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Investigation of Stress Concentration Factor for Keyway on Shaft

under Different Loading Conditions: A Case Study
Hiren. R. Prajapatia, Bhavesh P. Patelb, N. V. Patelc
a

Ph. D. Scholar, Faculty of Engineering and Technology,

Ganpat University, Ganpat Vidhyanagar - 384012, Mehasana, Gujarat, India.
b
Associate Prof. Department of Mechanical Engineering, U. V. Patel College of Engineering,
Ganpat University, Ganpat Vidhyanagar - 384012, Mehasana, Gujarat, India.
c
M. Tech. Student, Department of Mechanical Engineering, U. V. Patel College of Engineering,
Ganpat University, Ganpat Vidhyanagar - 384012, Mehasana, Gujarat, India.

Abstract
A shaft is a rotating machine element which is used to transmit power from one place to another.
Shaft is subjected to torque due to power transmission and bending moment due to reactions on
the components that are supported by the shaft. Discontinuity added on the shaft for essential
functional requirements. There are different types of loading conditions carried (torsion,
bending, axial and combination of them) by shaft during working. Here, a case study is taken on
ball mill shaft keyway for investigation of stress concentration factor. In this paper, stresses are
calculated for ball mill shaft with keyway as discontinuity at various critical locations under
torsion, bending, axial and combined loadings. Also, stress concentration factor for keyway on
shaft is investigated by Xiaobin equations for all three loadings, i.e. torsion, bending and axial
and by Peterson equations for torsion and bending for range of shaft diameters from 10 mm to
500 mm as per standard sizes available for shaft. Comparisons are made with the results obtained
from Xiaobin equations and Peterson equations for Stress Concentration Factor (SCF) and it is
concluded that the SCF is reduced, if fillet radius of keyway is increased. FEA analysis is also
carried out and result shows the conformal agreement with theoretical calculations. At the end,
the optimal fillet radius is determined which reduces the stress developed in the shaft.
Keywords: Shaft; Keyway; Discontinuity; Stress analysis; Finite element analysis

a Corresponding author. Tel-+91 9724500859

E-mail address: hirs.mech1985@gmail.com

Prajapati H. et al./ University Journal of Research Vol. 01, Issue 01 (2015) ISSN: 00000000

Nomenclature

Tensile stress

Bending stress

Shear stress

Axial stress

Maximum stress

Theoretical stress concentration factor

Axial force

Bending moment

Torque or twisting moment

Effective Von Mises stress

Diameter or major diameter

Width of keyway

Radius of keyway

Stress concentration factor for axial load for keyway

Stress concentration factor for bending load for keyway

Stress concentration factor for torsional load for keyway

( )

Maximum axial stress

( )

Maximum bending stress

()

Maximum shear stress

N
SCF

Factor of safety
Stress concentration factor

1. Introduction
In industrial world many unexpected failures of equipment and various machine components
have occurred. A number of these failures have been due to poor design of equipment and
machines. However, it has been found that many failures have been caused by pre-existing
geometrical irregularities such as notches (circumferential), groove (V, U, Square), shoulders,
fillets, keyway, holes, threads etc. or flaws in materials that initiate cracks that grow and lead to
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fracture. These machine components contain geometrical irregularities due to design

requirements. These geometric discontinuities cause significant stress concentrations (Norton,
2006). To align the shaft, it must be coupled with the help of key, so keyway is needed in both,
the shaft and the hub to fit with shaft. This is one kind of discontinuity which reduces the
strength of the shaft. Stress concentration plays vital role in failure of machine parts. The failure
is initiated most of the time at the highly stressed regions. The chances of crack initiation are
very high at the keyway sections.

(a)

(b)

Figure 1. Peeling-type cracks in shafts originate at the keyway (Bonnett et. al., 1998)

Keys and keyways are one of the most common shafthub connections. The design is often
regulated by the standards that are almost half a century old, and most of the results reported in
the literature are based on experimental photo elastic analysis (Pedersen, 2009). However, the
keyway on the take-off end or driven end of the shaft is one of the most concern because it is
located in the area where the highest shaft loading occurs. When this loading has a high torsional
component, fatigue cracks usually emanate in the fillets or roots of the keyway. Keyways that
end with a sharp step have a higher level of stress concentration than those that use a sledrunner type of keyway. In the case of heavy shaft loading, cracks frequently emanate at this
sharp step. Figure 1(a) and (b) illustrate this type of failure. It is important to have an adequate
radius on the edges of the keyway (Bonnett et. al., 1998).

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It is remarkable that very little effort has been done to improve the design with respect to
minimizing the stress concentrations. In this paper, stress concentration factor for profile keyway
present in the ball mill shaft is calculated by using Xiobian equations for a given range of shaft
diameters (smaller to larger) in the PSG design data book (Kalaikathir, 2007) for/in different
loading conditions. A set of stress concentration factor curves/tables for keyway on shafts are
presented in this paper. The preliminary stress concentration factors for profile keyway under
bending, torsion, axial loading and combined loading for shaft design are also provided.

2. Case study: Design of ball mill shaft

In this research work, a ball mill shaft with keyway is taken for study. Figure 2 shows a portable
ball mill which is available in U. V. Patel College of Engineering.

Figure 2. Portable ball mill

Figure 3. Stepped shaft with keyway

The specifications of ball mill are given in the Table 1 and properties of shaft material are
presented in Table 2.
Table 1. Specifications of ball mill

Grinding capacity

: 20-25

Kg

Weight of the shell in full load capacity

: 193

Motor

: 1.5

Gearbox

: 40:1

Diameter of shaft at keyway section(D)

: 35

mm

Width of keyway (b)

: 10

mm

Depth of keyway in shaft (t)

:5

Radius of keyway (rk)

: 0.40

Kg
HP, 1480 rpm
worm reduction gear box

mm
mm
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Table 2. Shaft material and property of ball mill shaft

Material of shaft

: C40

Carbon steel

Yield stress range

: 290

MPa

Factor of safety (n)

: 1.5

So, based on the factor of safety, the allowable stress is calculated (193.33 MPa). From the given
data and dimensions torque (T = 284 103 Nmm), bending moment (M = 89933 Nmm) and
axial force (F = 469.5 N) is calculated (Norton et. at., 2006).

3. Stress analysis at keyway section

Keyway is the functional requirement that is always present in the shaft. Analytical analysis is
given below.

3.1 Shaft subjected to bending moment only

Maximum bending moment on the shaft can be calculated by using Eq. (6), in which the value of
K b = 2.81 taken from the reference (Xiaobin et. al., 2013) known as Xiobian equation and the
calculated value of bending stress (b )max is 60.06MPa.
32

( ) = 3

... (6)

3.2 Shaft subjected to torsion load only

Maximum shear stress on the shaft can be calculated by using Eq. (7), in which the value of K t =
2.6890 taken from the reference (Xiaobin et. al., 2013) known as Xiobian equation and the
calculated value of bending stress (max )max is 90.76 MPa.
16

= 3

... (7)

3.3 Shaft subjected to axial load only

Maximum axial stress on the shaft can be calculated by using Eq. (8), in which the value of K =
3.5423 taken from the reference (Xiaobin et. al., 2013) known as Xiobian equation and the
calculated value of bending stress (a )max is 1.7294 MPa.

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4

( ) = 2

...(8)

3.4 Shaft subjected to combined bending and torsional load

When there is no influence of axial load on shaft, the effective load (bending and torsion) is
calculated by Eq. (9) (Juvinall et. al., 2008).
=

32
3

( )2 + ( )2

... (9)

= 168.28MPa

3.5 Shaft subjected to combined axial, bending and torsional load

Whenever, the shaft is subjected to combine loading, the effect of all three loadings is more at
critical location compared to other locations in the shaft. In these cases, the failure theories are
used to calculate the combined stress at critical location and the calculated value is = 168.90
MPa.
32

= 3 ( +

2
8

) + 4 ( )2

... (10)

4. Calculation for stress concentration factor

By using Xiobians equations (Xiaobin et. al., 2013), stress concentration factor for profile
keyway present in the shaft is calculated for a given range of shaft diameters (smaller to larger)
as per the PSG design data book (Kalaikathir, 2007) under bending, torsion and axial loading
conditions for different r/b ratio which is given in Table 3.
Stress concentration factor for bending
r

r 2

r 2

K b = 4.30 50.80 (B) + 317.35 (B)

(11)

Stress concentration factor for torsion

K t = 3.91 40.67 (B) + 253.66 (B)

(12)

Stress concentration factor for axial

r

r 2

K a = 5.43 62.83 (B) + 390.97 (B)

(13)

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Where, the ratio of keyway radius (r) to keyway width (b) varies from 0.02 to 0.0832. i.e. 0.02
r

b 0.0832
Table 3. Calculation of SCF value from Indian standard data (Xiaobin et. al., 2013)

Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Shaft
dia.
(mm)
10
12
17
22
30
38
44
50
58
65
75
85
95
110
130
150
170
200
230
260
290
330
380
440

Up to

Width
(mm)

Height
(mm)

Radius
(mm)

r/b

12
17
22
30
38
44
50
58
65
75
85
95
110
130
150
170
200
230
260
290
330
380
440
500

4
5
6
8
10
12
14
16
18
20
22
25
28
32
36
40
45
50
56
63
70
80
90
100

4
5
6
7
8
8
9
10
11
12
14
14
16
18
20
22
25
28
32
32
36
40
45
50

0.16
0.25
0.25
0.25
0.4
0.4
0.4
0.4
0.4
0.6
0.6
0.6
0.6
0.6
1
1
1
1
1.6
1.6
1.6
2.5
2.5
2.5

0.04
0.05
0.04167
0.03125
0.04
0.0333
0.02857
0.025
0.0222
0.03
0.02727
0.024
0.02142
0.01875
0.02777
0.025
0.0222
0.02
0.02857
0.02539
0.02285
0.03125
0.02777
0.025

2.7757
2.5533
2.7342
3.022
2.7757
2.9592
3.1076
3.2283
3.3278
3.0616
3.1505
3.2635
3.3571
3.459
3.1337
3.2283
3.3278
3.4109
3.1076
3.2145
3.3046
3.0224
3.1337
3.2283

2.689
2.5106
2.6557
2.8867
2.689
2.8361
2.955
3.0517
3.1314
2.9181
2.9894
3.08
3.1549
3.2366
2.976
3.051
3.1314
3.198
2.955
3.0407
3.1129
2.8867
2.976
3.051

3.5423
3.2659
3.4908
3.8483
3.5423
3.77
3.954
4.1036
4.2268
3.8969
4.007
4.1472
4.2631
4.3893
3.9863
4.1036
4.2268
4.3297
3.954
4.0864
4.1981
3.8483
3.9863
4.1036

By using Petersons equations (Pilkey, 1997) stress concentration factor for profile keyway
present in the shaft is calculated for a given range of shaft diameters (smaller to larger) as per the
PSG design data book (Kalaikathir, 2007) under bending and torsion loading conditions for
different r/d ratio which is given in Table 4.

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Pilkey equation for bending (Pilkey, 1997)

0.1

0.1 2

0.1

0.1 2

= 1.426 + 0.1643 (/) 0.0019 (/)

...(14)

Pilkey equation for torsion (Pilkey, 1997)

= 1.953 + 0.1434 (/) 0.0021 (/)

(15)

Table 4. Calculation of SCF value from Indian standard data (Peterson equation) (Pilkey, 1997)

Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Shaft
diameter
(d) (mm)
10
12
17
22
30
38
44
50
58
65
75
85
95
110
130
150
170
200
230
260
290
330
380
440

Up
To
12
17
22
30
38
44
50
58
65
75
85
95
110
130
150
170
200
230
260
290
330
380
440
500

Width Height
(mm) (mm)
4
5
6
8
10
12
14
16
18
20
22
25
28
32
36
40
45
50
56
63
70
80
90
100

4
5
6
7
8
8
9
10
11
12
14
14
16
18
20
22
25
28
32
32
36
40
45
50

Radius
(r)
(mm)
0.16
0.25
0.25
0.25
0.4
0.4
0.4
0.4
0.4
0.6
0.6
0.6
0.6
0.6
1
1
1
1
1.6
1.6
1.6
2.5
2.5
2.5

r/d

Kb

Kt

0.01600
0.02083
0.01470
0.01136
0.01333
0.01052
0.00909
0.00800
0.00689
0.00923
0.00800
0.00705
0.00631
0.00545
0.00769
0.00666
0.00588
0.00500
0.006956
0.006153
0.005517
0.007575
0.006578
0.005681

2.3786
2.1708
2.4553
2.7247
2.5513
2.8153
3.0034
3.1828
3.4088
2.9829
3.1828
3.3722
3.551
3.7995
3.2408
3.463
3.67
3.952
3.3951
3.5941
3.7797
3.2637
3.4843
3.7291

2.7672
2.5929
2.831
3.0522
2.9103
3.1257
3.2763
3.4173
3.5907
3.26
3.4173
3.563
3.697
3.8761
3.4623
3.6315
3.7839
3.981
3.5804
3.7287
3.8622
3.4799
3.6474
3.8263

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In the next section, the comparisons of results obtained from Xiobian equations and Peterson
equations are given with the help of charts for bending and torsion load.

4.1 Stress concentration factor for bending and torsion

6
5
4
Kb peterson
Kb xiobian

3
2
1
0
0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Figure 4. Stress concentration factor for bending (Kb) vs. Filler radius (r)
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0

kt peterson
kt xiobian

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Figure 5. Stress concentration factor for bending and torsion (Kt) vs. Filler radius (r)

From this Figure 4 and Figure 5 it is concluded that fillet radius increases then SCF for bending
and torsion decreases. Xiobian equation of SCF is calculated based on r/b ratio where Peterson
equation of SCF is calculated based on r/d ratio. In Xiobian equation, SCF value is accurate at
critical location. There is no such guideline provided by Peterson to calculate the stress
concentration factor for axial loading (Ka) whereas by using Xiobian equation, Ka is calculated
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easily.
5. Finite element analysis (FEA)

Figure 6. Stepped shaft with keyway fixed at one side

Figure 6 shows that the fixed support is applied on opposite side of keyway on the shaft. Now,
different kinds of loads are applied on this shaft and observed the FEA results.

Figure 7. Axial stress analysis

Figure 8. Bending stress analysis

Figure 9. Maximum shear stress analysis

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Figure 10. Combined bending and torsion stress analysis

Figure 11. Combined axial, bending and stress

torsional stress analysis

6. Comparison of analytical and FEA analysis

In Table 5, comparisons of analytical results and FEA results of stress analysis under different
loading conditions are given.
Table 5 shows that FEA results matches with the theoretical calculation with minor errors at
acceptable levels.
The maximum deformation appears at the keyway corner section of the shaft. The maximum
stress also appears at the keyway section. So it denotes that the critical portion of the shaft is
keyway.

Table 5. Comparison of analytical and FEA analysis

Analytical
analysis
(MPa)

FEA
Analysis

Maximum axial stress

1.72

1.60

6.9

Maximum shear stresses

90.76

94

3.6

Maximum shear stresses

90.76

92

2.2

Maximum bending stress

60

61

1.6

Combined bending and shear stress

168.28

165.61

1.5

Combined of axial, bending and shear stress

168.90

165.89

1.7

Sr.
No.

Types of stress (MPa)

(MPa)

(%)
Error

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7. Calculation for stress reduction

In this case, the fillet radius is taken as 0.4 mm. Now, if it is increased, stress value can be
decreases. In Xiaobin equation (Xiaobin et. at., 2013), keyway radius to width (r/b) ratio is given
for a range of 0.02 to 0.0832. In ball mill application keyway width (b) = 10 mm and take r/b
ratio 0.04 to 0.0850 and calculate different stress value. Now reduction in stress value is given in
Table 6.
Table 6. Calculation of stress reduction

Keyway radius (b) in mm

Sr.

Different

Max. stress

No.

Stress (MPa)

0.4

0.5

0.6

0.7

0.8

0.832

0.850

reduction in %

Axial stress

1.72

1.59

1.49

1.43

1.41

1.41

1.42

18 %

Bending stress

60

59

54

51

49

48

48.5

20 %

Torsional stress

90

84

80

77

76

76.5

76.9

15 %

From the above Table 6 it is concluded that when fillet radius of keyway increases up to some
level, stress value decreases. If further keyway radius is increased (after 0.850 mm), the stress
value increases. As a result, from that it is possible to find the optimal value of fillet radius which
gives minimum stress value.

8. Conclusion
By theoretical calculations, stresses are calculated for ball mill shaft with keyway as
discontinuity at various critical locations. In this paper, stress concentration factor for keyway as
discontinuity on shaft is investigated by using Xiaobin equations for all three loading torsion,
bending and axial and by using Peterson equations for torsion and bending for total range of shaft
diameters from smaller to larger (10 mm to 500 mm) given in the PSG design data book.
Comparisons are made for results obtained from Xiaobin equations and Peterson equations and it
is conclude that the SFC is reduced if radius of rotation is increased. FEA analysis is also carried
out and a result shows the conformed agreement with theoretical calculations. At the end, the
optimal fillet radius is found out which will reduce the stress developed in the shaft with keyway.

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Reference
Bonnett A. H., (1998). Cause, analysis and prevention of motor shaft failures. U.S. Electrical
motors, Division of Emerson Electric, ST. Louis, Missouri, IEEE. 166-180.

Juvinall R. C; Marshek K. M (2008). Fundamentals of Machine component design. Fifth edition,

John-Wiley and Sons.
Kalaikathir (2007), Design data, PSG College of Technology, Kalaikathir Achchagam,
Coimbatore, India.

Norton, R. L., (2006). Machine design: an integrated Approach. Third edition, Pearson
Education, Upper Saddle River, NJ.

Pedersen, N. L., (2009). Stress concentrations in keyways and optimization of keyway design.
Journal of Strain Analysis, 45, 593-604.
Pilkey, W. D. (1997). Petersons stress concentration factors. Third edition, John-Wiley and
Sons, New York.

Xiaobin Le P.E.; Mr. Zelong Le (2013). Stress concentration factors due to typical geometric
discontinuities for shaft design by numerical simulation. American Society for Engineering
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