Keyways and splines are precision-engineered features on shafts and hubs that transmit torque and prevent relative rotation between connected components.
Keyways are longitudinal slots cut into shafts and mating components that accommodate rectangular keys to transmit torque. Splines are a series of axial ridges or teeth on a shaft that mesh with grooves in a mating hub, providing a more uniform torque distribution and allowing axial movement while maintaining rotational synchronization. Both are critical for connecting rotating elements like gears, pulleys, and couplings to shafts in mechanical systems.
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Keyways use a single rectangular key in slots for torque transmission, while splines use multiple interlocking teeth around the entire circumference for more uniform load distribution and potential axial movement.
Use splines for higher torque applications, when axial movement is required during operation, or when precise angular positioning is critical. Keyways are suitable for moderate torque applications where cost is a primary concern.
Common failures include key shearing, keyway deformation (broaching), fretting corrosion, and stress concentration cracks at keyway corners due to improper fit or overload.
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