Abreham Debris Couplinig Design

UNIVERSAL COUPLINSIGN
Wolkite University
Collage of engineering and technology department of
mechanical engineering
Design of flexible coupling for medium trucks
Name Id SEC
Abraham deberis Eng. 044/09 A
Submitted to MR. Yonatan

Submission date …………….
PREPARED BY ABREHAM.D 1
Abstract
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. A Universal coupling is a special type
of coupling in which misalignment of shafts is allowed. Shafts are free to move any direction in order
to transmit torque or power from one shaft to Another. In this project work a Universal coupling was
designed, in which safe torque on shafts and pin Size of cross determined.
Chapter one
1. Introduction:
Couplings are mechanical elements that ‘couples’ two drive elements which enables motion to be
transferred from one element to another. The drive elements are normally shafts. We tend to see lot of
applications of the couplings mainly in the automobiles, for example the drive shaft which connects the
engine and the rear axle in a bus or any automobile is connected by means of a universal joint. [1]
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.
There are various types of coupling based on area of application and misalignment or degree of freedom
to move in any direction. Such as the universal coupling allows the shafts to move in any directions. The
different types of alignments are: [2]
1.1. Objectives of the study
 The main objectives of this project work is to do the detail design of universal coupling for 2020
GMC Canyon 2WD Crew Cab 128" Denali car model
1.2. Specific objectives
 To calculate the dimensions shaft, pin, forks, yoke and operating angle
 To know the application area
 To generate 3D solid works and
 Checking the safety of design
1.3. Methods and Materials
1.3.1. Methods
Selection of Literature review

Detail design of
material on related
the component
design
Conclusion and
Software design
recommendation
1.3.2. Materials
A wide range of metals and synthetic are used in the manufacturing of universal
joint coupling, although synthetic are generally suitable only low stress and force
application. Common material used includes, stainless steel, steel, mild steel.
Naval steel and other similar alloys.
Chapter two
2. Literature review
The first person known to have suggested its use for transmitting motive power was GerolamoCardano,
an Italian mathematician, in 1545, although it is unclear whether he produced a working model. In
Europe, the device is often called the Cardan joint or Cardan shaft. Christopher Polhem of Sweden later
reinvented it, giving rise to the name Polhemsknut in Swedish.
Gaspar Schott ((1664), who called it the paradoxum, but mistakenly claimed that it was a constant-
velocity joint. Shortly afterwards, between 1667 and 1675, Robert Hooke analysed the joint and found
that its speed of rotation was no uniform, but that this property could be used to track the motion of the
shadow on the face of a sundial. The first recorded use of the term universal joint for this device was by
Hooke in 1676, in his book Helios copes. He published a description in 1678, resulting in the use of the
term Hooke's joint in the English-speaking world. In 1683, Hooke proposed a solution to the non-uniform
rotary speed of the universal joint: a pair of Hooke's joints 90° out of phase at either end of an
intermediate shaft, an arrangement that is now known as a type of constant-velocity joint.
The term universal joint was used in the 18th century and was in common use in the 19thcentury. 19th
century uses of universal joints spanned a wide range of applications. Numerous universal joints were
used to link the control shafts of the Northumberland telescope at Cambridge University in 1843. The
term Cardan joint appears to be a latecomer to the English language. [3]
2.2. Coupling:
Couplings are mechanical elements that ‘couples’ two drive elements which enables motion to be
transferred from one element to another. The drive elements are normally shafts. Couplings are used to
connect two shafts for torque transmission in varied applications. It may be to connect two units such as a
motor and a generator or it may be to form a long line shaft by connecting shafts of standard lengths say
6-8m by couplings.
2.3. Types of coupling:
Based on the area of applications there are various types of coupling available. But they are generally
categorized in the following varieties-[1]
1) Rigid Couplings
2) Flexible Couplings
2.4. Rigid Couplings:
Rigid Couplings are mainly used in areas where the two shafts are coaxial to each other. There are many
types of couplings that fall under the rigid couplings category. They are
1) Flanged Coupling
2) Muff coupling
Figure2.1 Flanged coupling figure2.2 Muff coupling
2.5 Flexible Couplings:
Flexible couplings are normally used in areas where the coaxially between the connecting shafts is not
always assured and in areas where there is a possibility of occurrence of shocks in the transmission is
applicable. They are also called as Elastic Couplings. By construction these couplings tend to have an
elastic member in between the two connecting entities. The different types of flexible couplings are
1) Universal Couplings (OUR CONCERN)
2) Bibbly Coupling
3) Gear Tooth Coupling
4) Tyre couplings
5) Elastomeric Couplings
6) Flanged Pin Bush Coupling
7) Oldham coupling
Figure 2.3 Flanged Pin Bush Couplings figure 2.4 Bibbly Coupling
Figure 2.5 Oldhams Coupling figure 2.6 Universal Coupling
2.6, Universal Coupling or Hooke’s coupling:
A universal joint is a joint or coupling that allows the shafts 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. The universal joint is not a constant velocity joint.
Figure. 2.7
2.7. A simple brief about Universal Coupling:
A universal joint is like a ball and socket joint that constrains an extra degree of rotational freedom. Given
axis 1 on body 1, and axis 2 on body 2 that is perpendicular to axis 1, it keeps them perpendicular. In
other words, rotation of the two bodies about the direction perpendicular to the two axes will be equal.
In the picture, the two bodies are joined together by a cross. Axis 1 is attached to body 1, and axis 2 is
attached to body 2. The cross keeps these axes at 90 degrees, so if you grab body 1 and twist it, body 2
will twist as well.
A Universal joint is equivalent to a hinge-2 joint where the hinge-2's axes are perpendicular to each other,
and with a perfectly rigid connection in place of the suspension. Universal joints show up in cars, where
the engine causes a shaft, the drive shaft, to rotate along its own axis. At some point you'd like to change
the direction of the shaft. The problem is, if you just bend the shaft, then the part after the bend won't
rotate about its own axis. So if you cut it at the bend location and insert a universal joint, you can use the
constraint to force the second shaft to rotate about the same angle as the first shaft. [4]
Figure 2.8 brief about Universal Coupling
2.8. Types of Universal coupling:
The universal couplings are categorized as-[5]
1) Single joints
2) Double joints
3) Telescopic or assembled joints
 Single joints Universal coupling:
Precision single joints suit angles up to 45° and speeds to 4000 r/min. Shaft sizes 6 to 50 mm, dimensions
to DIN 808.
 Double joints Universal coupling:
Precision double joints suit angles up to 90° and give constant velocity output. Shaft sizes 6 to 50 mm,
dimensions to DIN 808.
Figure 2.9 single joint figure 2.10 Double joints
 Assembled joints Universal coupling:
Telescopic universal joint with plain bearings either to standard lengths or customized to your
requirements. Angles up to 45° per joint and speeds to 1000 r/min, Type HA offers higher speeds.
Figure 2.11 telescopic joint
2.8. Field of Applications of Universal Coupling:
Typical applications of universal joints include-
 AUTOMOBILE and Aircraft Appliances
 Control mechanisms
 Electronics instruments
 Medical & optical device
 Ordinance radio Sewing machines
 Textile machineries etc.
Chapter three
3. Conceptual design
Types of universal coupling joints Single joints Double joints Telescopic or assembled joints Cross
type’s universal joint, Hooke type universal joint, Double Hooke CV type universal joint, Tracta CV
type universal joint, Rzeppa type universal joint and Carl Weiss CV type universal join
3.1. Concept generation one
a simple type universal joint calld Single joints It have an inclination angle and have both side
yoke
3.2.concept generation two
The other type of universal joint and a complex one and we use this type of joint for heavy duty
truckes. And have high torque and power transmission Consists of many components like nideel
roller bearing, criclip, spider etc
3.3. Concept evaluation
Criteria Weight Concept one Concept two
Sipilicity 25% 4 1.5 4 2.3

Sutaible for midium 50% 8 3.6 3 3
trucks
Inclination angle 40% 8 3.1 8 1.7
Sum 8.2
3.4 concept selection
We select concept generation one its our choice becouse it full fill most of my criteria on the
concept evaluation table that means it is simple and suitable for medium duty trucks.
Chapter four
4. Detail design
4.1. Product design specification
For a 2020 GMC canyon model car specification
P =308hp = 230kw at N = 6800 r.p.m.
T = 725ft-lb = 373Nm = 373*103Nmm at N = 4000 r.p.m
Considering cost, strength, ease of access taken into account the selected material for this design
Is MILD STEEL.
Material property steel (190mild) for shaft steel (AISI4130) for pin
Ultimate strength (Us) 841Mpa 1110Mpa
yield strength (Ys) 247Mpa 951Mpa
Design for the shafts
To calculate the diameter of shaft use the formula below.
π
T= 16 *τs*d3
To determine diameter of shaft first we calculate the allowable shear stress for the shaft, as we know from
earlier the maximum stress of the material is determined from: 18% times of its ultimate strength.
τs= 18%* Us = 0.18*841Mpa = 151Mpa
π
373*103Nmm = *151 N/mm^2*d3
16
373000/29.65 = d3 12558.9= d3 d= 23.25mm say 30mm
d= 30mm
Length of shaft Ls = 2.6d+0.8d = 2.6*30mm+0.8*30mm = 102mm
Design for pin
Since the pin is in double shear, therefore the torque transmitted, is done
π
T = 2* (dp) 2*τp*d
4
From this relation, the diameter of pin may be determined. And allowable shear stress of pin 18% times
its ultimate strength so we can determine
τp= 0.18*1110Mpa τp= 199.8Mpa
π
373*103Nmm = 2* (dp) 2*199.8N/mm^2*24mm
4
373000Nmm =7532.28 (dp)2
373000/7532.28 = dp2
50= dp2
dp = √ 50
dp =7 .04 say 15mm
Length of pin 0.25d + 3.6d = 0.25*30mm+3.6*30mm= 115.5mm
2D drawing of universal coupling and its dimension [6]
Design for yoke
Total diameter of yoke = 0.5d+2.2d+0.5d = 3.2d =3.2*30mm = 96mm
Outer shaft diameter of yoke = 1.8d = 1.8*30mm = 54mm
Side Thickness of yoke = 0.5d = 0.5*30mm = 15mm
Front thicknees of yoke = 0.6d = 0.6*30mm = 18mm
Dimeter of Space for fork = 2.2d = 2.2*30mm = 66mm
Hole dimeter for pin of yoke = 0.6d = 0.6*30 = 18mm
Design for forks
Diameter of forks df = 1.8d = 1.8*30mm = 54mm
Length of forks Lf = 1.7d = 1.7*30mm = 51mm
Diameter of forks for pin = 0.6d =0.6*24mm = 18mm
Outer diameter of forks around of pin = 1.1d = 1.1*30mm = 33mm
Design for key
If d is the diameter of the shaft, then, dimensions of Taper Sunk Key are calculated
Width of key, w = 0.25 d + 2 mm = 0.25*30mm+2mm = 9.5mm
Thickness of key, t = 0.67 w (at the thicker end) = 0.67*9.5mm = 6.4mm
Standard taper = 1:100
Height of head, h = 1.75 t = 1.75*6.4mm = 11.2mm
Width of head, b = 1.5 t = 1.5*6.4mm = 9.6mm
Design for operating angles¿) [7]
Note: When a single Hooke's coupling is used, the ratio of the driving and driven shaft speeds is given by
N1 co s 2θ
=
N 1−co s¿ 2 α∗sin 2 θ
Where
N= Speed of the driving shaft in r.p.m.,
N1= Speed of the driven shaft in r.p.m.,
α= Angle of inclination of the shafts, and
θ= Angle of the driving shaft from the position where the pins of the driving shaft fork are in the plane of
the two shafts.
N=6800r.p.m
N1=?
The angles shown on this chart are the maximum universal joint operating angles recommended by
Spicer Engineers and are directly related to the speed of the driveshaft [8]
The maximum operating angles for the universal joint which have speed of 4000r.p.m is given as 4.2 0
from this we can calculate the Angle of inclination of the shafts (α)
4000 r . p . m co s 2θ 1 1
Nr . p . m = from trigonometry sin^2θ = 2 - 2 cos2θ
1−co s¿ 2 α∗sin 2 θ
sin2θ = ½ - ½*cos (2*4.2) = 0.5-0.5*cos8.4 = 0.005
sin2θ = 0.005
To Calculate Maximum Torque:-

Tmax =𝒑×𝟔𝟎/𝟐𝝅 𝑵
Tmax = 373×𝟏𝟎3×𝟔𝟎/𝟐𝝅 ×4000 = 890 N-m
The calculation of maximal load force at yoke joint of (F)

T = R F sin∝
=0.035× F × sin (4.2)
F = 347KN
h = 2d= 60mm, b = 1.75d= 52.5mm
Resisting Bending Torque (Wb)

Wb = 𝑏ℎ2/10 = 0.052×0.062/10 = 1.87× 10-6𝑚3
Resistant Shear Torque (Ws)
Ws = ℎ𝑏2/5=1 /5 × 0.055 × 0.0202= 3.7× 10-6𝑚3
The Bending Stress (bmax)
бmax =𝐹. 𝑐/𝑊𝑏 = 347×10^3×0.065/1.87×10-6 = 12.1 MPa
The Shear Stress (𝝉𝒎𝒂𝒙)

𝜏𝑚𝑎𝑥 =𝐹. 𝑎/𝑊𝑠 = 347×103×0.035/3.7×10-6 = 3.28 MPa
Bending stress on the link are 11.2 MPa The design is safe because the material bending stress is 136
MPa
Shear stress on the link 3.28 MPa The design is safe because the material shear stress is 151MPa
Chapter five
5.1 Discussion:
Mechanical couplings have a principal use in the connection of rotating shafts for the transfer of rotary
motion and torque. As with all mechanical devices, a coupling must match its’ intended purpose and
application parameters, including many different performance, environmental, use and service factors.
There are various reasons for which a coupling fails, such as-improper installation, excessive vibration,
abnormal noise and chattering etc. The failure of coupling can be minimized by proper maintenance, such
as-checking and changing lubricant regularly, performing visual inspection, checking signs of wear and
fatigue and cleaning coupling regularly etc.
Chapter six
6. Conclusion:
Mechanical design is a complex undertaking, requiring many skills. Design of Universal coupling was
done in this project work. In designing problem safe torque on shaft was determined. The pin size and
yoke (diameter) was determined considering shearing stress and bending stress taken into account. The
application of a universal coupling also studied in this project work.
References:
[1]: http://www.brighthubengineering.com/machine-design/43237-shaft-couplingstypes/#imgn_1
[2]: https://learnmech.com/design-and-fabrication-of-universal-join
[3]: Mills, Allan, "Robert Hooke's 'universal joint' and its application to sundials and the sundialclock",
Notes & Records of the Royal Society, 2007, accessed online2010-06-16
[4]: http://ode-wiki.org/wiki/index.php?title=Manual:_Joint_Types_and_Functions
[5]: http://www.techdrives.co.uk/Multimedia/Shaft%20Couplings/shaft-couplings-universaljoints-
feb13.pdf
[6]: Textbook of machine drawing third edd Dr.K.L.Narayana, DR.P.Kanniah ad K.venkata Reddy and
Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA tortuka
[7]: koyo® derive shaft for steel production/industrial equipment pdf
[8]:www.spicerparts.com

Abreham Debris Couplinig Design

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UNIVERSAL COUPLINSIGN

Submitted to MR. Yonatan

different types of alignments are: [2]

1.1. Objectives of the study

GMC Canyon 2WD Crew Cab 128" Denali car model

1.2. Specific objectives

 To know the application area

 To generate 3D solid works and

 Checking the safety of design

1.3. Methods and Materials

Selection of Literature review

an Italian mathematician, in 1545, although it is unclear whether he produced a working model. In

reinvented it, giving rise to the name Polhemsknut in Swedish.

intermediate shaft, an arrangement that is now known as a type of constant-velocity joint.

term Cardan joint appears to be a latecomer to the English language. [3]

2.3. Types of coupling:

categorized in the following varieties-[1]

2.4. Rigid Couplings:

Figure2.1 Flanged coupling figure2.2 Muff coupling

2.5 Flexible Couplings:

1) Universal Couplings (OUR CONCERN)

3) Gear Tooth Coupling

6) Flanged Pin Bush Coupling

Figure 2.5 Oldhams Coupling figure 2.6 Universal Coupling

2.6, Universal Coupling or Hooke’s coupling:

2.7. A simple brief about Universal Coupling:

will twist as well.

Figure 2.8 brief about Universal Coupling

2.8. Types of Universal coupling:

The universal couplings are categorized as-[5]

3) Telescopic or assembled joints

 Single joints Universal coupling:

 Double joints Universal coupling:

dimensions to DIN 808.

Figure 2.9 single joint figure 2.10 Double joints

 Assembled joints Universal coupling:

Figure 2.11 telescopic joint

2.8. Field of Applications of Universal Coupling:

Typical applications of universal joints include-

 AUTOMOBILE and Aircraft Appliances

 Medical & optical device

 Ordinance radio Sewing machines

 Textile machineries etc.

3.1. Concept generation one

3.2.concept generation two

3.3. Concept evaluation

Criteria Weight Concept one Concept two

Sipilicity 25% 4 1.5 4 2.3

3.4 concept selection

4.1. Product design specification

For a 2020 GMC canyon model car specification

P =308hp = 230kw at N = 6800 r.p.m.

T = 725ft-lb = 373Nm = 373*103Nmm at N = 4000 r.p.m

Design for the shafts

To calculate the diameter of shaft use the formula below.

τs= 18%* Us = 0.18*841Mpa = 151Mpa

373000/29.65 = d3 12558.9= d3 d= 23.25mm say 30mm

Length of shaft Ls = 2.6d+0.8d = 2.6*30mm+0.8*30mm = 102mm

Design for pin

its ultimate strength so we can determine

τp= 0.18*1110Mpa τp= 199.8Mpa

373000Nmm =7532.28 (dp)2

dp =7 .04 say 15mm

Length of pin 0.25d + 3.6d = 0.25*30mm+3.6*30mm= 115.5mm

Length of shaft Ls = 2.6d+0.8d = 2.630mm+0.830mm = 102mm

Length of pin 0.25d + 3.6d = 0.2530mm+3.630mm= 115.5mm

sin2θ = ½ - ½cos (24.2) = 0.5-0.5*cos8.4 = 0.005