Reduction of elastic stress concentrations in end-milled keyed connections

Frozen-stress, three-dimensional models were used to study the elastic stress distribution in both metric and inch rectangular, parallel, standard keys, shafts and hubs with end-milled keyways, loaded in torsion. The coefficient of friction between the shaft and the hub was measured and the surface conditions were arranged to simulate typical prototype friction. Positions and magnitudes of the peak shear stresses were determined in the prismatic part and at the ends of keys and keyways. The axial position of torque application to the hub, the key length and key-end shape were altered to investigate their effects on the stress distributions. The maximum shear stresses in the shaft occur in the keyway end if the key is not chamfered. The maximum stress in the standard metric shaft is 25 percent greater than in the inch standard. Changing the axial position of torque application from the middle to the front increases the peak stresses by about 13 percent. Doubling the length of hub and key reduces the stresses by about 25 percent. Filing off parts of the key to prevent contact at the keyway end reduces the maximum stresses by 11 percent.