362 Design of Machine Elements

The dimensions of the key are, has a corresponding recess. The diameters of the
22x 14 x 140 mrn (v) spigot and the recess are machined with more
Step WI Check for stresses in key accuracy. During the assembly, the spigot fits into
From Eq. (9.27), the recess and the two flanges are located precisely
with respect to each other. This ensures alignment
2M. 2 (3 978 873.s8)
of the axes of the two shafts.
dbl 80(22)(140) There are two types of rigid flange couplings-
= 32.3 N/mmt .',c < 40 Ninrm2 unprotected and protected. The flange coupling
shown in Fig. 9.33 is the unprotected type of
From Eq. (9.28),
coupling. The revolving bolt heads and nuts are
4M, 4(.3 978 873.58) dangerous to the operator and may lead tc accident.
' dht 80(l4xt40) Protected type flange coupling is shown in Fig.
9.34. ht this case, protecting circnmferential rims
= 10l.5Nimm2 ...o" 1120N/mm2 cover the bolt heads and nuts. In case of fa"ilure of
The design of key is safe frorn shear and bolts while the machine is being run, the broken
compression considerations. pieces will dash against this rim and eventually fail
down. This protects the operator against injuries.
9.21 RIGID FLANGE COUPLINGS
Protecting
circumferential
A flange coupling consists of two flanges-one rims
keyed to the driving shaft and the other to the Spigot and
recess
driven shaft as shown in Fig. 9.33. The two flanges
are connected together by means of four or six
bolts arranged on a circle concentric with the axes
of the shafts. Power is transmitted from the driving

Fig.9.34 Protected Type Rigid Coupling .

The rigid flange couplings have the following

Driving advantages:
Driven
shaft shaft (i) Rigid coupling has high torque transmitring
capacity.
Fig. 9.33 Unprotectetl Type Flange Coupling (ii) Rigid coupling is easy to assemble and
dismantle.
shaft to the left side flange through the key. It is (iii) Rigid coupling has simple construction. It is
then transmitted from the left side flange to the
easy to design and manufacture.
right side flange through the bolts. Finally, power The rigid flange couplings have the following
is transmitted from the right side flange to the disadvantages:
driven shaft through the key. Since ffange coupiing (i) It is a rigid type of
is rigid type of coupiing, provision should be made
coupling. It cannot
tolerate misalignment between the ar,es of
fbr precise location of the axes of two shafts. The two shafts.
mating flanges have spigot and recess for precise (ii) It can be used only where the motion is fi-ee
location. The left side flange has a cylindrical from shocks and vibrations-
projection called spigot while the right side flange (iii) It requires more radial space.

L,-
 Shqr. Keys and Couplings g6g

-
Rigid flange couplings are widely used for three distinct regions-inner hub, central flange
:-an:rnirting large torques. with boltholes and peripheral outer rim as shown in
The 1lange of the protected type coupling has Fig. 9.35. The hub is provided with a keyway. The

Outer rim
tt Central portion
of flange

d6 D

ln--4*ln
Fig.9.35 Proportions of Rigid Coupling

i:inction of the hub is to transmit the torque from (iv) t: thickness offlanges
:n; shaft to the centrai flange and vice versa.
1le central portion of the flange has holes to t:0.5 d
;;cornmodate the bolts. Torque is transmitted from (v) /r = thickness ofprotecting rim
..ne flange to the other by means of these bolts. tt:0.25 d
ilhe outer circumferential rim is for the purpose of
(vi) d,: diameter of spigot and recess
to cover the projecting bolt heads and nuts.
"alet1'
\ arious dimensions of flanges are shown in Fig. d,: l'5 d
;.-15. Many times" the dimensions of the flanges are (vii) Do : outside diameter of flange
:siculated by using standard proportions in terms
Do: gd + 2t)
-.: shaft diameter. Shop-floor engineers have used
such empiricai formulae for many years without In the above relationships, d is the shaft
.nr problem. It is easy to design the coupling diameter.
*sing these standard proportions, because no stress The number of bolts (A) is also decided from the
.lnalr,sis is involved. The dimensions calculaied by shaft diameter in the following way:
rese formulae result in robust design. The standard l/: 3 for shafts up to 40 mm diameter
:roportions for various dimensions of the flange /i : 4 for shafts from 40 to 100 mm diameter
rroun in Fig.9.35 are as follows: N: 6 for shafts from 100 to 180 mm diameter.
tl1 d,,: outside diameter of hub
The analysis of rigid coupling can be done by
dd= 2d tu'o different ways, depending upon the clearance
t ii) /,, : length of hub or effective length of key between the boit and the hole. In the first approach,
the bolts are fitted in reamed and ground holes. In
11,:1-5 d
this case, there is no clearance and the bolts are
r iii) D = pitch circle diameter of bolts finger tight. Therefore, power is transmitted by
D:3d means ofshear resistance ofthe bolts. In the second
 approach, the bolts are fitted in large clearance Case Il Bolts Fitted in Large Clearance
holes. In this case, bolts are tightened rvith a pre- Holes When the bolts are fitted in large clearance
load and power is transmitted by means of friction holes, the above analysis is not applicable. In this
between the two flanges. case, the bolts are sufficiently tightened with a pre-
Case I Bolts Eitted in Reameil anil Ground load and the torque is transmitted from one flange
Holes The forces acting on individual bolts due to to the other by means of friction between them. For
transmission of the torque are shown in Fig. 9.36. uniformly distributed pressure, the friction radius
Equating the extemal torque with the resisting torque, RTis given by,

M,: P* f2 r, t o _2 rnj -nl r

(a)
^r-1;1r"-R) (9.42t
where,
where, (Fig. 9.35)
M,= Iorque transmitted by the coupling (N-mm)
P: force acting on each bolt (N)
Ro: outer radius of the flange (Do /2) (mm)
D: pitch circle diameter of bolts (mm)
R,: radius of the recess (d,12) (mm)
Assume that,
N: number of bolts.
P;: initial tension in each bolt (N)
p : coefficient of friction between flanges
The friction force will be (1t P,M) and the torque
is given by,
M,:FPiNRl (e.43)
Flanges have complex shape and the easiesr
method to make the flanges is casting. Flanges are
usually made of grey cast iron of grade FG 200.
The bolts, keys and shaft are made of plain carbon
steels on strength criterion.
Fig. 9.36 Shear Resistance ofBolts

It should be noted that the bolts are subjected to 9.22 DESIGN PROCEDURE FOR RIGID
direct shear stress due to the force P and not torsional FLANGE COUPLING
shear stress. No torque is acting about the axis of the
bolt. The force P results in only direct shear stress. The basic procedure for finding out the dimensions
The direct shear stress in the bolt is given by, of the rigid flange coupling consists of the
P following steps:
'-(A (b)
(i) Shaft Diameter Calculate the shaft diameter by
lq-') using the following two equations:
where,
60 x 106(kw)
?: shear stress in the bolt (N/mm2) M,=
d, :
nominal diameter of the bolt (mm)
Zo,
From (a) and (b),
16 Mt
and T:
8M, ltd ,3
-
L_
rDNdi
(e.41)
(ii) Dimensians of Flanges Calculate the dimen-
Equation (9.a1) is used to determine the nominal sions of the flanges by the following empirical
diameter of the bolts. The above analysis of the equations:
coupling is based on the assumptionthat the bolts are dn: 2d
fitted in rimmed and ground holes. The bolts are finger lh: l'5d
tight in these holes and there is no clearance between D:3d
the holes and the nominal diameter of the bolts. t:0.5d

h
 tt: 0.25d 2M,
d,: l'5d or . (e.47)
NdrtD
Do:
2t) (4d +
The torsional shear stress in the hub can be Equation (9.47) is used to check the compressive
calculated by considering it as a hollow shaft stress in the bolt.
subjected to torsional moment M,. (io) Dimensions of Keys Determine the standard
The inner and outer diameters of the hub are d cross-section offlat key from Table 9.3. The length
and d,, respectively. The torsional shear stress in the
ofthe key in each shaft is {,. Therefore,
hub is given by,
M,r
I: ln
L- With these dimensions of the key, check the
J shear and compressive stresses in the key by Eqs
-
lr@1-d4)
'':--i-
' (e.44)
(9.27) and (9.28) respectively.

dh
__2M,
,-
f- dbt
2
The flange at the junction of the hub is under
shear while hansmitting the torsional moment M,.
and "r:ffi
From Fig. 9.35,
area under shear: (tc d) x t
!-"*pt" 929 A rigid coupling is used to
transmit 20 kllr power at 720 rpm. There are
shear force : area x shear stress : n drlt four
bolts and the pitch circle diameter qf the bolts
resisting rorque = shear force 4n) is 125 mm. The botts are made of sreel 45Cg (Syr:
"(\2 ) 380 N/mm2) and thefactor of safety is 3. Determine
the diameter of the botts.
M,: {trdotqx!
'2 Assume that the bolts are
finger tight in reamed
and ground holes.
or M,=ivdfut
I
(e.4s)
Solution
(iii) fti6^r7rr of Bolts Decide the number
of bolts Given kW: 20 n = 720 rpm
using the following guidelines: Forbolts, Su,:380 N/mm2 (/.r):3
N=3 for d<40mm D:t25mm N:4
N=4 for 40<d<l00mm Step I Permissible shear stress
i/:6 for 100<d< lg0mm ,S.,u :0.577 5,,:0.577 (3g0) : 219.26
Determine the diameter of the bolt by Eq. (9.a1). N/mm2
Rearranging the equation, E" = 219.26
r - ------
(fs) 3 = j3.09 N/mm'
,z 8M,
' nDNr (e.46) Step II Diameter of bolts
-
The torque transmitted by the shaft is given by,
where c is the permissible shear stress for the
bolt
material. _ 60xt}o(tw)60x 106(20)
The compressive stress ^,' 2En
in the bolt can be 2r(720)
determined by refering to Fig. 9.35 again. : 265 258.23 N-mm
crushing area of each bolt: drt
From Eq. (9.46),
crushing area of all bolts :1/d,l
8M' g(265258.23\
compressive force = Ndrto,
' _ nDNr
.12
n(t2l()(73.09)
D
torque=(Nd,to,1 x!* dr= 4.3 mm
366 Desicn of Machine Elements

E."*pt" 921 A rigid coupling is used to factor for the application is 1.5, i.e., the desigri
transmit 50 kW power at 300 rpm. There are six torque is 1.5 times of the rated torque. Selecr
bolts. The outer diameter of the flanges is 200 mm, suitable materials .for various parts of the coupling.
while the recess diameter is I50 mm. The cofficient design the coupling and specify the dimensions ol
ofJiiction between the flanges is 0. I 5. The bolts are its components.
made of .steel 45CB (Syt: 380 N/mm2) and thefactor
of saJbty is 3. Deterntine the diameter of the bolts,
Solution
Given kW:37.5 zr : 180 rpm
Assume that the bolts are fitted in large
clearance holes. design torque : 1.5 ( rated torque)

Step I Selectiott of materials

:Solution (i) The shafts are subjected to torsional shear
Given kW: 50 r: 300 rpm p:0.15 stress. On the basis of strength, plain carbon
For bolts, Sr,: 380 N/mm2 (fs):3 N: 6
steel of grade 40C8 (.tr,/ : 380 N/mm2) is
For flanges, Do:200 mm Dr: 150 mm used for the shaft. The factor of safety for
Step I Permissible tensile stress the shafts is assumed to be 2.5.

6.=J
s,, 3g0 126.67Nr'mm-
_ __. ) (ii) The keys and bolts are subjected to shear
'(fn 3
and compressive stresses. On the basis of
strength criterion, plain carbon steel ofgrade
Step ll Preload in bolts 30C8 (S// : 400 N/mm2) is selected for the
The torque transmitted by the shaft is given by, keys and the bolts. It is assumed that the
compressive yield strength is 150% of the
60 x l06(kw) 60 x lo615o) tensile yield strength. The factor of safery'
tv't 2nn
2.r (300) for the keys and the bolts is taken as 2.5.
: I 591 549.4 N-mm (iii) Flanges have complex shape and the easiest
l (R.l-R:) 2(too3-7sr) method to make the flanges is casting. Grel'
- __+_
R, -.---, -., =gg.l mm cast iron FG 200 (5,, : 200 Nimm2) is
' 3 6i - Ri\ 31loo, -is,) selected as the material for the flanges from
From Eq. (9.43), manufacturing considerations. It is assumed
A[' 159r 549'4 that ultimate shear strength is one half of the
P
' = ttN Rr- 0.15(6X88.1) = 2o 072.51N ultimate tensile strength. The factor of safefy
for the flanges is assumed as 6, since the
Step III Diameter of bolts permissible stress is based on the ultimate
Due to pre-load of 20 072.51 N, the bolts are sub- strength and not on the yield strength.
jected to tensile stresses.
/
Step Il Permissible stresses
-\ (i) Shqft
p, =l '! lalo.
' \4)' t.u 0'5S'/ 0.5(380)
,, 4P, 4(20072.51\ ,:' - - = 76N/mm2
ul - ( ls) ( [s) (2-s\
' fto, n(126.67)
(ii) Keys and bolts
dt: l4'2mm
S.," o'5'sr/ o'5(4oo)
= goN/mm:
E1aTPlg i.2a h is required to design a rigid ": (,ft)- ("ft)- (2.s)
type o.f .flange coupling to connect lwo shafts. The
srn, 1.5 ,sJ/ l'5(4oo)
input shaft transmits 37.5 kW power at 180 rpm to o' : -:--_. =
(,8)
- (2.s)
= 24oN/mm:
the output shaft thrcugh the coupling. The serttice Us)
 ,3t Flanges dr:2d:2 (60): 120 mm

f, o'5S,, o'5(2oo) lo: t.sd: l.s (60) : 90 mm

-=
' (f, =
(,s)- (6)
=t6.6jN/mm2 D :3d:3(60) : 180 mm
t: 0.5d = 0.5(60) : 30 mm
Step III Diameter of shafts
tt: 0.25d : 0.25(60) : l5 mm
Taliing into consideration the service factor of 1.5,
d,= l.Jfl:1.5(60):90 mm
Do: (4d +2tt) : 4(60) + 2(15) : 270 mm
the design torque is given by,
60 x 106(kw)
lvl,: x(1.5) The above dimensions of the flange are shown
' ^
zltn in Fig. 9.37.The thickness of recess is assumed as

: 60 x 106 (37.s) 0.s) 5 mm. The hub is treated as a hollow shaft

,"(180) subjected to torsional moment. From Eq. (9.44).
:2984155.18 N-mm
x@f - d4) r(2oa - 604 )

l6Mt t6 (2 984 I 55. I 8) "2232

-_
t- or 76: : 19 085 175.37 mma
ttd' nd3
.'. d = 58.48 or 60 mm ,=0, -l2o -6omm
'22
Step IV Dimensions of flnnges
The dimensions of the flanges are as follows,

270(&.

12A
4 holes
1 80 pcd

Fig.9.37 Dimensions of Flange with Recess

The torsional shear stress in the hub is given by, Step V Diameter of bolts
The diameter of the shaft is 60 mrn.
M
Mtl (2 e84 l 55.1 8) (60)
N/mm 40 < d < 100 rnm
' = 9.38
JJ (r9 085 175.31)
The number of bolts is 4.
r< 16.61N/mm2 From Eq. (9.46),
The shear stress in the flange at the junction of 8M, 8(2984155.18)
,2=;Dty,
the hub is determined by Eq. (9.45) t = nlt8Oyl+r*
2M, 2(298415s.18) dt-- 11.49 or l2 mm
L-
The compressive stress in the bolt is determined
trdi r ir (120)2 (30)
by Eq. (9.47).
= 4.40N/mm2 2M, 2(2 984 l5s.18)
r < 16.67 N/mm2 o,: frdrtD= (4X12X30X180)
The stresses in the flange are within limits.
= 23.03N/mm2
968 Dr"g" E M^rhirrt Hrr*ffi

o. < 240 N/mnr2 between axes cf the input and output shafts are
shown in Fig. 9.38. A flexible coupling can tolerate
Step W Dimensions of keys
0.5 mm of iateral or axial misalignment and 1.5'of
From Table 9.3, the standard cross-section of the
angular misaiignment.
flat key fbr a 60-mm diameter shaft is 18 x 11 mm.
The length of the key is equal to lr. Ar, lnput shaft Output shaft

The dimensions of
90 mm.
From Eq. (9.27),
the
t
t-' th-
90mm
flat key are 18 x 11 x
mffi
(a) Lateral misalignment

2M,
' dbt
T:J

z< 80 N/mm2
2(2984 ls5.r8)
(60) (l 8) (90)
2

ffi'b
(b)Axial misalignment

ffi@
From Eq. (9.28),
_ 4M, _ 4(2 984 155.18)
oc
dht (60x1lxeO)

= 200.95 N/mm2 (c) Angular misalignment

o"<240 N/mm2 Fig. 9.38 Types of Misalignment

The shear and compressive stresses induced in
the key are within permissible limits.
9.23 BUSHED-PIN FLEXIBLE COUPLING
Rigid coupling can be used only when there is
perfect alignment between the axes of two shafts
and the motion is free from vibrations and shocks.
In practice, it is impossible to obtain perfect
alignment of shafts. Misalignment exists due to the
fbllowing reasons:
(i) deflection ofshafts due to lateral forces;
(ii) error in shaft mounting due to manufacturing
tolerances;
(iii) use of two separately manufactured units such
as an electric motor and a worrn gear box; and
(iv) thermal expansion of the par1s.
If rigid coupling is used in such circumstances,
the misalignment causes excessive bearing reactions
resulting in vibrations and wear. To overcome this
problem, flexible coupiings are used. A flexible
coupling employs a flexibie elcment like a rubber
The construction of the flexible coupling is
shown in Fig. 9.39. It is similar to the rigid type of
flange coupling except for the provision of rubber
bush and pins in place of bolts. The coupiing
consists of two flanges, one keyed to the input
shaft and the other to the output shaft. The two
flanges are connected together by means of four or
six pins. At one end, the pin is fixed to the output
flange by means of a nut. The diameter'of the
pin is enlarged in the input flange where a rubber
bush is mounted over the pin. The rubber bush is
provided with brass lining at the inner surface. The
lining reduces the wear of the inner surface of the
rubber bush. Power is transmitted from the input
shaft to the input flange through the key. It is then
transmitted from the input flange to the pin through
the rubber bush. The pin then transmits the power
to the output flange by shear resistance. Finally,
power is transmitted from the output flange to the
output shaft through the key.
The bushed-pin type flexible coupling has

bush befween the driving and the driven flanges. following advantages:
This flexible rubber bush not only accommodates (i) It can tolerate 0.5 mm of lateral or axial
the misalignment but also absorbs shocks and misalignment and l.5o of angular misalign-
vibrations. The basic types of misalignment ment.
 r ii I It prevents transmission of shock from one (iv) It is simple in construction and easy to
shaft to the other and absorbs vibrations. assemble and dismantle. It is easy to design
, ru I It can be used for transmitting high torques. and manufacture the coupling.

Pin.
Brass
lining

Fig. 9.39 Flexible Coupling

The disadvantages of bushed-pin type flexible (11) lh= length of hub or effective iength of key
;q)upiing are as follows: 11,:7.5 d
ri) The cost of flexible coupling is moie than (iii) ,: pitch circle diameter of pins
that of rigid coupling due to additional parts. D:3d to 4d
rii) It requires more radial space compared with (iv) I :thickness ofoutput flange
other types of coupling.
Flerible bushed-pin type couplings are exten- t:0.5 d
lr in practice due to their advantages.
el.v used (v) tr : thickness ofprotective rim
The dimensions of the flanges of flexible tt:0.25 d
bu:hed-pin coupling are calculated by using stan- (vi) d' : diameter of pin
:.rrd proportions in terms of shaft diameter. There 0.5d
J __
rs a basic difference between the flanges of rigid ,JN
(f,
-
.nd flexible couplings. In rigid coupling, two flang-
where ly' is the number of pins and d is the shaft
:s are identical except for the provision of spigot
diameter.
md recess. In flexible coupling, the input flange
Other dimensions of flanges, viz., outer diameter
lcccrmmodates the rubber bushes of comparatively
or thickness ofthe input ffange are calculated after
,uge diameter than the diameter of the pins accom-
deciding the dimensions of the rubber bushes.
:nodated in the output flange as shown in Fig. 9.39.
In analysis of flexible coupling, it is assumed
Therefore, the diameter of holes and the thick-
that the power is transmitted by the shear resistance
-ess of the two flanges are ditTerent. The standard
of the pins. As the flange on the input shaft rotates,
::oportions for various dimensions of the flanges it exerts a force P on each rubber bush. The
rhour in Fig. 9.39 are as follows: resisting forces on the rubber bushes are shown
til do: outside diameter olhub in Fig. 9.40. Equating the couples due to resisting
d1,:2d force with the torque,
 370 Design of Machine Elements

Cross-section of The permissible intensity of pressure between

the rubber bush and the cast iron flange is usually
I N/mm2. The ratio of length to the outer diameter
for the rubber bush is usually assumed as l.
Therefore,
L=t (e.4e)
Db
and p,= 1N/mm2
Substituting the above relationship in Eq. (9.48),

Lt. =! D? DN (9.50)
'2u
Fig. 9.40 Resisting Forces in Rubber Buslrcs The outer diameter of the rubber bush is
obtained by the above equation.
M,:Px{rn (a) The pin is subjected to direct shear stress due
2 to the tbrce P. Refer to Fig. 9.39 again. The direct
where,
shear stress in the pin is given by,
M,: torque transmitted by the coupiing (Ti-mm)
P : force acting on each rubber bush or pin (N) a- l
P
(c)
2:pitch circle diameter of bushes or pins (mm)
(x")
N:number of bushes or pins
The projected area of the rubber bush is shown From (a) and (c),
in Fig.9.4l. The force P is equal to the product 8M,
of the projected area and the intensity of pressure. e=- (e.s l )
x ai orv
Therefore,
According to Indian standarde, the allowable
P:(Dnl)xp, (b)
shear stress for pins is 35 N/mm2.
where,
The pin is also subjected to bending moment and
Du: outer diameter of the bush (mm) the calculations ofbending stresses are explained in
lr: effective length of the bush in contact with the examples
the input flange (mm) The flanges of flexible bush coupling are made
p- : permissible intensity of pressure between of grey cast iron of grade FG 200. The pins are
the flange and the rubber bush (N/mm2) made of carbon steel. The recommended type
of fit between the shaft and the hub is H7-j7.
The maximum allowable peripheral speed of the
Pm coupling is 30 m/s.

""ffi,
Projected area
There are two important features of
bush coupling, which are different than rigid flange
coupling. They are as follows:
(i) As shown in Fig. 9.39, there is a gap or
flexible

clearance between the driving and driven

Fig. 9.41 Projected Area of Rubber Buslt
flanges of flexible bush coupling. This
gap is essential for taking care of angular
From, (a) and (b), misalignment between the two shafts. There
I is no such clearance between the flanges of
M,: D616 DN (9.48) rigid coupling. Therefore, rigid coupling
tp,
cannot tolerate any angular misalignment.
e IS 2693-1980: Specification for bush-type flexible coupling lbr power transmission.

L-
(ii) In case of rigid coupling, the torque is The torsional shear stress in the hub can be

transmitted by means of bolts' These bolts calculated by considering it as a hollow shaft

subjected to torsional moment M,' The inner and
are rnade of steel and resisting shear or tensile
stresses are high. Therefore' the diameter
of outlr diameters of the hub are d and d,,respectively'
the bolts or the pitch circle diameter of bolts The torsional shear stress in the hub is given by'
is comparatively less than that of flexible _ M,r
L-
bush coupling. On the other hand, the torque J
is transmitted by means of a force passing n(di-- d")
,-
through a rubber bush in case of flexible bush
coupling. The permissible pressure between
the rubber bush and cast iron flange is only I
,: 4L
2
juriction with
N/mm2. Therefore, the diameter of the pin or The shear stress in the flange at the
by Eq. (9'45)' It is given by'
pitch circle diameter of pins is comparatively the hub is calculated
iarge than that of rigid flange coupling' It I
shJuld be noted that for connecting shafts Ur'= di'tt
,n
of a particular size, flexible bush coupling (iii) Diametet of Pins The number of pins
eitheihas greater number of bolts (or pins)
than rigid coupling or has larger bolt circle
is usually 4 or 6. The diarneter of the pins is
calculated by the following empirical equation'
diameter than rigid coupling' This reduces
the force acting on the bolts (pins) and lowers ) --0.s d (e.s2)
bearing pressure on the rubber bush'
ul-
'
be '/N
Couplings, whether rigid or flexible' should Determtne the shear stress in the pins bY Eq.
located very near to the bearing on the shaft' This
(e.s 1).
reduces the bending moment acting on the shafts 8M,
due to coupling forces. This is the most satisfactory ' rd?DN
location of couPling.
The shear stress calculated by the above equation
the
9.24 DESIGN PROCEDURE FOR should be less than 35 N/mm2. Also, determine
bending stresses in the pins and confitm that it is
FLEXIBLE COUPLING
within limit.
The basic procedure for finding out the dimensions (ia) Dimensions of Bushes Calculate the outer
of bushed pin type flexible coupling consists of the diameter of the rubber bush by Eq' (9'50)' It is
following stePs: given by,
(i) Shaft Diametet Calculate the shaft diameter I
by using the lbllowing two equations:
M':to;nrv
lo6(kw) and ,= 16 Ml
60 x Calculate the effective length crf the rubber bush
M,:- ,n,- orrt by the following relationshiP,
(.ii) Dimensions of Flanges Calculate the Ir= Dn
dimensions of the ffanges by the follou'ing (a) Dimensions of Keys Determine the standard
empirical relationshiPs: cross-section of flat key frorn Table 9'3' The length
dh:2d of the key in each shaft is /;, . Therefore,
ln - l'5d I :ln
D :3dto4d With the above dimensions of thc key, check
t : 0.5d the shear and compressive stresses in the key by
\: 0.2sd Eqs (9.27) and (9.28) respectively'
 2M, 32Mh 32(2381.32x22.5)
' dbt
6b:---; or 152--
ftdl rdt,1
4M,
d, = 15.33 mm (ii)
' dht

!""-pt" ggg A fiexible coupling, illustrated

in Fig. 9.39, is used to transmit 15 kW power at
100 rpm. There are six pins and their pitch circle
diameter is 200 mm. The effective length of the bush
(l), the gap between two flanges and the length of
the pin in contact with the right hand
flange are
35, 5 and 23 mm respectively. The permissible
shear and bending stresses for the pin are 35 and
I 5 2 N/mm2 respectively. Calculate:
(i) pin diameter by shear consideration; and
(ii) pin diameter by bending consideration.
Solution
>l d l+
Given kW: 15 n = 100 rpm
For pins, z: 35 N/mmz on:152 N/mm2 Fig.9.42
N:6 D:200mm
Step I Pin diameter by shear consideration !."-pt" 921 h is required to design a bushed-
pin typeflexible coupling to connect the output shaft
tt
60 x l06
_ _
(kw) 60 x 106(ls) of an electric motor to the shaft of a centrifugal
' 2nn 2r (t00) pump. The motor delivers 20 kW power at 720 rpm.
The starting torque of the motor can be assumed to
= I 432 394.49 N-mm
be 150% of the rated torque. Design the coupling
From Eq. (9.51),
and specify the dimensions of its components.
8 M, 8(t 432 394.49')
-------;--------=-- Solution
n d: DN xd,')1zoo11oS
Given kW = 20 n:720 rpm
d,:9.32mm (i) design torque: 1.5 (rated torque)

Step II Pin dinmeter by bending consideration Step I Selection of materials

The force acting on each bush P and torque M, are
(i) The shafts are subjected to torsional shear
related by the following expression, stress. On the basis of strength, plain carbon
steel of grade 40C8 (Sr, = 380 N/mm2) is
M.:P*2tlr
'2 used for the shafts. The factor of safety for
the shaft is assumed as 2.
.D 2M, 2fi, 432 394.49\
-#=2387.32N (ii) The keys are subjected to shear and
DN (200x6) compressive stresses. The pins are subjected
to shear and bending stresses. On the basis
It is assumed that the force p is uniformly of strength criterion, plain carbon steel of
distributed over the bush length of 35 mm as shown
grade 30C8 (Su,:400 N/mm2) is selected for
inFig.9.42. At the section-XX,
the keys and ihe pins. The factor of safety
for the keys and the pins is taken as 2. It is
Mu= P['.f]= (2387.32x22.5) N-mm assumed that the compressive yield strength
is 150% of the tensile yield shength.
 Shafts, KeYs and CouPlings 373
-
(iii) Flanges have complicated shape and the D:4d:4(30) : 120 mm
economic method to make the flanges t:O.sd:0.5(30) - l5 mm
is casting. Grey cast iron of grade FG t\:0.25d:0.25(30):7.5 or 8 mm
200 (S,,r : 200 N/mm2) is selected as the The hub is treated as a hollow cylinder subjected
material for the flanges from manufacturing to torsional moment.
considerations. It is
assumed that the From Eq. (9.44),
ultimate shear strength is one-half of the , n@1,- d4l ;r(oo4-304)
ultimate tensile strength. The factor of safety J: 32-: n
for the flanges is assumed as 6, since the
permissible stress is based on the ultimate
: I lg2823.46mma
strength and not on the yield strength. do 60
y:J-!J-='"-30mm
Step Il Permissible sttesses
22
(i) Shaft The torsional shear stress in the hub is given by,
S,l (397 887.36) (30)
0'5(380)
__ M,, _
0'5'S.v/
,- = t0.01Nimm2
(A)- (fs)- (2)
=95N/mm2 ' .t i 1e2823.46)
(ii) Keys t < 16.67 Nlmm2
to'' 0'5S" 0'5(400) The shear stress in the flange at the junction of
.: (F)-
' (A)- (2\
= 100 N/mm2
the hub is determined by Eq. (9.45). It is given by,

S,o l'sE'r 1'5(400) 2(3e7 887.36)

^-
o,: =
- - =300N/mm2 --2M, -
I - -)
= 4.69N/mm2
, fr) (,fr) (2) 7td; t n (60)20s)
(iii) Pins t <16.67 N/mm2
r: 35 N/rnm2 (As Per IS 2693l-1980) The stresses in the flange are within limit.
t'" 4oo lr
- - - 2 = 2oo N/mm2
o': Step Diameter of Pirts
\fsr- The number of pins is selected as 6.
(iv) Flanges l/: 6

,- s,, o'5s,, o'5(2oo) From Eq. (9.52), the diameter of the pin is given by,
' (A)= (/s) - 6 =16.6'rNrmm2
)_ 0.5 d 0.5(30)
= 6.72 or 7 mm
Step Ill Diameter of shafts
of
'
u1 -:-
Jlr Jo
The starting torque of the motor is 150% the
The shear stress in the Pin is calculated by Eq.
rated torque. Therefore,
(e.51).
6o x l06tkWl
Ia,:----
' _ x(1.5) 8M, _ 8(397 887.36)= 28.72Nimm2
zftn --
T:_
"
60x t06(20) (1.5) :397 r dl oN n Q\2 (20\16\
887-36 N-mm
2 tt (120) r< 35 N/mm2
16M. t6(397 887.36) Tire clesign is safe on the basis ofshear strength.
t:--! or 95= 'Ihe bending stresses in the pin will be determined
Tidt nd3
d:27.13 or 30 mm at a later stage. after deciding the dimensions of the
rubber bushes.
Step lV Dimensions of flnnges
The dimensions of flanges are as follows: StepW Dimensions of bushes
dh:2d:2(30) = 60 mn The permissible intensity of pressure between the
th:1.sd: 1.5(30) : 45 mm rubber bush and the cast iron flange is taken as
I N/mm?. The ratio of effective length to diameter diameter pin is not sufficient to withstand bending
for the rubber bush is assumed as l. strbsses and the minimum diameter of the pin
Frorn Eq. (9.50), should be l2 mm. Therefore, bending becomes the
987.36) criterion of design.
nz _2M, _2(397
"b- DN - (trox6) As shown in Fig. 9.43, the diameter of the pin
should be enlarged at the section-W n order to fix
or Du = 33.25 ot 35 mm
the pin in the driven flange. This enlarged diameter
Dt : lu:35 mm is taken as (12 + 6) or 18 mm. Other dimensions
Step WI Bending stresses in pins of the pin and the bush are shown in Fig. 9.2M. The
As shown in Fig. 9.40, the force P acting on each thickness of the brass lining is 2 mm. Therefore, the
pin depends upon the torque and the relationship is
given by,
M,:PxlxN
2
,,qW+.KD
Therefore.

P: 2M.
'
DN
2(397 887.36\
(120X6)
=1105.24N
M12 x 1.75
'The subassembly of the bush and the pin is
shown in Fig. 9.43.lt is assumed that the force P
is uniformly distributed over 35 mm of effective
length (/r) of the bush. At the section-XX, 30+{
F-35--NsF
r-;1 l- Fig.9.44 Dimensions of Buslt and Pin

inner diameter of the rubber bush is (18 + 4) or 22

mm. The minimum thickness of the rubber bush is
t
d1
usually 10 mm. Therefore, the outside diameter of the
rubber bush is (22 + 20) or 42 mm. The dimensions of
T the driving flange are shown in Fig. 9.45.
StepWI Dimensions of keys
From Table 9.3, the standard cross-section ofa flat
sunk key for 30 mm diameter is 8 x 7 mm. The
Fi9.9.43 Bearing Moment at Section XX length of the key is equal to /0.

u," = p( s*I) = nos.24(t*I) l:lh=45mm

\. 2) 2) \ The dimensions of the flat key are 8 x7x 45
= (1105.24 x22.5) N-mm mm.
32 M h 32(1105.24x22.51 From Eq. (9.27),
o^: ---=: or 200: -_--____:-
' itdi ndi , : rr, _ 2(397 887.36) kj8.42N/mm:
=
4 :10.82 or 12 mm dht (30x7x4s)
In the initial stages, the diameter of the pin was ?< l00N/mm2
calculated as 7 mm by using empirical formula. From Eq. (9.28),
It was sufficient to keep the maximum shear
stress within limit. The shear stress induced in the o-(=", -2(397887'36) =l68.42Nimm2
pin was 28.72 N/mm2 and the limiting stress was dht(30)(7x4s)
35 N/mm2. However, it is observed that a 7 mm q < 300 N/mm2
 Shafts, KeVs and CouPlings 375

8ffi
Fig. 9.45 Dimensions ofDrioingFlange

The shear and compressive stresses induced in Forcoils, Sr,:220 N/mm2 (fs):2.5
the key are within permissible limits and the design R:30 mm
is safe. cross-section:4 x 2 mm

Step I Permissible shear stress

I."*Pt" 9.r5 A multifiex 720
fiexible coup.ling,
rPm, is shown S"r: 0.577 Sr,:0'577 (220): 12694 N/mm2
ffi{7s kw power at
in Fig. 9.46. It consists of two flanges keyed to the
,:" t", = 126'94 = 50.78 N/mm2
driviig and driven shafts and connected together
by *ins of a number of coils. The coils are placed
(F) 2.s

in the slots on the periphery of the flanges at a Step Il Number of coils

distance of j0 mm from the axes of the shafts' The The torque transmitted by the coupling is given by,
coils hqve a rectangular cross-section 4 x 2 mm 60xl06(kw) 60xl06(15)
and are made of stiel FeE 220 (Sr, = 220 N/mm2)'
rvrt
2nn 2n (720)
The factor of safety is 2.5. Calculate the required : 198 943.68 N-mm
number of coils.
Each coil subjected to double shear and the
is
Coil
expression for torque is derived in the following way'
Shear resistance of one coll:2Ar
:
Shear resistance of N coils 2At N
Resisting torque = Mt:2At NR (a)
where,
I: cross-sectional area of wire for the coil
N= number of coils
R : radial distance ofcoil from the axis ofthe
shaft
Reananging the terms of Eq. (a),
Fig.9.46 Multifux CouPling
]\r- M.
r
r98 943.68
2ArR 2(4 x 2X50.78X30)
Solution
Civen kW= l5 n=720rqm = 8.19 or 9 coils