• Couplings are necessary to connect one shaft to

INTRODUCTION
another or to couple a drive shaft to a driven shaft.
• A coupling is a device used to connect two shafts
together at their ends for the purpose of
transmitting power.
• The primary purpose of couplings is to join two
pieces of rotating equipment while permitting some
degree of misalignment or end movement or both.
• The difference between a clutch & a coupling is that
a clutch can be disengaged or engaged at the will of
the operator whereas a coupling is regarded as
being fixed.
1
 PURPOSES OF A COUPLING
• To provide for the connection of shafts of units
that are manufactured separately such as a
motor and a pump, turbine & generator. etc.
• 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.
• To alter the vibration characteristics of rotating
units. 2
 CLASSIFICATION OF COUPLINGS
Couplings can be classified as;
• Rigid Couplings: which are used to connect two
shafts whose axes are collinear. They do not permit
relative rotation and axial motion between them.
Ex: Sleeve or muff coupling
Marine type flange coupling
Protected or unprotected flange coupling.
Within the scope of the syllabus, we discuss only design of flange
coupling.
3
 CLASSIFICATION OF COUPLINGS
• Flexible Couplings: which are used to connect two shafts
whose axes are non-collinear, i.e. The shafts may have a
slight axial or angular misalignment.
• They permit relative rotation and variation in alignment of
shafts within certain limits.
Ex: Oldham’s coupling
Universal coupling
Pin or bush type flexible coupling.
Within the scope of the syllabus, we discuss only design of Pin or bush type flexible
coupling.
4
Sleeve or Muff coupling • It consists of a cast
iron sleeve having a
keyway throughout
its length.
• The ends of the shaft
butt against each
other in the middle of
the sleeve.
• A long mild steel
taper sunk key is
driven through the
shaft & the sleeve.
5
Marine type Flange coupling • This is also called
solid or forged flange
coupling & generally
used in marine
engines.
• In this coupling, the
ends of the shafts are
forged into flanges
and joined together
by means of tapered
headless bolts.

6
 Flange coupling
(Unprotected/Protected type)
• This coupling consists of two
separate cast iron flanges
which are keyed to the ends
of the two shafts.
• Also the flanges are
fastened together by means
of tight fitting bolts.
• Sunk taper keys of
rectangular or square cross
section are used.
7
Oldham’s coupling • An Oldham coupler is a
method to transfer torque
between two parallel but not
collinear shafts.
• It 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.
• Often springs are used to
reduce backlash of the
mechanism. The coupler is
much more compact than, for
example, two universal joints.
Universal Coupling • A universal joint, universal
coupling, or Hooke's joint is a
joint that allows the rod to
'bend' in any direction, and is
commonly used in shafts that
transmit rotary motion.
• It consists of a pair of hinges
located close together, oriented
at 90° to each other, connected
by a cross shaft.
• Even when the input drive
shaft axle rotates at a constant
speed, the output drive shaft
axle rotates at a variable speed,
thus causing vibration and
wear.
Pin or Bush type • The pin type flexible
Flexible Coupling coupling permits variation in
alignment of shafts within
certain limits.
• The driving pins are rigidly
fastened to one of the
flanges while they are
covered with leather or
rubber washers and kept
loose in the other flange.
• This type of coupling is
commonly used for directly
connecting an electric
motor to a machine.
 DESIGN OF FLANGE COUPLING
(Page No 251 & 252, Fig 13.1(a) & 13.1(b), Page 250, Mahadevan DDHB )

TERMINOLOGY OF FLANGE COUPLINGS :

d Diameter of bolt, D Diameter of shaft
D1 Diameter of hub, D2 Pitch circle diameter of bolts
D3 Outside diameter of flange, t Thickness of flange
L Length of hub, i Number of bolts
s Allowable shear stress in the shaft
k Allowable shear stress in the key
b Allowable shear stress in the bolt
f Allowable shear stress in the flange
'
c or b
Allowable crushing or bearing stress in the key
Design procedure for Flange Couplings :
9.55 106 P
(1) Torque transmitted T N - mm
n
16T
(2) Diameter of shaft D 3 mm (Select std size from T 3.5a, P57)
s

1 3
(3) No of bolts required i D 2 to D 2  Eqn 13.1(a), P 251
40 80
' i ' should be an even number.
0.423D
(4) Bolt diameter d 7.5 mm  Eqn 13.1(c), P 251
i
Select std dia of bolt from first column of T 9.8, Page 140.

(5) Hub diameter D1 (1.5D 25) mm  Eqn 13.1(d)2, P 252

(6) Bolt circle diameter D2 (D 3.2d ) mm  Eqn 13.1(e), P 252

Dr P R Venkatesh,
1 Mech Dept, RVCE,
Bangalore
Design procedure for Flange Couplings (Contd...)
(7) Check for shear stress in the bolt :
Torque capacity based on shear of bolts
id 2 D2
T b
 Eqn 13.2(c), P 252
8
Find b (induced ) which should be less than b (allowable)
Otherwise, increase the value of d & check again.
(8) Hub Length L (1.2 D 20) mm Eqn 13.1(g), P 252

(9) Design of flange :

(a ) Outside dia of flange D3 D1 6d  Eqn 13.1(f), P 252
(b) Thickness of flange t 0.35D 9 Eqn 13.1(h), P 252
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Design procedure for Flange Couplings (Contd...)
(10) Check for shear stress in the flange :
Torque capacity based on shear of flange
f D12t
T  Eqn 13.2(e), P 252
2
Find f (induced ) which should be less than f (allowable)
Otherwise, increase the value of t & check again.
(11) Selection of the key & length of key
Select dimensions (b & h) from T 4.1, page 69
corresponding to the shaft diameter D.
2T 4T
Find length of key using b & h
k D l c D l
Select the higher of the two values as length of key.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Design procedure for Flange Couplings (Contd...)
Note : If it is given that the key is equally stong in shearing & crushing,
always select a square key, i.e. b h.
(12) Draw a neat & proportionate sketch
Fig 13.2, Page 233 (Unprotected type or Cast iron flange coupling )
Fig 13.3, Page 233 ( Protected type or Cast iron pulley coupling )

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Note : If the streses or material is not given, assume;
C 40 steel for shaft, key & bolts (Table 1.8, Page 464)
yt 324 MPa, Taking FOS as 2.5,
Permissible shear stresses
0.5 324
s k b 64.8 65 MPa
2.5
Crushing strength of key c =2 k = 2 65 130 MPa
The flange is always made of Cast iron.
From T 1.17, page 472, for ordinary Grey cast iron,
Ultimate tensile strength ut 124 MPa, Take FOS =4
0.5 124
Shear stress in the Cast iron flange f 15MPa
4 16
 Problem 1
Design a protected type cast iron flange coupling
for a steel shaft transmitting 30 KW at 200 rpm.
The allowable shear stress in the shaft and key
material is 40 Mpa. The maximum torque
transmitted to be 20% greater than the full load
torque. The allowable shear stress in the bolt is 60
Mpa and the allowable shear stress in the flange is
25 Mpa.
17
Data : Power P=30 KW, n =200 rpm, Tmax 1.2 T
As the shaft & key & bolts are made of same material (steel)
The permissible shear stresses s k 40 MPa
Crushing strength of key c =2 = 2 40 80 MPa
k

Shear str ess in bolt b 60MPa

Shear stress in the Cast iron flange f 25MPa
Solution :
9.55 106 30
(1) Torque transmitted Tmax 1.2 = 1.719 × 10 6 N - mm
200
6
16 Tmax 16 1.719 10
(2) Diameter of the shaft D 3 3

s 40
D 60.26 mm 63 mm std size (From T 3.5a, P57)
1
(3) No of bolts required : i D 2  Eqn 13.1(a), P 251
40
1
i 63 2 3.575 4 bolts ( Always even number )
40 18
 0.423D
(4) Bolt dia : d 7.5 Eqn 13.1(c), P 251
i
0.423 63
d 7.5 20.82 mm 22 mm
4
( Std dia of bolt from first column of T 9.8, Page 140)
(5) Hub diameter : D1 (1.5 D 25)  Eqn 13.1(d), P 252
D1 (1.5 63 25) 120 mm
(6) Bolt circle diameter : D2 ( D1 3.2d )  Eqn 13.1(e), P 252
D2 (120 3.2 22) 190 mm
(7) Check for shear stress in bolts :
id 2 D2
Torque based on shear of bolts T b
 Eqn 13.2(e), P 252
8
2
4 20 205
1.719 106 b
τ b = 13.34MPa < 60MPa
8
b (induced ) b (allowable shear stress in the bolt ). Hence safe.
19
(8) Hub Length : L (1.2 D 20) Eqn 13.1(g), P 252
L (1.2 63 20) 96 mm

(9) Design of flange :

(a ) Outside dia of flange : D3 ( D1 6d )  Eqn 13.1(f), P 252
D3 (120 6 22) 252 mm

(b) Thickness of flange : t (0.35 D 9) Eqn 13.1(h), P 252

t (0.35 63 9) 31 mm

(10) Check for shear stress in flange :

f D12t
Torque based on shear of flange T  Eqn 13.2(e), P 252
2
f 1342 31
1.719 106 τ f = 1.97 MPa < 25 MPa
2
f (induced ) f (allowable shear stress in the flange). Hence safe.
20
(11) Selection of key :
From table 4.1. page 69, for shaft size 58 mm to 65 mm,
Width of the key b = 18 mm, thickness of key h = 11 mm.
2T 2 1.719 10 6
Considering shear of key, b 18
k lD 40 l 63
Length of key l 76 mm
4T
Considering crushing of key, h
c lD

4 1.719 106
11 31.6 Mpa Length of key l 124 mm
80 l 63
Selecting the higher value, length of the key l = 124 mm

21
(12) Draw a neat & proportionate sketch
Fig 13.3, Page 233 ( Protected type or Cast iron pulley coup ling)

22
 Problem 2
In a flange coupling used to connect two coaxial
shafts of diameter 80 mm to transmit 60 KW at 200
rpm, 6 bolts of M14x1.5 on a bolt circle diameter
of 210 mm are used. If the flange thickness is 20
mm and the hub diameter is 145 mm , determine;
(i) Shear stress induced in the shaft
(ii) Shear stress induced in the bolt
(iii) Shear stress induced in the flange. 23
Data : Power P 60 KW , n 200 rpm, D 80 mm, D1 145 mm, D2 210 mm
Bolt size M 14 1.5 d 14 mm, pitch 1.5 mm
Flange thickness t 20 mm
9.55 106 60
Torque transmitted T =2.865 106 N-mm
200
(i ) Shear stress induced in the shaft s :
16T 16 2.865 106
Assuming key way factor of 0.75, s 38 MPa
D3 (80)3 0.75
(ii ) Shear stress induced in the bolt b :
b id 2 D2
The torque transmitted through bolts T
8
6 142 210
2.865 10 6 b
b 29.54 MPa
8
(iii ) Shear stress induced in the flange f :
Torque capacity based on shear of the flange at the hub diameter
D12t 1452 20
T f
2.865 10 6 f
f = 4.34 MPa
2 2 24
 Problem 3
Design a flange coupling to connect a motor shaft
and a centrifugal pump shaft for the following
specifications; Pump output 3000 liters/min, Total
head of water 20 m, Pump speed 600 rpm, Pump
efficiency 70%. Use C 40 steel for shaft & key & C
35 steel for bolts based on a factor of safety 2.
Shear stress in the cast iron flange is limited to 15
MPa.
25
Data : n 600 rpm , H 20 m, pump 70% 0.7
3000 10 3
Q 3000 liters / min 0.05 m3 / sec,
60
Liquid pumped is water Mass density, 1000 kg / m3
Solution :
Power of the motor necessary to drive a pump :
gQH
P= KW where;
1000 pump
mass density of liquid pumped (kg / m 3 )
g Gravitational acceleration 9.81 m / sec 2
Q Volume flow rate of liquid (m3 / sec)
H Pressure head against which pump is working (meters )
1000 9.81 0.05 20
P 14 KW
1000 0.7
Use this value of P & design as per
Dr P R Venkatesh, Mechthe
Dept, procedure
RVCE, explained before.
Bangalore
DESIGN OF FLEXIBLE COUPLING (Fig 13.6 a Page 255)
TERMINOLOGY OF FLEXIBLE COUPLINGS :
d Diameter of pin, d1 Diameter of bigger end of pin
db Outside dia of rubber bush, lb Length of rubber bush
pb Allowable bearing pressure in rubber bush 1MPa
F Load acting on each pin
c Gap between the two flanges = 5 mm
D1 Diameter of hub, D2 Pitch circle diameter of bolts
D3 Outside diameter of flange, t Thickness of flange
L Length of hub, i Number of bolts
s Allowable shear stress in the shaft
k Allowable shear stress in the key
b Allowable shear stress in the bolt
f Allowable shear stress in the flange
'
c or b
Allowable crushing or bearing stress in the key
Design procedure for Flexible Couplings :
9.55 106 P
(1) Torque transmitted T N - mm
n
16T
(2) Diameter of shaft D 3 mm (Select std size from T 3.5a, P57
s

1 3
(3) No of bolts required i D 2 to D 2  Eqn 13.1(a), P 251
40 80
' i ' should be an even number.
0.423D
(4) Bolt diameter d 7.5 mm  Eqn 13.1(c), P 251
i
Select std dia of bolt from first column of T 9.8, Page 140.

(5) Hub diameter D1 (1.5D 25) mm  Eqn 13.1(d), P 252

(6) Bolt circle diameter D2 (D 3.2d ) mm  Eqn 13.1(e), P 252

Dr P R Venkatesh,
1 Mech Dept, RVCE,
Bangalore
Design procedure for Flexible Couplings (Contd...)
(7) Assume bigger dia of pin d1 = 2d
(8) Assume 2 mm thick brass bush surrounded by
6 mm thick rubber bush.
Outside dia of rubber bush db d1 2(2 6) (d1 16) mm
(9) To find length of bush :
D2
Torque transmitted T iF Find F=? Projected area
2 of rubber bush

But F pb lb db Find lb ? lb
d
b

(10) Check for principal stresses in pin :

4F
(a ) Shear stress in the pin = 2
d
M lb d3
(b) Bending stress in the pin where M F c &Z
Dr P R Venkatesh,ZMech Dept, RVCE, 2 32
Bangalore
(c) Principal stresses in the pin
1 2 2
(i ) Max normal stress max 4 allowable
2
1 2
(ii ) Max shear stress max 4 2 allowable
2
(11) Length of hub L (1.2 D 20) mm Eqn 13.1(g), P 252
(12) Design of flange :
(a) Outside dia of flange : D3 ( D1 6d ) Eqn 13.1(f), P 252
(b) Thickness of flange : t (0.35D 9)  Eqn 13.1(h), P 252
(13) Selection of key :
From table 4.1. page 69, select b & h for shaft size D
2T
Considering shear of key , b Length of key l ?
k lD

4T
Considering crushing of key , h Length of key l ?
c lD

Select the higher value, length of the key.

(14) Draw neat & proportionate sketch
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Projected area
of rubber bush

lb
d
b
31
 Problem 1
Design a bushed pin type flexible coupling to
connect a motor shaft to a pump shaft transmitting
20 KW at 1440 rpm. The allowable shear and
crushing stress for steel shafts, keys & pins are 40
MPa & 80 MPa respectively. The allowable shear
stress for the cast iron flange is 10 MPa and the
allowable bearing pressure in the rubber bush is
0.5 MPa.
32
Data : Power P 20 KW , n 1440 rpm,
The permissible shear stresses s k p 40 MPa
Crushing strength of key c =Bending stress in pin p 80 MPa
Shear stress in the Cast iron flange f 10 MPa
Allowable bearing pressure in rubber bush pb 0.5MPa
Solution :
9.55 106 20
(1) Torque transmitted T = 132.64 × 10 3 N - mm
1440
3
16 Tmax 16 132.64 10
(2) Diameter of the shaft D 3 3

s 40
D 25.65 mm 28 mm std size (From T 3.5a, P57)
1
(3) No of bolts required : i D 2  Eqn 13.1(a), P 251
40
1
i 28 2 2.7 4 bolts ( Always even number )
40
33
 0.423 D
(4) Bolt dia : d 7.5 Eqn 13.1(c), P 251
i
0.423 28
d 7.5 13.42 mm 14 mm
4
( Std dia of bolt from first column of T 9.8,Page 140)
(5) Hub diameter : D1 (1.5 D 25)  Eqn 13.1(d), P 252
D1 (1.8 28 20) 70 mm
(6) Bolt circle diameter : D2 ( D1 3.2d ) Eqn 13.1(e) P 252
D2 (70 3.2 14) 115 mm
(7) Assume bigger dia of pin d1 2d 2 14 28 mm
(8) Assume 2 mm thick brass bush surrounded by
6 mm thick rubber bush around the pin.
Outside dia of rubber bush db 28 2(2 6) 44 mm
34
 D2
(9)To find length of bush : Torque transmitted T iF
2
3 115
132.64 10 4 F F=577 N
2
But F pb lb d b 577=0.5 lb 44 lb 27 mm
(10) Check for principal stresses in pin :
4 F 4 577
(a) Shear stress in the pin = 2 2
3.75 MPa
d 14
M
(b) Bending stress in the pin
Z
lb 27
where M F c 577 5 10.67 10 3 N mm
2 2
d3 143 10.67 103
&Z 269.4 mm3 = 39.6 MPa
32 32 269.4
35
(10)(c) Principal stresses in the pin
1 2 2
(i ) Max normal stress max 4 allowable
2
1
39.6 39.62 4(3.75) 2 40 MPa 80 MPa ( allowable )
2
1 2 2
(ii ) Max shear stress max 4 allowable
2
1
39.62 4(3.75) 2 20.15 40 MPa ( allowable )
2
(11) Length of hub L (1.2 D 20) mm  Eqn 13.1(g), P 252
L (1.2 28 20) 54 mm
(12) Design of flange :
(a) Outside dia of flange : D3 ( D1 6d ) Eqn 13.1(f), P 252
D3 (70 6 14) 154 mm
(b) Thickness of flange : t (0.35D 9)  Eqn 13.1(h), P 252
t (0.35 28 9) Dr19P Rmm
Venkatesh, Mech Dept, RVCE,
Bangalore
(13) Selection of key :
From table 4.1. page 60, for shaft size 22 to 30 mm
b = 8 mm & h = 7 mm
2T
Considering shear of key, b
k lD

2 132.64 103
8 Length of key l 30 mm
40 l 28
4T
Considering crushing of key, h
c lD

4 132.64 103
7 Length of key l 34 mm
80 l 28
Select the higher value, length of the key l = 34 mm
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
(14) Check for shear stress in the flange
D12t
Torque based on shear of flange T f
 Eqn 13.2(e), P 252
2
f 702 19
132.64 10 3 τ f = 0.91 MPa < 10 MPa
2
f (induced ) f (allowable shear stress in the flange). Hence safe

(15) Draw neat & proportionate sketch

38
 Problem 2
A bush type flexible coupling has four pins of size M16
made of steel having an allowable shear stress of 60
MPa. The outside diameter and length of rubber bush
on the pin are 38 mm & 45 mm respectively. The pins
are located on a pitch circle diameter of 200 mm. The
allowable bearing pressure in the rubber bush is 1
MPa. If the coupling rotates at 900 rpm, calculate the
power that can be transmitted. Check whether the size
of the pin is acceptable for this power transmission.
39
Data : i 4, pb 1 MPa, d 16 mm, n 900 rpm
The permissible shear stresses p 60 MPa p 120 MPa
Outside dia of rubber bush db 38 mm
Length of rubber bush lb 45 mm
Pitch circle diameter of pins D2 200 mm
Solution :
D2
(1) Torque transmitted T iF where F pb lb d b
2
200
F 1 45 38 1710 N . T 4 1710 684 × 10 3 N - mm
2
9.55 106 P
(2) Power transmitted by coupling : Torque T
n
6
3 9.55 10 P
684 10 = P = 64.46 KW
900 40
(3) Check for principal stresses in pin :
4 F 4 1710
(a) Shear stress in the pin = 2 2
8.5 MPa
d 16
M
(b) Bending stress in the pin
Z
lb 45
where M F c 1700 5 47 103 N mm
2 2
3 3
d 16
Z 402.12 mm3
32 32
10.67 103
= 117 MPa
269.4
41
(c) Principal stresses in the pin
1 2 2
(i ) Max normal stress max 4 allowable
2
1
117 117 2 4(8.5) 2 117.6 MPa 120 MPa ( allowable )
2
1 2 2
(ii ) Max shear stress max 4 allowable
2
1
117 2 4(8.5) 2 59.11 60 MPa ( allowable )
2
As the maximum normal & shear stresses induced in the pin
are less than their permissible values, size of pin is acceptable.

42