Shafts and Couplings

10.1. INTRODUCTION

Shaft is'a rotating member used to transmit power by torsion' An axle is a machine member loaded mainly in bending and carries rotating parts such as wheels and gears. An axle may either be stationary or rotating. Short shafts and axles are called as spindles. shafts may be classifred as transmission shafts zrnd machine shat'ts. Transmission sha{ts are those used to transmit power from the source to the machines. counter shafts or jack shafts, line shafts and head shalts and all other factory shafting come under transmission shafts. Machine shafts are those which are integral with the machine itself. Shafts are usually of circular cross-section. Sometimes shaits are made hollow to reduce the weight or to accommodate another coaxial shaft. Rarely square' cross or elliptical section shafts are used. Transmission shafts carry pulleys, gears or wheels. Hence they are subjected to bending in addition to torsion. In $ome cases as in axial flow compressors and turbines, shafts are subjected to axial load also. invariably fluctuating or alternating loads, the material for shafts should be ductile, tough and fatigue resistant. For light loads rnild steel may l-'e used. For higher strJngth ailoy sieels of nickel, nickel chromium and chrome-vanadium steel with proper heat treatment are used.

Asshaftsaresubjectedtocombinedbendingandtwistingrnomenlrsand

1A.2

MACHINE DESIGN

10.2. DESICN CONSIDERATIONS

Shllts are designeti for strength or rigiditv or irtr both. The strength of the shirlt is ()f irnportance rvhere shocli and cyciic loads ate present. 'fhe sl-rafts invariably frril b.y iatiguc and {ailure starts from the point of stress conccntration such as key slots, threadecl portion etc. Iiigidity is the consideration for long sha{ts wirich are subjected to bending rnonrt:nt ancl torque. Due to the deflection of'sha{t, the positiun oi'the gear mounted on tltc sha{t changes resulting in stlcss concentration. dynamic load :rnd noise in ilcirfs. Il critical speed o{'the engine is near t.he nirtulal frequetrcy of tire shaft, the torsional or lateral vibrations of the sh:rfts rvili br: violent ar-rd the shaft will fail. In thc clesign ol machine. after desig'ling all othu' courponents, if it happened that natural licqr-rency of thc system is near the cxciting ii-equenc-v ol the machine, shaft clirrnotcr should be alterecl to change thc natural licquency oi thr: system.
St:urrl:rrd diametct
o1'

the shafts in ntm.

lt, ro,7,3, 9. 10, Ll-, 12, 14, 16, 18,20,22,

Zrt, 28, 32,36, 40, 45, 50,56. 63, ?1. 80, 90.

r00, 110, 125, t40,160, 180, 200,22A,240,26{J,

2S0, 300, 320, 340, 360, 380, 400, 420. 440, 45A,

480, 500, 530, 560, 600.

1O.3 S'.TRESSES

IN TI{E SIIAFT

Whcn a circular shaft of diamcter cl is strbjcctecl to a sicaclv torque'l'Fig. 10-1.

lVl:rximurn shear stress

'

167 * .liJ

10.1)

ffi&
Fig.
10.1

SHAFTS AND

COUPLINGS

10.3

I{' the shaft is subjected to a beuding moment M along with tl-re torque, T. Fig.
10.2.

tffii
T

'f

Fig. 10.2
Shcar stress due to the torque
167 t=od,

['icnding stress due to the bending moment,

i\,I o= 32 .r

Ilesuitaat maximum shear stress, r,,,.*=

r-rjI r/o2+412
16

=# fi'l?-

"'

(10'2)

When a shaft is subjected to a steady bencling moment. I\4 a steady torque, T and an axial load F (Fig. 10.3).

Fig. 10.3

'Ictsile stress due to the axial

load

4F =^d'
Ilending stress due to the moment
32
X,I

n rl3

10.4

MACHINE DESIGN

Iiesultant direct stress (tensile or compressive) is given by

o=32M 4F "+-; nd" nrl"

=4(M*ry) 8 7rd'l,
Shcar stress due to torque,

"
Resuitant rnaximum shear stress.

167
ir rl3

rrnax=2l\Jo"+4T-

llre

16

ndo

r'*[n.ryY I uj

(10.3)

However, for long shafts (slender shafts) subjected to compressive loads, the stress may not correspond to simple uniform distribution. In such cases, it should be considered as a column to find out stresses. In shalting practice, a factor cr called column factor is introduced to take the column effect into account. Stress due to the load,

=
The column effect is given by,
c = --Lt

er4F

"d,
loads

1^ for compressive . 1 - 0.0044: k

10.1.
cr

= I for tensilc loads.

The values of cr are tabulated in Table

Table 10.1: Colunn factor

l.n<

50 1,00

75 7.49

100

115
2.O2

7.t2

1.28

1.78

SHAFTS AND COUPLINGS

10.5

Ilence rnaximum shear stress rn a shaft subjected to cornbined torque, bending moment and axial loading is given by

_rc
fid"

d*[vi.*i

(10.4)

s'afts are seldom under constant torque and bending moment. Hence {atigue is to be taken into accot:nt for design. 'fhe-effect clepends on thc nature ol variation oi bendingl moment and torque. For design, faciors K, and K6 are introduced for torque and bending moment respecti'ery. Trre factors depend .n the application of the shafts.
Design torque

=4"7

Design B.M. = Ku x M.

'Iho values of I(i and K6 are tabulated in Table Table

1O.2:

10.2.

Shock and Fatigue Factors for Shafts

Nature of loading
St:rtionary shafts
Gradually applied load Suddeniy applied load
1.0 1.0

7.5 to 2.0

1.5 to 2.0

Rotating shafts
Gradually applied load
Suddenly applied ]oad with minor shock Suddenly applied load with heavy shock
1.5

1.0

1.5 to 2.0

1.0 to 3.0 1.5 to 3.C

2.0 to 3.0

by I! T in Eqs. (10.1) to (10.4).

Hence maxirnum'shear stress may be obtained by replacing N{ by K6Mand T

Hollow s\afts: Modulus of horlow section of inner diarneter d and outer diameter
D is given
by

Modulus in bending

"JD^-d^)
q4 D
2

=# r'

(1

- k4), rvhere

k = ci,zD

10.6

MACHINE DESIGN

Similarly modulus of the section in torsion

=-#r'(1-k4)
If 'a hollow sha{t is subjected to a bending moment, torque and axiai ioad, then tensile stress due to axial load and bending moment,
o =,r

32KbM
D3

(1- k1

,r D'?

g4F (r - k'/)
i

=;Ftr-B{n,,**{Ptr.L'r
Shcar stress due to torque, .

=
'r

19

4t T

D_(1:k')
+ 4 t2

Maximum shear stress,

,^u=

i,^,loz

,*"*=,,o#-r.1[,*r,'.{**.*,
subjected

u.u,,}'

f'

..

(105)

This is a generalised equation for maximum shear'streSs for a hollow shaft

to bending moment, torque and axial force. For solid shafts, k = 0.

10.4. EFFECT OF KEYWAYS concentration at and near the corners of the keyrvay. The effect is more when the shaft, is subjected to shock and fatigue loads. The weakening effect of the keyluav can be computed by the following expression,
h C=1.0+0.2Y d+l.ra

Keyway cut into the shaft affects the strength of the shaft due to stress

where C is a factor similar to stress concentration {'actor.

w is width of the h is depth of the

keywaS,

key'way

d is diameter of the shaft.

lf there is a keyway the

design stress is to be divided by the factor C.

I'\rr standard keyway with

d ,, w=;andh=* d
the factor C=1.2.

SHAFTS AND COUPLINGS

10.7

The length of the key does not al'fect the stlength of the shaft. Also, bending appliecl sirnultaneously with torsion does not affect the strength additional so far as thc kc.v is concerned. 10.5. DESIGN OF SIIAFTS Por designing shafts for strength, the maximum shear stress tneory is found io give satisfactory results as the shaft materiai is ductile in nature. The shear stresses {i;u1d hy Eqs (10.1) to (10.5) should not exceed t}re design shear stress. The allowable shear stress lies betrveen 15 to 40 N/mrn2 for mild steels and 20 to 60 N/mm2 for cast steels and 50 to 125 N/mm2 for ailoy steels.

\\{hile designing shafts for rigidity as per code for design of shafting, the shaft should not deflect more than 1mm per metre length of the shaft, or twist should not cxceed 0.25" per.metre of shaft for machine tools and 3" per metre for line shafts'
'I'wist in radians per unit length is given by

0Tr IGJyG
10.G.

(10.6)

COUPLINGS
Couplings are used to connect sections of long transmission shafts and to connect

the shaft of a driving machine to the siraft of a driven machine. This provides a permanent connection. clutches permit easy and quick engagement and
disengagement of two shafts. couplings are classified into two main tlpes viz. Rigid and flexible and further classification is shown in Table 10'3'

Tal:le 10.3: Couplings

Rigid Tlpe
a

Box or rnuff cuuPling Ciamp coupling Flange coupling Bushed pin type coupling

Couplings

Oldhan coupling
Flexible Type
C-clan'rp coupiing

Rubber pad cotlpling Universal coupiing

coupiings take care of small misaligninent in the shaft axes, either lateral or angular,

Rigid coupiings are employed where shafts are properly aligned. Flexible

depending on the type of couPling-

t0.B

MACHINE DESIGN

I0.7. DESIGN AND SELECTION OF COUPLINGS

)\l[any tl'pes of couplings are standarclised fbr intcrchangeability. A]l dimensions rvi ,-:Lruplirgs a.e proportional to the dianeter of the shaft. Hence problem o. cotrlrlirlgs, rcduces to designing of shatt and selcction fu1 -suitablc urupling- To e,sure sati: opclation, the stresses in couplings can be chcckcd rvith allowable values. The diiuncter of sl-raft is decided by torque and bencli,g r.nr-rment c.,ring on it. I(}.I]. I}OX COUPLING OR MUFF COUPLING

'lhis is the simplest of rigid type coupli,gs a^d co,sists <-rt' a steel or casr ircn slt'cvc fittcd on to the ends of the sha{ts aucl ser:urcd to thclu by means of taper pins or het' (Fig. 10.4a and 10.4b). I'.lver is transmitted from one shaft to the other shait bv means o{. a ke-v or 1ln and a sleeve. Hence for satislactory worldng. all thc elenrcnr_s should be strong r:uriuglt to transrnit the tor.que. Lct T be the torque to be trausmitted by the corLpling.'I'lrcq thc shear stress in thc shaft should not exceed the penlissible shear. str.css of'the sha{t.
11,. 1=-;S[T";l n cl'

16T..

1().7

'['lte slecve can be considered as a ]roilow.cylincler w'ith outsidc diamcter ittsidr. tii:utrctcr d.
.['he srrear stress

Il
(

and
r().8
)

in the sree'e

=;#fi_,;,.,..,,,

u,ltcrt

k=rl,l)

TAPER KEY

MUFF COUPI,ING

D=1.5d

KBY TYPE

/=:Jd

Fig. 10.4 (a)

SHAFTS AND COUPLII{GS

10.9

D=

MUFF COUPLING - I'IN TYPE

1-5

d; l=3 d;

dp = 0.25 t<t0'3 ci;

c=0

75 tl

Fis, 10.a (b)

IlI order that both sleeve and sha{t are equally strong ard they are subjected to peillissible shear siresses, the relatiolr betrveen d and l) can be obtained by
eqr-ratirlg Eqs. (10.7) and (10-8).

,=
llcnce T"5/t"7 = 2
'

r..,.i,=

@L}_-B

.", l

Iisually the sleeve is made up of cast iron and shaft of stcel

'

l-k4r k:l

tsh
Ts1

lil+2k:J-I=o
,solving fbr k, 1,rk = Did--L.37
(

10.9)

I-Ictcc in design practice, D = 1.5d girrcs sati-<iactory resuits Length of the uoupling is lixed by tire mininium lenglir of the iiey atd can br: taken as 3d

ln tire <:ase of taper pin joints, piurr of standarci diamcters tIS : 2393 -. 1963) slr,rrrid b<'us,:d. The pin is subjectetl to doul-rle shcat :tud the sliear strcss is givt'tt
hy

10.10

MACHINE DESIGN

r=:SIrpl
zx
Where
[Tn1 is.

r;d
1

..... (10.10)

lx

a!

the allowabie shear stress for the pin.

In practicr' the diameter of the pin lies between 0.25 to 0.3d For kcys, liter selecting standard size of key from Table 8.3, the length of the
kev is determhed on the basis of shear failure. '
?rnd cheched

,27 =,lh
"

..... (10.11)

{br compressive strength.

Compressive stress

in the

key

o"=*<locJ

.... (10.12)

where [T] and [o"] are the allowable stresses in the key in shear and compression respectively. The length of the key is the efl'ective lengih of the key on any one of the shafts,.which is also equal to half the length of the sleeve.

If the stresses

are more, the length of the key and hence the length of the rnuff

or sleeve should be increased suitably

10.9. CI.AMP COUPLING OR SPLTT MUFF COUPLING The clarnp coupling, which is a modification of sleeve coupiing, is made in two parts. Which are bolted together as shown in Fig. 10.5. The advantage ofthis coupling is that the position of shafts need not be change<l fcir fitting or dismantling of the coupling. Because of the convenience and low cost, these couplings are used even for heavy duty and moderate speeds. Generally, sleeve is made up of cast iron.

In the clamp coupling the'power from driving shaft to sleeve and sleeve to driven sha{t is transmitted both by key and friction between sleeve and shaIt. The exact amount shared by these two is unpredictabie. Hence in practice it is so desigrred that the design torque can be transmitted by either oue of these. The key design is similar to one used for muff coupling. For tl-re design of bolts, the bolts should be capable of exerting suffrcient force to cause necessary fiiction between mulf and shaft to transnrit the torque. Let
d1,

be the diameter of the bolt (effective)

shaft

n number of bolts on either side of the

o1 allowable tensile stress on the bolts.

SF{AFTS AND COUPLINGS

0.1

.1

Maximuur force that can be exerted by the bolts on one side of tire shatt,

F=n+di;or

..... 11C.13)

E=0.5d;- D=2.5 io3d,

du= o.z5 to

L=3.2 to4.5dj

o 4d.

Fig. 10.5: Clamp couPling

Il' p is the pressure on the sirait zrnd rnuil sur-lace due tiuiliu-n pressure distribution over the surlace,

tLr

the fbrce. then for

r'=F-j;AAAr=;
F

..... i i0.14)

I r.a
2

'fr=

r,

if pr is the co-efficient of friction , Pr-essure x Area x Ra{ius.

betlveen tl-re shalt and sleeve, {'r-iction forque.

l'

"Tai *11--: totJ x j lLd

1n d L"'!1
,t

=F5l"[aflto't
Dcsign torque

..... .10.i5) '1

"

=fta3 lt"l

10.i2

N4ACHINE DES]GN

Iirluating Design torque to Frictiou torquc

,|a3t'"t=r' t"4(ti;lorl

rd
1

..)

10.16

tul
'l':tlrtrg
n

l'

d',

]' _
=

[T"]
o1

2rpn

- 4;$-

0.3 and

'jlr tr. l

/dnf
i,-l=-

idJ
d1, d,

,22.6
1

10.17)

4.75

lrt Prirctice the diameter of bolt lies betrveen 0.25d io 0.4d. The spacing cii'bolts sltorrld be lixed by considering provision firr tightcuing rtntl mlnulacturipg
corrsirlclaLious.

I(}"IO. I|I-ANGE COUPLING

I;'lrrrrge crrupling

keyecl

bolts as showu in Fig. 10.6. Alignment of the shaits can be ensured by a projection in brre trl the llanges artl a corresporlriing rectss iu the othct. fllurge. This is known a$ a'rtrgistet'. The ilange coupling can be clesignecl b.v the tirlkrwing prricedure and r:onrpared u'ith the empirical proportions vice versa.

to l,hc two sha{ts to be coupled and thc fla*ges arc c.,,ccted by means

is widely used as rigid type r:,upriug.'l'w. similar.llangcs

are

oi

Fig. 10.6: Flange coupling

SHAFTS AND COUPLINGS

10.13

Design procedure:

1.

F-rom the power to be transrnitted and given r.p.m., diameter of the shaft d is determired as detailed in article 10.3. This gives the bore diameter of the

flange.

2. Diameter of the boss d1 can be {ixed as two times the diameter of the sha{t
ar-rd checked

for shear failure considering boss as a hollow shaft. Generally,

the flange is made of casi iron.

3. The key

cross-section

is taken from Table 8.3. and the lengtli is frxed by

to

shear consideration. The length should be checked for crushing failure.

4. Ldngth of the

boss

is frxed by the minimum length of the key required

transmit the required torque.

5. Nuinber of bolts is found out by the empiricai relation n = 0.02d + 3, where is expressed in mm.

Take the nearest larger even number of bolts except f<rr shaft of diameters Iess than 40 mm rvhich are made with 3 bolts.

6. Bolt circle diameter may.be taken as dz=2d+50. 7. Diameter of the bolt. d6 is determined by shear failure of the
around the boss.
bolts. is just

8. 'Ihickness of the flange is deterrnined by shear failure; minimum area 9. 'Ihickness of the flange is
flangc. checked

f6r cnrshing failure of bolt against the

10. Outer diameter

of the flange is detern'rined by giving suitable radial thickness beyond the bolt hole.

IO,TI. MARINE T\?N FLANGE COUPLING

Coupiing for mariae propeller shafts shouli be ol high streirgth and reliability. 'Iherefore, the ends of the shafts are forged to fornr flanges as shou'n in Fig. 10.7. To ensure alignment of the shaft, a spigot is formed in one of the {langes and a corresponding recess in the flange. IS 3653 - 1966 gives the proportions oftlee.forged end type rigid coupiings for different shaft diameters.
4.')
i I

L..

10.14

MACHINE DESIGN

Number of bolts may be chosen as fbllows:

i ir*rt

rlia rnrn of bolts

35 to 55

56

to

150

151 to ;120 I

szr tn
10

ggo

Above 390
12

Fig. 10.7: Marine Type flange Coupling

I().
I

2. I'I,EXIBLE COUPLINGS

alignment iu rl:pr:ncls on the instrument used fbr aligning. orle canrrot expect sarne field ln solne cases ,r,,Lrplirrgs iu aero erngines a.ud rvatel purlrps in agricultural rnoney spent on rrliurunoDt is not possible and in sotue otlter cases the timc and rvili be a rvaste. Hence to takc tnisalignt.ncnt into acccrunt {lexible couplings' rrligu,ro,t iusteilcl ol tigid couplings are used'

Misalignnrerrtinslraftsoccurinvariousclegreesastheaccuracyofalignment

tr\ {lcxitrle couplings, flexibility is obtained by:

1.

l,oosellr iitted parts (flexible pin, chain

et<:)-

2. lr'lexible or resilient parts (leatlr'er

)

clisc, tlexible {lange crtc'l

l].llar.dparticlesarrangedlbrslictingactiorrairdrnadeclosetits(o}dham, (' llan{c, Utrivcrsal couplirrgs ctc

'fy1;ical iicxibie coupliugs are shov'n

iu Fig'

10'S

t<.r

10'1ll'

ill llexib]e flange couplings, the be:iring pl'essllre on the projccted area of rubber in lirrsh is lir-r'riied to 2 N/mm2- The dc-"igl of tlexiLrie llanp|er coui:ling is iliustrated
t.lroitltim 10.B.

SHAFTS AND COUPLINGS

Fig. 10.8: Flexible flange coupling.

Fig. 10.9: Leather disc coupling.

MACHINE DESIGN

Fig. 10.10: Flexible pin coupling

Fig. 10.11: C Flange Coupling

'l'he dinrensions of Ilexible flange in 'I'nble 10.4 and 10.5 respectivell'.

couplir-rg.

bush tl'pe and tiisc tlpe are given

SHAFTS AND COUPLINGS

10.17

Tzrble 10.4: Cast Iron Flexible Flange Couplings (Refer Fig. 10.8)
Coupling
No.
B1 P'2 B3 P'4
Br)
D D(i
P,7

Bush Type
t

I{,V per 100 rpm

t2-16
L6-22

80125128i18
1001

10

53 trJ

8
10

20

0.4 0.6 0.8

30 I 30 | 20

t2 t2
15 15 15

22 22

2 2 4

22-30
30-45 45-56 56-75

1121 38

ls2l22
i
35

10 qn 4 4
,L

1321 55 I 40 I 30 1701 80 I 45

t2
12 12 16

t20
130 190

25 30
40 40

a.o 6.0 16.0

25.O AZ.U

20011001 56 I 40

4
5
5

75-85
85-1 10
1

250i1401 63 I 45
31511801 80

22 22
28

t)

B8 Be

50

250
315 400

6
8
o

i16
18 18

10-130

40012121 90 I 56 500128011001 60

45
4i)

6 6

Bio

'130-150

28

74.0

Table 10.5: Cast Iron Flexible Coupling - Disc Type (Refer Fig. 10.9)
Coupling
No.

kW per 100 rpm

12-16 16-22 30 38
55 18 20

Dl
D2 D3
D4

15,16 16,18
18,25

IU

8153
10163 10173 121e0 12 I 120
I

6
tJ

0.!13

L2 12 15 15

0.67
1.1

22-30
30-45 45-56 56-75

22 30
JJ

b 8 8 8

25,30

3.0 4.6 6.8 18.0 28.0 57.0

D5 D,, D7

80
100 140 180

40 45

i
I

35.40 40,45

15

rz

I rso
I

,),
22
28

i
|

r-6 I ieo

i2
L2

l)r] l)g
Dro

+s,so so,ss
5a)

ro i zro

2l.2
280

55 60

28

rs I 31s rs i +oc
I

16
16

'10.18

MACHINE DESIGN

Olclharn's Coupling: 1)ltl]rarrr,scouplingconsistsoftwollangesrvithadiagonalrcctangulargrooveof on either side l.cated at right ,f"pth ir;;h widttrt. The central disc cr'ntains tongucs

irtlglestrle:tclrotirerandslidesinthegrooveso{tl-reiianges.Wl.reneverthereisa of sum axes, sliding occurs in both grooves the vectorial

sn)all (lisplaccment of shaft rvhr'n lltcv arc rotatirrg. coli[oLlr.

1,llClll()vt]ll]elltbeingequaitoaxisdisplacerrrer-rt..I.hiskcepsbtltl-raxesur-rstraitred

parallel but not 'l'his coupling is mainly used to connect shatts which are
.l]-ris can aiso take up sligiri atlgular rnisalignrnent'

tl're bearing pressure on ton'lre ctesign of Oldiratn's coupling is basecl on untl gltlrtt'e. proportional to the radius Assutning that the bearing pressllre p is ciistributccl

'[]rc

:rs slt.n,n in l'i;1. 10.12

TONGUE

i=0.45d L = 4d Oldham's CouPling Fig. 10'12: G 'l\rrtlue =2xAverage Pressure x t\rea x D.istauce of the C
D

=3to4d

-Zr.j^P tlhxil ZO

1,

=l
s

pL2

Illce

r=1n.
,2

'l'{)r'qrlc =

,D2

-u-

'''

(10'18)

of the tongue ' h can be I(ecping the pressure below 8 N/rnur2 the thickness are lixed by propor:tions' ,',,nrp.,rJ Otl". ai*"r"ions of the coupiing

flniversal Joint:

ssion of powcr to sha{ts inclined at Uliversal joints are rvidely used ltrr transmil is tl'rat the angular vclocity varies by 37o anglcs as high as 30'. The disadvantage {br' :10' and 55% for 40'' This is overcome by for' 10" i.clination, 1sE i; in*, zs'/' vrith o" tf'" driven side' The doublc hoohe's coupling along pt.ovirlilrg similar

"orpfnf

SHAFTS AND COUPLINGS

10.19

a spliued sha{t is widely used in machine tools :rnd automobiles where the .load is nl(rvulg rclative to the prime mover. 'lhc c.upling is shown in Fig. r0.13. The coupling shouid be checked ibr shcaring of tl-re pins, sirearing of the sleeve etc.

Fig. 10.13: Universal joint or Hooke's coupling

Table 10.6: fIP Ratings of 'Iyre Coupling

a-,;,trli,rg
No

HP/rpm
0.14 0.28 0.60 1.09 L.48 2.32 3.70 4.5 5.6 9.5 14.0

Torque N.m
1000

14i^
2tJ

Ma*. I rnz : tr4a.ss i" rpnl i Lg m2 I kS.

40
55 70

I
2
:J 4,

6300 5000 4000 3300 2800

0.14 0.22 0.51 0.95

1.9

9.5

2000 4300 7800 10600 16600 26300 32300 40000 68000 100000 140000 207000 300000

30 40 50

t3.4
22

85
105 120

.jr.;)
46 65

5 6
7

60
75

2500 2L30

o-z 5.8 q, 16.4 34.6 59

104

90
105
1.20

140
1b(, 18{) 22{) 26{} 29{\

ti
9

r900
1?00 L420 1?50 1100 1000
8BO

t25
175

IO

140 1{i0 190

?68

l1

li60
510
73C

l2

r9.50
28.8
.41.9

220

320
36i)

203
312

_1'1
t.
2.

260

985

Wciglrt and GD2 .ialues are stated for mean bore size I).
Coupling with peripheral speed 35 nrAec requires dlrranric balrurcing lCourtesy Fenner (India) Limitcdl.

!
,l

MACHINE DESIGN

Table 10.7: Dimensions of Tyre coupling

Size
Max
Bor-e

Min.
:10

C trb
I
I I

D
a.)

N{

Approx. Mass (kg)

40i
r,0 60
I I
I

l3
18 18

105 133 165

197

22
no

38

89 109

100

n3-I \'." 43*l I z5

ns*
85
OQ

45
l-)0

r25
144

70

EQ

70i
80 e0
100

20 26
20
CL

714
128

to
95
110

45

I I ro
13l1i 13i I 131 i 131 |

,,
,n ,u
rn
2s 25

trb
I I
I I I

2t1
235 254
279

t67
188

re lNotel

ls""\

76

t43 t49
155 181

57

t02
104

85 90
I

2t6
233 264

124
140

60
b5 76

rr0
r2c

t08

I I

r02

39

314

152

t20

zs beyond

M apart can -1r-- r^^^+^l ..ic ' Note 1: Shait ends although normally located.distance between the shaft ends for tfl"* sufficient space t""
proJer ct

t)re llanges as shown' l"';;; ----'-----*-r:r-rd l1oat and misalignment'

G is the arnount by which clamping Ilore limits H? unless otherwise specilied' the tyre' G'r is G' plus the wrqnch ring screws need to l" *ltt'Jtu*" to release e' The use of shortened wrench rqill to release the t,T
clearauce allowance required aliow this clearance to be reduced'

Table 10.8: Service F'actor for Tyre Couplings

Prime Mover

Driven Machine

Electric
Motor
1 1

Steam engine
1.5 1.5

Multi
2 2

cYl.

I.C. engine

Single cYl. I.C. engine

2.5 2.5
4.5

Diesel engine

li""tt utt Otives Normal

\leclrine Tools Lathes,
metal and wood working
Plancrs

,.

.l

2.5
J

,1

-O

Papei nlal<ing rnachinerY Beating engines single drive

machines

2.5 2

AR

5.5
5

&

refiners
5
1

4.5 5.5 2.5

Winders

6
o

Plinting

Presses
1.5

Pun-rps Centrifugal

Continued.

SHAFTS AND COUPLINGS

Prime Mover

Driven Machine Multiple crank

Single crank

Electric

Motor
9

Steam engine
2.5 3.5 3.5
J.O J.C

Multi
3:5
5 5 5 5

cyl.

Single cyl.

[.C. engine

I.C. engine
4.5 5.5
5.5
IE

Diesel englne
5 6 6

Rolling Mills
Rubber Mills & Calenders
S

6 6
5

ep

arators-Centrifugal
2
1.5

5.5

Textile Machilery Loorns

Spinning Winders and Haulages
10 hrs.

2.5
2

J.D

4.5 3.5

4.
6

3.5

5.5

Allow

10olo

extra

to 18 hrs'

25o/c

extra

18 hrs to 24 hrs'

Table 10'9: APPlication Factor F

Driven Machine
Blowers

I Electnc

Moto'
1.5
2

Steam engine
2 2.5 2.5 J.D

Multi

cyl.

Singie cyl.

I.C. engine I.C. engine

4.5

Diesel engine 4
5 5

Cement mill machinerY Compressors MultiPle crank Single crank

Conveyors Fluctuating load Shuttle of Reversing Steady load Cranes Cross travel

2
3
q

5.5 4.5
5.5

6
5

2.5
J.D

3.5
5

6
4 5

1.5 2

2 2.5
J.D

3.5 4.5
5

Long travel

2.5 3.5

4.5
5

5.5
b o

Auxiliary hoist, main hoist and slewing Fans Up to 20 h.P Over 20 h.p uP to 75 h.P Mine ventilating or over
75 h.p Generators SteadY l,oading

5.5 2.5 3.5 4.5 2.5 4.5 5.5

I
1.5 2
1

1.5 2

4
5
J

2.5 1< 2.5 o<

3.5
.,

Laundry machinerY Genera I{ydro Extractors

2
e

9<
5

5 6

10.22

MACHINE DESIGN

Table 10.10: Speed Factor K

R.P.1\{ 10 15

K
0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.05 1.10
1.15 1.20

R.P.M
150 160 170 180 190

K
2.00 2.10
2.2C

R.P.M
500 525 550 575 600

K
5.20 5.42 5.65 5.87 6.10 6.32 6.55 6.77 7.00 ?.16 7.24 7.40 7.60 7.80 8.00 8.20 8.40 8.60 8.80 9.00 9.08 9.20 9.40

R.P.M
1050 1100 1150

K
9.75 10.10 10.45 10.80 11.10 11.40
11.70

20
9r,

2.30 2.40 2.50

I

1200 1250 1300 1350 1400 1440 1450 1460 1500 1550 1600 1650 1700 1750 1800 1850 1900 1950 2000 3000

30
.1:)

200

625
650

40 45
l-;0

210 220
230

2.59 2.68 2.77 2.86 2.95 3.04 c lc 2.)9 3.31 3,40 3.62 3.85 4.07 4.30 4.52 4.75 4.97

675
700

12.00 12.20
12.25

55 60 65 70 75 80 85 90 95
100

240 250 260 270

280

720
730 750
I lc

12,30 12.54

t270
12.90
13.05

1.25 1.30 1.35 1.40 1.45 1.50 1.60 1.70 1.80 1.90

800

290
300

825
850

13.20 13.35 13.50 13.65 13.80 13.90 14.00 15.00

325
350

875
900 09( 950 960 975 1000

375
400 425 450 475

110 724 130 140

SHAFTS AND COUPLINGS

10.23

Table
Mark of Coupling
C1 C3 C5 C7 C9

10.11 GD"

HPi
RPM

Max. RPM

No.

Stock

of
pms

nominal
Bore

Max. Bore

A
3 r2"
4-5/8', 5-3/t"

lnass in kg

tb. fr2
0.166 0.497

0.0048 3000 0.0096 3000 0.0226 3000 0.0333 3000 0.0425 3000 0.0600 3000 0.4722 2550 0,1130 2300 0.2400 1990 0.3450 1990 0.3900 1665 0.4800 1665 0.6750 1530 0.9450 1530
1.27 1.6't 4 b
b
t)

Y{
V2"

7/8'
1"
1-Y2"

1-3/8', 1-5/8',
M.

u16"
7/8" 1-U8" lVq;'

1-318"

l- +t

U8'

5/8'

v8'
U8'

6 8
11

1.492
L.92

1-3/8" 6-U8', 7/8" 1" 1,-s/t' 6-5l8'

2Vt"

9-3/,"

)Ur'

t-3/8" l-.r/6

U8' 3-3/8',
3/16', 3/16', 3/16', 4Yz" 4Yz"
4-3/a" 5U2" I

2.89 5.97
10.66 17.88 41.20

c11 c13 c15

c17 019

8 b 8

2U)"
2Y2"
2-3/a"

7V2"

tl
22 27

1-U8"

3-U8'
10"
17Y2"

1-3/8"

lYt"
1-3/a"

3-5/8',

lVz"
2-118"

6 10 8
10 10

3-7/8" 4-7/8"

Vt"
y4

t-7/8"
2-U8" 2-3/8" 2-5/8" 2-7/8"
J 6',

lwz"
4"
4U2"

2-U8"

62 80

49.97 127.40 166.71 152.27

c27
c23 c2s
c27

13-3/+" 4-7/8. 2-7/32"

t3-3/{ 5-3l8.
15"

1/q"
9 1/o"

8-U8'
I -Jt6

93

4V2"

4-7/8"

Ya"

99
137

14
16 18 18 16

15'
18', 19Vq"

6-U8', 3-U8', 6-5/86-5/8',

lt"

8-7l8',

201.76 418.43 570

849 1480
a

c29
c31
cl33

1270
1190 1120 1000

3-U8'.

V{
Vq"

10'
10-3/a,"

205 260 315 344

1Vz"

6Y2"

3-V8"
3-5/8"

2.L4 3.10 4.45 6.10 8.30

11.75

4"

20V2"

6-7/8"

Vt"
Va" Vq"

llVz'
12Vz^

c35 c37
039

4tr'{
4Vz"
a

8'
9'.

6-7ly', 4-7/8"
25Y2"
See

880
820

18
18

4-3l8"

See

2584 4456

10"

28"

Note

5Yl"

Note
Yq" Vn"

c41 c43 c45

750 720 670

20 18 18

,yt'
6" 6Vt"

11'

3lVz" below

5h"
q-3h" 7-5t8"

Below

7461
12679
169?0

1lU2' 3512"
L2Y2"

16.75

lq"

Note: For coupling size C 37 and above, the boss diameter (H) and loss length (B) will change according to the bore diameters.

MACHINE DESIGN

Table 10.12: Physical Characteristics

Torque (Nm) Normal Maximum
1\{oment

,i

Maximum

Size

Max.Speed

of Inertia
MR2 (N.m2) 0.0148 0.0349 0.1030 0.1811 0.3679

(rev/min)
4500 4500 4000 3600
3

l?;1:":'.11 Misarirnment tti-l"r i 12*11"1ffi1ur1*

P40

2t
53 106

64
160

r50
F60 F70
FBO

318
487

L62 253
365 505

100

759 1096

26 i 'u ] ,o 4t I ,, I ,t

r | 1r i 13 13 I

13

r.;

F90

2880 2600 2300 2050

0.6374
1.1989

F F F

100 110 120

t5t7
2137 3547

el | ,n i ,o 126 12.6 13.3

128 ] ,o L, zs6 i r, I
F80
43

63 i ,r |

26

772
1182

t.6012
3.4302
10.13 F70
40
15

no

'fable
Coupling Size l\{.mm Clarnping Screw
E4O'F

F50'r 25
15

F601'

F90
46

F100 48
ao

F110 44 32

F120 49 35

22
15

24

24

N.m Torque

'I I-lexagon Socket Caphead Clamping Screws on these Table

L
114 145 34 40 40 50 50 50
4
5 5 5 10

sizes

10.14

OiI Qty
(Litre)
EK

25 30 35 45 50 55 65

55 70

l4
24 30 40 45 50

170 185

60 80
100

0.07 0.14 0.22 0.35

0.5

80 105 130
160.

L75 215 240

260 310

85
105 115 L25

220
2r;t0

L25
150 170

290
320 350

10 10

170

c.8

i50

200

tl
Continued

SHAFTS AND COUPLINGS

Table 10.14 (Cbntd.)

B

10.25

CI
10
10

c2
.31

c:t
75

L
180

L,,

c,.

D1

D2

Oil Qty
(Litre)
l.J

370 410 490 550 (;16

50

380 430 490 545 590 680 760

230 250
310 350 400 440 510

50 50 60 60 70
70

47 63
77

95
110 130 135

200

10 10 16 16
1b

240
270
'300

3.4 5.5
7.5

tlt) 85
108

676 136

170 170

330 360

11.0 14.0

10.13. TYRE COUPLINGS

Fig. 10.12 gives another flexible coupling called tyre coupii,g. Trre Hp rotating and dimensions are given in Table 10.6 and 10.7. respectively. The service factor is given in table 10.8. The coupling is to be selected using the following:
Dcsign HP = Average HP x Serwice factor

HPzrp*:!948aE! rpm
'fhis is to be compared with tabie 10.6 and suitable coupling is to be selected. coupling element in the form of ty're is used in coupling called ty're coupling. The tlT e is open at one line so that it can be inserted fiom side. This coupling consists of bosses and a holding plate on either end of the shaft. The holding plate clamps the tvpe by allowing it to rest on a groove provided. coupling and decoupling ofjoint can be done by positioning or removing the tjn:e. Life of tyre coupling very much depends on quality of the tyre. By virtue of complicated shape of tyre and its flexibility, stress calculations cannot be rnade to ascertain the strength. Ilolver.er basecl on operating experience, ratings by tyre coupiings tbr various sizes are
obtained.

'lorque ratings and dimensional details are given and as in other cases,.service factor can be used as per table.
Design po'*,er ueslgTt [orqtle

= Nominal power x =ffiNnr

Service lactor

Desisn Dower in IcW x 1000 x 6O - -

whcle u = rpm of shaft Normally the coupling ra,ill be available with pilot bore ancl boring to be done so as to get transition frt on the shaft,.

MACHINE DESIGN

*iF"

Irr
lE
LD
B FLANGE

Ix

rl-[ tlG

srzEs

F 70 TO F

1m

FFLNG

H FLANG

Fig. Fenartex Coupiirrgs

SHAFTS AND COUPLINGS

10.27

MATEBIAL

Tyre:

Natural

Synrhetic rubber impreg'

nated with Canvas/RaYon 'Hubs: Cast lror/M S. Selection lrrmulr:

CIJSHIONTYP

H.P. Psr 100 R.P.M.=

f73l-

H.P. x

103 Service x16q1or

STANDARD SIZES

Stanrlirrcl Sizes
No
(

lxlc
Nr,.

11;

l\
c \.{

lll
i\.t

N{:u
RPI\,I

tr{ax Rzrtiug

(lootinous llatine Unrlcr Slcrrly

lol<l NIU

Al)pr!xiNate
Diurcnsions in MN,ls
(.1

NM

ll)'1rr 5u5 120 990 t440 2.(t10 100 ttsM RI'M ITPNT RPI\,1 RPM ITPIU
2 .2
3

I.'

(i
18

i
-..1

\(|5t :\051\

I
4

6000 Ncminal Nouriual Norninal 6000 5500 5500

1.3

35 .25
.1

5
.5

68
90

:i5
29

56 63
BO

19

35 .52
7
1.3 1.3 2.O

20 25 2(i

22 22
1B

79
1.15 2 2
3

t.5
2
.l
tl
(';

90
9? 07

30
35 45

5 10 10

-:c

t.5

!5
25
2S

80 80

5500 5500 5250 5250 4600 4400 4400 4200 4200 3750 3750 3200 3200 2800 2600 2500 22tO
1700 1300
I

30 30 40 50 80
130 160 160

0.4
cr.14

8
.8

1,0 1.0

22 22

i
I

A 1.5

t07 45
16

l5
20 30
45 55

0.21 0.28
o.4'2

7.2 1.6 2.5

15
2.0

80 50 103 lt9
51

29

-r' lii
it
t0

'l
:

4
4

4 (i

20 135
hU

95
10

I2
IS 22

60
65

1t
45 49

2t l9
28

itl

0.63 o.77
{).98 lu.9ti

6.0
7 7

.l,l

4.5
6 6
?.3 r

55
9.5

62 77
75 6?

70
70 80 110 150 150

28

trI3

t4:) 53
48 5:l 45 66 55 72

l(i

200 220 330 450 450 650 900

1?50

95
12
15

,\tri
;\!()
A2(;
A:10

I
lli
22 30
44

76

7t t46
53 39
,i4

50

I
t1
15

2Si 205 80
s,t iJ0 (i0 (j0

i4-

5I
5(;
5G

154
2.1 2.1 3.1

ls
l6
1s

r;3

220 300 600

1200

t2 t2 l8
49

2l)
2tt

l0 95
212
9l-)

'6i
6t
65 68 42
45

i5
2

30 i
60

30 40 tt0

.\(i(,
AS2

s5 s0
105

42
I6.8
ri3.6 98

30
{i0
21

245 70
r

10

40
;J3

ii,

2i;

120
242 4ii4

t0
50 20

,t
::r

ii0 ,\:i00
r\1

3500
7000

16r
722

96 88 64 22'l 9C 260
2
:10

50 48
45

l.l0
171

2400 5500

I97
140

242
541

r\(iI)0

6500

i5.2

530

l3 291

3l

10.28

MACHINE DESIGN

IO.T4. GEAIT COUPLING

Gcar coupling consists of boss and Ilange .ioirred by external arrd intcrna.l spur gsrrr.ilg. 'Ihc llanges are bolted to get coupling. The Ilanges can be movcd axially fbr cliscpgagcment and is provided lvith O rings ibr providing seal tirr lubricants- (iear csupling is a rigid coupling with some flexibiiity bccause o{' rtsitrg cun'ed exteruai trrcrth. Strcnglh ol gear coupiing is verl' higir and this is the most compact coupling

lirr lriglr

l)(rtvcr trans,rtission.

litvt, r,cri good life and may not requirc any replacenrent in 5 yenrs. Prrrblems cgrrnccLed rvith keying is solved by sirrinl< litting tl-rc hub on thc shaft. These tvpe 6l urtrplings are widely used in rolling mill applications where loads alc' heavv trnd
f1uctrrating-

,i'hc torquc ratings and dimensional dctails ele given in Tablcs. These couplings

FULL GEAR COUPLINGS

Fig.

SHAFTS AND COUPLINGS

10.29

s
@

n o
E N
@

6 O

E N

6 e

r
6

6 O N

N N E

ul
N

q
E

a
N E

&
6
@

o r
r
6

o
H

n N n o @
N

o
m N

e 6

r
6 H

O N 6

o N
6 N
@

m
N

n N
N

h N

o
a o

G]

a 6 e o o 6
6

o
N
@

o o N
o
6 O N

r m
E

z trl

Q O

o
e @ o a

N
h O

o o
h r O E N

r e r
O

r
O

o E
N

a x F
b!

0)

ca

4 N b

o n
O N N

O N O N

o N

a N

o N

o o a o o

o o a
o

o N

n m
o N

o @
a

O
(!' o

;iM

N a

e 6

O N

Er

>;
OL a!

xa

o O
@

o o
@

O O

o s
m m

O O O

o n

o O o N
N

O a N

O N

o O

O r

rE
o
@ @

()
E J
6 o

d a 6

AO

o rc
N C O O N 6

o o o o C
E a

o m
@

6 ts

-a /. I

O o 4

c O

O O @ N

O a 6

o o
6 O

c o

o o o E
D O

O O O a 6
h N

o N

oit LCa p

n o
o

o o
o

o o N
N

ieE Ed.
@a
oa5 NrI

& o
O

n r
o

o
@

n
@

o o

o O