COUPLINGS

Shaft Coupling
Shafts are usually available up to 7 metres length due to inconvenience in transport. In order to
have a greater length, it becomes necessary to join two or more pieces of the shaft by means of a
coupling. Shaft couplings are used in machinery for several purposes, the most common of
which are the following:
1. 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.
2. To provide for misalignment of the shafts or to introduce mechanical flexibility.
3. To reduce the transmission of shock loads from one shaft to another.
4. To introduce protection against overloads.
5. It should have no projecting parts.
Note: A coupling is termed as a device used to make permanent or semi-permanent connection
where as a clutch permits rapid connection or disconnection at the will of the operator.

Requirements of a Good Shaft Coupling

A good shaft coupling should have the following requirements:
1. It should be easy to connect or disconnect.
2. It should transmit the full power from one shaft to the other shaft without losses.
3. It should hold the shafts in perfect alignment.
4. It should reduce the transmission of shock loads from one shaft to another shaft.
5. It should have no projecting parts.

Types of Shafts Couplings

Shaft couplings are divided into two main groups as follows:
1. Rigid coupling. It is used to connect two shafts which are perfectly aligned. Following types
of rigid coupling are important from the subject point of view:
(a) Sleeve or muff coupling.
(b) Clamp or split-muff or compression coupling, and
(c) Flange coupling.
2. Flexible coupling. It is used to connect two shafts having both lateral and angular
misalignment. Following types of flexible coupling are important from the subject point of view:
(a) Bushed pin type coupling,
(b) Universal coupling, and
(c) Oldham coupling.

Sleeve or Muff-coupling
It is the simplest type of rigid coupling, made of cast iron. It consists of a hollow cylinder whose
inner diameter is the same as that of the shaft. It is fitted over the ends of the two shafts by means
of a gib head key, as shown in Fig. below. The power is transmitted from one shaft to the other
shaft by means of a key and a sleeve. It is, therefore, necessary that all the elements must be
strong enough to transmit the torque. The usual proportions of a cast iron sleeve coupling are as
follows:
Outer diameter of the sleeve, D = 2d + 13 mm
and length of the sleeve, L = 3.5 d
where d is the diameter of the shaft.

In designing a sleeve or muff-coupling, the following procedure may be adopted.

Let T = Torque to be transmitted by the coupling, and
τc = Permissible shear stress for the material of the sleeve which is cast iron.
The safe value of shear stress for cast iron may be taken as 14 MPa.
We know that torque transmitted by a hollow section,

From this expression, the induced shear stress in the sleeve may be checked.
2. Design for key
The key for the coupling may be designed in the similar way as discussed before. The width and
thickness of the coupling key is obtained from the proportions.
The length of the coupling key is atleast equal to the length of the sleeve (i.e. 3.5 d). The
coupling key is usually made into two parts so that the length of the key in each shaft,

After fixing the length of key in each shaft, the induced shearing and crushing stresses may be
checked. We know that torque transmitted,

Note: The depth of the keyway in each of the shafts to be connected should be exactly the same
and the diameters should also be same. If these conditions are not satisfied, then the key will be
bedded on one shaft while in the other it will be loose. In order to prevent this, the key is made in
two parts which may be driven from the same end for each shaft or they may be driven from
opposite ends.

Example 1. Design and make a neat dimensioned sketch of a muff coupling which is used to
connect two steel shafts transmitting 40 kW at 350 r.p.m. The material for the shafts and key is
plain carbon steel for which allowable shear and crushing stresses may be taken as 40 MPa and
80 MPa respectively. The material for the muff is cast iron for which the allowable shear stress
may be assumed as 15 MPa.

Solution: Given: P = 40 kW = 40 × 103W; N = 350 r.p.m.; τs = 40MPa = 40 N/mm2; σcs = 80

MPa =80 N/mm2; τc = 15 MPa = 15 N/mm2
The muff coupling is shown in Fig. above. It is designed as discussed below:
1. Design for shaft
Let d = Diameter of the shaft.
We know that the torque transmitted by the shaft, key and muff,

We also know that the torque transmitted (T),

2. Design for sleeve

We know that outer diameter of the muff,
D= 2d + 13 mm = 2 × 55 + 13 = 123 say 125 mm Ans.
and length of the muff,
L = 3.5 d = 3.5 × 55 = 192.5 say 195 mm Ans.
Let us now check the induced shear stress in the muff. Let τ c be the induced shear stress in the
muff which is made of cast iron. Since the muff is considered to be a hollow shaft, therefore the
torque transmitted (T),

Since the induced shear stress in the muff (cast iron) is less than the permissible shear stress of
15 N/mm2, therefore the design of muff is safe.

3. Design for key

From Table given in the notes for keys, we find that for a shaft of 55 mm diameter,
Width of key, w = 18 mm Ans.
Since the crushing stress for the key material is twice the shearing stress, therefore a square key

∴
may be used.
Thickness of key, t = w = 18 mm Ans.
We know that length of key in each shaft,
l = L / 2 = 195 / 2 = 97.5 mm Ans.
Let us now check the induced shear and crushing stresses in the key. First of all, let us consider
shearing of the key. We know that torque transmitted (T),

Now considering crushing of the key. We know that torque transmitted (T),

Since the induced shear and crushing stresses are less than the permissible stresses, therefore the
design of key is safe.

Clamp or Compression Coupling

It is also known as split muff coupling. In this case, the muff or sleeve is made into two halves
and are bolted together as shown in Fig below. The halves of the muff are made of cast iron. The
shaft ends are made to abutt each other and a single key is fitted directly in the keyways of both
the shafts. One-half of the muff is fixed from below and the other half is placed from above.
Both the halves are held together by means of mild steel studs or bolts and nuts. The number of
bolts may be two, four or six. The nuts are recessed into the bodies of the muff castings. This
coupling may be used for heavy duty and moderate speeds. The advantage of this coupling is that
the position of the shafts need not be changed for assembling or disassembling of the coupling.
Flange Coupling
A flange coupling usually applies to a coupling having two separate cast iron flanges. Each
flange is mounted on the shaft end and keyed to it. The faces are turned up at right angle to the
axis of the shaft. One of the flanges has a projected portion and the other flange has a
corresponding recess.
This helps to bring the shafts into line and to maintain alignment. The two flanges are coupled
together by means of bolts and nuts. The flange coupling is adopted to heavy loads and hence it
is used on large shafting. The flange couplings are of the following three types:
1. Unprotected type flange coupling.
In an unprotected typeflange coupling, as shown in Fig below, each shaft is keyed to the bossof a
flange with a counter sunk key and the flanges are coupled together by means of bolts.
Generally, three, four or six bolts are used. The keys are staggered at right angle along the
circumference of the shafts in order to divide the weakening effect caused by keyways.

2. Protected type flange coupling.

In a protected type flange coupling, as shown in Fig below the protruding bolts and nuts are
protected by flanges on the two halves of the coupling, in order to avoid danger to the workman.
The thickness of the protective circumferential flange (tp) is taken as 0.25 d. The other
proportions of the coupling are same as for unprotected type flange coupling.
 3. Marine type flange coupling.
In a marine type flange coupling, the flanges are forged integral with the shafts as shown in Fig
below. The flanges are held together by means of tapered headless bolts, numbering from four to
twelve depending upon the diameter of shaft.
Flexible Coupling
We have already discussed that a flexible coupling is used to join the abutting ends of shafts
when they are not in exact alignment. In the case of a direct coupled drive from a prime mover to
an electric generator, we should have four bearings at a comparatively 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 misalignemnt of the shaft without undue
absorption of the power which the shaft are transmitting. Following are the different types of
flexible couplings:
1. Bushed pin flexible coupling, 2. Oldham's coupling 3. Universal coupling

Bushed-pin Flexible Coupling

A bushed-pin flexible coupling, as shown in Fig below, is a modification of the 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 connection between
them and the drive takes place through the medium of the compressible rubber or leather bushes.
Oldham Coupling
It is used to join two shafts which have lateral mis-alignment. It consists of two flanges A and B
with slots and a central floating part E with two tongues T1 and T2 at right angles as shown in
Fig below. The central floating part is held by means of a pin passing through the flanges and the
floating part. The tongue T1 fits into the slot of flange A and allows for ‘to and fro’ relative
motion of the shafts, while the tongue T2 fits into the slot of the flange B and allows for vertical
relative motion of the parts. The resultant of these two components of motion will accommodate
lateral misalignment of the shaft as they rotate.
Universal (or Hooke’s) Coupling
A universal or Hooke’s coupling is used to connect two shafts whose axes intersect at a small
angle. The inclination of the two shafts may be constant, but in actual practice, it varies when the
motion is transmitted from one shaft to another. The main application of the universal or
Hooke’s coupling is found in the transmission from the gear box to the differential or back axle
of the automobiles. In such a case, we use two Hooke’s coupling, one at each end of the
propeller shaft, connecting the gear box at one end and the differential on the other end. A
Hooke’s coupling is also used for transmission of power to different spindles of multiple drilling
machines. It is used as a knee joint in milling machines.