MECHANICAL COUPLINGS

I. Introduction

Mechanical coupling is a fundamental concept in the field of mechanical engineering that

involves the connection of two or more components in a mechanical system to transmit motion,

force, or power. Couplings are essential for the efficient operation and synchronization of

various machinery and mechanisms.

II. Importance of Mechanical Coupling

Mechanical coupling is of paramount importance in the field of mechanical engineering and

plays a crucial role in the efficient and reliable operation of various machines and systems. Here

are some key reasons why mechanical coupling is significant:

Power Transmission: Mechanical couplings are primarily used to transmit power from one

component to another within a mechanical system. They enable the transfer of torque or force

from a power source, such as an electric motor or engine, to driven components like pumps, fans,

conveyors, and generators. By providing a secure and efficient power transfer mechanism,

couplings ensure that machines and systems can perform their intended functions effectively.

Motion Synchronization: In many mechanical systems, different components need to operate in

synchronization to achieve the desired output. Mechanical couplings allow for the precise

coordination of rotational or linear motion between interconnected parts. For example, in

complex machinery like robotics or CNC machines, couplings help synchronize the movements

of multiple axes, ensuring precise positioning, machining, or assembly processes.

Compensation for Misalignment: In practical applications, it is common for mechanical

components to be slightly misaligned due to manufacturing tolerances, installation errors, or

system dynamics. Mechanical couplings can accommodate and compensate for these

misalignments. They can handle angular, parallel, or axial misalignments, thereby reducing

stresses and minimizing wear on connected components. By allowing flexibility in the system,

couplings help maintain smooth operation and extend the service life of machinery.

Damping and Vibration Isolation: Mechanical couplings can provide damping and vibration

isolation characteristics, which are crucial in many applications. Vibrations and shocks generated

during operation can cause excessive stress, noise, and even damage to the machinery. By

incorporating flexible elements, such as elastomers or springs, into the coupling design,

vibrations can be attenuated and isolated, resulting in improved system performance, reduced

wear, and enhanced operator comfort.

Maintenance and Serviceability: Mechanical couplings offer convenience in system assembly,

maintenance, and repair. They allow for the easy disconnection and reconnection of components,

enabling efficient inspection, replacement, or repair of individual parts without extensive

disassembly of the entire system. This feature is particularly beneficial in industries where

downtime is costly, such as manufacturing, power generation, and transportation.

System Adaptability and Flexibility: Couplings provide flexibility and adaptability in mechanical

systems. They allow for the interchangeability of components and facilitate system upgrades or
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modifications without major redesign. By selecting appropriate couplings, engineers can

accommodate changes in power requirements, operating conditions, or component replacements,

resulting in improved system versatility and scalability.

Overload Protection: In certain situations, mechanical couplings can act as overload protection

devices. They are designed to fail or disengage in case of excessive torque or force, thereby

preventing damage to expensive components or machinery. This feature helps safeguard

equipment and ensures that the system remains intact even under unexpected or extreme

operating conditions.

III. Types of Mechanical Couplings

There are various types of mechanical couplings available; each designed to suit different

applications and operating conditions.

● Sleeve or Muff Couplings

Sleeve or muff couplings are the simplest type of mechanical couplings. They consist of a hollow

cylinder or sleeve with keyways on the inner surface that fits over the ends of two shafts. A key

is used to transmit torque between the shafts and the sleeve, ensuring a secure and precise

connection. Sleeve couplings are relatively easy to install and are commonly used in low-speed

applications.
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Figure 1: Sleeve or Muff Couplings

● Flange Couplings

Flange couplings are widely used in high-speed applications and where the two shafts are not

axially aligned. They consist of two flanges that are bolted together, with each flange attached to

a shaft. Flange couplings can transmit high torque and are suitable for applications where the

shafts need to be disconnected frequently.

Figure 2: Flange Couplings

● Universal Joints

Universal joints, also known as Cardan joints, are used to transmit torque between two shafts that

are not in a straight line. They consist of two yokes that are connected by a cross-shaped

member. The yokes are attached to the shafts, and the cross transfers torque from one shaft to the
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other while allowing for angular misalignment. Universal joints are commonly used in drive

shafts for vehicles, heavy equipment, and industrial machinery.

● Gear Couplings

Gear couplings are designed to transmit high torque between two shafts that are not perfectly

aligned. They consist of two hubs with external teeth that mesh together, transmitting torque

between the shafts. Gear couplings are relatively compact and can accommodate angular,

parallel, and axial misalignments. They are commonly used in heavy-duty applications such as

pumps, turbines, and compressors.

● Disc Couplings

Disc couplings are flexible couplings that can transmit high torque and accommodate angular

and axial misalignments. They consist of two hubs with sets of thin metal discs arranged

alternately and bolted together. The discs allow for angular and axial misalignments, and the

metal material provides damping characteristics. Disc couplings are commonly used in

applications such as turbines, compressors, and generators.

● Grid Couplings

Grid couplings are used to transmit high torque and accommodate angular and axial

misalignments. They consist of two hubs connected by a flexible grid made of metal or plastic.

The grid provides flexibility while transmitting torque and it can compensate for misalignment.

Grid couplings are commonly used in pumps, conveyors, and compressors.

● Jaw Couplings
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Jaw couplings are flexible couplings that can accommodate angular and axial misalignments.

They consist of two hubs with sets of interlocking jaws that mesh together, transmitting torque

between the shafts. The jaws provide flexibility while transmitting torque and can compensate

for misalignment. Jaw couplings are commonly used in pumps, compressors, and machine tools.

III. Factors to Consider in Coupling Selection

Selecting the right coupling is crucial for the efficient and reliable operation of mechanical

systems. There are several factors to consider when choosing a coupling for a specific

application. Here are some important factors to take into account during the coupling selection

process:

● Torque and Power Requirements

Determine the maximum torque and power that the coupling needs to transmit without failure or

slippage. Consider both the peak and continuous torque values. Ensure that the selected coupling

has a torque rating that exceeds the system requirements to provide a safety margin.

● Misalignment Compensation

Evaluate the degree and type of misalignment present in the system. Consider angular

misalignment, parallel misalignment, and axial misalignment. Choose a coupling that can

accommodate the anticipated misalignment to prevent excessive stresses on the system

components.

● Operating Conditions

Assess the operating environment, including temperature, humidity, presence of contaminants,

and exposure to corrosive substances. Consider factors such as vibrations, shocks, and dynamic
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loads that the coupling may experience during operation. Select a coupling that can withstand the

anticipated operating conditions without compromising performance or longevity.

● Speed and RPM Range

Determine the rotational speed requirements of the coupling. Consider the maximum and

minimum RPM (revolutions per minute) range that the coupling needs to operate within. Ensure

that the selected coupling is capable of handling the specified speed range without exceeding its

critical speed or causing excessive wear.

● Space Limitations

Evaluate the available space for coupling installation. Consider the dimensions and physical

characteristics of the coupling to ensure it can fit within the allocated space. Take into account

any restrictions on coupling length, diameter, or shaft clearance.

● Installation and Maintenance

Assess the ease of installation and alignment of the coupling. Consider the accessibility for

coupling assembly and disassembly during maintenance and repairs. Evaluate the required

lubrication and maintenance intervals for the selected coupling type.

● Cost and Availability

Consider the cost-effectiveness of the coupling in relation to the system's budget and

requirements.

Assess the availability and lead time of the selected coupling from suppliers. Evaluate the

coupling's overall lifecycle cost, including maintenance, replacement, and downtime

considerations.
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● Specific Application Requirements

Take into account any specific application requirements, such as electrical insulation, corrosion

resistance, or compliance with industry standards or regulations. Consider any unique

characteristics of the application that may necessitate the use of a specialized coupling type.

IV. Design Considerations for Mechanical Couplings

When designing mechanical couplings, several factors need to be taken into consideration to

ensure optimal performance, reliability, and longevity. Here are some important design

considerations for mechanical couplings:

● Material Selection

Selecting the appropriate material is crucial to ensure the coupling's strength, durability, and

resistance to wear and corrosion. Consider the mechanical properties of the material, such as

strength, stiffness, and fatigue resistance, in relation to the application's torque and power

requirements. Evaluate the compatibility of the material with the operating environment,

including temperature, humidity, chemicals, and potential corrosive substances.

● Size and Geometry

Determine the appropriate size and dimensions of the coupling based on the application

requirements and available space. Consider the shaft sizes and the desired clearance between the

coupling and adjacent components. Ensure that the coupling dimensions and geometry do not

interfere with the surrounding machinery and allow for proper installation, alignment, and

operation.

● Load Distribution
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Design the coupling to distribute the transmitted load evenly between the connected components.

Consider the coupling's structural design, including the shape, thickness, and reinforcement

features, to minimize stress concentrations and prevent premature failure. Ensure that the

coupling's load capacity is sufficient to handle the anticipated torque, shock loads, and dynamic

forces without exceeding its fatigue limits.

● Damping and Resonance

Consider the damping characteristics required for the application. Incorporate appropriate

damping elements, such as elastomers or springs, to reduce vibrations and dampen resonant

frequencies.

Analyze the system dynamics to avoid coupling designs that could introduce or amplify resonant

vibrations, which can lead to excessive wear and component failure.

● Lubrication and maintenance

Determine the lubrication requirements of the coupling and ensure proper lubrication access

points. Incorporate features that allow for easy maintenance, such as grease or oil fittings,

inspection ports, and disassembly/reassembly procedures. Consider the coupling's expected

service life and design it for longevity, minimizing the need for frequent maintenance or

replacement.

● Coupling type and flexibility

Choose the appropriate coupling type based on the application's torque, misalignment, and

operating conditions. Evaluate the flexibility requirements of the coupling to accommodate

potential misalignments between the connected shafts. Consider the coupling's ability to
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compensate for angular, parallel, and axial misalignments while maintaining efficient power

transmission.

● Manufacturing and quality control

Ensure that the coupling design is manufacturable within acceptable tolerances and consistent

quality. Perform thorough quality control inspections during manufacturing to verify

dimensional accuracy, material integrity, and functional performance.

Comply with relevant industry standards and regulations to ensure the coupling's reliability and

safety.

● Testing and Validation

Conduct testing and validation procedures to ensure that the coupling design meets the desired

performance criteria. Perform structural analysis, finite element analysis (FEA), or other

simulation techniques to evaluate the coupling's mechanical behavior and performance under

various operating conditions. Validate the coupling's performance through prototype testing,

including torque capacity, misalignment compensation, fatigue life, and vibration damping

characteristics. By considering these design factors, engineers can develop mechanical couplings

that are optimized for their intended applications, ensuring reliable and efficient power

transmission, proper load distribution, and extended service life. It is crucial to collaborate with

experienced coupling manufacturers, utilize engineering tools, and perform thorough testing to

validate the coupling's design before implementation in real-world applications.

V. Requirements of a Good Shaft Coupling

A good shaft coupling should have the following requirements:

1. It should be easy to connect or disconnect.

2. It should transmit the full power from one shaft to the other shaft without losses.
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3. It should hold the shafts in perfect alignment.

4. It should reduce the transmission of shock loads from one shaft to another shaft.

5. It should have no projecting parts.

VI. Numerical examples

Example 1

Design a muff coupling is used to connect two steel shafts transmitting 40kW at 350 rpm. The

material for the shafts and key is plain carbon steel for which allowable shear and crushing

stresses are 40 MPa and 80 MPa, respectively. The material for the muff is cast iron for which

the allowable shear stress may be assumed as 15 MPa.

Given

P =40 kW

N =350 rpm

τ s=40 MPa

σ cs=80 MPa

τ c =15 MPa

1. Design for shaft

60 P
T=
2 πN
3
60 ×40 × 10
T=
2 π ×350

T =1100 N −m = 1100× 103 N −mm

3 π 3
1100× 10 = ×τ ×d
16 s
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3 π 3
1100× 10 = × 40 ×d
16
3
3 1100× 10
d=
7.86

d=52 say 55

2. Design of sleeve

D = 2d + 13mm

D = 123 mm

Length of the muff

L = 3.5d = 3.5 x 55

L = 192.5 say 195 mm

Since the muff is considered to be a hollow shaft, therefore the torque transmitted (T)

( )
4 4
3 π D −d
1100× 10 = × τc ×
16 D

( )
4 4
3 π 125 −55
1100× 10 = × τc ×
16 125

N
τ c =2.97 2
mm

Since the induced shear stress of the muff is less than the permissible shear stress, the design of

the muff is safe.

3. Design of key

From design table, a shaft of 55mm diameter requires a key with width = 18 mm

Since the crushing stress is twice the shearing stress, a square key is required for the design.

Hence, w = t = 18 mm

The length of the key in each muff is l = L/2 = 97.5 mm

Let us now check the induced shear and crushing stresses on the key
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Induced shear stress on the key

3 d
1100 × 10 =l ×w × τ ×
2

3 55
1100× 10 =97.5 ×18 × τ ×
2

N
τ =22.8 2
mm

Induced crushing stress on the key

3 t d
1100× 10 =l × ×σ cs ×
2 2

3 18 55
1100× 10 =97.5 × × σ cs ×
2 2

N
σ cs=45.6 2
mm

Since the induced shear and crushing stresses on the key are less than the permissible stresses,

the design is safe.

Example 2

Design a clamp coupling to transmit 30kW at 100 rpm. The allowable shear stress for the shaft

and key is 40MPa and the number of bolts connecting the two halves are six. The permissible

tensile stress for the bolts is 70MPa. The coefficient of friction between the muff and the shaft

surface is 0.3.

Given

P = 30 kW, N = 100 rpm; τ =40 MPa ; n = 6; σ t=70 MPa; μ=0.3

1. Design of shaft

60 P
T=
2 πN
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3
30× 10 ×60
T=
2 π ×100
3
T =2865 N−m=2865 ×10 N −mm

Torque transmitted by shaft

π 3
T= × τ ×d
16

3 π 3
2865 ×10 = × 40× d
16

d=71.4 say 75 mm

2. Design of muff

D = 2d + 13 mm

D = 2(75) + 13

D = 163 say 165 mm

Total length of the muff

L =3.5d = 3.5(75) = 262.5 mm

3. Design for key

From Table 1

Width of key, w = 22m

Thickness of, t = 14 mm

l = L/2

Length of the key = L/2 = (262.5/2) mm

4. Design for bolts

Let d b = root or core diameter of bolt

The torque transmitted (T)

π 2
T= × μ ( d b ) σ t ×n × d
16
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6 π 2
2865 ×10 = ×0.3 ( d b ) 70 × 6 ×75
16

d b = 22mm

Table 1. Proportions of standard parallel tapered and Gib head keys

Example 3

Design a cast iron protective type of flange coupling to transmit 15 kW at 900 rpm from an

electric motor to a compressor. The service factor is 1.35. Use the following permissible stresses

for the design:

Shear stress for shaft, bolt and key material = 40 MPa

Crushing stress for bolt and key = 80 MPa

Shear stress for cast iron = 8 MPa

Given
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P = 15kW; N = 900 rpm; service factor = 1.35;

τ s=τ b=τ k =40 MPa ; σ cb=σ ck =80 MPa ; τ c =8 MPa

1. Design for hub

60 P
T=
2 πN
2
60 ×15 ×10
T= =159.13 N−m
2 π ×900

Since the service factor is 1.35, therefore the maximum torque transmitted by the shaft
3
T max=1.35 × 159.13=215 N −m=215 ×10 N−m

The torque transmitted by the shaft (T),

3 π 3 π 3
215 ×10 = × τ s ×d = × 40 × d
16 16

d = 30.1 say 35 mm

Outer diameter of the hub

D =2d = 2 x 35 = 70 mm

Length of hub

L = 1.5d = 1.5 x 35 = 52.5 mm

The maximum torque transmitted (Tmax)

( )
4 4
3 π D −d
215 ×10 = × τc ×
16 D

( )
4 4
π3 70 −35
215 ×10 = × τ c × =63147 τ c
16 70

τ c =3.4 MPa

2. Design for key

Since the crushing stress for the key material is twice its shear stress, therefore a square key may

be used. From Table 1, we find that for a shaft of 35 mm diameter,

Width of key, w = 12 mm

Thickness of key, t = w = 12 mm

The length of key (l) is taken equal to the length of hub.

∴ l = L = 52.5 mm

Considering the key in shearing, the maximum torque transmitted (Tmax),

3 d 35
215 ×10 =l× w × τ k × =52.5× 12× τ k × =11025 τ k
2 2

τ k =19.5 MPa

Considering the key in crushing, the maximum torque transmitted (Tmax),

3 t d 12 35
215 ×10 =l× × σ ck × =52.5 × × σ ck × =5512.5 σ ck
2 2 2 2

σ ck =39 MPa

3. Design for flange

The thickness of flange (tf) is taken as 0.5d.

h t f =0.5 d=0.5 × 35=17.5 mm

The maximum torque transmitted (Tmax)

τ c =1.6 MPa

Since the induced shear stress in the flange is less than 8 MPa, therefore the design of flange is

safe.

4. Design for bolts

Let d1 = Nominal diameter of bolts.

Since the diameter of the shaft is 35 mm, therefore let us take the number of bolts,

n=3

and pitch circle diameter of bolts,

D1 = 3d = 3 × 35 = 105 mm

and pitch circle diameter of bolts,

The bolts are subjected to shear stress due to the torque transmitted. We know that the maximum

torque transmitted (Tmax)

3 π 2 D1
215 ×10 = × ( d 1 ) ×τ b × n×
4 2

3 π 2 105
215 ×10 = × ( d 1 ) ×40 × 3×
4 2

d1 = 6.6mm

Assuming coarse threads, the nearest standard size of bolt is M8.

Other proportions of the flange are taken as follows:

Outer diameter of the flange,

D2 = 4 d = 4 × 35 = 140 mm

Thickness of the protective circumferential flange,

tp = 0.25 d = 0.25 × 35 = 8.75 say 10 mm Ans.