SHAFT COUPLINGS

Couplings are mechanical devices which connect one shaft

to another or to couple a drive shaft to a driven shaft.

1. To provide for the connection of shafts of units that are

manufactured separately, such as a motor and a generator, and to
provide for disconnection for repairs or alterations;
2. To join two shafts of smaller lengths for having required length;
3. To allow misalignment of the shafts, i.e., to introduce mechanical
flexibility;
4. To reduce the transmission of shock loads from one shaft to
another;
5. To protect against overloads;
6. To1:26
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PM the vibration characteristics of rotating units. 1
 SHAFT COUPLINGS

There are two general types of couplings:

Rigid

&

Flexible

There is another named Universal Coupling

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 Conditions for using Shaft
Couplings
1. With shafts having collinear axes: Rigid
couplings are used.
2. With shafts having lateral misalignments:
Flexible couplings are used.
3. With shafts having intersecting axes, in
which case a universal coupling is
employed.

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 Shaft Alignments

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 Rigid Couplings

This coupling provides no flexibility or

resilience, and therefore, used for those
shafts that are perfectly aligned, both
lateral and angular, in order to avoid
excessive loads on the coupling on the
shafts as well as on the shaft bearings.

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 Common Rigid Couplings

Sleeve or Muff Coupling: with key

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Sleeve or Muff Coupling: with taper pins

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 Sleeve or Muff Coupling

It is a hollow cylinder fitted over

the ends of the two shafts to be
connected and keyed there on by a
sunk key;
The three links act as a single
rigid member;
The joint is made with the help of
screws and pins with pressure fits;
The coupling is simple in design
and manufacture.

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 Sleeve or Muff Coupling

Disadvantages of the coupling are the

difficulties in disassembly that is either the
sleeve must be shifted along the shaft at least
half of its length or the shafts must be drawn
apart to free the entire length of the coupling;

Shafts should be accurately aligned since any

misalignment of shaft axes due to careless
assembly or deformation under load, may give
rise to forces that can deflect the shafts. Any
such deflection has adverse effects on the
assembly.
The material of the sleeve is usually CI.

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 Sleeve or Muff Coupling
The sleeve and key should safely resist
the torsional moment, Mt of the shaft;
Moments of each of the shearing &
crushing resistance of the key should be
equal to the torsional moment of the
shaft;
The effective length of the key is only
that part of the coupling key that is in
one of the two shafts connected;
Often the coupling key is made in two
parts, one in each shaft;
The taper pin is checked for induced
shear stress as less than the allowable
shear stress of the pin.
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 Sleeve Coupling: Design Equations

Considering the polar section modulus for a hollow

shaft,
D4 d 4
ZP =
16 d
Mt fs
= , or Mt = ZP xfs
J r
16Mt d
fs = ,
(D 4 d 4 )
D = outside dia, d = inside dia, fs = induced shearing stress in the sleeve,
Mt = Torsional moment to be transmitted from one shaft to other
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 Sleeve Coupling: Design
considerations

For ease of calculation of diameter, first the dimensions are

fixed from proportions and then the sleeve is checked for
the induced shear stress so that it is safe.

The proportions are:

D = 2 d + 12.5,
l = 3.5d
For sleeve coupling with taper pin the proportions are:
D = 1.5 d ,
l = 3d
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 Sleeve Coupling: Design
considerations

Location of sleeve from one edge of the sleeve, e = 0.75 d

Mean diameter of the pin, d pin = 0.20 d to 0.25d

After the dimensions are fixed on the basis of proportions the

pin is checked for induced shear stress:
2Mt 2
= 2x xdpin xfs
d 4
Induced shear stressfs < Allowableshear stressof the pinmaterial

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 Clamp or Split Muff Coupling

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 Clamp or Split Muff Coupling

Clamp coupling is a compression coupling - a modification of

sleeve coupling;
Made in two parts, which are machined and finished off to fit
the periphery of the shaft on both ends;
Its construction permits ready and quick assembly and
disassembly;
Two halves of the coupling are clamped tightly against the
surface of the shaft ends by through bolts so that the torsion
moment is transmitted by friction.
In large couplings a key is inserted between the shafts and
coupling for transmitting the main torsion moment.

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 Clamp or Split Muff Coupling

Proportions
l = 5d to 3.5d;
D=4d to 2d;

Even with the keys it is assumed that torque is

transmitted by bolts; so bolts are designed on the
basis of friction force.

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 Clamp Coupling: Design Equations

Clamping load on the shaft due to z number of bolts

= (z/2) (/4)dc2 x ft.
where z- is the total number of effective bolts for both
shafts.
dc = diameter of the bolt used for clamping.
ft= allowable tensile stress in the bolt.
Clamping pressure intensity between shaft & sleeve
p = Load/projected area = Load/(d x l/2)
Tangential force per unit area of shaft
F = x pressure = [ x (/4)(dc2 x ft x z)]/dl
= coefficient of friction between the shaft and
sleeve material. An average value of = 0.3.
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 Clamp Coupling: Design Equations

The torsion moment transmitted by the coupling

M = F x area x d/2 = [ x (/4)(dc2 x ft x z)]/dl x (dl/2)(d/2)
= (2 /16)(dc2 x ft x z x d x )

Torsion moment M must be equal to the torsion moment

Mt to be transmitted by the coupling M = Mt

Power transmitted by the coupling W = Mt (Nm/s)

= angular velocity of shaft
Load that can be taken by each bolt, P = (/4)dc2 x ft. = 4 Mt /(zd)

From this size of the bolt can be calculated on assuming its number.
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 Flange Coupling: Rigid

A rigid flange coupling consists of two CI flanges mounted

and keyed on the ends of each shaft and tied together by a
series of concentrically placed bolts.

For the sake of precise alignment provisions are there for

machined centering surfaces on the ends of the flange.
Bolts are carefully fitted in reamed holes, no clearance
allowed so that each bolt take its share of proportionate
load.
A protecting flange is provided for the safety of projecting
bolt heads & nuts.

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 Flange Coupling: Rigid

Advantages
Ensures most accurate, rigid and strong
connection of shafts.

Disadvantages
Presence of flange requires the
mountings like gears, pulleys,
flywheels, bearings etc. to be of split
type.

Uses
Steam turbo-generators, vertical hydro-
turbines, marine propeller shafts etc.
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 Rigid Flange Coupling

Without protecting flange

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 Rigid Flange Coupling

With protecting flange

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 Design Considerations
d14 d 4
1. Hub as hollow shaft: Mt = x xfs
16 d1
Empirically, 16Mt d1
fs = 4 4
d1 = 1.75 d + 6.5 mm (d1 d )

2. Length of hub = length of key, width of

key is 0.25d. Shaft & key are of same
material. Length of key is 1.5d. Thickness
of key is determined pursuing standard
procedure of designing for shear &
crushing.
4
3. Empirically, no. of bolts is, z= d + 3; d in mm
150
Usually the value is 4 to 8.

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 Design Considerations

Shear stress
4. Shear force occurs when finished bolts
are fitted in reamed holes. Shearing force
applied on bolts for pitch circle diameter
M
(PCD) of R2 is, P = t
R2
PCD depends on (i) hub dia, (ii)
clearance, (iii) radius of head of socket
wrench (1.85d0 + 8 mm), d0 being bolt
diameter.

R2= radius of hub + clearance + radius of

head of socket wrench.
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 Design Considerations
5. Total shearing force applied on bolts is,

P= d 02 x z x fs
4
Mt 2
= d 0 x z x fs
R2 4
From this bolt diameter d0 can be calculated.

Crushing stress
6. Bolts are subjected to crushing stress
against flange of thickness t2, P = z x d 0 x t2 x fc
t2 can be calculated from this. Empirically,
t1
t2 = + 6.5 mm t1 being the thickness of hub.
2

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 Design Considerations

Bolts under tension

7. When bolts are not finished, holes are not
reamed and clearance exists between hole and
bolt surface, bolts are subjected to
sufficient tension to produce frictional
force on mating surfaces of flanges. This
friction transmits torque. The force of
friction,
P = z x x Pi , = coeff of friction &
Pi = tightening force of bolt .
P
Pi =
z

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 Design Considerations

Due to tightening stress induced in the bolt

being higher, taken as 30% more. So, for
core diameter of bolt being dc,

dc2 x ft = 1.3Pi
4

From this core diameter of bolt dc can be

calculated.

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 FLEXIBLE COUPLINGS

Flexible couplings are designed to transmit torque smoothly

while permitting some axial, radial, and angular
misalignment.
The flexibility is such that when misalignment does occur,
parts of the coupling move with little or no resistance.
Couplings may allow parallel misalignment 0.127 - 0.762 mm
or more.
Typical allowable angular misalignment is 3.
Axial movement allowed (end float) is up to 0.762 mm for
many types of couplings.

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 FLEXIBLE COUPLING

Two categories

1. Couplings with incorporated flexible members that

anticipates both misalignment and impact. No
lubrication needed.

2. Couplings with flexibility by the use of rigid

members. These couplings are rigid slip couplings
and universal-joint couplings and should be
lubricated.

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 FLEXIBLE COUPLING
Bushed Pin Type

A coupling with incorporated

flexible member like bush
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 Bushed Pin Type Flexible
Coupling

This is the simplest and commonest type

of coupling.
It transmits motion from one half of
flange to the other half through bolts.
Flanges are fitted with axial clearance.
Pins are rigidly bolted to one flange
and loosely fitted in the other. They are
easily removable.
This coupling allows parallel
misalignment of shafts up to 0.5 mm,
angular misalignment up to 1.5o and a bit
axial displacement.
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 Bushed Pin Type Flexible
Coupling

The coupling flanges are made

from cast iron or steel
forgings or steel castings.
Pins are made from normalized
steel.
Bushes are made of rubber,
leather, asbestos or jute.
Sleeves around pin are of
brass.

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 Design Considerations

1. Rubber Bush: against bearing

Bearing Stress on the rubber bushes.
The force F applied at each pin to transmit the
given torsional moment is,

F= Mt / (z x R)
where Mt is the torsional moment ,
R is the radius of the pitch circle,
z is the number of pins used,
z = (d/25) +3 (d in mm).

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 Design Considerations
The outer diameter of the rubber bush
d1 = diameter of pin + 2 x thickness of brass sleeve +2 thickness of
rubber bush.
The rubber bushes are available in thickness of 6 7.5 mm for
bores up to 25 mm and for larger bores thickness of 9 mm.
The thickness of brass sleeve may be taken as 1.5 mm.
Projected area A = d1 x l , Force F = p x A = p x d1 x l
l being the length of the bush & p the allowable bearing pressure.
Value of p for the rubber is taken as 0.35 N/mm2 . From this
equation length of the bush l can be determined.
To make bush safe against bearing, diameter of pin on bush half is
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made higher than threaded half.
 Design Considerations

2. Threaded part of pin: against shear stress

The threaded length of the pin on which the nut is to be

tightened should be as short as possible, so that shear can be
taken by the unthreaded neck.

Shear stress due to the transmitted torsional moment Mt

on diameter do will be,

So, induced shear stress fs = F / area of neck = F / (/4) do2

Induced fs should be less than the allowable fs.

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 Design Considerations
3. Bending Stress
The pin is loosely held on the bush half, there is clearance between
flanges, rubber is compressible. These cause a cantilever effect and
pin is then subjected to bending.

F l1

d0
dp

l-c
l c
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 Design Considerations

The clearance between the flanges is usually 5-9 mm.

The load F on the pin is uniformly distributed on the length
(l - c), therefore, the arm under bending moment up to the
reduced area = (l - c) / 2 + C = l1

Maximum bending moment = F x l1

Induced bending stress will be

fb = F l1 / ( / 32) d03
This value should be less than the allowable bending stress.

After calculation of the bending & shear stresses, the pin

should be checked against principal bending & shear stresses.
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 Design Considerations

4. Initial tightening stresses

Nuts should not be tightened unnecessarily to avoid
creation of excess shear stress to be induced.

Empirical dimensions
Outer diameter of hub =2d
Length of the hub = 1.5d
Diameter of pin do = 0.5 d/z1/2
PCD of pins = 3d 4d
Thickness of the RHS flange = 1/2t1+6.5 mm
Thickness of the LHS flange = length of bush - C
Width of the flanges = bush length + 10 mm

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 Slip Coupling

A slip coupling permits relative rotation, or slip, between

the driving shaft and the driven shaft.

Its like a safety device that prevents damage to rotating

parts because of overloading.

Slip begins if the load exceeds by 10 - 20 % of the max

load that the shafts and other parts are designed for.

There are many variations in the form of this coupling.

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 Slip Coupling

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 Slip Coupling
The flanged hub A is keyed to the driving shaft. The driven
shaft is keyed to the flanged hub B with friction discs attached
to both sides of the flange.

A number of springs are fitted by screwing the nuts to create

a pressure on the friction surfaces that ensures a constant
maximum moment of friction transmitted by the coupling.

In case of an overload (when torsion moment Mt friction

moment Mf ) on the coupling, the discs start to slip.

Further increase of torsion moment on the shaft is safe-

guarded against failure.

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 Design Considerations

Slip in this coupling occurs frequently, and no measurable wear

takes place. So, uniform pressure (p) is assumed. The axial force
Fa is given by
2
Fa =
4
(2
d 2 d 1 p )
Tangential force for two friction surfaces is,
2
Ft = 2 Fa = 2 ( d 22 d 21 ) p = ( d 2 d 21 ) p
4 2

The mean radius at which the tangential force acts

d + d1 d 2 + d1
rm = 2 =
2 x 2 4
The frictional torsion moment transmitted by the coupling is
d +d
Mt = Ft x rm =
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( )
4 8
( )
d22 d 21 p x 2 1 = d22 d 21 ( d2 + d1 ) p
42
 Design Considerations

The torsion moment Mt can be equated to the torsion

moment to be transmitted by the coupling.
The bearing pressure p should be as low as possible to
increase the life of the coupling. The desirable value for the
bearing pressure is p = 0.4 - 0.5 N/mm2 and 0.7 N/mm2 .
The ratio of diameter d2 and d1 approximately, d2/d1 = 1.6.
The number of springs ranges from 6 to 16 for a shaft
diameter of 55 mm to 160 mm.
The axial load (tensile load) coming on all the bolts can be
calculated from relation axial force Fa.
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 END

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