COUPLINGS

1. Sleeve or muff-coupling
Outer diameter of the sleeve
D

= 2 d + 13 mm

Lenght of the sleeve,

Let

= Diameter of the shaft L

Torque to be transmitted by the coupling

fs1

Permissible shear stress for the matrial of the sleeve which

is cast iron. (140 kg/cm2)

2. Clamp or compression coupling

= 3 . 5d

Diameter of the muff or sleeve

D

= 2 d + 13 mm

Lenght of the sleeve,

L

= 3 . 5d

3. Design of muff and key

The muff and key are designed in the similar way as discussed in muff
coupling
4. Design of clamping bolts
Let
T = torque transmitted by the shaft,
d = diameter of shaft,
db = root or effective diameter of the bolt,
n = number of bolts,
ft = permissible tensile stress in the bolt material,
= coefficient or friction between the muff and the shaft, and
L = length of muff,
We know that the force exerted by each bolt

db X f t
4
2

Force exerted by each bolt on each side of the saft,

n
db X f t X
4
2
2

Let p be the pressure on the shaft and the muff surface due to the force, then
for uniform pressure distribution over the surface,
p=

Force
Projected area

n
d Xft X
4 b
2

1
L.d
2
2

Frictional force between each shaft and muff,

F= X pressure X area

X pX

1
dL
2

n
db X f t X
4
2 1
X
X dL
1
2
L.d
2
2

n
db X f t X X
4
2
2

2
d .f n
8 b t
2

and the torque that can be transmitted by the coupling,

d
T =F X
2
.

2
d
db . f t n
8
2
2

2
. db f t n d
16
2

From this relation, the root diameter of the bolt (db) may be evaluated.
Solution : given. Horsepower transmitted,
P = 40 h.p
Speed of the shaft,
N =100 r.p.m
Allowable shear stress for the shaft and key,
fs =400kg/cm2
Number of bolts, n = 6
Permissible tensile stress for the bolts,
ft = 700 kg/cm2
Coefficient of friction between the muff and the shaft surface,
= 0.3
First of all, let us find the torque transmitted by the shaft.
Let
T = Torque transmitted by the shaft

Using the relation

P X 4,500
T=
with usual notations
2 N

40 X 4,500
=268.4 kgm
2 X 100

28,640 kgm
1. Design of the shaft
Let d = diameter of the shaft
Using the relation

T = d 3 fs
with usual notations
16
or
d 3=

16 T 16 X 28,640
=
=364.5
fs
X 400

d= 3 364.5=7.1447.5 cm

Ans

2. Design for muff

Diameter of muff,
D=2 d +1.3 cm
D=2 X 7.5+1.3=16.316.5 cm Ans

Total length of the muff,

L=3.5 d=3.5 X 7.5=26.25 cm Ans
3. Design for key
The width and the thickness of the key for shaft diameter of 75 mm
(from table 13.1) are as follows :
Width of the key,
w = 22 mm Ans
Thickness of the key,
t = 14 mm Ans
Length of the key,
= Total length of the muff
= 26.25 mm Ans
4. Design for the bolts
Let db = root diameter of the bolt
Using the relation
2
T = . d b f t n d with using usual notations
16
2

or
d 2=

16 T
2 f t n d

16 X 28,640
=4.914
0,3 X 2 X 700 X 6 X 7.5

d b= 4.914=2.2152.5 cm

13.16 Design of flange coupling

Consider a flange coupling as shown in Fig. 13.12 and 13.13.
Let

d = Diameter of the shaft or inner diameter of the hub,

D = Outer diameter of the hub,
D1 = Nominal or outside diameter of bolt,
D1 = diameter of bolt circle,
N = number of bolts,
Tf = thickness of flange
fs = allowable shear stress for the shaft, bolt and key material,
fs1 = Allowable shear stress for the flange material i.e cast iron, and
fc = allowable crushing stress for bolt and key material.

(1) Design for hub

The hub is designed by considering it a hollow shaft, transmitting the same
torque as that of a solid shaft.
4
4

D d
T
=
fs(
)

16
D

d
3
4
fs D ( 1k ) (wherek = )
16
D

(2) Design for flange

The flange at the junction of the hub is under shear while transmitting the
torque T.

T =Circumference of hub X Thickness of flange X

Shear stress of flange X Radius of hub
D . tf . f s1

D D2
=
f .t
2
2 s1 f

Load on each bolt

2
d1 X f s
4
total load on each bolt
2
d1 X f s X n
4
And the torque transmitted,
D

T = d 21 X f s X n X 1
4
2
Area resisting crushing of all the bolts
nd 1 t f
And the crushing strength of all the bolts
(nd 1 t f ) f c
(nd 1 t f )

D1
2

From this equation the induced crushing stress in the bolts n be checked.
The other proportions are taken as follows :
Outer diameter of the flange
D1+ ( D1D ) =2 D1D
Thickness of the protective circumferential flange
0.25 d
(1) Design for hub
The outer diameter of the hub is given by
D=2 d=2 X 8
=16 cm
Considering the hub as a hollow shaft, we shall check the induced
shear stress for the hub material which is cast iron. We know that

T=

D 4 D4
f s1
16
D

43,000=
f s 1=

)
4

16 8
f s1
16
16

43,000 X 16 X 16
(16 48 4 )

57 kg /cm2
Since the induced shear stress is less than 800 kg/cm2 ; therefore it is
safe.
(2) Design for key
From Table 13.1, the proportion of key for 8 cm diameter shaft are :
Width of key, w = 22 mm
= 2.2 cm
Thickness of key, t = 14 mm
= 1.4 cm
The length of the key is obtained by considering the key in shearing
and crushing. We know that
d
T =l. w . f s . (considering shearing of key )
2
4,300=l X 2.2 X 500 X
l=

43,000 X 2
=9.8 cm
2.2 X 500 X 8
T =l X

Also

43,000=l X
l=

8
2

1. t
d
X fc X
2
2

(considering crushing of key)

1.4
8
X 1,500 X
2
2

43,000 X 2 X 2
1.4 X 1,500 X 8

10.24 cm

Taking larger of two values, we have length of the key,

l=10.24 cm11 cm
Design for flange
The thickness of the flange is taken as healf the diameter of shaft, i.e.

t f =0.5 d=0.5 X 8
4 cm
Considering the flange at the junction of the hub under shear, we shall
check the induced shearing stress in the flange. We know that
2
D
T=
f .t
2 s1 f
2

43,000=
f s 1=

16
f X4
2 s1

43,000 X 2
2
X 4=26.7 kg/cm
2
X 16 X 4

Since the induced shear stress in the flange is less than 80 km/cm2,
therefore it is safe.
Deisgn for bolts
Since the diameter of shaft is 8 cm, therefore
Number of bolts = 4 Ans
Pitch circle diameter of the bolts,
D 1=3 d=3 X 8=24 cm
Let d1 be the diameter of the bolts. Since the bolts are subjected to
shear stress due to the torque transmitted, therefore
D1
2
T = d1 X f s X n X
4
2

24
43,000= d 21 X 500 X 4 X
4
2
Or
d 21=

43,000 X 4 X 2
X 500 X 4 X 24

2.27

d 1= 2.27
1.506 cm

Assuming coarse threads, the nearst standard size of bolt is

d 1=M 16 Ans

Considering the crushing of the bolts, we shall check the induced

crushing stress in the bolts. We know that
D
T =n . d 1 . t f . f c X 1
2
43,000=4 X 1.6 X 4 X f c X
f c=

24
2

43 ,000 X 2
4 X 1.6 X 4 X 24

140 kg/cm2
Since the induced crushing stress of the bolt material is less than 1,500
kg/cm2, therefore it is safe.
The other proportions are taken as follows :
Outer diameter of the flange
2 D1 D
2 X 2416=32 cm Ans
Thickness of the protective circumferential flange
0.25 d=0.25 X 8
2 cm Ans
Example 13.6 (S.I Units). A marine type flange coupling is used to
transmit 3.75 MW at 150 r.p.m. The allowable shear stress in the shaft
and bolts may be taken as 50 N/mm2. Determine the shaft diameter
and the diameter of the bolts. (London University)
Solution
Given. Horse power transmitted,
6W
P=3. 75 MW=3.75 X 10
N=150 r . p . m

Speed
Allowable shear stress in the shaft and bolts,
2
f s=50 N /mm
Diameter of the shaft
Let
d = Diameter
Using the relation

T=

P X 60
2 N

3.75 X 106 X 60
2 X 150

0. 24 X 106 N m
0.24 X 109 Nmm
We know that the torque transmitted,

T = f s d3
16
0.24 X 109 =
d 3=

X 50 X d 3
16

0.24 X 109 X 16
=24.44 X 10 6
X 50

24 .44 X 106=290.2300 mm Ans

Diameter of the bolts
Let
From the table 13.2, we find that the number of bolts for shaft diameter
of 300 mm are 10, i.e
n=10 Ans
And pitch circle diameter of the bolts,
D 1=1.6 d=1.6 X 300=480 mm Ans
since the bolts are subjected to shear stress due to the torque
transmitted, therefore
D

T = d 21 X f s X n X 1
4
2

480
0.24 X 109 = d12 X 50 X 10 X
4
2
3

94. 26 X 10 d 1
d 21=

0.24 X 109
=2546
94.26 X 103

d 1 = 2546=50.46

According to IS : 4218-1967 (table 10.1), the standard size of the bolt

is M 56 Ans.
In designing the bushed-pin flexible coupling, the proportions of the
rigid type flange coupling are modified. The main modification is to
reduce the bearing pressure on the rubber or the leather bushes and it
should not exceed5 kg/cm2. In order to keep the low bearing pressure,
the pitch circle diameter and the pin size is increased.
Let l = length of the bush in the flange
D2 = diameter of the bush
Pb = bearing pressure on the bush or pin
N=number of pins, and
D=diameter of pitch circle of the pins
The bearing load acting on each pin,
F=Pb X d 2 X l
total bearing load on the bush or pins
F X n=Pb X d 2 X l X n
And the torque transmitted by the coupling
D
T =F X n X
2
Pb X d 2 X l X n X

D
2

We know that the bending stress,

l
F +0.5
2
M
f= =
Z
3
d
32 1

Since the pin is subjected to bending and shear stresses, therefore the
design must be checked either for the maximum principal stress or
maximum shear stress by the following relations.
Maximum principal stress
1
[ f + f 2 +4 f 2s ]
2
And the maximum shear stress on the pin
1
f 2 +4 f 2s
2
We know that the torque transmitted,

T=

P X 4,500
2 N

50 X 4, 500
=35.8 kg . m
2 X 1,000

3,580 kg . cm
We have discussed in rigid type of flange coupling that the number of
bolts for 50 mm diameter shaft are 4. In the flexible coupling, we shall
use the number of pins as 6.
N= 6 Ans
Diameter of the pins,
0.5 d
d 1=
n

0.5 X 5
=1.02 cm
6

Overall diameter of rubber bush,

d 2=2.4 +2+0.2+2+0.6=4 cm Ans
And diameter of the pitch circle of the pins,
D=2 d +d 2 +2 X 0.6
2 X 5+ 4+ 1.2=15.2 cm Ans

Let l= length of the bush in the flange

We know that the bearing load acting on each pin,
F=Pb X d 2 X l
4.5 X 4 X l=18 l kg
And the torque transmitted by the coupling,
D
T =F X n X
2
3,580=18 l X 6 X
l=
And

15.2
2

3,580 X 2
=4.364.4 cm Ans
18 X 6 X 15.2

F=18l=18 X 4.4=79.2 kg

direct stress due to pure torsion in the coupling halves,

f s=

F
2
d
4 1

79.2
=25.2 kg/cm 2

X 23
4

M =F

( 12 +0.5)

M =79.2

( 4.42 +0.5)=214 kgcm

Bending stress,
f=

f=

M
M
=
Z
3
d
32 1
214
2
=273 kg /cm

3
X2
32

Maximum principal stress

1
2
2
[ f + f +4 f 2 ]
2

1
2
2
[
273+ 273 + 4 X 25.2 ]
2

275 .3 kg/cm2
And maximum shear stress
1
2
2
2
[ 273 + 4 X 25.2 ]=138.8 kg /cm
2
In the designing a universal coupling, the shaft diameter and the pin
diameter is obtained as discussed below. The other dimensions of the
coupling are fixed by proportions as shown in Fig. 13.18
Let T = Torque to be transmitted by the shafts,
D = diameter of the shaft
Dp = diameter of the pin, and
Fs and fs1 = allowable shear stress for the material of the shaft and pin
respectively.
We know that

T=

f d3
16 s

Or

d= 3

16 T
fs

Since the pin is in double shear, therefore

T =2 X d 2p X f s 1 X d
4
d p=

2T
f s1 X d

Note. When a single Hooks coupling is used, the ratio of the driving
and driven shaft is given by
N 1cos 2 sin 2
=
N1
cos
N 1=

N cos
2
2
1cos sin

Where n = speed of the driving shaft in r.p.m

N1 = speed of the driven shaft in r.p.m
Angle of inclination of the shafts
Angle of the driving shaft from the position where the pins of the
driving shaft fork are in the plane of the two shafts.
Example 13.8 an universal coupling is used to connect two mild steel
shaft transmitting a torque of 500kg-m. assuming that the shafts are
subjected to torsion only, find the diameter of the shafts and pins. The
allowable shear stresses for the shaft and pin may be taken as 600
kg/cm2 and 280 kg/cm2 respectively.
Solution
Given. Torque to be transmitted,
T= 500 kg.m = 50,000 kg-cm
Allowable shear stress in the shafts,
fs = 600 kg/cm2
allowable shear stress in the pins
fs1 = 280 kg/cm2
Diameter of the shafts

Let
d= Dameter of the shafts
Using the relation

3
T= f sd
16
with usual notations

3
50,000= X 6000 d
16
3

d=

50,000 X 16
=425
X 600

d= 3 425=7.5 cm Ans
Diameter of the pins
Let dp = Diameter of the pins
Using he relation

T =2 X d 2p X f s 1 X d
with usual notations
4
50,000=2 X
2

d p=

2
d X 280 X 7.5
4 p

50,000 X 4
=15.15
2 X 280 X 7.5

d p= 15.15=3.920 r 4 cm Ans

T = P X 4500 / 2II N
N = F X 2II R n
N = FR X 2 II n
N = T X 2 II n