Design of Coupling

Prof. K .A. Chaudhari

DME
Subject Code: 3171917
Content

• Types of coupling
• Design of Muff coupling
• Clamp coupling
• Rigid flange coupling
• Bush pin type flexible coupling
Coupling
A mechanical device that
permanently joins two rotating shafts to each
other.
Purposes
• To provide for the connection of shafts of
units that are manufactured separately
such as a motor and generator and to
provide for disconnection for repairs or
alternations.
• To provide for misalignment of the shafts or
to introduce mechanical flexibility.
• To reduce the transmission of shock loads
from one shaft to another.
• To introduce protection against overloads.
Requirements of a Good Shaft Coupling

• easy to connect or disconnect.

• transmit the full power from one shaft to the other shaft without losses.
• hold the shafts in perfect alignment.
• reduce the transmission of shock loads from one shaft to another shaft.
• no projecting parts
Types of Shafts Couplings

Rigid coupling
• connect two shafts which are perfectly aligned
1. Sleeve or muff coupling.
2. Clamp or split-muff or compression coupling, and
3. Flange coupling
Flexible coupling
• connect two shafts having both lateral and angular misalignment.
1. Bushed pin type coupling,
2. Universal coupling, and
3. Oldham coupling.
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.
A good coupling, rigid or flexible, should satisfy the following
requirements:

• 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.
MUFF COUPLING (sleeve coupling or box coupling)

hollow cylinder

sunk key

• made of cast iron

• The torque is transmitted from the input shaft to the sleeve through the
key. It is then transmitted from the sleeve to the output shaft through the
key.
Advantages of muff coupling
• It is the simplest form of coupling with only two parts, viz., sleeve and key.
It is simple to design and manufacture.
• It has no projecting parts except the key head. The external surface of the
sleeve is smooth. This is an advantage from the standpoint of safety to the
operator.
• It has compact construction with small radial dimensions.
• It is cheaper than other types of coupling.
Disadvantages of muff coupling
• Muff coupling is difficult to assemble or dismantle. The sleeve has to be
either shifted over the shaft by half of its length or the ends of the shafts
have to be drawn together or apart by half length of the sleeve.
• It is a rigid type of coupling and requires accurate alignment of shafts. It
cannot tolerate misalignment between the axes of two shafts. The
misalignment of shafts, caused by inaccurate assembly, induces forces,
which tend to bend the shafts.
• Since there is no flexible element in the coupling, it cannot absorb shocks
and vibrations. It can be used only where the motion is free from
vibrations.
• It requires more axial space compared with flange couplings.
 Design of a muff coupling

Muff coupling is usually designed on shop

floors by assuming standard proportions
for the dimensions of the sleeve.
These empirical relationships were
developed by practicing engineers on the
basis of their past experience.
In general, such proportions result in
robust design.
For the sleeve of muff coupling, the
standard proportions used in practice are
as follows:
D = (2d + 13)mm……………………………..1
L = 3.5 d ………………………………….2

D = outer diameter of the sleeve (mm)

L = axial length of the sleeve (mm)
d = diameter of the shaft (mm)
 DESIGN PROCEDURE FOR MUFF COUPLING
I. Calculate the diameter of each shaft
by the following equations:

II. Calculate the dimensions of the sleeve

by the following empirical equations,

D = (2d + 13) mm and L = 3.5 d

Also, check the torsional shear stress
induced in the sleeve by the following
equations:
𝑇 𝜏
=
𝐽 𝑟
 DESIGN PROCEDURE FOR MUFF COUPLING
III. Determine the standard cross-section of flat sunk key from Table(next slide).
The length of the key in each shaft is one-half of the length of the sleeve.
Therefore,

With these dimensions of the key, check the shear and compressive stresses in
the key by Eqs
and

The shafts and key are made of plain carbon steel. The sleeve is usually made
of grey cast iron of Grade FG 200.
Dimensions of square and rectangular sunk
keys ( in mm )
Example-1

Design a muff coupling to connect two steel shafts transmitting 25 kW power

at 360 rpm. The shafts and key are made of plain carbon steel 30C8 (Syt = Syc =
400 N/mm2). The sleeve is made of grey cast iron FG 200 (Sut = 200 N/mm2).
The factor of safety for the shafts and key is 4. For the sleeve, the factor of
safety is 6 based on ultimate strength.
Solution:
Given data: kW = 25 n = 360 rpm
For shafts and key, Syt = Syc = 400 N/mm2 (fs) = 4
For sleeve, Sut = 200 N/mm2 (fs) = 6
Step I Permissible stresses
For the material of shafts and key,
 Example-1

For sleeve material,

Step II Diameter of each shaft

Example-1

Step III Dimensions of sleeve

D = (2d + 13 ) = 2 × 45 + 13 = 103 or 105 mm

L = 3.5d = 3.5 (45) = 157.5 or 160 mm

The torsional shear stress in the sleeve is calculated by treating it as a hollow

cylinder.
Example-1

Step IV Dimensions of key

From Table1, the standard cross-section of flat sunk key for a 45 mm diameter
shaft is 14 × 9 mm. The length of key in each shaft is one-half of the length of
sleeve. Therefore,

The dimensions of the key are 14 × 9 × 80 mm.

Step V Check for stresses in key

The design of the key

is safe from shear and
compression
considerations.
Split Muff Coupling

Click here to view 3D

Split Muff Coupling

• also called compression coupling or split muff coupling.

• It is a rigid type of coupling.
• sleeve is made of two halves, which are split along a plane passing through
the axes of shafts.
• The construction of the clamp coupling is shown in Fig.
• The two halves of the sleeve are clamped together by means of bolts
which can be four or eight and always in multiples of four and are placed
in recesses formed in the sleeve halves.
Split Muff Coupling

• The torque is transmitted by means of frictional force on the surface of

the shaft. There is also a key between the shafts and sleeve, which also
transmits torque. It is not possible to find out what percentage of torque is
transmitted by friction or by the key. In design, it is assumed that total
torque is transmitted by friction as well as by the key. In other words, the
key is designed for total torque. Also, the clamping bolts are designed for
total torque.
• Power is transmitted from the input shaft to the sleeve and from the
sleeve to the output shaft by means of the key and friction between the
sleeve halves and the shaft.
Split Muff Coupling
Advantages
• It is easy to assemble and dismantle.
• It can be easily removed without shifting the shaft in axial direction, unlike
solid muff coupling.
• As compared with flange coupling, clamp coupling has small diametral
dimensions.
Disadvantages
• difficulty in dynamic balancing of the coupling. Therefore, it is not possible
to use the clamp coupling for high-speed applications.
• Clamp coupling is unsuitable for shock loads.
• necessary to provide a guard for the coupling to comply with the factory
regulation act.

Application of clamp coupling is for line shaft in power transmission.

Split Muff Coupling
Design Considerations
• A fundamental difference between the working of muff and clamp
couplings In muff coupling, torque is transmitted by shear resistance of
keys. On the other hand, torque is transmitted partly by means of friction
between the sleeve halves and the shaft and partly by shear resistance of
key in case of clamp coupling.
• Clamp coupling is usually designed on the basis of standard proportions
for sleeve halves and clamping bolts.
For sleeve halves,
D = 2.5d………(3)
L = 3.5d……….(4)
where
D = outer diameter of sleeve halves (mm)
L = length of sleeve (mm)
d = diameter of shaft (mm)
Split Muff Coupling
Design Considerations
For clamping bolts,
d1 = 0.2d + 10 mm……5
when d < 55 mm
And
d1 = 0.15d + 15 mm…..6
when d > 55 mm
where,
d1 = diameter of clamping bolt (mm)
the diameter of the clamping bolts can be calculated from the first principle.
Let us assume that even with key, the torque is transmitted only by the
friction between the shaft and the coupling halves.
The clamping force of each bolt is given by,
where
P1 = tensile force on each bolt (N)
…..7 d1 = core diameter of clamping bolt (mm)
Ϭt = permissible tensile stress (N/mm2)
Split Muff Coupling
Design Considerations
It is assumed that half the number of bolts give clamping pressure on input
shaft and the remaining half on the output shaft. Therefore, clamping force
on each shaft is given by,

where, n = total number of bolts

N = clamping force on each shaft (N)
As shown in Fig., the frictional force is (fN) and
frictional torque is given by,
Forces on Shaft

where, f = coefficient of friction & From expression (a) and (b),

and …..7
DESIGN PROCEDURE FOR CLAMP COUPLING

1. Calculate the diameter of each shaft by the following equations:

The shaft, key and clamping bolts are usually made of plain carbon steel.
2. Calculate the main dimensions of the sleeve halves by using the following
empirical equations:
D = 2.5 d and L = 3.5 d
The sleeve halves are made of grey cast iron of Grade FG 200.
Determine the standard cross-section of the flat key from Table 1. The length
of the key in each shaft is one-half of the length of sleeve. Therefore,
𝐿
𝑙=
2
DESIGN PROCEDURE FOR CLAMP COUPLING

With these dimensions of the key, check the shear and compressive stresses
in the key by Eqs.
2𝑀𝑡 4𝑀𝑡
𝜏= and 𝜎𝑐 =
𝑑𝑏𝑙 𝑑ℎ𝑙
3. Calculate the diameter of clamping bolts by using Eqs

Alternatively, standard proportions can be used for calculating the bolt

diameter. Equations 5 and 6 are used for this purpose.
The coefficient of friction between the sleeve halves and the shaft is
usually taken as 0.3.
Example no.2
It is required to design a split muff coupling to transmit 50 kW power at 120
rpm The shafts, key and clamping bolts are made of plain carbon steel 30C8
(Syt = 400 N/mm2). The yield strength in compression is 150% of the tensile
yield strength. The factor of safety for shafts, key and bolts is 5. The number
of clamping bolts is 8. The coefficient of friction between sleeve halves and
the shaft is 0.3.
I. Calculate the diameter of the input and output shafts.
II. Specify the length and outer diameter of the sleeve halves.
III. Find out the diameter of clamping bolts assuming that the power is
transmitted by friction.
IV. Specify bolt diameter using standard empirical relations.
V. Specify the size of key and check the dimensions for shear and
compression criteria.
Solution
Given
kW = 50 n = 120 rpm m = 0.3
For shafts, key and bolts Syt = 400 N/mm2 (fs) = 5 n = 8 Syc = 1.5 Syt
1. Permissible stresses
For the material of shafts, key and bolt,

2.Diameter of each shaft

3. Length and outer diameter of sleeve halves
D = 2.5 d = 2.5 (80) = 200 mm
L = 3.5 d = 3.5 (80) = 280 mm …..(ii)

4. Diameter of clamping bolts—Friction basis From Eq.

5. Diameter of clamping bolts—Empirical relation

d1 = 0.15d + 15 = 0.15 (80) + 15 = 27 mm (iv)

6. Dimensions of key
From Table1, the standard cross-section of flat key for an 80 mm diameter
shaft is 22 × 14 mm. The length of the key in each shaft is one-half of the
length of the sleeve half.
Therefore,

The dimensions of the key are,

22 × 14 × 140 mm (v)

7. Check for stresses in key

The design of key is safe from shear and compression considerations.

 3D
RIGID FLANGE COUPLINGS

Flanges

driven shaft

driving shaft

bolts Key

Unprotected Type Flange Coupling

Protected Type Rigid 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.
RIGID FLANGE COUPLINGS- Design Considerations

Proportions of Rigid Coupling

• Flange of the protected type coupling has three distinct regions—inner

hub, central flange with bolt holes and peripheral outer rim as shown in
Fig.
• The hub is provided with a keyway
• The function of the hub is to transmit the torque from the shaft to
the central flange and vice versa.
• The central portion of the flange has holes to accommodate the
bolts. Torque is transmitted from one flange to the other by means
of these bolts.
• The outer circumferential rim is for the purpose of safety to cover
the projecting bolt heads and nuts.
• Various dimensions of flanges are shown in Fig above.
• 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 formulate result in robust
design.
• The standard proportions for various dimensions of the flange
shown in Fig (Slide no. 33).
DESIGN OF RIGID FLANGE COUPLINGS

I. dh = outside diameter
of hub
dh = 2d
II. lh = length of hub or
effective length of key
lh = 1.5 d
III. D = pitch circle
diameter of bolts
D = 3d
IV. t = thickness of flanges
t = 0.5 d
IV. t1 = thickness of protecting rim
t1 = 0.25 d
IV. dr = diameter of spigot and recess
dr = 1.5 d
IV. D0 = outside diameter of flange
D0 = (4d + 2t1)
Where d=the shaft diameter.
RIGID FLANGE COUPLINGS- Design Considerations

The number of bolts (N) is also decided from the shaft 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.

The analysis of rigid coupling can be done by two different ways,

depending upon the clearance between the bolt and the hole
1. Bolts Fitted in Reamed and Ground Holes: In this case, there is no
clearance and the bolts are finger tight. Therefore, power is transmitted
by means of shear resistance of the bolts.
2. Bolts Fitted in Large Clearance Holes: bolts are tightened with a preload
and power is transmitted by means of friction between the two flanges.
RIGID FLANGE COUPLINGS- Design Considerations

1. Bolts Fitted in Reamed and Ground Holes:

The forces acting on individual bolts due to
transmission of the torque are shown in Fig.
Equating the external torque with the resisting
torque,

where,
Mt = torque transmitted by the coupling (N-mm)
P = force acting on each bolt (N)
D = pitch circle diameter of bolts (mm)
N = number of bolts.
RIGID FLANGE COUPLINGS- Design Considerations

1. Bolts Fitted in Reamed and Ground Holes:

It should be noted that the bolts are subjected
to direct shear stress due to the force P and not
torsional shear stress. No torque is acting
about the axis of the bolt. The force P results
in only direct shear stress.
The direct shear stress in the bolt is given by,

where,
t = shear stress in the bolt (N/mm2)
d1 = nominal diameter of the bolt (mm)
RIGID FLANGE COUPLINGS- Design Considerations

1. Bolts Fitted in Reamed and Ground Holes:

From (a) and (b),

Equation (C) is used to determine the nominal diameter of the bolts.

The above analysis of the coupling is based on the assumption that the bolts
are fitted in rimmed and ground holes. The bolts are finger tight in these holes
and there is no clearance between the holes and the nominal diameter of the
bolts.
RIGID FLANGE COUPLINGS- Design Considerations

2. Bolts Fitted in Large Clearance Holes

When the bolts are fitted in large clearance holes, the above analysis is
not applicable. In this case, the bolts are sufficiently tightened with a
preload and the torque is transmitted from one flange to the other by
means of friction between them. For uniformly distributed pressure, the
friction radius Rf is given by,

D
where, (Fig.in slide 35)
Ro = outer radius of the flange (Do /2) (mm)
Ri = radius of the recess (dr /2) (mm)
Assume that,
Pi = initial tension in each bolt (N)
m = coefficient of friction between flanges
RIGID FLANGE COUPLINGS- Design Considerations

2. Bolts Fitted in Large Clearance Holes

The friction force will be (µ Pi N) and the torque is given by,

✓ Flanges have complex shape and the easiest method to make the
flanges is casting.
✓ Flanges are usually made of grey cast iron of grade FG 200. The
bolts, keys and shaft are made of plain carbon steels on strength
criterion.
RIGID FLANGE COUPLINGS- Design Procedure

1. Shaft Diameter
Calculate the shaft diameter by using the following two equations:

2. Dimensions of Flanges
Calculate the dimensions of the flanges by the following empirical equations:
RIGID FLANGE COUPLINGS- Design Procedure
2. Dimensions of Flanges
• The torsional shear stress in the hub can be calculated by considering it as
a hollow shaft subjected to torsional moment Mt.
• The inner and outer diameters of the hub are d and dh respectively. The
torsional shear stress in the hub is given by,

The flange at the junction of the hub is under shear while transmitting
the torsional moment Mt. From Fig.

area under shear = (π dh) × t

shear force = area × shear stress = π dhτt
RIGID FLANGE COUPLINGS- Design Procedure
2. Dimensions of Flanges

3. Diameter of Bolts
Decide the number of bolts using the following guidelines:

N = 3 for d < 40 mm
N = 4 for 40 ≤ d < 100 mm
N = 6 for 100 ≤ d < 180 mm
RIGID FLANGE COUPLINGS- Design Procedure
3. Diameter of Bolts
Determine the diameter of the bolt by Eq. C
Rearranging the equation,

where τ is the permissible shear stress for the bolt material.

The compressive stress in the bolt can be determined by referring to

Fig.
crushing area of each bolt = d1t
crushing area of all bolts = Nd1t
compressive force = Nd1tσc
I

Equation (I) is used to check the compressive stress in the bolt.

RIGID FLANGE COUPLINGS- Design Procedure
3. Dimensions of Keys
Determine the standard cross-section of flat key from Table. The length of the key in
each shaft is lh. Therefore,
l = lh

With these dimensions of the key, check the shear and compressive stresses in
the key by Eqs
Example: A rigid coupling is used to transmit 20 kW power at 720 rpm. There
are four bolts and the pitch circle diameter of the bolts is 125 mm. The bolts
are made of steel 45C8 (Syt = 380 N/mm2) and the factor of safety is 3.
Determine the diameter of the bolts. Assume that the bolts are finger tight in
reamed and ground holes.
Solution:
Given kW = 20 n = 720 rpm
For bolts, Syt = 380 N/mm2 , (fs) = 3
D = 125 mm N = 4
Step I Permissible shear stress

Step II Diameter of bolts

Example: A rigid coupling is used to transmit 50 kW power at 300 rpm. There
are six bolts. The outer diameter of the flanges is 200 mm, while the recess
diameter is 150 mm. The coefficient of friction between the flanges is 0.15.
The bolts are made of steel 45C8 (Syt = 380 N/mm2) and the factor of safety is
3. Determine the diameter of the bolts. Assume that the bolts are fitted in large
clearance holes.(Assignment)

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.
Solution:
Given
kW = 37.5 n = 180 rpm , Design torque = 1.5 ( rated torque)
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.
Solution:
Given
kW = 37.5 n = 180 rpm , Design torque = 1.5 ( rated torque)

Step I Selection of materials

1. The shafts are subjected to torsional shear stress. On the basis of strength,
plain carbon steel of grade 40C8 (Syt = 380 N/mm2) is used for the shaft. The
factor of safety for the shafts is assumed to be 2.5.
2. The keys and bolts are subjected to shear and compressive stresses. On the
basis of strength criterion, plain carbon steel of grade 30C8 (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.
Step I Selection of materials
3. Flanges have complex shape and the easiest method to make the flanges
is casting. Grey cast iron FG 200 (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, since the permissible
stress is based on the ultimate strength and not on the yield strength.
Step II Permissible stresses
Step III Diameter of shafts
Taking into consideration the service factor of 1.5, the design torque is given
by,

Step IV Dimensions of flanges

dh = 2d = 2 (60) = 120 mm
lh = 1.5d = 1.5 (60) = 90 mm
D = 3d = 3(60) = 180 mm
t = 0.5d = 0.5(60) = 30 mm
t1 = 0.25d = 0.25(60) = 15 mm
dr = 1.5d = 1.5(60) = 90 mm
D0 = (4d +2t1) = 4(60) + 2(15) = 270 mm
Step IV Dimensions of flanges

The thickness of recess is assumed as 5 mm.

The hub is treated as a hollow shaft
subjected to torsional moment. From Eq.
Step IV Dimensions of flanges

Step V Diameter of bolts

The diameter of the shaft is 60 mm.
40 < d < 100 mm
The number of bolts is 4.
Step V Diameter of bolts
The compressive stress in the bolt is determined Using

Step VI Dimensions of keys

From Table, the standard cross-section of the flat key for a 60-mm diameter
shaft is 18 × 11 mm. The length of the key is equal to lh. Or,

l = lh = 90 mm
The dimensions of the flat key are 18 × 11 × 90 mm.
Step VI Dimensions of keys

The shear and compressive stresses induced in the key are within permissible
limits.
FLEXIBLE COUPLING

Misalignment exists due to the following reasons:

• deflection of shafts due to lateral forces;
• error in shaft mounting due to manufacturing tolerances;
• use of two separately manufactured units such as an electric motor and a
worm gear box; and
• thermal expansion of the parts.
If rigid coupling is used in such circumstances, the misalignment causes
excessive bearing reactions resulting in vibrations and wear. To overcome this
problem, flexible couplings are used.
FLEXIBLE COUPLING

• A flexible coupling consist of a flexible

element like a rubber bush between the
driving and the driven flanges.
• This flexible rubber bush not only
accommodates the misalignment but also
absorbs shocks and vibrations.
• The basic types of misalignment between
axes of the input and output shafts are
shown in Fig.
• A flexible coupling can tolerate 0.5 mm of
lateral or axial misalignment and 1.5° of
angular misalignment.
BUSHED-PIN FLEXIBLE COUPLING
BUSHED-PIN FLEXIBLE COUPLING

advantages:
• It can tolerate 0.5 mm of lateral or axial misalignment and 1.5° of angular
misalignment.
• It prevents transmission of shock from one shaft to the other and absorbs
vibrations.
• It can be used for transmitting high torques
• It is simple in construction and easy to assemble and dismantle. It is easy
to design and manufacture the coupling.
Disadvantages
• The cost of flexible coupling is more than that of rigid coupling due to
additional parts.
• It requires more radial space compared with other types of coupling.
BUSHED-PIN FLEXIBLE COUPLING

• The dimensions of the flanges of flexible bushed-pin coupling are

calculated by using standard proportions in terms of shaft diameter.
basic difference between the flanges of rigid and flexible couplings are
• In rigid coupling, two flanges are identical except for the provision of
spigot and recess.
• In flexible coupling, the input flange accommodates the rubber bushes of
comparatively large diameter than the diameter of the pins
accommodated in the output flange. Therefore, the diameter of holes and
the thickness of the two flanges are different.
 BUSHED-PIN FLEXIBLE COUPLING
The standard proportions for various
dimensions of the flanges are

1. dh = outside diameter of hub

dh = 2d
2. lh = length of hub or effective length of
key
lh = 1.5 d
3. D = pitch circle diameter of pins
D = 3d to 4d
4. t = thickness of output flange
t = 0.5 d
5. t1 = thickness of protective rim
t1 = 0.25 d
6. d1 = diameter of pin
05.d
d1 =
√𝑁
where N is the number of pins and d is the
shaft diameter.
 BUSHED-PIN FLEXIBLE COUPLING
• Other dimensions of flanges like outer diameter or thickness of the input
flange are calculated after deciding the dimensions of the rubber bushes
• it is assumed that the power is transmitted by the shear resistance of the pins.
• As the flange on the input shaft rotates, it exerts a force P on each rubber
bush.
• The resisting forces on the rubber bushes are shown in Fig.
Equating the couples due to resisting force with the torque,

where,
Mt = torque transmitted by the coupling (N-mm)
P = force acting on each rubber bush or pin (N)
D = pitch circle diameter of bushes or pins (mm)
N = number of bushes or pins

Resisting Forces in Rubber Bushes

BUSHED-PIN FLEXIBLE COUPLING

The projected area of the rubber bush is

shown in Fig.
The force P is equal to the product of the projected area and the intensity of
pressure.
Therefore,

where,
Db = outer diameter of the bush (mm)
lb = effective length of the bush in contact with the input flange (mm)
pm = permissible intensity of pressure between the flange and the rubber
bush (N/mm2)
From, (a) and (b),

1
BUSHED-PIN FLEXIBLE COUPLING

The permissible intensity of pressure between the rubber bush and the cast iron
flange is usually 1 N/mm2.
The ratio of length to the outer diameter for the rubber bush is usually assumed as
1. Therefore,

Substituting the above relationship in Eq. 1

The outer diameter of the rubber bush is obtained by the above equation.
BUSHED-PIN FLEXIBLE COUPLING

The pin is subjected to direct shear stress due to the force P. The direct shear stress
in the pin is given by,(refer fig.)

From (a) and (c),

According to Indian standard, the allowable shear stress for pins is 35 N/mm2.
The pin is also subjected to bending moment.
BUSHED-PIN FLEXIBLE COUPLING

Material
• The flanges of flexible bush coupling are made of grey cast iron of grade FG 200.
• The pins are made of carbon steel.
• The recommended type of fit between the shaft and the hub is H7-j7.
• The maximum allowable peripheral speed of the coupling is 30 m/s.
 BUSHED-PIN FLEXIBLE COUPLING
Features of flexible bush coupling
1. there is a gap or clearance between the driving and driven flanges of flexible
bush coupling. This gap is essential for taking care of angular misalignment
between the two shafts. There is no such clearance between the flanges of
rigid coupling. Therefore, rigid coupling cannot tolerate any angular
misalignment.
2. In case of rigid coupling, the torque is transmitted by means of bolts. These
bolts are made of steel and resisting shear or tensile stresses are high.
Therefore, the diameter of the bolts or the pitch circle diameter of bolts is
comparatively less than that of flexible bush coupling. On the other hand, the
torque is transmitted by means of a force passing through a rubber bush in
case of flexible bush coupling. The permissible pressure between the rubber
bush and cast iron flange is only 1 N/mm2. Therefore, the diameter of the pin
or pitch circle diameter of pins is comparatively large than that of rigid flange
coupling. It should be noted that for connecting shafts of a particular size,
flexible bush coupling either has greater number of bolts (or pins) than rigid
coupling or has larger bolt circle diameter than rigid coupling. This reduces the
force acting on the bolts (pins) and lowers bearing pressure on the rubber
bush.
DESIGN PROCEDURE FOR FLEXIBLE COUPLING

(i) Shaft Diameter

(ii) Dimensions of Flanges

The torsional shear stress in the hub can be calculated by considering it as a
hollow shaft subjected to torsional moment Mt. The inner and outer
diameters of the hub are d and dh respectively. The torsional shear stress in
the hub is given by,

The shear stress in the flange at the junction with the hub is calculated by

(iii) Diameter of Pins

shear stress in the pins

The shear stress calculated by the above equation should be less than 35
N/mm2. Also, determine the bending stresses in the pins and confirm that it is
within limit.

(iv) Dimensions of Bushes

the outer diameter of the rubber bush

effective length of the rubber bush by the following relationship,

lb = Db
(v) Dimensions of Keys
Determine the standard cross-section of flat key from Table. The length
of the key in each shaft is lh . Therefore,
l = lh
A flexible coupling, illustrated in Fig. is used to transmit
15 kW power at 100 rpm. There are six pins and their
pitch circle diameter is 200 mm. The effective length of
the bush (lb), the ga between two flanges and the length
of the pin in contact with the right hand flange are 35, 5
and 23 mm respectively. The permissible shear and
bending stresses for the pin are 35 and 152 N/mm2
respectively. Calculate:
(i) pin diameter by shear consideration; and
(ii) pin diameter by bending consideration.
It is required to design a bushed pin type flexible coupling to connect the
output shaft of an electric motor to the shaft of a centrifugal pump. The
motor delivers 20 kW power at 720 rpm. The starting torque of the motor can
be assumed to be 150% of the rated torque. Design the coupling and specify
the dimensions of its components.