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COUPLINGS:

1.0 Introduction:
A coupling is a device used to connect two shafts together at their ends for the purpose of transmitting
power. Couplings do not normally allow disconnection of shafts during operation, however there are torque
limiting couplings which can slip or disconnect when some torque limit is exceeded.

The primary purpose of couplings is to join two pieces of rotating equipment while permitting some degree
of misalignment or end movement or both. By careful selection, installation and maintenance of couplings,
substantial savings can be made in reduced maintenance costs and downtime.

Figure 1: A rotating Coupling

1.1 Uses of Couplings

Shaft couplings are used in machinery for several purposes; the most common are the following.

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(i) To provide for the connection of shafts of units those are manufactured separately such as
a motor and generator and to provide for disconnection for repairs or alterations.
(ii) To provide for misalignment of the shafts or to introduce mechanical flexibility.
(iii) To reduce the transmission of shock loads from one shaft to another.
(iv) To introduce protection against overloads.
(v) To alter the vibration characteristics of rotating units

1.2 Types
In general there are two types of couplings namely rigid couplings and flexible couplings

1.2.1 Rigid Couplings

In the rigid couplings, the two shafts are aligned straight, allowing a constant rotational velocity with zero
backlash, high torsional stiffness and torque transmission. Also, they are generally simple in structure; with
their small size, their moment of inertia and price are low. A rigid coupling is a unit of hardware used to
join two shafts within a motor or mechanical system. It may be used to connect two separate systems, such
as a motor and a generator, or to repair a connection within a single system. A rigid coupling may also be
added between shafts to reduce shock and wear at the point where the shafts meet.

Figure 2: Rigid Coupling

When joining shafts within a machine, mechanics can choose between flexible and rigid couplings. While
flexible units offer some movement given between the shafts, rigid couplings are the most effective choice
for precise alignment and secure hold. Rigid couplings help to maximize performance and increase the
expected life of the machine. Rigid couplings are available in three basic designs to fit the needs of
different applications.

(a) Sleeve or Muff couplings are the most affordable and easiest to use. They consist of a single tube
of material with an inner diameter that's equal in size to the shafts. The sleeve slips over the shafts
so they meet in the middle of the coupling. A series of set screws can be tightened so they touch
the top of each shaft and hold them in place without passing all the way through the coupling.

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Figure 3: Sleeve or Muff couplings:

(b) Clamped, Flange or Compression rigid couplings come in two parts and fit together around the
shafts to form a sleeve. They offer more flexibility than sleeved models, and can be used on shafts
that are fixed in place. They are generally large enough so that screws can pass all the way through
the coupling and into the second half to ensure a secure hold. Flanged rigid couplings are designed
for heavy loads or industrial equipment. They consist of short sleeves surrounded by a
perpendicular flange. One coupling is placed on each shaft so the two flanges line up face to face.
A series of screws or bolts can then be installed in the flanges to hold them together. Because of
their size and durability, flanged units can be used to bring shafts into alignment before they are
joined together.

Figure 4: Clamped, Flange or Compression Coupling

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Where: d is the shaft diameter

D is the hub diameter =2d

Dc is the pitch circle diameter

Do is the outer diameter

(c) Forge or Marine type Coupling: In this type the ends of shafts are forged to form flanges. To
ensure alignment of shafts a spigot is formed in one of the flanges and the corresponding recess is
provided in other flanges. This coupling is used for marine propeller shafts.

Figure 5: Forge or Marine type coupling

1.2.2 Flexible Couplings

Flexible couplings are used to transmit torque from one shaft to another when the two shafts are slightly
misaligned. Flexible couplings are designed to transmit torque while permitting some radial, axial, and
angular misalignment. Flexible couplings can accommodate angular misalignment up to a few degrees and
some parallel misalignment. Flexible couplings can accommodate varying degrees of misalignment up to
3°. In addition to allowing for misalignment, flexible couplings can also be used for vibration damping or
noise reduction. These are leaf spring and bellows type and many other.

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Some application of flexible couplings are printing machines, roll forming machines, laminating machines,
corrugated paper machines and paper making machines require an extreme and variable parallel offset.

1.2.3 Functions of Flexible Couplings

Following are the functions of a flexible coupling
 Transmit Power
 Accommodate misalignment
 Allow axial displacement
 Insure no loss of lubricants in grease packed couplings
 Easy to install and disassemble
 Accept torsional shock and dampen torsional vibration
 Stay rigidly attached to the shaft.
 Withstand temperatures of environment or heat of friction.

Figure 6: Leaf spring type coupling

Figure 7: Bellows and Chain Coupling

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Figure 8: Chain Coupling

Chain Couplings advantages:

 Easy to disassemble and reassemble
 Fewer number of parts

Chain Couplings disadvantages:

 Speed limited due to difficulties in maintaining balancing requirements
 Requires lubrication
 Limited allowable axial displacement

1.2.4 Beam Couplings

A beam coupling, also known as helical coupling, is a flexible coupling for transmitting torque between
two shafts while allowing for angular misalignment, parallel offset and even axial motion, of one shaft
relative to the other. This design utilizes a single piece of material and becomes flexible by removal of
material along a spiral path resulting in a curved flexible beam of helical shape. Since it is made from a
single piece of material, the Beam Style coupling does not exhibit the backlash found in some multi-piece
couplings. Another advantage of being an all machined coupling is the possibility to incorporate features
into the final product while still keeps the single piece integrity.

The most common applications are attaching encoders to shafts and motion control for robotics.

Figure 9: Beam Coupling

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1.2.5 Diaphragm Couplings

Diaphragm couplings transmit torque from the outside diameter of a flexible plate to the inside diameter,
across the spool or spacer piece, and then from inside to outside diameter. The deforming of a plate or
series of plates from I.D. to O.D accomplishes the misalignment.

1.2.6 Disc Couplings

Disc couplings transmit torque from a driving to a driven bolt tangentially on a common bolt circle. Torque
is transmitted between the bolts through a series of thin, stainless steel discs assembled in a pack.
Misalignment is accomplished by deforming of the material between the bolts.

1.2.7 Fluid Couplings

These are used in excavators and other mobile machines where the means of power drive is either hydraulic
or pneumatic

Figure 10: Fluid Couplings

1.2.8 Gear Couplings

A gear coupling is a mechanical device for transmitting torque between two shafts that are not collinear. It
consists of a flexible joint fixed to each shaft. The two joints are connected by a third shaft, called the
spindle.

Each joint consists of a 1:1 gear ratio internal/external gear pair. The tooth flanks and outer diameter of the
external gear are crowned to allow for angular displacement between the two gears. Mechanically, the
gears are equivalent to rotating splines with modified profiles. They are called gears because of the
relatively large size of the teeth.

Gear couplings and universal joints are used in similar applications. Gear couplings have higher torque
densities than universal joints designed to fit a given space while universal joints induce lower vibrations.
The limit on torque density in universal joints is due to the limited cross sections of the cross and yoke. The
gear teeth in a gear coupling have high backlash to allow for angular misalignment. The excess backlash
can contribute to vibration. Gear couplings are generally limited to angular misalignments, i.e., the angle of
the spindle relative to the axes of the connected shafts, of 4-5°. Universal joints are capable of higher
misalignments.

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Figure 11: A gear coupling

Gear Couplings advantages:

 Allows freedom of axial movement
 Capable of operating at high speeds
 Low overhung weight
 Good balance characteristics.
 Long history of successful applications

Gear Couplings disadvantages:

 Requires lubrication.
 Separation of greases into soaps and oils.
 Centrifugal effect on oils / sludge formation.
 Temperature limitation due to lubricant

1.2.9 Oldham Couplings

An Oldham coupling has three discs, one coupled to the input, one coupled to the output, and a middle disc
that is joined to the first two by tongue and groove. The tongue and groove on one side is perpendicular to
the tongue and groove on the other. The middle disc rotates around its center at the same speed as the input
and output shafts. Its center traces a circular orbit, twice per rotation, around the midpoint between input
and output shafts. Often springs are used to reduce backlash of the mechanism. An advantage to this type of
coupling, as compared to two universal joints, is its compact size. The coupler is named for John Oldham
who invented it in Ireland, in 1821, to solve a paddle placement problem in a paddle steamer design.

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Figure 12: Assembled Oldham Coupling Oldham coupler, disassembled

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The figures below show different types of Couplings

2.0 ANALYSIS OF FORCES IN COUPLINGS:

The analysis of couplings is done in order to calculate different forces which are supplied in it when it is
working. This helps the coupling to work in safe condition. The following are important factors to be
considered when calculating different types of couplings.

(a) Reamed and Ground Coupling. When the holes in which the bolts are fitted are reamed and
ground, the bolts are finger tight. The torque is transmitted by the shear resistance of bolts is given
as.
D
Mt  PN ………………………………………………………. (1)
2
Where: Mt is Torque transmitted by bolts (N/mm)
P is shearing force acting in each bolt (N)
D is diameter of coupling at the centre of the holding bolts (mm)
N is number of bolts

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But the direct shear stress in the bolt is given by
P 4P
  ………………………………………………………. (2)
A d 2
Where: d is the shank diameter of bolts

Substituting 2 in 1 ad making stress to be the subject

8M t
 ………………………………………………………… (3)
NDd 2
In an assumption of the flexible coupling, it is assumed that the power transmitted by the shear resistance of
pins, it is similar in both cases.

NB. According to maximum-shear stress theory of failure:

Ssy =0.5Syt ………………………………………………………... (4)

Where: Syt is the yield strength of the material in tension (N/mm2)

Ssy is yield strength of material in shear (N/mm2)

Therefore:
S sy 0.5S yt
 max   …………………………………………. (5)
fs fs

fs is the factor of safety used to determine the shaft diameter.

(b) Large Clearance Hole

When the bolts are in large clearance holes, the above analysis does not hold, in this the bolts are
tightened sufficiently with a pre- load and 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

3 3
2( Ro _ Ri )
Rf  2 3 ………………………………………………….. (6)
3( Ro _ Ri )
Where: Ro is the outer radius of the flange
Ri is the radius of the recess

Assuming that Pi = Initial tension in each bolt (N)

µ= Coefficient of friction between flanges

The Friction force is given by µPiN………………………………….. (7)

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Then the torque transmitted is given by
M t  Pi NR f …………………………………………………….. (8)

3.0 Requirement for good shaft alignment/Good alignment set-up

 It should be easy to connect to or disconnect the coupling.
 It should transmit the full power from one shaft to another without losses.
 Sometimes it should allow misalignment (angle shift) between the two adjacent shaft rotation
axis.
 It is the goal to minimize the remaining misalignment in running operation in order to
maximize power transmission and to maximize machine running time(coupling and bearing
sealing lifetime)
 It should have no projecting parts.
 It is recommended to use manufacturer’s alignment target due to the fact that when the
machine is at operation temperature the alignment condition is perfect.

3.1 Tools for measuring shaft axis alignment condition

 It is possible to measure the alignment with dial gages or filler gages using various
mechanical setups.
 It is recommended to take care of bracket sag, parallaxes error while reading the values.
 It is very convenient to use laser shaft alignment technique to perform the alignment task
within highest accuracy.
 It is required to align the machines better; the laser shaft alignment tool can help to show the
required movements at the feet positions.

4.0 Couplings Maintenance and Failure

Coupling maintenance is generally a simple matter, requiring a regularly scheduled inspection of each
coupling. This consists of the following.

 Performing visual inspection, checking for signs of wear or fatigue and cleaning the coupling
regularly
 Checking and changing the lubricant regularly or the lubricated coupling. This maintenance is
required annually for most couplings and more frequently in adverse environments or in
demanding operating conditions.
Even with proper maintenance, however, couplings can fail under the following reasons:
 Improper installation
 Poor coupling selection
 Operation beyond design capabilities
The only way to improve coupling life is to understand what caused the failure and to correct it prior to
installing a new coupling. Some external signs that indicate potential coupling failure include:
 Abnormal noise, such as screeching, squealing or chattering.
 Excessive vibration or wobble.
 Failure seals indicated by lubricant leakage or contamination.

4.1 Checking Coupling Balance

Couplings are normally balanced at the factory prior to being. Balancing can be difficult and expensive, and
is normally done only when operating tolerances are such that the effort and the expense are justified. The
amount of coupling unbalance that can be tolerated by any system is dictated by the characteristics of the
specific connected machines and can be determined by detailed analysis or experience.

4.2 Shaft Couplings Selection and Installation.

Proper installation selection and installation can be critical in function of rigid and flexible shaft couplings.
These can affect not only the function of the coupling but also the driving and driven components. During
installation there general guidelines that are applied to all.

In general, couplings are divided into two main groups namely solid couplings and flexible couplings

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 In solid couplings there flange, sleeve or muff and forge or marine couplings
 In flexible couplings there bushed pin type, universal, Oldham,slip, bellows, spider or jaw,
Thomson, disc etc.

Worked examples
Example 1:
A rigid coupling is used to transmit 20kW power at 720 rpm. There are four bolts and the pitch diameter of
the bolts is 125mm. The bolts are made of steel 45C8 (Syt=380 N/mm2) and the factor of safety is
3.Determine the diameter of the bolts, assuming that the bolts are finger-tight in the reamed and ground
holes.

Solution:
Power
From , Mt  ………………………………………….……….….1

But   2n and n is in rpm………………………………….…...2

60 x10 6 x 20
Mt   265,258.26 N  mm
2 (720)

Also, From
Ssy= 0.577Syt
= 0.577(380)
= 219.26N/mm2

8M t
 ……………………………………………………3
NDd 2
S sy 219.26
    73.03 N / mm 2
fs 3
Making d the subject of the equation

8M t
d2  ………………………………………………......4
ND

8(265258.23)

 (125)(4)(73.09)

d = 4.3mm

Example 2:

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A rigid coupling is used to transmit 50kW power at 300 rpm. There are six bolts. The outer diameter of
flanges is 200mm, 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=380M/mm2) and the factor of safety is 3.
Determine the diameter of the bolts assuming that the bolts are set in large clearance holes.

Solution:

Power
Mt 


60 x10 6 (50)
Mt 
2 (300)

=1591549.4 N-mm

3 3
2( Ro  Ri ) 2[(100) 3  (75) 3 ]
Rf    88.1mm
3( Ro  R i ) 3[(100)  (75) ]
2 2 2 2

From M t  Pi NR f the initial tension in each bolt can be found.

1591549.4
Therefore, Pi   20072.51N
(0.15)(6)(88.1)

Due pre-load of 20072.51N, the bolts are subjected to tensile stress. The permissible tensile stress σt is
given by:
S yt 380
b    126.67 N / mm 2
fs 3

d 2 t d 2  4(20072.51)
Also Pi  ,
4  (126.67)

d=14.2mm

Example 3:
A flexible coupling is used to transmit 15kW power at 100 rpm. There are six pins and their pitch circle
diameter is 200mm. The length of a pin in contact with the left hand flange, the gap between the two
flanges and the length of bush in contact with the right hand flange are 23, 5 and 35mmrespectively. The
permissible shear and bending stresses in the pin are 35 and 152N/mm 2 respectively. The permissible
pressure for the rubber bush is 1N/mm2. Calculate
(a) Pin diameter by shear consideration.
(b) Pin diameter by bending consideration
(c) Outer diameter of the rubber bush.

Solution:

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Power
(a) From; M t 


60 x10 3 (W )(15) x10 3 ( mm)

Mt 
2 (100)( rev  sec onds)

=1432394.5N-mm

2 M t 1432394.5
Also P    2387.32 N
DN (200)(6)

4 P 4( 2387.32
d2  
 35

d= 9.32mm

(b) Consider the figure (a) below.

Mb =P (5+17.5) =2387.32(22.5) N-mm

32M b
b  ,
d 3

32 M b 32(2387.32)(22.5)
d3   ,
 b  (152)

d =153.33mm

(c) P =1D0 Pm
2387.32 = (35) D0 (1),

D0 =68.21mm

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