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This topic explains the design of key,
pin joint and bolt and nut joint. It
involves analysis on bolt and nut joint
carrying a direct load or eccentric
load. It also explains the design joints
of welding.
Mechanical engineering
department
Politeknik Merlimau
hamdi@pmm.edu.my


JJ513 Engineering Design Design of Mechanical Joint
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THE BIG PICTURE



OBJECTIVES OF THIS CHAPTER
After completing this chapter, you will be able to:
1. Explain the purpose of the key
2. Sketch and name various types of key such as parallel keys, taper keys, gib-head keys, pin
keys, woodruff keys, etc.
3. Apply mathematical analysis for rectangle and parallel key based on sheer stress and
compressed stress.
4. List the advantages and disadvantages using pin and bolt and nut as the method of
joining.
5. Analyze the factors of bolt and nut joint failures.
6. Analyze bolt and nut joints by shearing load.
7. Analyze bolt and nut joints shearing caused by eccentric load.
8. Calculate the bolt size and maximum load.
9. State the advantages and disadvantages of welded joints.
10. Sketch the basic symbol for welded joint.
11. Apply the mathematical analysis for welded joint
12. Determine the weld throat and safe load.
13. Determine the welded joint size caused by eccentric load.


3 - 1
KEY DESIGN
3 - 2
DESIGN OF PIN JOINT, BOLT, AND
NUT JOINT
3 - 3
WELDED JOINTS DESIGN
JJ513 Engineering Design Design of Mechanical Joint
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3-1 THE KEY DESIGN
A key is a machinery component placed at the interface between a shaft and the hub of a
power-transmitting element for the purpose of transmitting torque [figure 3-1]. Key is placed so
that part of it lies in a groove cut on the shaft, called key seat, and part of it fits into a groove cut
in hub, called key way. Therefore, after the assembly locked together by the key, the shaft and
hub will rotate together.


Figure 3-1 key position applied to a shaft

Square and Rectangular Parallel Keys
The most common type of key for shafts up to 6 inches in diameter is the square key, as
illustrated in figure 3-2. The rectangular key is recommended for larger shafts and is used for
smaller shafts where the shorter height can be tolerated.

Figure 3-2 Square key


JJ513 Engineering Design Design of Mechanical Joint
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Figure 3-3 Illustration of keys. (a) dimensions of shaft with keyway in shaft and hub; (b) square
parallel key; (c) rectangular parallel key

Taper Keys and Gib Head Keys
Taper keys are designed to be inserted from the end of the shaft after the hub is in position
rather than installing the key first and then sliding the hub over the key as with parallel keys.
The gib head key has a tapered geometry inside the hub that is the same as that of the plain
taper key. But the extended head provides the means of extracting the key from same end at
which it was installed. This is very desirable if the opposite end is not accessible to drive the key
out.

(a) (b)
Figure 3-4 (a) Tapered key; (b) Gib Head key

JJ513 Engineering Design Design of Mechanical Joint
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Pin Keys
The pin keys are a cylindrical pin placed in cylindrical groove in the shaft and hub. Lower stress
concentration factors results from this design as compared with parallel or tapered keys. A close
fit between the pin and the groove is required to ensure that the pin does not move and that the
bearing is uniform along the length of the pin.

Figure 3-5 Pin keys

Woodruff Keys
Where light loading and relatively easy assembly and disassembly are desired, the woodruff key
should be considered. The circular groove in the shaft holds the key in position while the mating
part is slid over the key.

Figure 3-6 Woodruff keys



JJ513 Engineering Design Design of Mechanical Joint
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Stress Analysis
There are two basic modes of potential failure for keys transmitting power:
(1) shear across the shaft/hub interface
(2) Compression failure due to the bearing action between the sides of the key and the shaft
or hub material.
Figure 3-7 shows the idealized case in which the torque on the shaft creates a force on the left
side of the key.

Figure 3-7 Forces on a key

Key design is successful if failure from shear or compression is prevented, both of which are
considered here:
1. Failure due to shear:

(3.1)

The design shear stress is

(3.2)

Above equation (3.2) is independent of the height h. to avoid failure due to shear

(3.3)




JJ513 Engineering Design Design of Mechanical Joint
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2. Failure due to compressive or bearing stress. The compression or bearing area of the key
is

(3.4)
The compressive or bearing design stress is

(3.5)

Above equation (3.5) is independent of the width w. Failure due to compressive or
bearing stress can be avoided if

(3.6)

Noted:
The allowable normal stress
all
and the allowable shear stress

for ferrous and nonferrous

metals for various types of loading may be represented by,
Shear:

(3.7)
Compressive:

(3.8)
*S
y
is a Yield Strength

Example problem 3-1
Given: A 4-in-diameter shaft with a hub is made of high-carbon steel. A square key made of low-
carbon steel has a width and height of 1 in. assume a torque value at 2-in radius.

Find: The critical length of the key while assuming a safety factor of 2 and considering both
compression and shear.

Solution: from table A.1 (appendix) the yield strength for the shaft and hub is S
y
= 55 ksi. From
equation (3.7) and (3.8)

Thus, the design stresses are

JJ513 Engineering Design Design of Mechanical Joint
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For a shaft with circular cross section

The maximum torque acting on the shaft at a radius of 2 in is

The maximum force is

From table A.1 (Appendix) the yield strength for the key is S
y
= 43 ksi. From equation (3.7) and
(3.8)

The design stresses are

For equation (3.2)

Thus, to avoid key shear failure, the key should be at least 8.035 in long. From equation (3.5)

To avoid key compressive or bearing failure, the key should be at least 7.144 in long. Therefore,
failure will first occur from key shearing, and the key must be at least 8.036 in long.





JJ513 Engineering Design Design of Mechanical Joint
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3-2 THE DESIGN OF BOLT AND NUT JOINT


Figure 3-8 Bolt and Nut

The bolt and nut shown in figure 3-8 can be thought of as a spring system, as shown in figure 3-
9. The bolt is viewed as a spring in tension with stiffness k
b
. The joint, with a number of
members being joined, is viewed as a compressive spring with stiffness k
j
.


Figure 3-9 bolt-and-nut assembly modeled as bolt-and-joint spring

Bolt stiffness
A bolt with tread is considered as a stepped shaft. The root diameter is used for the threaded
section of the bolt, and the crest diameter is used for the unthreaded section, called the shank.










JJ513 Engineering Design Design of Mechanical Joint
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Figure 3-10 Bolt and nut. (a) Assembled; (b) stepped-shaft representation of shank and
treaded section.
Figure 3-10(a) shows a bolt-and-nut assembly and figure 3-10(b), the stepped-shaft
representation of the shank and the threaded section. In figure 3-10(b) the effective length of
the shaft and the threaded section includes additional lengths extending into the bolt head and
nut. Making use of equation:

)
Where d
c
= crest diameter, m
d
r
= root diameter,m

Joint stiffness
Determining joint stiffness is much more complicated than determining bolt stiffness. Thus, an
approximation is that the stress included in the joint is uniform throughout a region surrounding
the bolt hole with zero stress outside this region. Figure 3-11 shows the conical frustum stress
representation of the joint in a bolt-and-nut assembly.


a) b)
JJ513 Engineering Design Design of Mechanical Joint
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Figure 3-11 Bolt-and-nut assembly with conical frustum stress representation of joint

In calculating stiffness, always use the smallest of frustum cone diameters. For the member
closet to the bolt head or to the nut, d
i
= d
w
= 1.5d
c
.

(a) Joint Stiffness for same material.

The expression for joint stiffness is

Where A
i,
B
i
= numerical constants given in table 3-1 below:

Table 3-1 Constants used in joint stiffness formula

Material Modulus of
elasticity,
E(GPa)
Numerical constant
A
i
B
i
Steel 206.8 0.78715 0.62873
Aluminum 71.0 0.79670 0.63816
Copper 118.6 0.79568 0.63553
Gray cast iron 100.0 0.77871 0.61616






JJ513 Engineering Design Design of Mechanical Joint
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(b) Joint stiffness for different materials
The equation is

]

Where;
L
i
= axial length of the frustum cone
d
i
= frustum cone diameter; d
i
= 1.5d
c


The resulting joint stiffness is

Once the joint and bolt stiffnesses are known, the dimensionless stiffness parameter can be
calculated from equation

Strength
The proof load of a bolt is the maximum load that a bolt can withstand without acquiring a
permanent set. The proof strength is the limiting value of the stress determined by using the
proof load and the tensile stress area. Although proof strength and yield strength have
something in common, the yield strength is usually higher because it is based on a 0.2%
permanent deformation.

The proof strength S
p
, as defined by the Society of Automotive Engineers (SAE), the American
Society For Testing and Materials (ASTM), and International Organization for Standardization
(ISO) specifications, defines bolt grades or classes that specify material, heat treatment, and
minimum proof strength for the bolt or screw. Table 3-1 gives the strength information for
several metric grades. Metric grade numbers from 4.6 to 12.9, with higher numbers indicating
greater strength.







JJ513 Engineering Design Design of Mechanical Joint
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Table 3-2 strength of steel bolts for various sizes in millimeters


Table 3-2 gives the dimensions and the tensile stress areas for M coarse and fine threads.

Table 3-3 Dimensions and tensile stress areas for M coarse and fine threads.



JJ513 Engineering Design Design of Mechanical Joint
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Bolt Preload-static loading
The bolt failure safety factor

(3.9)

Where A
t
= tensile stress area given by table 3-2
P
i
= preload, N
P
max,b
= maximum load applied to bolt, N
C
k
= dimensionless stiffness parameter


Figure 3-12 Separation

Equation 3.9 suggests that the safety factor is maximized by having zero preload on the bolt. For
statiscally loaded bolts where separation is not a concern, this certainly true. However, a preload
is often applied to bolted connections to make certain that members are tightly joined in order
to minimize tolerances and provide tight fits. Further, many applications require members to
avoid separation as shown in figure 3-12. Thus, the safety factor guarding against separation is

(3.10)
Where P
max,j
= maximum load applied to joint, N.

The amount of preload that is in practice applied to bolts under static conditions is therefore a
compromise between bolt overloading (where zero preload is most beneficial) and separation
(where a larger preload is desirable). The preload is given for reused and permanent connections
as

} (3.11)
Where P
p
= proof load, S
p
A
t
.
for reused connection
for permanent connections
JJ513 Engineering Design Design of Mechanical Joint
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Example problem 3-2


Figure 3-13. (a) Hexagonal bolt-and-nut assembly and dimensions. (b) Dimension of frustum
cone. (All dimensions are in millimeters)

Given:
A hexagonal bolt-and-nut assembly, shown in figure 3-12 is used to join two members. The bolt
and the nut are made of steel, and the frustum cone angle is 30. The thread crest diameter is 14
mm, and the root diameter is 12 mm.

Find:
1. Find the bolt and joint stiffnesses as well as the dimensionless stiffness parameter. Use
the modulus of elasticity and Poissons ratio from table 3-1, and consider the cases
where
a. Both members are made of steel.
b. The 15 mm thick member is made of steel, and the 10 mm thick member made of
aluminum.
2. Determine the maximum load for bolt-and-nut joint failure while assuming reused
connections and a static safety factor of 2. Assume a 5.8 grade and coarse threads.

Solution:
1. The bolt stiffness

)
JJ513 Engineering Design Design of Mechanical Joint
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a) Steel joint.

) (

)

241 GN/m

The dimensionless stiffness parameter gives

b) Steel-aluminum joint
As shown in figure 3-12, the members have to consider as 3 frusta. The member
stiffnesses are:






For the 1
st
frusta,
We know that the material is steel; from table 3-1, we know E = 206.8 GPa and

{
[ ]
[ ]
}




d
1

1
st
frusta
10
25
12.5
2
nd
frusta
3
rd
frusta
JJ513 Engineering Design Design of Mechanical Joint
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For the 2
nd
frusta,
We need to obtain the d
2
first as shown in figure below

Thus, d
2
= 21 + 2(5.77) = 32.54

{
[ ]
[ ]
}

For the 3
rd
frusta,
We know that the material is aluminum; E= 71 GPa and the d
3
= d
1
= 21.

{
[ ]
[ ]
}

2.620 GN/m
Thus,

The dimensionless parameter for steel-aluminum joint is

10
x
30
21
d
2
JJ513 Engineering Design Design of Mechanical Joint
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2. From table 3-1 for 5.8 grade, S
P
= 380 MPa; and from the table 3-3 for crest diameter of
14 mm and coarse threads, A
t
= (84.3 + 157)/2 = 120.7 mm
2
. For reused connections,

The maximum load that the bolt can carry while assuming a safety factor of 2 is

The maximum load before separation occurs is

Thus, failure due to separation will occur before bolt failure.





















JJ513 Engineering Design Design of Mechanical Joint
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3-3 THE WELDED JOINTS DESIGN

The welding is a process of joining together two or more metal parts. It is done by heating the
surfaces, to be connected, to a high temperature and then adding additional molten metal,
which fuses with and combines the two surfaces. The molten or fused metal is deposited
between the parent metal parts, which are also fused metal gets cooled; the parent metal parts
are joined by this new metal.

Some advantages of welded joints over threaded fasteners are that they are inexpensive and
there is no danger of joint loosening. The welding allows the arrangement of the structure
components, in such a way, the joint provides maximum efficiency but it is possible in case of
bolted joints. Additions and alterations can be easily made in the existing structures. In welded
connections, the tension members are not weakened as in the case of bolted joint. A welded
joint has a great strength. Sometimes, the members are of such a shape that they afford
difficulty for riveting. But they can easily weld. The welding provides very rigid joints. It is
possible to weld any part of structure at any point. But bolting requires enough clearance. The
process of welding takes less time than the bolting. No need to drilling and measuring.

Some disadvantages of welded joints over threaded fasteners are that they produce residual
stresses; they distort the shape of the member, metallurgical changes occur, and disassembly is
a problem. As there is an uneven heating and cooling, during the fabrication, therefore the
members may get distorted or additional stresses may develop. It requires a highly skilled labor
and supervision. As the welded joints are rigid joints, therefore they have to be treated as such
in their design. The inspection of welding work is more difficult than bolting work.

There are many configurations of welds and manufacturing process for producing them. Figure
3-12 shows the standard symbols for welds, indicating that weld joints offer considerable design
flexibility. Although welded joints are available in a wide variety of forms, only the fillet weld is
considered here.

JJ513 Engineering Design Design of Mechanical Joint
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Figure 3-14 Basic weld symbols
A fillet weld, shown in figure 3-13 , is made with equal legs. The thinnest section is then at the
throat of the weld, at 45 from the legs. The governing stress in fillet welds is shear on the throat
of the weld, as show in figure 3-13. Observe from this figure that in the fillet weld aligned
parallel to the load, the shear stress occurs along the throat of the fillet parallel to the load. In a
fillet weld aligned transverse to the load; the shear stress occurs at 45 to the load, acting
transverse to the axis of the fillet.
JJ513 Engineering Design Design of Mechanical Joint
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Figure 3-15 Fillet weld. (a) Cross section of weld showing throat and legs; (b) shear planes.

Static Axial and Direct shear loading
Total weld throat area is

Where h
e
= weld leg length, m

= weld length, m



Welding-distortion or deformation or warping of weldments during welding is a natural outcome
of intrinsic non uniform heating and cooling of the joint. The distortion energy theory says that
failure occurs due to distortion of a part. Distortion energy theory is

JJ513 Engineering Design Design of Mechanical Joint
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Where

= Yield Strength of the material part.

Eccentric static load, F is

Where

= safety factor


Example problem 3-2

Weld joints subjected to static axial and direct shear loading. Estimate the static strength of a
parallel loaded fillet weld. The plates in figure below are 12 mm thick and made of steel having
yield strength, S
Y
350 MPa. They are welded together by convex fillet welds along sides AB and
CD, each of which is 50 mm long. With a safety factor of 3, what static load, F can be carried
using a 6 mm weld leg?
















Analysis
Total weld throat area is

A B
C
D
l =50 mm
JJ513 Engineering Design Design of Mechanical Joint
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Distortion energy theory is

Thus, the eccentric static load is

JJ513 Engineering Design Design of Mechanical Joint
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APPENDIX

TABLE A.1: Properties of ferrous metals

TABLE A.2: Properties of non-ferrous metals








JJ513 Engineering Design Design of Mechanical Joint
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REFERENCES

Anon. (2010, februari 7). Parallel Keys Flat Keys Machine Keys Shaft Keys Sizes and Prices.
Retrieved may 30, 2012, from CTS Enterprises Ltd (Machine Key Manufacturer) web site:
http://www.machinekey.org/parallel-keys-machine-keys/
Bernard J.Hamrock, S. R. (2005). fundamentals of machine elements 2nd edition. kuala lumpur:
The McGraw Hill Companies.
KHURMI, R. S. (2007). Strength of Materials. new delhi: S. Chand & Co.
Krok, P. (2006, march). wikepedia foundation inc. Retrieved june 18, 2012, from wikepedia wed
site: http://eo.wikipedia.org/wiki/Dosiero:Bolt-with-nut.jpg
Mott, r. L. (2004). Machine Elements in Mechanical Design 4th Edition. New Jersey: Pearson
prentice hall.
Robert C. Juvinall, K. M. (2000). Fundamentals of Machine Component Design 3rd Edition. new
york: John Wiley & Sons, Inc.