Mahatma Gandhi Missions

College of Engineering and Technology

Noida, U.P., India

Mini Project Report

on

Flexible bush pin type coupling

as

part of B. Tech Curriculum

Submitted by:

1
 P. Deepak Kumar

VI Semester

1209540038

Under the Guidance of:

Mr. Umesh Yadav

Submitted to:

HOD

Mechanical Engineering Department,

MGM COET,

Noida

2
 Mahatma Gandhi Missions

College of Engineering and Technology

Noida, U.P., India

Department of Mechanical Engineering

CERTIFICATE

This is to certify that Mr. P. Deepak Kumar B. Tech. Mechanical Engineering,

Class TT-ME and Roll No. 1209540038 have made a mini project on the topic
Flexible type bush pin coupling. His mini project report during the academic

3
year 2014-2015 as the part of B. Tech Mechanical Engineering curriculum was
excellent.

(Guide) (Head of the Department)

4
 Acknowledgement

I would like to express my deep sense of gratitude to my supervisor for his in

depth guidance, support and encouragement throughout this project work. Moreover, I would
acknowledge the Department of Mechanical Engineering for providing me the consent to
perform experiment in the laboratory. I sincerely thank to all the faculty and staff members of
Department of Mechanical Engineering for their support throughout this work.

P. Deepak Kumar

(1209540038)

Date:

Place: Noida, Uttar Pradesh

5
6
 Abstract

This report is based on the concept of coupling and a general program has been made for flexible
bush pin coupling. Coupling means a mechanical device which is used to connect two shafts for
transmission of power. Coupling has been used in various machines like vehicles, pumps etc.
There are many types of coupling based on their nature of work.
This report explains about types of coupling in brief and flexible bush pin bearing in detail. The
design, material, advantages, disadvantage of flexible bush pin bearing has been done. A
generalized program on flexible bush pin bearing along with output has been made using c
programming language.

7
 Content

Page No.

Acknowledgement

Abstract

Content

1. Chapter-1 Coupling

1.1 Uses

1.2 Requirements of good shaft alignment

1.3 Coupling maintenance and failure

1.4 Coupling materials

1.5 Applications

2. Types of coupling

2.1 Rigid coupling

2.1.1 Sleeve coupling

2.1.2 Flange coupling

8
2.1.3 Clamp coupling

2.1.4 Tapered shock load

2.1.5 Flexible coupling

2.1.6 Bush pin type flange coupling

2.1.7 Beam coupling

2.1.8 Grid coupling

2.1.9 Oldham coupling

2.3 Other couplings

3. Flexible bush pin coupling

4. Program for bush pin flange coupling

5. References

Chapter-1

Coupling

9
A coupling is a device used to connect two shafts together at their ends for the purpose of
transmitting power. Couplings do not normally allow disconnection of shafts during operation,
however there are torque limiting couplings which can slip or disconnect when some torque limit
is exceeded.

The primary purpose of couplings is to join two pieces of rotating equipment while permitting
some degree of misalignment or end movement or both. By careful selection, installation and
maintenance of couplings, substantial savings can be made in reduced maintenance costs and
downtime.

1.1 Uses

Shaft couplings are used in machinery for several purposes. The most common of which are the
following.

1. To provide for the connection of shafts of units that are manufactured separately such as a
motor and generator and to provide for disconnection for repairs or alterations.
2. To provide for misalignment of the shafts or to introduce mechanical flexibility.
3. To reduce the transmission of shock loads from one shaft to another.
4. To introduce protection against overloads.
5. To alter the vibration characteristics of rotating units.
6. To connect driving and the driven part

1.2. Requirements of good shaft alignment

1. It should be easy to connect or disconnect the coupling.

2. It does allow some misalignment between the two adjacent shaft rotation axes.

3. Its goal should be to minimize the remaining misalignment in running operation so as to

maximize power transmission and to maximize machine runtime (coupling, bearing and
ceilings lifetime).
4. It should have no projecting parts.
5. It is recommended to use manufacturer's alignment target values to set up the machine
train to a defined non-zero alignment, due to the fact that later, when the machine is at
operation temperature, the alignment condition is perfect

10
1.3. Coupling maintenance and failure

Coupling maintenance is generally a simple matter, requiring a regularly scheduled

inspection of each coupling. It consists of:
1. Performing visual inspections, checking for signs of wear or fatigue, and cleaning
couplings regularly.
2. Checking and changing lubricant regularly if the coupling is lubricated. This maintenance
is required annually for most couplings and more frequently for couplings in adverse
environments or in demanding operating conditions.
3. Documenting the maintenance performed on each coupling, along with the date.
Even with proper maintenance, however, couplings can fail. Underlying reasons for
failure, other than maintenance, include:

1. Improper installation
2. Poor coupling selection
3. Operation beyond design capabilities.

The only way to improve coupling life is to understand what caused the failure and to
correct it prior to installing a new coupling. Some external signs that indicate potential
coupling failure include:

1. Abnormal noise, such as screeching, squealing or chattering

2. Excessive vibration or wobble
3. Failed seals indicated by lubricant leakage or contamination.

1.4. Coupling Materials

The various types of coupling and its parts manufactured from the following materials:
Shaft Collars and Rigid Couplings:
1. Steel: 1215 bar
2. Aluminum: 2024-T351 bar
3. 303 Stainless Steel: Type 303 austenitic, non-magnetic bar
4. 316 Stainless Steel: Type 316L austenitic, non-magnetic bar
5. Plastic: Acetal

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Quick Clamping Shaft Collars:
1. Aluminum Body: 6061-T651 bar
2. Handle: 6063-T651

Heavy Duty Shaft Collars

1. Steel: 1215 bar or A519 Hot Finished 1026 Carbon Steel

Beam Couplings:
1. Aluminum: 7075-T651 extruded and drawn aluminum bar
2. 303 Stainless Steel: Type 303 austenitic, non-magnetic bar

Oldham Couplings:
1. Aluminum Hubs: 2024-T351 or 7075-T651 bar
2. Torque Disks: Acetal, Nylon 11, or PEEK

Bellows Couplings:
1. Aluminum Hubs: 2024-T351 or 7075-T651 bar
2. Bellows: Type 321 stainless steel

Jaw Couplings:
1. Aluminum Hubs : 2024-T351 or 7075-T651 bar
2. Spiders: Polyurethane

Disc Couplings:
1. Aluminum Hubs: 2024-T351 or 7075-T651 bar
2. Disc Springs: Type 302 stainless steel

Center Spacer: 2024-T351 bar, 7075-T651 bar, or acetal bar

12
Chapter-2

Types of coupling

These are some of the types of couplings used in the industry and day to day life.

2.1 Rigid coupling

A rigid coupling is a unit of hardware used to join two shafts within a motor or mechanical
system. It may be used to connect two separate systems, such as a motor and a generator, or to
repair a connection within a single system. A rigid coupling may also be added between shafts to
reduce shock and wear at the point where the shafts meet.

When joining shafts within a machine, mechanics can choose between flexible and rigid
couplings. While flexible units offer some movement and give between the shafts, rigid
couplings are the most effective choice for precise alignment and secure hold. By precisely

13
aligning the two shafts and holding them firmly in place, rigid couplings help to maximize
performance and increase the expected life of the machine. These rigid couplings are available in
two basic designs to fit the needs of different applications. Sleeve-style couplings are the most
affordable and easiest to use. They consist of a single tube of material with an inner diameter
that's equal in size to the shafts. The sleeve slips over the shafts so they meet in the middle of the
coupling. A series of set screws can be tightened so they touch the top of each shaft and hold
them in place without passing all the way through the coupling.

Clamped or compression rigid couplings come in two parts and fit together around the shafts to
form a sleeve. They offer more flexibility than sleeved models, and can be used on shafts that are
fixed in place. They generally are large enough so that screws can pass all the way through the
coupling and into the second half to ensure a secure hold. Flanged rigid couplings are designed
for heavy loads or industrial equipment. They consist of short sleeves surrounded by a
perpendicular flange. One coupling is placed on each shaft so the two flanges line up face to
face. A series of screws or bolts can then be installed in the flanges to hold them together.
Because of their size and durability, flanged units can be used to bring shafts into alignment
before they are joined together. Rigid couplings are used when precise shaft alignment is
required; shaft misalignment will affect the coupling's performance as well as its life. Examples:

2.1.1 Sleeve coupling

A sleeve coupling consists of a pipe whose bore is finished to the required tolerance based on the
shaft size. Based on the usage of the coupling a keyway is made in the bore in order to transmit
the torque by means of the key. Two threaded holes are provided in order to lock the coupling in
position.
Sleeve couplings are also known as Box Couplings. In this case shaft ends are coupled together
and abutted against each other which are enveloped by muff or sleeve. A jib head sunk keys hold
the two shafts and sleeve together. in other words, this is the simplest type of the coupling. It is
made from the cast iron and very simple to design and manufacture. It consists of a hollow pipe
whose inner diameter is same as diameter of the shafts. The hollow pipe is fitted over a two or
more ends of the shafts with the help of the taper sunk key. A key and sleeve are useful to
transmit power from one shaft to another shaft.

14
2.1.2. Flange coupling
This coupling has two separate cast iron flanges. Each flange is mounted on the shaft end and
keyed to it. The two flanges are coupled together with the help of bolts and nuts. The projected
portion of one of the flanges and corresponding recess on the other flange help to bring the shaft
into line and to maintain alignment. A flange which is provided with a shroud which shelters the
bolts heads and nuts is called protected type flange coupling.

2.1.3. Clamp or split-muff coupling

In this coupling, the muff or sleeve is made into two halves parts of the cast iron and they are
join together by means of mild steel studs or bolts. The advantages of this coupling is that
assembling or disassembling of the coupling is possible without change the position of the shaft.
This coupling is used for heavy power transmission at moderate speed.

2.1.4. Tapered shaft lock

A tapered lock is a form of keyless shaft locking device that does not require any material to be
removed from the shaft. The basic idea is similar to a clamp coupling but the moment of rotation
is closer to the center of the shaft. An alternative coupling device to the traditional parallel key,
the tapered lock removes the possibility of play due to worn keyways. It is more robust than
using a key because maintenance only requires one tool and the self-centering balanced rotation
means it lasts longer than a keyed joint would, but the downside is that it costs more.

2.2. Flexible coupling

Flexible couplings are used to transmit torque from one shaft to another when the two shafts are
slightly misaligned. Flexible couplings can accommodate varying degrees of misalignment up to
3 and some parallel misalignment. In addition, they can also be used for vibration damping or
noise reduction. This coupling is used to protect the driving and driven shaft members against
harmful effects produce due to misalignment of the shafts, sudden shock loads, shaft expansion
or vibrations etc.

2.2.1. Bush pin Type flange coupling

15
This is used for slightly imperfect alignment of the two shafts. This is modified form of the
protected type flange coupling. This type of coupling has pins and it works with coupling bolts.
The rubber or leather bushes are used over the pins. The coupling has two halves dissimilar in
construction. The pins are rigidly fastened by nuts to one of the flange and kept loose on the
other flange. This coupling is used to connect of shafts which having a small parallel
misalignment, angular misalignment or axial misalignment. In this coupling the rubber bushing
absorbs shocks and vibration during its operations. This type of coupling is mostly used to
couple electric motors and machines.

2.2.2. Beam Coupling

Fig. Beam Coupling

A beam coupling, also known as helical coupling, is a flexible coupling for transmitting torque
between two shafts while allowing for angular misalignment, parallel offset and even axial
motion, of one shaft relative to the other. This design utilizes a single piece of material and
becomes flexible by removal of material along a spiral path resulting in a curved flexible beam
of helical shape. Since it is made from a single piece of material, the Beam Style coupling does
not exhibit the backlash found in some multi-piece couplings. Another advantage of being an all
machined coupling is the possibility to incorporate features into the final product while still
keeps the single piece integrity.

16
Changes to the lead of the helical beam provide changes to misalignment capabilities as well as
other performance characteristics such as torque capacity and torsional stiffness. It is even
possible to have multiple starts within the same helix.

The material used to manufacture the beam coupling also affects its performance and suitability
for specific applications such as food, medical and aerospace. Materials are typically aluminum
alloy and stainless steel, but they can also be made in acetal, maraging steel and titanium. The
most common applications are attaching encoders to shafts and motion control for robotics.

2.2.3. Grid Coupling

A grid coupling is composed of two shaft hubs, a metallic grid spring, and a split cover kit.
Torque is transmitted between the two coupling shaft hubs through the metallic grid spring
element.

Like metallic gear and disc couplings, grid couplings have a high torque density. A benefit of
grid couplings, over either gear or disc couplings is the ability their grid coupling spring
elements have to absorb and spread peak load impact energy over time. This reduces the
magnitude of peak loads and offers some vibration dampening capability. A negative of the grid
coupling design is that it generally is very limited in its ability to accommodate misalignment.

2.2.4. Oldham Coupling

Fig. Oldham Coupling

17
An Oldham coupling has three discs, one coupled to the input, one coupled to the output, and a
middle disc that is joined to the first two by tongue and groove. The tongue and groove on one
side is perpendicular to the tongue and groove on the other. The middle disc rotates around its
center at the same speed as the input and output shafts. Its center traces a circular orbit, twice per
rotation, around the midpoint between input and output shafts. Often springs are used to reduce
backlash of the mechanism. An advantage to this type of coupling, as compared to two universal
joints, is its compact size. The coupler is named for John Oldham who invented it in Ireland, in
1821, to solve a paddle placement problem in a paddle steamer design.

2.3. Other Couplings

1. Bellows coupling low backlash
2. Elastomeric coupling
3. Bushed pin coupling
4. Donut coupling
5. Spider or jaw coupling
6. Geislinger coupling
7. Resilient coupling
8. Roller chain and sprocket coupling
9. Schmidt coupling

18
Chapter -3

Flexible Bush Pin Coupling

Flexible coupling is used to join the abutting ends of shafts when they are not in exact alignment.
In the case of a direct coupled drive from a prime mover to an electric generator, we should have
four bearings at a comparatively close distance. In such a case and in many others, as in a direct
electric drive from an electric motor to a machine tool, a flexible coupling is used so as to permit
an axial misalignment of the shaft without undue absorption of the power which the shaft are
transmitting.

A bushed pin flexible coupling is a modification of the rigid type of flange coupling. The
coupling bolts are known as pins. The rubber or leather bushes are used over the pins. The two
halves of the coupling are dissimilar in construction. A clearance of 5mm is left between the face
of the two halves of the coupling. There is no rigid connection between them and the drive takes
place through the medium of the compressible rubber or leather bushes.

19
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 leather
bushes and it should not exceed 0.5 N/mm2. In order to keep the low bearing pressure, the pitch
circle diameter and the pin size is increased.

Let l= Length of bush in the flange

d2= Diameter of bush,
Pb= Bearing pressure on the bush or pin,
N= Number of pins, and
D1= Diameter of pitch circle of the pins

We know that bearing load acting on each pin,

W =P b d 2 l

Therefore, total bearing load on the bush or pins

W n=Pb d 2 l n

And the torque transmitted by the coupling,

D1 D
T =W n ( )
2
=Pb d 2 l n( 1 )
2

The threaded portion of the pin in the right hand flange should be a tapping fir in the coupling
hole to avoid bending stresses.
The threaded length of the pin should be as small as possible so that the direct shear stress can
be taken by the unthreaded neck.

Direct shear stress due to pure torsion in the coupling halves,

20
 d

( 1)2
4
W
=

Since the pin and the rubber or leather bush is not rigidly held in the left hand flange, therefore
the tangential load (W) at the enlarged portion will exert a bending action on the pin. The bush
portion of the pin acts as a cantilever beam of length l. Assuming a uniform distribution of the
load W along the bush, the maximum bending moment on the pin,

l
M =W ( + 5 mm)
2

The bending stress,

d1




32
l
W ( +5 mm)
M 2
= =
Z

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
max = + 2 + 4 2
2

And the maximum shear stress on the pin

21
 1 2
min =
2
+ 4 2

Fig. Flexible bush pin coupling

22
 Fig. AutoCAD model of flexible bush pin coupling

3.1 Advantages

1. It can tolerate 0.5mm of lateral or axial misalignment and 1.5 degrees of angular misalignment.
2. Prevents transmission of shock from one shaft to the other and absorbs vibrations.
3. It can be used for transmitting high torques.
4. It is simple in construction and easy to assemble and dismantle.
5. It is easy to design and manufacture the coupling.
6. For the same size of shafts, flexible bush coupling has larger number of bolts or larger pitch circle
diameter than rigid type coupling. This reduces the force acting on the pins and lowers bearing
pressure on the rubber bush.

3.2. Disadvantages

There are following disadvantages of using flexible bush pin coupling:

1. The cost of flexible coupling is more than that of rigid coupling due to additional parts.
2. It requires more radial space compared with other types of coupling.
3. Maximum allowable peripheral speed of the coupling is 30m/s.

23
Chapter -4

General Program

Program for designing a bush pin flexible coupling.

24
#include<stdio.h>
#include<conio.h>
#include<math.h>
void main()
{
float
p,t,tous,width,sigs,touc,pb,no,D1,d1,d,n,d2,l,w,tmean,tou,m,z,sig,D,L,tf,sigmax,toumax,tmax,tou
k,sigck;
printf("Enter the value power Watt\n");
scanf("%f",&p);
printf("\nEnter the speed rpm\n");
scanf("%f",&n);
printf("\nEnter the allowable shear and crushing stress for shaft and key in MPa\n");
scanf("%f %f",&tous, &sigs);
printf("\nEnter the allowable shear stress for flange material MPa\n");
scanf("%f",&touc);
printf("\nEnter the value of allowable bearing pressure for rubber bush in MPa\n");
scanf("%f",&pb);

//******************************************
//Design for pins and Rubber bush
//******************************************

tmean=((p*60)/(2*3.14*n));
tmax =1.2*tmean*1000;
printf("\nmaximum torque transmitted is N-mm %f",tmax);
// diameter of shaft
d=(pow((tmax*16)/(3.14*tous),0.33));
printf("\nThe diameter of shaft is (mm) %f",d);

//Diameter of pin
if(d<35)
{no=3;
if ((d>36)||(d<55))
no=4;
if((d>56)||(d<150))
no=6;
if((d>151)||(d<230))
no=8;
if((d>231)||(d<390))
no=10;}
else
no=12;

d1=((0.5*d)/(pow(no,0.5)));
printf("\n The diameter of pin is(mm) %f",d1);

25
 //overall diameter of rubber bush
d2=d1+16;
printf("\n The overall diameter of rubber bush (mm) %f",d2);

//diameter of the pitch circle of the pins

D1=((2*d)+d2+(2*6));

l=(tmax/(pb*d2*n*(D1/2)));
printf("\n The pitch circle diameter is (mm) %f",D1);
printf("\n The length of the bush in the flange (mm) %f",l);

w=pb*d2*l;
printf("\nBearing load acting on each pin is MPa %f",w);

//Direct stress due to pure torsion in the coupling halves

tou= w/((3.14/4)*(pow(d1,2)));

m=w*((l/2)+5);
z=((3.14/32)*(pow(d1,3)));

//Bending stress
sig=(m/z);
printf("\nBending stress is MPa%f",sig);

//Maximum principal stress

sigmax=0.5*(sig+(pow((pow(sig,2))+(4*(pow(tou,2))),0.5)));
printf("\n The value of maximum principal stress MPa %f",sigmax);

// Maximum shear stress

toumax=0.5*(pow((pow(sig,2))+(4*(pow(tou,2))),0.5));
printf("\nMaximum shear stress MPa %f",toumax);

//Checking of design
if((toumax<tou)&&(sigmax<sigs))

printf("\nDesign of pin and rubber bush is safe");

else
printf("\nDesign of pin and rubber bush is not safe. We have to increase the diameter and
calculate again");

//**********************************
//Design for Hub
//**********************************

26
 D=2.00*d;
L=1.5*d;

printf("\n Outer diameter of hub and length of hub (mm)= %f %f",D,L);

//Checking for failure of hub

touc=(tmax*16*D)/(3.14*((pow(D,4))-(pow(d,4))));
printf("\nInduced shear stress for hub material is (MPa)=%f",touc);

if (touc<tous)
printf("\nDesign of hub is safe");
else
printf("\nDesign of hub is not safe. We have to change the dimensions of the hub");

//**************************************
//Design for Key
//**************************************

if(d<=44)
{width=14;
t=9;}
else if((d<=85)&&(d>44))
{width=25;
t=14;}
else if((d<=150)&&(d>85))
{width=40;
t=22;
}
else if((d<=230)&&(d>150))
{width=56;
t=32;
}
else
{width=100;
t=50;}

//Checking for failure of key under shearing and crushing

touk=tmax/(L*width*(d/2));
printf("\n Key under shearing force (MPa)= %f",touk);

sigck=tmax/(L*(t/2)*(d/2));
printf("\n Key under crushing stress (MPa)= %f",sigck);

if((touk<tous)&&(sigck<sigs))

27
 printf("\nDesign of key is safe");
else
printf("\nDesign of key is not safe. we Have to chnage the dimensions of key");

//********************************************
//Design for Flange
//********************************************

tf=(0.5*d);
printf("\nThickness of flange is (mm)= %f",tf);

//Checking the design of flange under induced shear stress

touc=(tmax*2)/(3.14*tf*(pow(D,2)));
printf("\n Induced shear stress in the flange is (MPa)= %f",touc);

if(touc<tous)
printf("\nDesign of flange is safe");
else
printf("\nDesign of flange is not safe. We have to change the thickness of flange");

getch();
clrscr();
}
//****************************************************
//THE END
//****************************************************

Output

28
Bibliography

29
1. "Pump Couplings from John Crane Meta stream and Power stream at Total Pump
Solutions". Totalpumps.co.nz. Retrieved 7 January 2015.
2. "Lovejoy, Inc.: Products: Couplings & Power Transmission: Shaft Locking Devices".
Lovejoy-inc.com. Retrieved 7 January 2015.
3. "U.S. Tsubaki POWER-LOCK Catalog" (PDF). Ustsubaki.com. Retrieved 7 January
2015.
4. "Power Lock". Tsubakimoto.com. Retrieved 7 January 2015.
5. "NEF Taper-Lock Series". Tsubakimoto.com. Retrieved 7 January 2015.
6. "Why a Grid Coupling - Features & Benefits, Design Basics, and Element Options".
Couplinganswers.com. Retrieved 2014-12-22.
7. Boyle, B. (2008). "Tracking the causes of coupling failure". Plantservices.com. Retrieved
7 January 2015. Explore coupling maintenance and the telltale signs of failure to
maximize coupling life and ensure reliable system operations

30