Lecture 1: Design of Rigid (Flange) Couplings

Course: Machine Design

Prepared by: Prof. Ramadan Ibrahim El-Soeudy
Faculty of Engineering – Suez Canal University

1. Introduction

A mechanical coupling connects two shafts to transmit torque and motion.

Rigid couplings are used when shafts are perfectly aligned and no flexibility is required.
They ensure a solid mechanical connection between driving and driven shafts.

Applications:

• Pumps and compressors

• Machine tools
• Gearboxes and conveyors

2. Functions of Couplings

1. Transmit torque and power between shafts.

2. Maintain alignment and position.
3. Allow easy assembly/disassembly of connected parts.
4. Provide mechanical safety (some couplings act as torque limiters).

3. Types of Rigid Couplings

1. Sleeve (Muff) Coupling

o Simple hollow cylindrical sleeve.
o Easy to manufacture, used for small power.
2. Split Muff (Clamp) Coupling
o Two halves joined with bolts; easy to assemble.
3. Flange Coupling
o Two flanges keyed to the shafts and bolted together.
o Used for heavy-duty applications.
4. Design of Flange Coupling

4.1. Design Steps

1. Determine given data

o Power 𝑃(kW)
o Speed 𝑁(rpm)
o Material properties (for shaft, key, bolts, flange)
2. Calculate torque transmitted:

9550 × 𝑃
𝑇= (N\cdotpm)
𝑁

3. Design the shaft:

o Assume shaft material and allowable shear stress 𝜏𝑠 .
o Shaft torque capacity:

𝜋
𝑇= × 𝜏𝑠 × 𝑑 3
16

• Solve for shaft diameter 𝑑.

 4. Design the flange bolts:
o Number of bolts = 4, 6, or 8 (commonly 4 or 6).
o Bolts arranged on a pitch circle of diameter 𝐷𝑏 .
o Shear load per bolt:

2𝑇
𝐹𝑏 =
𝑛 × 𝐷𝑏

• Bolt shear stress check:

𝐹𝑏
𝜏𝑏 = 𝜋 ≤ 𝜏𝑏,𝑎𝑙𝑙𝑜𝑤
2
𝑑 𝑏
4

5. Design the flange:

o Flange thickness 𝑡𝑓 ≈ 0.5𝑑
o Hub diameter 𝐷ℎ ≈ 1.5𝑑
o Hub length 𝐿ℎ ≈ 1.25𝑑
6. Design the key:
o Transmits torque between shaft and flange hub.
o Shear stress in key:

2𝑇
𝜏𝑘 =
𝑑×𝐿×𝑤

• Crushing stress:

4𝑇
𝜎𝑐 =
𝑑×𝐿×𝑡

5. Example Problem

Given:

• Power 𝑃 = 20 kW
• Speed 𝑁 = 1000 rpm
• Shaft material: C45 steel, 𝜏𝑎𝑙𝑙𝑜𝑤 = 40 MPa
• Bolt material: Mild steel, 𝜏𝑏,𝑎𝑙𝑙𝑜𝑤 = 25 MPa
• Use 4 bolts on pitch circle diameter 𝐷𝑏 = 100 mm

Step 1: Calculate torque

9550 × 𝑃 9550 × 20
𝑇= = = 191 N\cdotpm
𝑁 1000
Step 2: Shaft design

𝜋
𝑇= × 𝜏𝑠 × 𝑑 3
16
𝜋
191 × 103 = × 40 × 𝑑 3
16
3 191 × 103 × 16
𝑑=√ = 21.2 mm
𝜋 × 40

Select d = 25 mm (standard).

Step 3: Bolt design

2𝑇 2 × 191 × 103
𝐹𝑏 = = = 955 N
𝑛𝐷𝑏 4 × 100
𝐹𝑏
𝜏𝑏 = 𝜋
2
4 𝑑𝑏

Assume 𝑑𝑏 = 10 mm:

955
𝜏𝑏 = = 12.2 MPa < 25 MPa ✓ Safe
0.785 × 102

Step 4: Flange dimensions

𝑡𝑓 = 0.5𝑑 = 0.5 × 25 = 12.5 mm

𝐷ℎ = 1.5𝑑 = 37.5 mm
𝐿ℎ = 1.25𝑑 = 31.25 mm

Step 5: Key design

Standard key for 25 mm shaft → 𝑤 = 8 mm, 𝑡 = 7 mm.

Let 𝐿 = 31.25 mm.

Check stresses:

2𝑇 2 × 191 × 103
𝜏𝑘 = = = 61.1 MPa
𝑑 × 𝐿 × 𝑤 25 × 31.25 × 8
4𝑇 4 × 191 × 103
𝜎𝑐 = = = 139.5 MPa
𝑑 × 𝐿 × 𝑡 25 × 31.25 × 7
Use key material with allowable stresses
𝜏𝑘,𝑎𝑙𝑙𝑜𝑤 = 80 MPa, 𝜎𝑐,𝑎𝑙𝑙𝑜𝑤 = 160 MPa→ Safe.

6. Final Design Summary

Component Symbol Dimension (mm) Check

Shaft diameter d 25 Safe
Bolt diameter d_b 10 Safe
Flange thickness t_f 12.5 –
Hub diameter D_h 37.5 –
Hub length L_h 31.25 –
Key 8 × 7 × 31.25 –

7. Notes

• Rigid couplings cannot accommodate misalignment.

• Always check both bolt shear and key stresses.
• For higher torque, increase the bolt circle diameter or number of bolts.

8. Review Questions

1. What are the advantages and limitations of rigid couplings?

2. How is torque transmitted in a flange coupling?
3. Why is the bolt circle diameter larger than the shaft diameter?
4. Explain the difference between sleeve and split muff couplings.
5. Design a flange coupling for 30 kW at 1500 rpm using 6 bolts.

Lecture 2: Design of Flexible Couplings

Course: Machine Design
Prepared by: Prof. Ramadan Ibrahim El-Soeudy
*Faculty of Engineering – Suez Canal University

1. Introduction

In many machines, shafts are not perfectly aligned, or slight misalignment occurs due to manufacturing
tolerances, shaft deflection, or thermal expansion.
Flexible couplings are used to transmit torque while accommodating small angular, axial, or parallel
misalignments between shafts.

Examples of use:

• Electric motor to pump

• Turbine to generator
• Compressor drives

2. Functions of Flexible Couplings

1. Transmit torque and motion between shafts.

2. Compensate for small misalignments (angular, axial, parallel).
3. Absorb vibrations and shocks, protecting connected machines.
4. Reduce maintenance and wear in rotating assemblies.

3. Types of Flexible Couplings

Type Description Applications

Bushed Pin Type Pins with rubber or leather bushes provide flexibility. Motors, compressors
Central disc slides between two flanges; accommodates
Oldham Coupling Light-duty machinery
parallel misalignment.
Universal (Hooke’s) Propeller shafts, steering
Allows angular motion between intersecting shafts.
Joint columns
 Type Description Applications
Teeth on hubs engage internal teeth in sleeve; for high
Gear Coupling Heavy-duty drives
torque with flexibility.

4. Design of Bushed Pin Flexible Coupling

The bushed pin type coupling is the most common flexible coupling in mechanical design courses.

It consists of:

• Two flanges, one with pins and the other with corresponding holes.
• Each pin carries a rubber or leather bush, providing cushioning.

5. Design Assumptions

• Power and speed are known.

• Shaft diameter is determined from torque and allowable shear stress.
• Torque is transmitted by shear and crushing through the rubber bushes and pins.

6. Design Procedure

Step 1: Calculate Torque

9550 × 𝑃
𝑇=
𝑁

Step 2: Determine Shaft Diameter

𝜋
𝑇= 𝜏 𝑑3
16 𝑠

Step 3: Pin Design

Let
𝑛= number of pins
𝐷𝑝 = pitch circle diameter
𝑑𝑝 = diameter of pin
𝐷𝑏 = bush outer diameter
𝑙= effective length of bush

Torque transmitted:

𝐷𝑝
𝑇 =𝑛×𝐹×
2
where 𝐹= tangential load on each pin.

Tangential load is limited by:

2𝐹
• Shear in pin: 𝜏𝑝 = 𝜋𝑑2
𝑝
• Bearing pressure on bush:

𝐹
𝑝𝑏 =
𝑑𝑝 × 𝑙

7. Example Problem

Given:

• Power 𝑃 = 30 kW
• Speed 𝑁 = 1000 rpm
• Shaft material: C45 steel, 𝜏𝑠 = 40 MPa
• 6 pins, each with bush outer diameter 𝐷𝑏 = 25 mm
• Pitch circle diameter 𝐷𝑝 = 3𝑑(three times shaft diameter)
• Allowable bearing pressure 𝑝𝑏 = 0.8 MPa

Step 1: Torque

9550 × 30
𝑇= = 286.5 N\cdotpm
1000

Step 2: Shaft Diameter

𝜋
286.5 × 103 = × 40 × 𝑑 3
16
3 286.5 × 103 × 16
𝑑=√ = 25.7 mm
𝜋 × 40

Select d = 30 mm.

Step 3: Pin and Bush Design

𝐷𝑝 = 3𝑑 = 3 × 30 = 90 mm

Torque transmitted:
 𝐷𝑝
𝑇 = 𝑛𝐹
2
286.5 × 103 = 6𝐹 × 45
286.5 × 103
𝐹= = 1061 N per pin
270

Bearing pressure:

𝐹
𝑝𝑏 = ≤ 0.8 MPa
𝑑𝑝 𝑙

Assume 𝑙 = 1.2𝑑𝑝

1061 = 0.8 × 𝑑𝑝 × (1.2𝑑𝑝 )

1061
𝑑𝑝2 = = 1106
0.96
𝑑𝑝 = 33.3 mm

Choose d_p = 35 mm, l = 1.2 × 35 = 42 mm.

Check shear stress:

2𝐹 2 × 1061
𝜏𝑝 = 2
= = 0.55 MPa ✓ Safe
𝜋𝑑𝑝 𝜋 × 352

8. Summary of Design

Component Symbol Dimension (mm) Remarks

Shaft diameter d 30 –
Pitch circle diameter D_p 90 –
No. of pins n 6 –
Pin diameter d_p 35 Safe
Bush length l 42 Safe

9. Design Notes

• Rubber bushes absorb shocks and vibrations.

• Do not exceed bearing pressure on bushes.
• Avoid excessive flexibility to maintain alignment accuracy.
• Alignment must still be within allowable limits (≤1° angular misalignment).
10. Review Questions

1. What is the function of a flexible coupling?

2. Compare rigid and flexible couplings in terms of application and performance.
3. What limits the torque capacity of a bushed pin coupling?
4. Why are bushes made of rubber or leather?
5. Design a flexible coupling for 40 kW at 1500 rpm with 8 pins.

Lecture 3: Coupling Failure Modes and Maintenance

Course: Machine Design
Prepared by: Prof. Ramadan Ibrahim El-Soeudy
*Faculty of Engineering – Suez Canal University

1. Introduction

Mechanical couplings, whether rigid or flexible, are critical in transmitting torque and maintaining alignment
between shafts.
However, improper selection, misalignment, or overload can lead to premature failure, vibrations, and costly
downtime.

This lecture explains common failure modes, causes, preventive measures, and maintenance practices for
couplings.

2. Common Failure Modes

Failure Mode Description Typical Cause

Fatigue failure of bolts Repeated cyclic loading causes cracks in Over-tightening, misalignment,
or keys bolts or keys. excessive torque.
Wear of bush or rubber
Loss of elasticity or material degradation. Heat, oil contamination, or aging.
elements
Shaft keyway damage Fretting or crushing of the key-seat region. Loose fitting, excessive vibration.
Flange crack or Cracks radiate from bolt holes or hub due to Improper design, overloading, or shock
deformation stress concentration. loads.
Rust or chemical degradation of metallic
Corrosion Moisture or improper lubrication.
parts.
Vibration or thermal cycling causes loss of Insufficient tightening torque or lack
Loosening of bolts
preload. of locking devices.
3. Analysis of Failure Causes

1. Misalignment
o Angular, parallel, or axial misalignment introduces bending stresses.
o Leads to fatigue in bolts and keys.
o Correction: Proper alignment during installation, periodic inspection.
2. Overload
o Excess torque beyond design value.
o Causes shear failure of bolts or keys.
o Correction: Select coupling with adequate torque rating and safety factor (usually 1.5 to 2.0).
3. Vibration and Shock Loads
o Dynamic loads accelerate wear and fatigue.
o Correction: Use flexible couplings with damping properties.
4. Poor Lubrication or Environment
o Corrosion and temperature accelerate wear.
o Correction: Apply protective coating or sealant, use suitable materials.

4. Design for Reliability

When designing a coupling, apply the following engineering considerations:

1. Material Selection:
Choose high-toughness steels or corrosion-resistant alloys.
2. Stress Concentration Reduction:
Provide fillets and smooth transitions near bolt holes or keyways.
3. Safety Factor:
For critical applications, use a factor of safety ≥ 2 for static and 3–4 for dynamic loading.
4. Balancing:
Balance rotating components to avoid vibration, especially at high speed.
5. Inspection Access:
Design for ease of disassembly and inspection.

5. Example Problem

A rigid flange coupling connects two steel shafts transmitting 40 kW at 1200 rpm.
The coupling uses 6 bolts on a 120 mm pitch circle.
Estimate the shear stress in bolts if the coupling fails due to bolt shear.
Compare the result to allowable stress 𝜏𝑎𝑙𝑙𝑜𝑤 = 25 MPa.

Step 1: Torque

9550 × 𝑃 9550 × 40
𝑇= = = 318.3 N\cdotpm
𝑁 1200
Step 2: Shear load per bolt

2𝑇 2 × 318.3 × 103
𝐹𝑏 = = = 884 N per bolt
𝑛𝐷𝑝 6 × 120

Step 3: Bolt stress

Assume bolt diameter 𝑑𝑏 = 12 mm:

𝐹𝑏 884
𝜏𝑏 = 𝜋 = = 7.8 MPa
𝑑 2 0.785 × 122
4 𝑏
𝜏𝑏 = 7.8 MPa < 25 MPa ⇒ Bolts are safe

If failure occurs due to misalignment or cyclic stress, fatigue may reduce allowable shear by 40–50%.

6. Maintenance Practices

1. Routine Inspection
o Check for loosened bolts, worn keys, or damaged bushes.
o Inspect rubber or leather elements for cracks or hardening.
2. Lubrication
o Lightly grease bolts, keys, and flexible elements to prevent corrosion.
o Avoid oil contamination on rubber components.
3. Alignment Check
o Verify angular and parallel alignment with dial gauges.
o Acceptable limits:
▪ Angular misalignment ≤ 1°
▪ Parallel offset ≤ 0.25 mm
4. Replacement Schedule
o Rubber bushes: every 1–2 years under normal use.
o Bolts and keys: inspect annually and replace if fatigue marks are visible.
5. Storage and Environment
o Keep couplings dry and clean.
o Avoid exposure to direct sunlight or chemicals for rubber components.

7. Common Troubleshooting Table

Problem Likely Cause Corrective Action

Excessive vibration Misalignment or imbalance Re-align shafts, balance coupling
Premature bush wear Oil contamination or heat Replace bushes, improve ventilation
Bolts loosening Insufficient torque Use lock washers or Loctite
Noise during operation Loose key or worn flange Re-tighten key, replace damaged flange
Shaft fretting Poor fit or high vibration Use interference fit or flexible coupling
 Problem Likely Cause Corrective Action

8. Safety Recommendations

• Always lock out power before maintenance.

• Never hammer or force-fit couplings on shafts.
• Use correct tools for alignment and tightening.
• Follow manufacturer torque specifications.
• Replace all flexible elements during overhaul.

9. Summary of Lecture

• Coupling failures result mainly from misalignment, overload, or poor maintenance.

• Proper design includes adequate safety factors, material selection, and balancing.
• Preventive maintenance ensures long service life and reliability of rotating machinery.

10. Review Questions

1. List five common failure modes of couplings.

2. What are the effects of misalignment on coupling performance?
3. How does vibration contribute to coupling failure?
4. Suggest three preventive maintenance actions for flexible couplings.
5. Explain why safety factors are higher for dynamic loading.