Chapter-One

1.1 Introduction Commented [h1]: Follow the given formats

Bush pin type flange coupling is used to connect of shafts which having a small parallel
misalignment, angular misalignment or axial misalignment. This is a modification of the protected
type flange coupling which has pins (covered by rubber or leather bushes) and it works with
coupling bolts. Generally, it is used to assemble electric motors and machines.

In the engines there is a cylindrical flange coupling to union assembled parts. The sensitive piece
is a flange to the parameters like moment, torque, etc. Normally the coupling problems treated as
a beam theory. As we know in mechanical engineering the coupling is used for connection of two
shafts to transmit the power. In gear unit applications the rigid coupling is designed especially for
this purpose. Commented [h2]: Give citation

In this design, the flanged join is modeled by using Solidwork.

Shafts are usually available up to 7 meters’ length due to inconvenience in transport. In order to Commented [h3]: Citation

have a greater length, it becomes necessary to join two or more pieces of the shaft by means of a
coupling. Couplings are mechanical elements that ‘couples’ two drive elements (shafts) which
enables motion to be transferred from one element to another.

Shaft couplings are used in machinery for several purposes, the most common of which are the
following:

 To provide for the connection of shafts of units that are manufactured separately such as Commented [h4]: Use similar bullets for similar
characteristics
a motor and generator and 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.
 It should have no projecting parts.
Also a good shaft coupling should have the following requirements:

 It should be easy to connect or disconnect.

 It should transmit the full power from one shaft to the other shaft without losses.
 It should hold the shafts in perfect alignment.
 It should reduce the transmission of shock loads from one shaft to another shaft.
 It should have no projecting parts.

1.2 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
misalignments. 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.

1.3 Components of Flexible Bush-Pin Coupling

1) Shaft 2) Key 5) Flange and hub
3) Pin 4) Nut and washer
1. Shaft Commented [h5]: Refer paragraph spacing from the given
formats
A shaft is a rotating machine element which is used to transmit power from one place to another. Commented [h6]: Use the same standard colors

The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked up
to the shaft. In order to transfer the power from one shaft to another, the various members such as
pulleys, gears etc., are mounted on it. These members along with the forces exerted upon them
causes the shaft to bending. In other words, we may say that a shaft is used for the transmission of
torque and bending moment. The various members are mounted on the shaft by means of keys or
splines.
 Figure 1: Shaft Commented [h7]: Which figure?

2. Key

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable
crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley to
accommodate a key.

Figure 2: Key

3. Pin

In a pin joint, a pin is used to fasten two rods that are under the action of a tensile force; although
the rods may support a compressive force if the joint is guided. Some pin joints such as universal
joints, use two pins and are used to transmit power from one rotating shaft to another.

Figure 3: pin

A pin joint permits a small amount of flexibility or one rod may be positioned at an angle (in the
plane containing the rods) with respect to the other rod, after providing suitable guides. Unlike in
cotter joints, the pin in a pin joint is not driven-in with a force fit, but is inserted in the holes with
a clearance fit. The pin is held in position, by means of a taper pin or a split pin provided at its end.

4. Nut and washer

 A split pin, made of steel wire of semi-circular cross-section is used for locking the nut. In
this arrangement, the split pin is inserted through a hole in the bolt body and touching just
the top surface of the nut. Then, the ends of the pin are split open to prevent it from coming
out while in use.
  A washer is a cylindrical piece of metal with a hole to receive the pin. It is used to give a
perfect seating for the nut and to distribute the tightening force uniformly to the parts under
the joint. It also prevents the nut from damaging the metal surface under the joint.

Figure 4: nut

Figure 5: washer

5. Flange

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 flange 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.

Figure 6: Flange
1.4 Objective
1.4.1 General objective
 To Design the flexible bush-pin coupling.

1.4.2 Specific objective

 To Design the components of flexible bush-pin coupling such as shaft, key, pin, bush,
nut, washer, flange and hub.
 To draw the component and assembly drawing in 2D and 3D by Solidwork.
 To select the appropriate material for the component.
 To modeled the flexible bush-pin coupling in Solidwork.

1.5 Problem of Statement

In designing the bushed-pin flexible coupling, the proportions of the rigid type flange coupling are
modified. In Rigid coupling the connection two shafts are perfectly aligned, where as in flexible
coupling the connection of two shafts are misaligned. Therefore, we cannot use rigid coupling Commented [h8]: Try to avoid use of first person in a
technical writing
where vibration and shock is needed, since it is aligned. But the flexible coupling important when
we needed vibration during rotational motion.

1.6 Methodology
Literature review and different paper works are made worldwide in developing and introducing
the coupling materials, Survey of previous relevant works, review of previous accomplished thesis
works, relevant articles and other documents on the project, Relevant data collection, interpretation
and analysis, Bushed pin flexible coupling model development and finally conclusion and
recommendation. The detailed designing procedure of this project took placed was pointed as
followed below.

 Selection of materials: the selection of material for the design is first requirement based
on the design given data. The selection of proper materials is depending up on Availability
of material, Suitability of material for working condition, Cost of material and Mechanical
prosperities (strength, toughness, corrosion resistance, machinability etc.)
 Design of bused pin flexible coupling: The designed parts of bushed pin flexible coupling
are pin, shaft, bush, nut, washer, flange and hub.
 Finally by using the Solidworksoftware the design is modeled. Commented [h9]: Re write the sentence
 Chapter-Two
2.1 Literature Review
A flexible coupling is a device which is use to connect two shafts for power transmission. Coupling
Corporation of America stated Flexible disk or ring pack couplings transmit force from one flange
to another by tension in the rings from the bolts in one flange, to the bolts in opposing flange. The
disks are separated from each other so that there is no sliding or no generation of heat.

S.B. Jaiswal, M.D. Pasarkar analyze coupling of different material which give satisfactory results.
As in the analysis the failure occurred along the weld on the flange side. It is suggested that new
material alloy steel can be used for better results. Lovejoy Torsional Couplings uses highly
versatile elastomeric element; that can allow parallel, angular, torsional and axial misalignment. It
can sustain substantial shock and vibration capabilities. According to a technical report of VFD
induced coupling failure was generated for Kop flex KD disc Coupling. This is used to transmit
torque and provide for both angular and axial misalignments. Shafts with a coupling comprised of
shaft mounted hubs connected through flexible disc packs with spacer or sleeve assemblies. This
type of couplings uses stainless steel discs as flexible members, providing high strength and good
corrosion resistance for heavy load. Stephen Jesse, J. Wesley Hines, James Kuropatwinski,
Andrew Edmondson, Thomas G. Carley concluded in their paper that as the misalignment between
the shaft increases it shows noticeable increase in the vibration and the generating temperature.

N. Cristello and I.Y. Kim (Canada) in this paper titled Design Optimization of an Automotive
Universal Joint Considering Manufacturing Cost in this research, universal joint designs are
analyzed and compared using a weighted sum of three objective functions: minimization of
machining cost, maximization of adjoining shaft joint angle, and minimization of total part
volume.

Literature cited revealed that for light load applications like lab testing setups, small power
generator unit etc. there is scope for design and development of flexible coupling for maintenance
free longer life. This type of coupling should be light, economical, easy to install, maintain and
overhaul.

XXX Commented [h10]: Write summarizations of the literature

review
 Chapter-Three
3.1 Material Selection
3.1.1 Introduction
The knowledge of materials and their properties is of great significance for a design engineer. The
machine elements should be made of such a material which has properties suitable for the
conditions of operation. In addition to this, a design engineer must be familiar with the effects
which the manufacturing processes and heat treatment have on the properties of the materials.
The selection of a proper material, for engineering purposes, is one of the most difficult problems
for the designer. The best material is one which serve the desired objective at the minimum cost.
The following factors should be considered while selecting the material:
 Availability of the materials,
 Suitability of the materials for the working conditions in service, and
 The cost of the materials.
The important properties, which determine the utility of the material, are physical, chemical and
important physical properties of some pure metals.

 Physical Properties of Metals: The physical properties of the metals include luster,
colour, size and shape, density, electric and thermal conductivity, and melting point. The
following table shows the important physical properties of some pure metals.

 Mechanical Properties of Metals: The mechanical properties of the metals are those
which are associated with the ability of the material to resist mechanical forces and load.
These mechanical properties of the metal include strength, stiffness, elasticity, plasticity,
ductility, brittleness, malleability, toughness, resilience, creep and hardness. We shall now
discuss these properties as follows:
 Strength. It is the ability of a material to resist the externally applied forces without
breaking or yielding. The internal resistance offered by a part to an externally applied force
is called stress.
 Stiffness. It is the ability of a material to resist deformation under stress. The modulus of
elasticity is the measure of stiffness.
  Elasticity: It is the property of a material to regain its original shape after deformation
when the external forces are removed. This property is desirable for materials used in tools
and machines. It may be noted that steel is more elastic than rubber.
 Plasticity: It is property of a material which retains the deformation produced under load
permanently. This property of the material is necessary for forgings, in stamping images
on coins and in ornamental work.
 Ductility: It is the property of a material enabling it to be drawn into wire with the
application of a tensile force. A ductile material must be both strong and plastic. The
ductility is usually measured by the terms, percentage elongation and percentage reduction
in area. The ductile material commonly used in engineering practice (in order of
diminishing ductility) are mild steel, copper, aluminum, nickel, zinc, tin and lead.
Note: -The ductility of a material is commonly measured by means of percentage elongation and
percentage reduction in area in a tensile test.

 Ferrous Metals
The ferrous metals are those which have iron as their main constituent. The ferrous metals
commonly used in engineering practice are cast iron, wrought iron, steels and alloy steels. The
principal raw material for all ferrous metals is pig iron which is obtained by smelting iron ore with
coke and limestone, in the blast furnace.
 Cast Iron: The cast iron is obtained by re-melting pig iron with coke and limestone in a
furnace known as cupola. It is primarily an alloy of iron and carbon. The carbon content in
cast iron varies from 1.7 per cent to 4.5 percent. It also contains small amounts of silicon,
manganese, phosphorous and sculpture. The carbon in a cast iron is present in either of the
following two forms:
1. Free carbon or graphite, and
2. Combined carbon or cementite.
Since the cast iron is a brittle material, therefore, it cannot be used in those parts of machines
which are subjected to shocks. The properties of cast iron which make it a valuable material for
engineering purposes are its low cost, good casting characteristics, high compressive strength,
wear resistance and excellent machinability. The compressive strength of cast iron is much greater
than the tensile strength.
  Alloy Cast Iron: The cast irons contain small percentages of other constituents like silicon,
manganese, sulphur and phosphorus. These cast irons may be called as plain cast irons.
The alloy cast iron is produced by adding alloying elements like nickel, chromium,
molybdenum, copper and manganese in sufficient quantities. These alloying elements give
more strength and result in improvement of properties. The alloy cast iron has special
properties like increased strength, high wear resistance, corrosion resistance or heat
resistance. gears, automobile parts like cylinders, pistons, piston rings, crank cases,
crankshafts, camshafts, sprockets, wheels, pulleys, brake drums and shoes, parts of
crushing and grinding machinery etc.
 Steel: It is an alloy of iron and carbon, with carbon content up to a maximum of 1.5%. The
carbon occurs in the form of iron carbide, because of its ability to increase the hardness
and strength of the steel. Other elements e.g. silicon, sulphur, phosphorus and manganese
are also present to greater or lesser amount to impart certain desired properties to it. Most
of the steel produced now-a-days is plain carbon steel or simply carbon steel. Carbon steel
is defined as steel which has its properties mainly due to its carbon content and does not
contain more than 0.5% of silicon and 1.5% of manganese. The plain carbon steels varying
from 0.06% carbon to 1.5% carbon are divided into the following types depending upon
the carbon content.
1. Dead mild steel — up to 0.15% carbon
2. Low carbon or mild steel — 0.15% to 0.45% carbons
3. Medium carbon steel — 0.45% to 0.8% carbon
4. High carbon steel — 0.8% to 1.5% carbon
 Alloy Steel: Alloy steel may be defined as steel to which elements other than carbon are
added in sufficient amount to produce an improvement in properties. The alloying is done
for specific purposes to increase wearing resistance, corrosion resistance and to improve
electrical and magnetic properties, which cannot be obtained in plain carbon steels. The
chief alloying elements used in steel are nickel, chromium, molybdenum, cobalt,
vanadium, manganese, silicon and tungsten Commented [h11]: Give citation for the above discussion

XXXX Commented [h12]: U are discussing different type of

metals with their properties due to availability, suitability
and cost of the materials. Then which material u are selected
on your design. Discuss more…….
3.1.2 Factor of safety
The design factor of safety is used for handling systematically the many and varied uncertainties
associated with specific design situation. It is most commonly applied to design in one of two
ways. Factor of safety may be used to reduce the known strength property of a chosen material
σ yields trength σ yield Commented [h13]: Write Eq. using Equation editor
, (σ allowable  and τ allowable  strength
)
F.s (2  F.s)
Many times workers have to work below heavy load such a high risk of work leads to select higher
factor of safety values. The dropping or slipping of weight is life hazards. So it has to be foolproof.
Select factor of safety as ‘3’ to this project, since the maximum strength for all selected material Commented [h14]: Why? Discuss

is about 390 Mpa, then the comfortable factor of safety is 3. Commented [h15]: Justify

The shear stress at the yield point in a simple tension test is equal to one-half the yield stress.
 yt  yt Commented [h16]: Plz write the equations properly,
  allowable  and  allowable   subscript are not clearly written
F .s 2  F .s

3.1.3 Material Selected Flexile Bushed-Pin Coupling
Based upon above discussed or mentioned the material selection for the flexible bush pin
coupling will be:
Table 1: The permissible stress and shear for the selected material Commented [h17]: Give citation

Material Parts (component) Yield strength in Permissible Permissible

Mpa stress in MPa shear in Mpa

Steel alloy 1040 Shaft, key, pin   

and nut
Cast iron Flanges   
Grade 60-40-18

Rubber and Brass Bush   

(rubber and brass)
 Chapter-Four
4.1 Design Analysis
4.1.1 Design of Flexible Bushed-Pin Coupling

Rubber bush
7 mm thick

Figure 7: Bushed-Pin coupling Commented [h18]: Where in the text is this figure
relevant?
4.1.2 Given Parameter of flexible bush-pin coupling Give citation if it is not drown by U

 Power of motor shaft transmitting, P = 50 Kw.

 Speed of motor shaft, N = 600 rpm.
 The type of design coupling is Flexible Bush Pin Coupling.

The material properties for the different components as discussed in Chapter-Three are as follow:

 The allowable shear and crushing stress for shaft, key and pin material is 62.5 Mpa and
125 Mpa respectively.
 The allowable shear stress for flange or hub material is 46 Mpa.
 The allowable bearing pressure for rubber bush is 0.5 N/mm2. Since the given speed is Commented [h19]: Why? Give clarification

high and keep the low bearing pressure, the pitch circle diameter and the pin size is
increased.
 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.
4.1.3 Design of shaft
 The maximum or permissible shear stress for the shaft material is 62.5 Mpa.
Let, d = Diameter of shaft.

 The maximum torque transmitted by the shaft,

60  P 60  50 103 W
T   795.7Nm
2π  N 2π  600
T  795.7 103 N - mm

 We also know that the torque transmitted by the shaft (T),

π
T  τ shaft  d 3
16
π
795.7  103 N mm   62.5 N  d3
16 mm 2
16  795.7  103 N mm 3
d3  40.18mm 3
π  62.5 N 2
mm
d  40.18 mm then tak e the standard diameter of shaft as 44 mm
4.1.4 Design of key
 The maximum or permissible crushing and shearing stress for the key material is 125 Mpa
and 62.5 Mpa respectively.

Since the crushing stress for key material is twice of its shear stress (i.e.  ck  2 k ), Therefore a
square key will be used. From the standard table find the width and thickness of key for the shaft
diameter of 40 mm.

 Width of key, w = 14 mm and,

 Thickness of key, t = 9 mm Commented [h20]: How? Clarification

The length of key (L) is taken equal to the length of hub, i.e.

L = 1.5d = 1.5 × 44 mm = 66 mm
Let us now check the induced stresses in the key considering it in shearing and crushing.

 Considering the key in shearing:

As we know, that torque transmitted,
 d
T  L w  τ 
k 2
44 mm
759.7  103 N mm  66 mm  14 mm  τ 
k 2
2  759.7  103 N
τ   39.15 Mpa
k 44  14  66 mm 2

∴ 𝜏𝑘 = 39.15 Mpa < 62.5 Mpa

 Considering the key in crushing:
We know the torque transmitted,

t d
T  L   σ ck 
2 2
4T 4  795.7  103 N mm
σ ck  
L  t  d 66 mm  9 mm  44 mm
σ ck  121.8 Mpa

∴ σ ck  121.8 Mpa < 125 Mpa

Since the induced shearing and crushing stress for the key is less than the permissible shearing
and crushing stress of 62.5 Mpa and 125 Mpa respectively.

∴ The Design for the key is safe