Question:

Your task is to design a rubber coupler for an automotive application, specifically to connect two rotating
shafts while accommodating misalignments and dampening vibrations. The coupler will be subjected to
varying torque loads and environmental conditions typical of automotive use. Provide a detailed design
proposal, including material selection, geometry considerations, and structural analysis.

Material Selection (Example):

Choose a high-grade synthetic rubber such as Natural rubber (NR) with a Shore A hardness of 60 for its
balance of flexibility and durability.

Coupler Geometry and Misalignment Compensation :

Design a flexible, disc-type coupler with an outer diameter of 100 mm and a thickness of 10 mm. Include
features for axial misalignment compensation up to ±3 degrees and angular misalignment compensation
up to ±5 degrees.

Structural Analysis and Torque Capacity :

Perform a structural analysis under varying torque loads, ranging from 100 Nm to 500 Nm. Determine
that the coupler should have a torque capacity exceeding 600 Nm to ensure a safety factor of at least
1.2.

Environmental Durability :

Consider an operating temperature range of -40°C to 120°C and ensure the rubber material is resistant
to automotive fluids, such as oil and coolant.

Manufacturability and Cost Considerations :

Choose injection moulding as the manufacturing process for its efficiency and consistency. These specific
numbers will provide a foundation for your design and analysis. Ensure that you perform detailed
calculations and analyses based on these values, considering real-world factors and safety margins.
Adjust parameters as needed based on the results of your analysis and the specific requirements of the
automotive application