Flexible Coupling:

We have already discussed that a flexible coupling is used to join the abutting e nds of
shafts. when they are not in exact alig nment. In the case of a direct coupled drive from a
prime mover to an electric generator, we should have four bearings at a compa ratively
close distance. In such a case and in many others, as in a direct electric drive from an
electric motor to a machine tool, a flexible coupling is used so as to permit an axial misalig
nemnt of the shaft without undue absorption o f the power which the shaft are transmitting.
Bushed-pin Flexible Coupling
A bushed-pin flexible co upling, as shown in Fig., is a modification of th e rigid type of
flange coupling. The coupling bolts are known as pins.

The rubber or leather bushes are used over the pins. The two halves of the coupling are
dissimilar in construction. A clearance of 5 mm is left between the face of the two halves of the
coupling. There is no rigid c onnection between them and the drive takes plac e through the
medium of the compressible rub ber or leather bushes.
1. Design for Shaft:

2. Design for hub

The hub is designed by considering it as a hollow shaft, transmitting the same torque (T) as
that of a solid shaft.

The outer diameter of hub is usually taken as twice the diameter of shaft. Therefore from
the above relation, the induced shearing stress in the hub may be checked.
The length of hub (L) is taken as 1.5 d.
3. Design for key
The key is designed with usual proportions and then checked for shearing and crushing
stresses. The material of key is usually the same as that of shaft. The length of key is taken
equal to the length of hub.

4. Design for flange

The flange at the junction of the hub is under shear while transmitting the torque.
Therefore, the torque transmitted,
T = Circumference of hub × Thickness of flange × Shear stress of flange × Radius of
hub

The thickness of flange is usually taken as half the diameter of shaft. Therefore from the
above relation, the induced shearing stress in the flange may be checked.
 In designing the bushed-pin flexible coupling, the proportions of the rigid type
flange coupling are modified. The main modification is to reduce the bearing pressure on
the rubber or leather bushes and it should not exceed 0.5 N/mm2. In order to keep the low
bearing pressure, the pitch circle diamete r and the pin size is increased.
Let l = Length of bush in the flange,
d2 = Diameter of bush,
Pb = Bearing pressure on the bush or pin,
n = Number of pins, and
D1 = Diameter of pitch circle of the pins.
We know that bearing lo ad acting on each pin,
W = pb × d2 × l
Then, Total bearing load on the bush or pins
= W × n = p b × d2 × l × n
And the torque transmitted by the coupling,

The threaded portion of the pin in the right hand flange should be a tapping fit i n the
coupling hole to avoid bending stresses.
The threaded length of the pin should be as small as possible so that the direc t shear stress
can be taken by the unthreaded neck.
Direct shear stress due to pure torsion in the coupling halves,

Since the pin and the rubber or

leather bush is not rigidly held in the
left hand flange, therefore the
tangential load (W) at the enla rged
portion will exert a bending action
on the pin as shown in Fig. The bush portion of the pin acts as a cantilever beam of length l.
Assuming a uniform distributi on of the load W along the bush, the maxi mum bending
moment on the pin,
We know that bending stress,

Since the pin is subjected to bending and shear stresses, therefore the design must be
checked either for the maximum principal stress or maximum shear stress by the following
relations: Maximum principal stress

and the maximum shear stress on the pin

The value of maximum principal stress varies from 28 to 42 MPa.

Note: After designing the pins and rubber bush, the hub, key and flange may be designed in
the similar way as discussed for flange coupling.

Problem:
Design a bushed-pin type of flexible coupling to connect a pump shaft to a motor shaft
transmitting 32 kW at 960 r.p.m. The overall torque is 20 percent more than mean torque.
The material properties are as follows:
(a) The allowable shear and crushing stress for shaft and key material is 40 MPa and 80
MPa respectively.
(b) The allowable shear stress for cast iron is 15 MPa.
(c) The allowable bearing pressure for rubber bush is 0.8 N/mm2.
(d) The material of the pin is same as that of shaft and key.
Draw neat sketch of the coupling.
Solution. Given: P = 32 kW = 32 × 103 W; N = 960 r.p.m. ; Tmax = 1.2 Tmean ; τs = τk
= 40 MPa = 40 N/mm2 ; σ cs = σ ck = 80 MPa = 80 N/mm2 ; τc = 15 MPa = 15 N/mm2 ;
pb = 0.8 N/mm2.
1. Design for pins and rubber bush
In order to allow for the bending stress induced due to the compressibility of the rubber
bush, the diameter of the pin (d1) may be taken as 20 mm. Ans.
The length of the pin of least diameter i.e. d 1 = 20 mm is threaded and secured in the right
hand coupling half by a standard nut and washer. The enlarged portion of the pin which is
in the left hand coupling half is made of 24 mm diameter. On the enlarged portion, a brass
bush of thickness 2 mm is pressed. A brass bush carries a rubber bush. Assume the
thickness of rubber bush as 6 mm.
So, Overall diameter of rubber bush,
d2 = 24 + 2 × 2 + 2 × 6 = 40 mm Ans.
and diameter of the pitch circle of the pins,
D1 = 2 d + d2 + 2 × 6 = 2 × 40 + 40 + 12 = 132 mm Ans.

Let l = Length of the bush in the flange.

We know that the bearing load acting on each pin,
W = pb × d2 × l = 0.8 × 40 × l = 32 l N
And the maximum torque transmitted by the coupling (Tmax),

l = 382 × 103/12 672 = 30.1 say 32

mm And W = 32 l = 32 × 32 = 1024 N
So, Direct stress due to pure torsion in the coupling halves,

Since the pin and the rubber bush are not rigidly held in the left hand flange, therefore the
tangential load (W) at the enlarged portion will exert a bending action on the pin. Assuming a
uniform distribution of load (W) along the bush, the maximum bending moment on the pin,
Maximum principal stress

And maximum shear stress

Since the maximum principal stress and maximum shear stress are within limits, therefore
the design is safe.

2. Design for hub

We know that the outer diameter of the hub,

D = 2 d = 2 × 40 = 80 mm
And length of hub, L = 1.5 d = 1.5 × 40 = 60 mm
Let us now check the induced shear stress for the hub material which is cast iron. Considering
the hub as a hollow shaft. We know that the maximum torque transmitted (Tmax),

τc = 382 × 103 / 94.26 × 103 = 4.05 N/mm 2 = 4.05 MPa

Since the induced shear stress for the hub material (i.e. cast iron) is less than the permissible
value of 15 MPa, therefore the design of hub is safe.
3. Design for key
Since the crushing stress for the key material is twice its shear stress (i.e. σ ck = 2 τ k ),
therefore a square key may be used. From Table 13.1, we find that for a shaft of 40 mm
diameter,
Width of key, w = 14 mm Ans.
and thickness of key,t = w = 14 mm Ans.
The length of key (L) is taken equal to the length of hub,
i.e. L = 1.5 d = 1.5 × 40 = 60 mm
Let us now check the induced stresses in the key by considering it in shearing and crushing.
Considering the key in shearing. We know that the maximum torque transmitted (Tmax),

Considering the key in crushing. We know that the maximum torque transmitted (Tmax),
 σ ck = 382 × 103/8400 = 45.48 N/mm2 = 45.48 MPa
Since the induced shear and crushing stress in the key are less than the permissible stresses
of 40 MPa and 80 MPa respectively, therefore the design for key is safe.
4. Design for flange
The thickness of flange ( tf ) is taken as 0.5
d. tf = 0.5 d = 0.5 × 40 = 20 mm
Let us now check the induced shear stress in the flange by considering the flange at the
junction of the hub in shear.

We know that the maximum torque transmitted (Tmax),

τc =382 × 103 / 201 × 103 = 1.9 N/mm2 = 1.9 MPa

Since the induced shear stress in the flange of cast iron is less than 15 MPa, therefore the
design of flange is safe.