Design of Coupling

A coupling can be defined as a mechanical device that permanently joins

two rotating shafts to each other.

Application:
For example, a coupling is used to join the output shaft of an engine to
the input shaft of a hydraulic pump to raise water from well.

A coupling is used to join the output shaft of an electric motor to the

input shaft of a gearbox in machine tools.

A coupling is also used to join the output shaft of an electric motor to

the input shaft of a compressor.

There is a basic difference between a coupling and a clutch. Coupling is

a permanent connection, while the clutch can connect or disconnect
two shafts.
 Types of Couplings
The shafts to be connected by the coupling may have
collinear axes, intersecting axes parallel axes with a
small distance in between.

When the axes are collinear or in the same line,

rigid or flexible couplings are used. While the
flexible coupling is capable of tolerating
Oldham coupling is used to connect two parallel shafts
when they are at a small distance apart.
Hooke’s coupling is used to connect two shafts having intersecting axes.
Rigid couplings
Flexible couplings
 The difference between rigid and
flexible couplings
A rigid coupling cannot tolerate misalignment
between the axes of the shafts. It can be used
only when there is precise alignment between
two shafts. On the other hand, the flexible
coupling, due to provision of flexible elements
like bush or disk, can tolerate 0.5° of angular
misalignment and 5 mm of axial displacement
between the shafts.
The flexible elements provided in the flexible
coupling absorb shocks and vibrations. There is no
such provision in rigid coupling. It can be used only
where the motion is free from shocks and vibrations.
Rigid coupling is simple and inexpensive. Flexible
coupling is comparatively costlier due to additional
parts
The coupling should be capable of transmitting
torque from the driving shaft to the driven shaft.
The coupling should keep the two shafts in
proper alignment.
The coupling should be easy to assemble and
disassemble for the purpose of repairs and
alterations.
The failure of revolving bolt heads, nuts, key
heads and other projecting parts may cause
accidents. They should be covered by giving
suitable shape to the flanges or by providing
guards
• The couplings are standardized and can be
purchased as readymade units.
• IS 6196–1971: Dimensions of fitted half
coupling.
• IS 2693–1964: Specifications for cast iron
flexible couplings
RIGID FLANGE COUPLINGS
A flange coupling consists of two flanges—on keyed to the
driving shaft and the other to the driven shaft as show. The two
flange are connected together by means of four or six bolts
arranged on a circle concentric with the axe of the shafts. Power
is transmitted from the driving shaft
to the left side flange through the
key. It is then transmitted from the
left side flange to the right side flange
through the bolts. Finally, power is
transmitted from the right side flange
to the driven shaft through the key.
The mating flanges have spigot and recess for precise location.
The left side flange has a cylindrical projection called spigot while
the right side flange has a corresponding recess. The diameters of
the spigot and the recess are machined with more accuracy.
During the assembly, the spigot fits into the recess and the two
flanges are located precisely with respect to each other.
This ensures alignment of the axes of the two shafts.
Unprotected and protected flange
coupling
 Advantages
(i) Rigid coupling has high torque transmitting
capacity.
(ii) Rigid coupling is easy to assemble and
dismantle.
(iii) Rigid coupling has simple construction. It is
easy to design and manufacture.
 Disadvantages
(i) It is a rigid type of coupling. It cannot tolerate
misalignment between the axes of two shafts.
(ii) It can be used only where the motion is free
from shocks and vibrations.
(iii) It requires more radial space.
Thank You
Design of Rigid Couplings
Many times, the dimensions of the flanges are
calculated by using standard proportions in
terms of shaft diameter. Shop-floor engineers
have used such empirical formulae for many
years without any problem. It is easy to design
the coupling using these standard proportions,
because no stress analysis is involved. The
dimensions calculated by these formulae result
in robust design.
The number of bolts (N) is also decided from the
aft diameter in the following way:
N = 3 for shafts up to 40 mm diameter N = 4
for shafts from 40 to 100 mm diameter
N = 6 for shafts from 100 to 180 mm diameter.
Shear Stress in Bolt
The compressive stress in the bolt
Torsional Stress in Hub
 The flange at the
junction of the hub is
under shear while
transmitting the
torsional moment Mt.

Key

Design
A key can be defined
as a machine element which is used to connect
the transmission shaft to rotating machine
elements like pulleys, gears, sprockets or
flywheels.
 Functions of Key
(i) The primary function of the key is to transmit
the torque from the shaft to the hub of the
mating element and vice versa.
(ii) The second function of the key is to prevent
relative rotational motion between the shaft and
the joined machine element like gear or pulley.
DESIGN OF SUNK KEYS: SQUARE AND
FLAT KEYS
• A sunk key is a key in which half the thickness of the key fits into
the keyway on the shaft and the remaining half in the keyway
on the hub. Therefore, keyways are required both on the shaft
as well as the hub of the mating element.
 Forces acting on Key
Transmission of torque from the shaft to the hub results in
two equal and opposite forces denoted by P. The torque Mt
is transmitted by means of a force P acting on the left
surface AC of the key. The equal and opposite force P,
acting on the right surface DB of the key is the reaction of
the hub on the key. It is observed that the force P on left
surface AC and its equal and opposite reaction P on the
right surface DB are not in the same plane. Therefore,
forces P1 (P1 = P) act as resisting couple preventing the key

to roll in the keyway.

The exact location of the force P on the surface
AC is unknown. In order to simplify the analysis,
it is assumed that the force P is tangential to the
shaft diameter.
Failure due to shear and Crushing
 Thank You
DESIGN PROCEDURE FOR RIGID
FLANGE COUPLING
II. Dimensions of Flanges
The inner and outer diameters of the
hub
(iii) Diameter of Bolts
The compressive stress in the bolt
 IV. Key Design

Example
It is required to design a rigid type of flange coupling
to connect two shafts. The input shaft transmits 37.5
kW power at 180 rpm to the output shaft through
the coupling. The service factor for the application is
1.5, i.e., the design torque is 1.5 times of the rated
torque. Select suitable materials for various parts of
the coupling, design the coupling and specify the
dimensions of its components.
The shafts are subjected to torsional shear
stress. On the basis of strength, plain carbon
steel of grade Syt = 380 N/mm2 is
used for the shaft. The factor of safety for the
shafts is assumed to be 2.5.
 The keys and bolts are subjected to shear and
compressive stresses. On the basis of
strength criterion, plain carbon steel of grade
Syt = 400 N/mm2 is selected for the keys
and the bolts. It is assumed that the
compressive yield strength is 150% of the
tensile yield strength. The factor of safety
for the keys and the bolts is taken as 2.5.
Flanges have complex shape and the easiest
method to make the flanges is casting. Grey
cast iron Sut = 200 N/mm2 is selected as the
 material for the flanges from manufacturing
considerations. It is assumed
that ultimate shear strength is one half of the
ultimate tensile strength. The factor of safety
for the flanges is assumed as 6.
Thank You