Keyway Calculator

Estimate keyway stress and safety factor from torque.

All tools free forever

Tip: Use shaft diameter and torque as baseline.

Results

11,000
Tangential force (N)
20.37
Shear stress (MPa)
61.11
Bearing stress (MPa)
5.891
Shear safety factor
4
Shaft keyseat depth (mm)
Linked Parameter Diagram
keyway

Input / Output Bars

Inputs

Shaft diameter40
Key width b12
Key height h8
Key length l45

Outputs

Tangential force11,000
Shear stress20.37
Bearing stress61.111
Shear safety factor5.891

Geometry View

Mechanical Geometry

keyway
Tangential force
11,000
Shear stress
20.37
Bearing stress
61.111
Shear safety factor
5.891
Shaft diameter
40
Key width b
12

Tool role and boundaries

Keyway Calculator is not a one-shot number widget. It is an engineering baseline tool for real shop-floor decisions. Estimate keyway stress and safety factor from torque. This tool supports geometry and fit logic where coordinate definitions and dimensional relationships must stay traceable.

Treat every output as a first-pass candidate, not an immediate production command: run defaults first, tune one variable at a time, and record machine, tooling, fixture, and material-lot context.

Fast baseline workflow

  1. Run once with defaults to confirm units and expected behavior.
  2. Lock constraints first (dimensions, machine limits, setup boundaries), then tune controls.
  3. Change one key variable per iteration and record why it changed.
  4. Check primary outputs against machine capability before secondary metrics.
  5. Validate first piece with conservative override before moving to target cycle.
  6. Store accepted values with revision tags so shift handoff stays reproducible.

Input strategy

Use a three-layer input model:

  • Constraint layer: dimensions, tolerances, travels, clamping, controller limits.
  • Control layer: speed, feed, engagement, compensation, cycle parameters.
  • Target layer: takt time, cost, scrap risk, tool-change frequency.

A common failure mode is pushing control values before constraints are stable. Lock constraints first, then build a stable operating window with small increments.

Output interpretation

Interpret results in order: primary safety checks first, then stability, then economics.

  1. Safety: no machine, tool, or fixture limit violations.
  2. Stability: load, thermal, and vibration behavior remains controlled.
  3. Economics: cycle and cost align with shift target.

Current focus outputs include Tangential force, Shear stress, Safety factor. If numbers conflict with floor behavior, verify units and inputs before changing strategy.

Geometry reference

Key and keyway load path

Use this figure to confirm variable naming and sign direction before entering values. This removes a common failure mode where the math is correct but variables are mapped to the wrong feature.

Typical failure modes and fixes

  • Sudden output jump: verify units, decimal precision, and input ordering first.
  • Unexpected trend: inspect workholding, tool condition, and thermal stability before retuning.
  • Big machine-to-machine delta: compare servo behavior, coolant coverage, spindle health, and compensation tables.
  • Shift handoff instability: enforce revision logging for program, tool, and parameter timestamp.

Keep rollback points and use single-variable increments to avoid coupled uncertainty.

FAQ

Can outputs be used directly for production?

Not immediately. Validate first piece, then short-run stability, then release to full production.

Why does floor behavior differ from computed values?

This is expected. Material lot, tool wear, thermal state, and machine dynamics all shift outcomes.

When should I recalculate?

Recalculate whenever tooling, fixturing, material lot, controller parameters, or takt target changes.

Final recommendation

Use Keyway Calculator inside a fixed loop: baseline, first-piece validation, single-variable tuning, parameter freeze, and revision tracking. The outcome is not just one result but a repeatable process capability.