10-15, p. 290, Text; E = 3 5/16 in.;
minimum shear-pin diameter = 3/8 in. with a rated torque of 22 in-kips. (a) For this torque,
compute the stress in the shear pin. (b) From the ferrous metals given in the Appendix, select
those that would give a resisting torque of about 110% of the rated value. Choose one,
specifying its heat treatments or other conditions.
Solution:
D = 2 in
E = 3 5/16 in = 3.3125 in
d = 3/8 in
T = 22 in-kips
(a) Stress in shear-pin
lb
E
T
F 64 6
3125 3
22
.
.
= = =

15

( )
( )
ksi s
s
12 60
8 3
64 6 4
2
.
.
= =

(b) Select material. ( ) ksi s
us
13 66 12 60 1 1 . . . = =
From appendix, Table AT 7, select Cold drawn, C1020 with s
us
= 66 ksi

SPLINES
537. A shaft for an automobile transmission has 10 splines with the following dimensions: D = 1.25
in., d = 1.087 in., and L = 1.000 in. (see Table 10.2, p. 287, Text). Determine the safe torque
capacity and horsepower at 3600 rpm of this sliding connection.
Solution:
D = 1.25 in, d = 1.087 in, L = 1.000 in, N
t
= 10, n = 3600 rpm
( )( )( )( ) lb in N r hL T
t m
= 1000
4
d D
r
m
+
=
Table 10.2 for 10 splines, sliding connection
D h 095 0. =
Then
( ) in h 11875 0 25 1 095 0 . . . = =
But
in
d D
h 0815 0
2
087 1 25 1
2
.
. .
=
= actual
in r
m
58425 0
4
087 1 25 1
.
. .
=
+
=
( )( )( )( )( ) lb in T = = 2 476 10 58425 0 000 1 0815 0 1000 . . . . - ans
( )( )
hp
Tn
hp 2 27
63000
3600 2 476
63000
.
.
= = = - ans

538. The rear axle of an automobile has one end splined. For this fitting there are ten splines, and D =
1.31 in., d = 1.122 in., and L = 1 15/16 in. The minimum shaft diameter is 1 3/16 in. (a)
Determine the safe torque capacity of the splined connection, sliding under load. (b) Determine
the torque that would have the splines on the point of yielding if the shaft is AISI 8640, OQT
1000 F, if one fourth of the splines are in contact. (c) Determine the torsional stress in the shaft
corresponding to each of these torques.
Solution:
D = 1.31 in, d = 1.122 in, L = 1 15/16 = 1.9375 in, N
t
= 10
D
r
= 1 3/16 in = 1.1875 in
( )( )( )( ) lb in N r hL T
t m
= 1000
4
d D
r
m
+
=
Table 10.2 for 10 splines, sliding connection
D h 095 0. =
Then
( ) in h 12445 0 31 1 095 0 . . . = =
16

But
in
d D
h 094 0
2
122 1 31 1
2
.
. .
=
= (actual)
in r
m
608 0
4
122 1 31 1
.
. .
=
+
=
(a) Safe Torque
( )( )( )( )( ) lb in T = = 32 1107 10 608 0 9375 1 094 0 1000 . . . . - ans
(b) Torque by splines required on the point of yielding with one fourth of splines in contact (Page
288).
From Table AT-7, AISI 8640, OQT 1000 F. s
y
= 150 ksi, s
s
= s
ys
= 0.6s
y
= 0.6(150) = 90 ksi
( )( )( )( )
kips in
D DL s
T
s
= |
\
|
(
= |
\
|
|
\
|
= 76 58
2
31 1
8
9375 1 31 1 90
2 8
.
. . .

lbs in T = 760 58,
(c) Torsional stress in the shaft
From safe torque of 1107.32 in-lb
( )
( )
psi
D
T
s
r
s
3368
1875 1
32 1107 16 16
3 3
= = =
.
.

- ans
From torque at the point of yield
( )
( )
psi
D
T
s
r
s
711 178
1875 1
760 58 16 16
3 3
,
.
,
= = =

- ans (too high)

539. An involute splined connection has 10 splines with a pitch P
d
of 12/24 (a) Determine the
dimension of this connection. (b) Compute the length of spline to have the same torsional
strength as the shaft when one fourth the splines carry the load; minimum shaft diameter is
9/16 in. (no sliding). Check for compression.
Solution:
N
t
= 10, P
d
= 12, D
r
= 9/16 in = 0.5625 in
(a) Dimension D
in
P
N
D
d
t
8333 0
12
10
. = = =
(b) Length of spline (same torsional strength as the shaft when one fourth the splines carry the load
(Page 288).
( )
in
D
D
L
r
2136 0
8333 0
5625 0
3 3
.
.
.
= = =

Check for compression.
Failure in compression is not likely (Page 289) and can be checked by using the projected
contact area.
Projected contact area:
( )( )
2
0356 0 8333 0 2136 0 2 0 2 0 in LD A
c
. . . . . = = = based on one-fourth of the teeth being under load.

COUPLINGS
540. A flange coupling has the following dimensions (Fig. 10.19, p. 291, Text): d = 5, D = 8 5/8, H = 12
, g = 1 , h = 1, L = 7 in.; number of bolts = 6; 1 x 1 -in. square key. Materials: key, cold-
drawn AISI 1113; shaft, cold-rolled, AISI 1045; bolts, SAE grade 5 (5.8). Using the static
17

approach with N = 3.3 on yield strengths, determine the safe horsepower that this connection
may transmit at 630 rpm.
Solution:

d = 5 in
D = 8 5/8 in = 8.625 in
H = 12 in = 12.25 in
g = 1 in = 1.5 in
h = 1 in
L = 7 in = 7.25 in
N = 3.3
n
b
= 630 rpm
Square key = 1 in x 1 in
Materials:
Key: cold-drawn AISI 1113, Table AT 7, s
y
= 72 ksi, s
ys
= 0.6s
y
= 0.6(72) = 43.2 ksi
Shaft: cold-rolled, AISI 1045, Table AT 8, s
y
= 85 ksi, s
ys
= 0.6s
y
= 0.6(85) = 51 ksi
Bolt: SAE Grade 5, h = 1 in. s
y
= 81 ksi, s
ys
= 0.6s
y
= 0.6(81) = 48.6 ksi
No given material for the flange.

Bolts in shear:
ksi
N
s
s
ys
s
73 14
3 3
6 48
.
.
.
= = =
s b
s N
h
F
4
2
=
8 2
2
H s N h FH
T
s b
= =
( ) ( )( )( )
kips in T = = 158 425
8
25 12 73 14 6 1
2
.
. .

lbs in T = 158 425,
( )( )
hp
Tn
hp 4252
000 63
630 158 425
000 63
= = =
,
,
,

Bolts in compression:
ksi
N
s
s
y
c
55 24
3 3
81
.
.
= = =
c b
hgs N F =
18

2 2
H hgs N FH
T
c b
= =
( )( )( )( )( )
kips in T = = 319 1353
2
25 12 55 24 5 1 1 6
.
. . .

lbs in T = 319 353 1 , ,
( )( )
hp
Tn
hp 533 13
000 63
630 319 353 1
000 63
,
,
, ,
,
= = =

Key in shear:
ksi
N
s
s
ys
s
09 13
3 3
2 43
.
.
.
= = =
( )( )( )( )
kips in
bdL s
T
s
= = = 570 296
2
25 7 5 25 1 09 13
2
.
. . .

lbs in T = 570 296,
( )( )
hp
Tn
hp 2966
000 63
630 570 296
000 63
= = =
,
,
,

Key in compression:
ksi
N
s
s
y
c
82 21
3 3
72
.
.
= = =
( )( )( )( )
kips in
tdL s
T
c
= = = 180 247
4
25 7 5 25 1 82 21
4
.
. . .

lbs in T = 180 247,
( )( )
hp
Tn
hp 2472
000 63
630 180 247
000 63
= = =
,
,
,

Shaft in shear:
ksi
N
s
s
ys
s
45 15
3 3
51
.
.
= = =
( ) ( )
kips in
s d
T
s
= = = 200 379
16
45 15 5
16
3 3
.
.

lbs in T = 200 379,
( )( )
hp
Tn
hp 3792
000 63
630 200 379
000 63
= = =
,
,
,

The safest horsepower is the lowest which is 2472 hp.

541. A cast-iron (ASTM 25) jaw clutch with 4 jaws transmits 50 hp at 60 rpm. The inside diameter of
the jaws is 3 in. Considering rough handling, choose N = 8 on ultimate strengths. Make
reasonable and conservative assumptions and compute (a) the outside diameter of the jaws, (b)
the length of jaws h.
19

Solution:
For ASTM 25, s
uc
= 97 ksi, in shear s
us
= 35 ksi (Table AT 6)
( )
lbs in
n
hp
T = = = 500 52
60
50 000 63 000 63
,
, ,

kips in T = 5 52.
(a) The outside diameter of the jaws
ksi
N
s
s
us
s
375 4
8
35
. = = =
Assume D
m
as the average diameter, t = thickness = D
o
D
i
, N
j
= number of jaws
Shear area,
( )
|
\
|
|
\
| +
|
|
\
|
=
|
|
\
|
=
2 2 2
1
2
1
i o i o
j j
m
s
D D D D
N
t
N
D
A

( )
2 2
2 2
32 4 4 2
1
i o
i o
s
D D
D D
A =
|
|
\
|
|
\
|
=

i o m
D D
T
D
T
F
+
= =
4 2

( ) ( )( )
2 2 2 2
128 32 4
i o i o i o i o s
s
D D D D
T
D D D D
T
A
F
s
+
=
+
= =

( )
( )( ) 9 3
5 52 128
375 4
2
+
=
o o
D D
.
.
By trial and error.
in D
o
466 7. = or in D
o
5 7. =
(b) The length of jaws h.
ksi
N
s
s
uc
c
125 12
8
97
. = = =
( )
2
i o j
c
D D h N
A

=
( ) ( ) ( )
i o i o i o j c
c
D D h
F
D D h
F
D D h N
F
A
F
s
= =
2 4
2 2

( )
( ) ( )
2 2
2
2
4
i o i o
i o
c
D D h
T
D D h
D D T
s
+
=
20

( )
( ) ( ) [ ]
2 2
3 5 7
5 52 2
125 12
=
.
.
.
h

in h 1833 0. = or in h
16
3
=

542. The universal joint shown is made of AISI 3150, OQT 1000 F; a = 2 7/16 in., D = 9/16; n = 400
rpm. (a) What torque may be transmitted for shear of the pin (N = 5 on ultimate)? (b)
Considering the pin as a simply supported beam of length a with the load distributed from a
maximum at the outer (triangular), compute the safe transmitted torque (Same N). (c) In order
not to have excessive wear on the pin, the average bearing pressure should not excced 3 ksi.
Compute this transmitted torque. (d) What is the safe power?

Solution:
For AISI 3150, OQT 1000 F, Table AT 7, s
u
= 151 ksi, s
us
= 113 ksi
N = 5
p
b
= 3 ksi
a = 2 7/16 in = 2.4375 in
D = 9/16 in = 0.5625 in
n = 400 rpm
(a) Torque transmitted for shear of the pin.
ksi
N
s
s
us
s
6 22
5
113
. = = =

Each shear area
( )( )( )
kips
D
s F
s
616 5
4
5625 0 6 22
4
2 2
.
. .
= =
|
|
\
|
=

( )( ) kips in Fa
Fa
T = = = = 687 13 4375 2 616 5
2
2 . . .
lbs in T = 687 13,

(b) Torque transmitted for shear of the pin (simply supported beam)
3
Fa
M T = =
( )( )
kips in T = = 563 4
3
4375 2 616 5
.
. .

lbs in T = 563 4,

21

(c) Torque transmitted for shear of the pin (p
b
= 3 ksi)
( ) Da
F
a D
F
A
F
p
b
b
2 2
= = =
( )( ) 4375 2 5625 0 2
3
. .
F
=
ksi F 23 8. =
3
Fa
M T = =
( )( )
kips in T = = 687 6
3
4375 2 23 8
.
. .

lbs in T = 687 6,
(d) Safe power
( )( )
hp
Tn
hp 97 28
000 63
400 563 4
000 63
.
,
,
,
= = =

544. A diagrammatic representation of a universal joint is shown, two yoke parts, the type being
similar to Figs. 10.28 and 12.10, Text. The pin extensions have a diameter D = in.; a = 11/16 in.,
material of all parts is 4340, OQT 800. Let N = 4 on ultimate stresses; n = 2400 rpm. Compute the
safe torque for (a) shear of pins, (b) the pin extensions in bending, assuming that the load
distribution is from zero at the outside pin ends to a maximum at the inside yoke surfaces, (c) an
average bearing pressure on pins of 4 ksi. (d) What is the corresponding horsepower capacity?

Solution:
For AISI 4340, OQT 800 F, Table AT 7, s
u
= 221 ksi, s
us
= 0.75s
u
= 0.75(221) = 166 ksi
N = 4
p
b
= 4 ksi
a = 11/16 in = 0.6875 in
D = 3/4 in = 0.75 in
n = 2400 rpm
(a) Torque transmitted for shear of the pin.
ksi
N
s
s
us
s
5 41
4
166
. = = =

Each shear area
( )( )( )
kips
D
s F
s
33 18
4
75 0 5 41
4
2 2
.
. .
= =
|
|
\
|
=

( )( ) kips in Fa M T = = = = 602 12 6875 0 33 18 . . .
lbs in T = 602 12,
22

(b) Torque transmitted for shear of the pin (simply supported beam)
3
2Fa
M T = =
( )( )
kips in T = = 401 8
3
6875 0 33 18 2
.
. .

lbs in T = 401 8,

(c) Torque transmitted for shear of the pin (p
b
= 4 ksi)
Da
F
A
F
p
b
b
= =
( )( ) 6875 0 75 0
4
. .
F
=
ksi F 063 2. =
3
2Fa
M T = =
( )( )
kips in T = = 9455 0
3
6875 0 063 2 2
.
. .

lbs in T = 5 945.
(d) Safe power
( )( )
hp
Tn
hp 02 36
000 63
2400 5 945
000 63
.
,
.
,
= = =

- End -

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