I am designing an engine driven system of belts and pulleys. The engine manufacturer has specified that the maximum torque that can be imposed on the engine by the system is 100 in-lb. After consulting with my coworkers, the overtorque protection method that I am leaning toward is to machine a groove in the splined shaft that will be driving this system to a diameter that will fracture if the torque exceeds 100 in-lb. This seems too simple to me. Can it be as easy as calculating the maximum tortional shear stress with Tc/J for a specific shaft material? What am I missing? Is there a better way to do this? Any input would be helpful.
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