1. Design and Analysis of Machine Elements by V.K.Jadon, S.

Verma
2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
by IK International

THAPAR INSTITUTE OF ENGINEERING AND

TECHNOLOGY

COUPLINGS

Submitted to:Dr. V.K. Jadon

Submitted By:Dharminder Singh (1055803)

Ravinder Singla

(1040897)

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

Contents

Introduction
Input Parameters
Analysis
Data Base Details
Algorithm
Examples

by IK International
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1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
by IK International

Introduction

Coupling:A coupling is defined as mechanical device that

permanently joins two rotating shafts to each others. The shafts
that are connected by the coupling can be disengaged only after
dismantling the coupling. There are two main applications of the
coupling. They are as follows: The most common application is joining of shafts of two
separately built or purchased units so that a new machine
can be formed. For example, a coupling is used to join the
shaft of an electric motor to the input shaft of a hydraulic
pump.
The maximum feasible length of one-piece shaft depends
upon the handling facilities, presses and machine tools.
Couplings are used to make long line shaft by joining
individual shafts.
Besides this the couplings are used to join shafts at angles, to
compensate for misalignment between the shafts, to prevent
the transmission of overload torque and to alter vibration
characteristics of the drive, in some cases.
Two shafts connected by the coupling may have
collinear axes, intersecting axes or axes that are parallel at a
small distance apart. Couplings are mainly classified into two
categories: 1.Rigid, 2.Flexible. The flexible coupling is

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
by IK International

capable of tolerating a small amount of misalignment

between the shafts, there is no such provision in case of rigid
coupling. In this report, the design is restricted to rigid and
flexible couplings which are as follows: Muff Coupling
Flange Coupling
Protective Flange Coupling
Bushed-Pin Flexible Coupling
Muff Coupling:It is simplest type of coupling, including two
parts sleeve and key. It is simple to design and manufacture. The
hollow cylinder which is fitted over the shafts is known as a
sleeve by means of a sunk key. The torque transmitted fro the
input shaft to the sleeve through the key. It is then transmitted
from the sleeve to the output shaft through the key. It thas
following advantages:1. Simplest form of all couplings.
2. No projecting part except the key head. Advantage from
the standpoint of safety of the worker.
3. Compact construction with small radial dimensions.
4. Cheaper than other types.
It has some disadvantages also like assemble or
dismantling, accurate alignment of shafts, motion should
be free from vibrations, more axial space etc.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
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Flange coupling:It is also a simple type of coupling than

others. Here it consists of two flanges one keyed to the driving
shaft and the other two the driven shaft. The two flanges are
connected with the help of four or six bolts arranged in a
concentric circle. Power is transmitted from one shaft to let side
flange through key, then transmitted from the left side flange to
the right side flange through bolts and finally from the right
hand side flange to the driven shaft through the key. It is rigid
type of coupling so the provision should be made for precision
location of the axes of the shaft. This is further divided into two
categories: Unprotected type flange coupling.
Protected type flange coupling.
It has following advantages:1. Muff coupling is employed for the shafts only up to 70
mm dia. There is no such limit in this coupling. These
have high torque transmission capacity.
2. Easy assembly and dismantling.
3. Simple construction.
Some adv. are also associated with type of coupling like
cant tolerate misalignment between the shafts, requires more
radial space etc.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
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Protective Flange Coupling:

In this type of coupling the bolts
head and nuts are covered by projecting circumferential rims.
In case of failure of bolts while the machine is being run, the
broken piece will dash against this rim and eventually fall
down. This protects the operator from injuries. The
construction of unprotected and protected flange coupling is
exactly identical except the protective rim.

Bushed-Pin flexible coupling:It is used where not perfect

aligning of shafts occurs or some vibrations come into picture. It
employees a flexible element like rubber bush between the
driving and the driven flanges. This flexible rubber bush
accommodates misalignment as well as absorbs shocks. It can
accommodate 0.5 mm of lateral or axial misalignment and 1.5o
of angular misalignment. The construction of this coupling is
same as rigid coupling except the provision of rubber bush and
pins in place of the bolts. The rubber bush is provided with brass
lining at the inner surface to avoid excessive wear of the rubber
component. Power is transmitted from the input shaft to the
input flange through key and from the flange to the pin through
the bush. The pin then transmits the power to the output flange
by shear resistance. Finally power is transmitted from output
flange to the output shaft through the key.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

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It has following advantages:1. It can tolerate 0.5 mm of lateral misalignment and 1.5o of
angular misalignment.
2. Prevents transmission of shock from one shaft to another.
3. Can transmit high torque.
4. Simple in construction easy to assemble and dismantle.
Adv. are also associated with this like, the cost of
flexible coupling is more, requires more redial distance etc.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
by IK International

Input Parameters
Input parameters for all the couplings are same i.e.
power rate and rpm.
Power (P):It is defined as rate of transmission of torque to be
transmitted from one shaft to another. This is generally
expressed in Watt(W) or Horse Power(HP).
RPM (N):RPM stands for rotation per minute or revolution per
minute. Means how much rotations it will take in one minute or
60 sec.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

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ANALYSIS
Muff Coupling:First we select the material for shaft and see Sut, Syt
from the given standard tables. Appropriate value of factor of
safety should be selected.
Symbols used in the design procedure:P = Power to be transmitted
Mt = Torque
Sut = Ultimate tensile strength of material.
Syt = yield strength of material
Mt = Twisting moment
= Shear stress
d = Shaft diameter
d1 = diameter of muff
L = Length of muff
b, h, l = breath, height and length of key resp.
Ssy = 0.5Syt
= Ssy /factor of safety
Design of shaft:
Mt = 60P103
2N
Where N is the no of rpm
given.
d3 = 16Mt

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

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Design of muff:
d1 = (2d+13) mm
L = 3.5 d
Design of key:
l = L/2
b = d/4, h = d/6
Now we standardize these dimensions using tables given in
report.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
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Flange coupling:First we select the material for shaft and see

Sut, Syt from the given standard tables. Appropriate value of
factor of safety should be selected.
Symbols used in the design procedure:P = Power to be transmitted
Mt = Torque
= Shear stress
d = Shaft diameter
d2 = Pitch circle diameter of bolt
t = Thickness of flange
d1 = Outside diameter of hub.
d3 = Outside diameter of flange.
lh = Length of the hub
db= diameter of bolt
n = No. of bolts
b, h, l = breath, height and length of key resp.
Ssy = 0.5Syt
= Ssy / factor of safety
Design of shaft:
Mt = 60P103
2N
Where N is the no of rpm
given.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
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d3 = 16Mt

Dimension of flange:
d1 = 2d
d2 = 3d
t = 0.5 d
d3 = d2+2db+10
Dimension of bolts:
n = (d / 50) +3
db = (0.5 d ) / n
Design of key:
l = L/2
b = d/4, h = d/6
Now we standardize these dimensions using tables given in
report.

In case of Protected type flange coupling design

everything will be same except we calculate here the thickness
of protecting rim and total thickness of flange i.e.,
thickness of protecting rim t1 = 1.25 t
thickness of flange t = 0.35 d +9.
outside diameter of flange d3 = d2+6db

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
by IK International

Bushed-Pin Flexible coupling:

First we select the material for shaft and
see Sut, Syt and from the given standard tables. Appropriate
value of factor of safety should be selected.
Symbols used in the design procedure:P = Power to be transmitted
Mt = Torque
= Shear stress
Fb = Force acting on each bush
d = Shaft diameter
d2 = Pitch circle diameter of bushes
n = No. of bolts
t = Output Flange Thickness
t1 = Input Flange Thickness
d1 = Outside diameter of hub.
d3 = Outside diameter of flange.
dbush= Diameter of bush
d0 = larger dia. of bolt
lbush=Length of bush
t2 = Thickness of protective rim.
lh = Length of the hub
db = diameter of bolt
b, h, l = breath, height and length of key resp.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

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Ssy = 0.5Syt
= Ssy / factor of safety
Design of shaft:
Mt = 60P103
2N
Where N is the no of rpm
given.
d3 = 16Mt

Dimension of flange:
d1= 2d
d2 = 3d
t = 0.5 d
t1 = lbush
d3 = (2d+6db)
Design of bush:dbush= d0+13
lbush= dbush
Fb= 2Mt / nd2
Fbearing = dbushlbushpm
pm=1.0 N/mm2 for rubber bush and C.I. flange.

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

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Design of key:
l = L/2
b = d/4, h = d/6
Now we standardize these dimensions using tables given in
report.

Data Base Details

Table for Properties of plain carbon Steel:Material

Sut (MPa)

Syt (MPa)

C07

350

196

C10

380

206

C14

420

216

C15

450

233

C20

480

245

C25

510

275

C30

550

294

C35

600

304

C40

600

324

C45

650

353

C50

700

373

C60

750

412

C65

736

422

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
by IK International

Table for Standard Shaft Diameter, d (mm)

6
25
71
200
380

8
28
80
220
400

10
32
90
240
420

12
36
100
260
440

14
40
110
280
450

16
45
125
300
480

18
50
140
320
500

20
56
160
340
530

22
63
180
360
560

1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

Table for Standard Key Dimension

Shaft Dia (mm)
Key (mm)
Above
Up
Breadth Height
to
6
2
2
2
8
10
3
3
10
12
4
4
12
17
5
5
17
22
6
6
22
30
8
7
30
38
10
8
38
44
12
8
44
50
14
9
50
58
16
9
58
65
18
11
65
75
20
12
75
85
22
14
85
95
25
14
95
110
28
16
110
130
32
18
130
150
36
20
150
170
40
22
170
20
45
22
170
200
45
25
200
230
50
28
230
260
56
32
260
290
63
32
290
330
70
36
330
380
80
40
380
440
90
45
440
500
100
50

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1. Design and Analysis of Machine Elements by V.K.Jadon, S. Verma

2. Machine Design Data Book by V.K. Jadon, S. Verma

by IK International
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Algorithm
1. Select the type of coupling to be designed.
2. Enter the power to be transmitted.
3. Enter the R.P.M.
4. Select the type of material to be used.
5. Calculate torque to be transmitted, Mt.
6. Design torque, Mtd
7. Calculate .
8. Calculate the diameter of shaft.
9. Standardize it from the table.
10. Calculate outer diameter of Muff.
11.Calculate shear failure and sleeve to transmit design
power, Mt sleeve.
12. Calculate length of Muff.
13. Calculate value of breadth, height and length of key and
standardize it from table
14. Check the design for safety.
15. If the design is safe then, give the output.
16. Design for flange coupling.
17. Calculate diameter of hub,d1.
18. Calculate number of bolts, n.
19. Calculate dia. Of bolts, db.
20. Pitch circle dia. Of bolts, d2
21. Outside diameter of flange, d3.
22. Calculate length of hub, l
23. Calculate flange thickness, t
24. Calculate rim thickness, t1.
25. Compute torsional capacity of flange , Mt_flange.
26. For bush type coupling
27. Calculate force acting on each bolt, Fb.
28. Bearing strength of rubber bush, Fbearing
29. Calculate torque transmitting capacity of bolt considering
shear failure, Mt bolt
30. Print the Parameters.