Machine element II

Prepared by Abyot Y.

Chapter Two
Couplings and Clutches
After completing this unit students should be able to
 Know the meaning of coupling
 Know the different types of couplings
 Know the meaning of clutch
 Know the different types of clutches

1
2.1. What is coupling?

 Shaft couplings are devices that connect two shafts to transmit power

from a drive shaft while absorbing some degrees of misalignment and

mounting errors between the two shafts.

2.1.2. Requirements of good shaft coupling

 It should be easy to connect or disconnect
 It should transmit the full power from one shaft to the other shaft

without loss
 It should hold the shafts in perfect alignment

 It should reduce the transmission of shock loads from one shaft to the

other shaft and have no projecting parts. 2

2.1.3. Types of shaft couplings
 Rigid coupling:- is the one that does not allow axial or radial
motion between the driving and the driven shafts. The following are
the types of rigid coupling.
I. Sleeve or muff coupling
II. Compression coupling
IV. Flange coupling
 Flexible coupling:- is used to transmit torque from the driver to the
driven machine while making allowances for minor shaft
misalignment and shaft end position changes between the two
machines.
I. Bushed pin type coupling
II. Universal coupling
IV. Oldham coupling
3
I. Sleeve or muff coupling
 This is the simplest type of rigid coupling consists of a hallow

cylinder whose inner diameter is the same as the shaft. It is fitted

over the ends of the two shafts by means of a gib head key. The
power is transmitted from one shaft to the other shaft by means of a
key and a sleeve or muff.

Sleeve or muff coupling 4

Design of sleeve or muff coupling
 Since the power is transmitted from one shaft to the other by means

of a key and sleeve it is necessary to design them. Mostly the muff

or sleeve is made from cast iron and the usual proportions are
 Outer diameter of sleeve (D) = 2d + 13 and

 Length of the sleeve (L) = 3.5d.

 The sleeve is designed by considering it as a hallow shaft.

5
Conti…
 The key is the mechanical element inserted between the shaft and

the hub in order to prevent relative motion between them. It is

always inserted parallel to the shaft axis. Keys are temporary
fastening elements subjected to considerable crushing and shearing
stresses. After fixing the length of the key the induced crushing and
shearing stresses can be determined by:-

6
Conti…
Example :- Design and make a neat dimensioned sketch of a muff
coupling which is used to connect two steel shafts transmitting 40KW
at 350rpm. The materials for the shafts and key is plain carbon steel
for which allowable shear and crushing stress may be taken as 40Mpa
and 80Mpa respectively. The material for the muff is cast iron for
which the allowable shear stress may be assumed as 15Mpa.

7
II. Clamp or compression coupling

 It is also known as split muff coupling. In this case the muff or

sleeve is made into two halves and are bolted together. Here a
single key is used . This coupling is used for moderate and heavy
duty speeds.

8
Conti…
 Advantages of clamp coupling

 Easy to assemble and disassemble

 Easy to remove without axial displacement of any shaft

 Its diametrical dimensions are small compared to muff

 Couplings strength is more compared to muff

 Disadvantages of clamp coupling

 Dynamic balancing is difficult hence it is not suitable for high speed

application.
 It can not absorb shock and vibration.

 Its cost is more as compared to muff coupling

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Design of clamp or compression coupling
 The muff is designed in the same way as the sleeve coupling.

 Design of clamping bolts

Let

T = Torque transmitted by the shaft,

d = Diameter of shaft,

db = Root or effective diameter of bolt,

n = Number of bolts,

σt = Permissible tensile stress for bolt material,

µ = Coefficient of friction between the muff and shaft, and L = Length of

muff. 10
Conti…
 We know that the force exerted by each bolt
=
 Force exerted by the bolts on each side of the shaft
= x n/2
 Let p be the pressure on the shaft and the muff surface due to the
force, then for uniform pressure distribution over the surface

P= =

11
Conti…
 Frictional force between each shaft and muff
F = µ × pressure × area = x µ x ½ dL
= µ
 The torque that can be transmitted by the coupling,
T = F x d/2 = µ x d/2
= xdxµ

12
Conti…
Example1:- Design a clamp coupling to transmit 30 kW at 100
r.p.m. The allowable shear stress for the shaft and key is 40 MPa and
the number of bolts connecting the two halves are six. The
permissible tensile stress for the bolts is 70 MPa. The coefficient of
friction between the muff and the shaft surface may be taken as 0.3.

Shaft diameter = 75mm

Sleeve diameter = 165mm

Length of sleeve = 262.5mm

Width of key = 22mm

Length of key = 14mm and diameter of bolt = 22.2mm 13

Flange coupling

 Flange coupling is a type of coupling used to connect two rotating

shafts. The flanges are set at the end of each shaft and joined by a
ring or bolts to form the drive. One flange have projected portion
and the other flange has corresponding recess.
Flange
Connectin
g bolt

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Conti…
 The flange couplings are of the following three types

A. Unprotected type flange coupling

B. Protected type flange coupling

C. Marine type flange coupling

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Design of flange coupling

Let
d = Diameter of shaft or inner diameter of hub,
D = Outer diameter of hub,
16
Conti…
d1 = Nominal or outside diameter of bolt,

D1 = Diameter of bolt circle,

n = Number of bolts,

tf = Thickness of flange,

τs , τb and τk = Allowable shear stress for shaft, bolt and key

material respectively

τc = Allowable shear stress for the flange material i.e. cast iron,

σcb, and σck = Allowable crushing stress for bolt and key material
respectively.
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Conti…
 Design for hub :-The hub is designed by considering it as a hollow

shaft, transmitting the same torque (T) as that of a solid shaft. The
outer diameter of hub is usually taken as twice the diameter of shaft.
Therefore from the above relation, the induced shearing stress in the
hub may be checked. The length of hub (L) is taken as 1.5 d.
 Design for key:-The key is designed with usual proportions and

then checked for shearing and crushing stresses. The material of key
is usually the same as that of shaft. The length of key is taken equal
to the length of hub.

18
Conti…
 Design for flange:- The flange at the junction of the hub is under
shear while transmitting the torque. Therefore, the torque
transmitted, T = Circumference of hub × Thickness of flange ×
Shear stress of flange × Radius of hub.

 The thickness of flange is usually taken as half the diameter of

shaft. Therefore from the above relation, the induced shearing stress
in the flange may be checked.
 Design for bolts:- The bolts are subjected to shear stress due to the

torque transmitted. The number of bolts (n) depends upon the

diameter of shaft and the pitch circle diameter of bolts (D1) is taken
as 3d. 19
Conti…
 Load on each bolt =

 Total load on all the bolts =

 The torque transmitted =

 From this equation, the diameter of bolt (d1) may be obtained.

Now the diameter of bolt may be checked in crushing. We know

that area resisting crushing of all the bolts = n × d1 × tf and
crushing strength of all the bolts = (n × d1 × t f ) σcb
20
Conti…
 Torque, T = (n × d1 × tf × σcb ) D1/2
 From this equation, the induced crushing stress in the bolts may be
checked.

Example1:- Design a cast iron protective type flange coupling to

transmit 15 kW at 900 r.p.m. from an electric motor to a compressor.
The service factor may be assumed as 1.35. The following permissible
stresses may be used : 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

Draw a neat sketch of the coupl 21

Flexible couplings
 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.

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I. Bushed pin coupling

 Is the modification of rigid type of flange coupling. The coupling

bolts are known as pins. The rubber or leather bushes are covered
over the pins. The two halves of the couplings are dissimilar in
construction.

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Design of bushed pin coupling
 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.

24
Conti…

25
Conti…
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 = pb × d2 × l

Total bearing load on the bush or pins = W × n = pb × d2 × l x n

The torque transmitted by the coupling, T = W x n x D/2

=
26
Conti…
 The threaded portion of the pin in the right hand flange should be a

tapping fit 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,

27
Conti…
 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 as shown in
Fig.
 The bush portion of the pin acts as a cantilever beam of length

 Assuming a uniform distribution of the load W along the bush, the

maximum bending moment on the pin,



 The bending stress (σ) =

28
Conti…
 Maximum principal stress =

 The maximum shear stress on the pin =

Example1:- Design a bushed-pin type of flexible coupling to connect

a pump shaft to a motor shaft transmitting 32 kW at 960 r.p.m. The
overall torque is 20 percent more than mean torque. The material
properties are as follows : (a) The allowable shear and crushing stress
for shaft and key material is 40 MPa and 80 MPa respectively. (b) The
allowable shear stress for cast iron is 15 MPa. (c) The allowable
bearing pressure for rubber bush is 0.8 N/mm2. (d) The material of the
pin is same as that of shaft and key.
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II. Universal coupling
 Is the type of coupling used to transmit torque and motion between

shafts that are not parallel but intersecting at an angle.

 A universal coupling is composed of two yokes.

 The yokes are connected by a cross shaped member called spider.

 The two shaft yokes are at right angles with each other.
Spider

The two
yokes 30
Conti…

Let

d = Diameter of shaft, dp = Diameter of pin, and τ and τ1 = Allowable

shear stress for the material of the shaft and pin respectively. We know
that torque transmitted by the shafts, 31
Conti…
 Since the pin is in double shear, therefore the torque transmitted,

 When a single Hooke's coupling is used, the ratio of the driving and driven

shaft speeds is given by

Where, N = Speed of the driving shaft in r.p.m.

N1 = Speed of the driven shaft in r.p.m.,

α = Angle of inclination of the shafts, and θ = Angle of the driving shaft

from the position where the pins of the driving shaft fork are in the plane
of the two shafts. 32
Conti…
 Maximum speed of driven shaft
 Minimum speed of driven shaft

Example1:- An universal coupling is used to connect two mild steel

shafts transmitting a torque of 5000 N-m. Assuming that the shafts
are subjected to torsion only, find the diameter of the shafts and pins.
The allowable shear stresses for the shaft and pin may be taken as 60
MPa and 28 MPa respectively .

33
IV. Oldham coupling

 Is a type of coupling which transmits torque between shafts through

mating slots on the center of discs mounted on the hub.

 There are three main parts in the Oldham coupling.

 These components are two flanges that are assembled with two

shafts and middle disc used to link the two discs by tongue and
grove.

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Design of Oldham coupling
 The design of Oldham coupling will be based on the allowable

pressure between the faces of the slots and the tongues.

 Because of the elasticity of the material the pressure distribution for

perfectly flat surfaces can be assumed to change on each side.

35
Conti…
 Distance to the pressure area centroid from the center line (L)
= X = where D is the diameter of the disc
 The total force on each side = where p = maximum pressure and
h is the depth of the slot or tongue.
 The torsional moment transmitted by both sides of the tongue will
be T = 2F x L = 2 x x =
 The power transmitted by this coupling is = =
 The different proportions of Oldham coupling are
Shaft diameter = d
Diameter of boss = d1= 2d
Diameter of the flange = D = 3d to 4d
Depth of the slot or tongue = h = t/2

36
Conti…
Width of the slot or tongue = D/6
Thickness of the disc = t/2
Thickness of the flange = 0.75d
Length of the boss = 1.74d

Example1:- Determine the main dimensions of Oldham coupling for a

shaft diameter to be 90mm. The shaft is required to transmit the full
torsional moment. Check the maximum power that can be transmitted
by this coupling for an allowable pressure between the slot and the
tongue to be 8.5N/mm2 and the speed of the shaft is 1000rpm.

37
2.2. What is Clutch?

 A Clutch is a mechanical device which is used to connect or

disconnect the source of power from the remaining parts so the power
transmission system at the will of the operator.
 Mechanical clutches provide either a positive (with no-slip) or a

friction-dependent drive (with some slip).

2.2.1. Types of mechanical clutches

I. Positive clutches
 Positive clutches are collars with jaws that interlock, one member

being rigidly attached to its shaft while the other slides on its shaft.
38
Conti…
 The positive clutches are used when a positive drive is required.
A positive drive is a drive without relative rotational motion
between the connected shafts.
 The simplest type of a positive clutch is a jaw or claw clutch as
shown by the next figures.

39
II. Friction clutches
 Works on the basis of the frictional forces developed between the
two or more surfaces in contact.
Advantages
 Can be used at high engagement speeds with out stopping the
power source.
 Smooth engagement
 Due to slip created b/n contacting surfaces, there is a minimum
shock.
Dis-advantages
 Costly
 Create high temperature

40
II. Types of friction type clutches
The major types of friction clutches are:-

a. Plate (disc) clutch (single plate or multiple plates:- Operates by

a principle of engaging and disengaging single or multiple rotating
friction discs.

41
b. Cone clutch:- Operates by a principle of engaging and disengaging
a cup and a follower cone.

42
Design of disc clutch
 In analyzing the performance of these devices we shall be
interested in:
 The actuating force
 The torque transmitted
 The energy loss
 The temperature rise
 Consider two friction surfaces maintained in contact by an axial
thrust (W) as shown in the figure.

43
Conti…
Let
T = Torque transmitted by the clutch,
p = Intensity of axial pressure with which the contact surfaces are
held together,
r1 and r2 = External and internal radii of friction faces,
r = Mean radius of the friction face, and
μ = Coefficient of friction.
 Consider an elementary ring of radius r and thickness dr as shown
in the above figure.
 The area of the contact surface or friction surface

44
Conti…
 Then, the normal or axial force on the ring, is given by

 The frictional force on the ring acting tangentially at radius r,

 The frictional torque acting on the ring, is

 Now, consider the following two cases

 When there is a uniform pressure
 When the pressure is uniformly distributed over the entire area
of the friction face as shown in the above figure, then the
intensity of pressure,

45
Conti…

where W = Axial thrust with which the friction surfaces are held
together. The frictional torque on the elementary ring of radius r and
thickness dr is known to be

 Integrating the above equation within the limits from r2 to r1 for the

total friction torque to be

46
Conti…
Where,

 Considering uniform axial wear:

The basic principle in designing machine parts that are subjected to

wear due to sliding friction is that the normal wear is proportional
to the work of friction. The work of friction is proportional to the
product of normal pressure (p) and the sliding velocity (V).

Therefore,

47
Conti…
 When the friction surface is new, there is a uniform pressure

distribution over the entire contact surface. This pressure will wear
most rapidly where the sliding velocity is maximum and this will
reduce the pressure between the friction surfaces. This wearing-in
process continues until the product p.V is constant over the entire
surface. After this, the wear will be uniform as shown in figure
shown here.

48
Conti…

Let p be the normal intensity of pressure at a distance r from the axis

of the clutch. Since the intensity of pressure varies inversely with the
distance, therefore
 The normal force on the ring,

Therefore, the total force acing on the friction surface,

Or

49
Conti…
 It is known that the frictional torque acting on the ring,

 Total frictional torque acting on the friction surface (or on the

clutch),

Where,

50
Conti..
Example1:- A single plate clutch with both sides on the
plate effective is required to transmit 25KW at 1600rpm.
The outer diameter of the plate is limited to 300mm and the
intensity of pressure between the plates not exceeded
0.07N/mm2. Assuming the uniform wear and coefficient of
friction 0.3. find the inner diameter of the plates and the
axial force necessary to engage the clutch.

Anws: d = 120mm , F = 2375N

51
Conti…

Example2:- A dry single plate clutch is to be designed for an

automotive vehicle whose engine is rated to give 100KW at 2400rpm
and a maximum torque 500Nm. The outer radius of the friction plate
is 25% more than the inner radius. The intensity of pressure between
the plate is not exceeded 0.07N/mm2. The coefficient of friction may
be assumed 0.3. The helical springs required by this clutch to provide
axial force necessary to engage the clutch are eight. If each spring
has stiffness equal to 40N/mm. determine the dimensions of the
friction plate and initial compression spring in the springs. Anws,
r1=237.5mm, and r2=190mm
52
Conti…
Example3:- A single plate clutch with both side of effective
has outer and inner diameter of 300mm and 200mm
respectively the maximum intensity of pressure at any point
in contact surface is not exceeded 0.1N/mm2. If the
coefficient of friction is 0.3, determine the power
transmitted by the clutch at a speed of 2500rpm.

Anws : P = 61.6x103 W

53
Design of cone clutch
 In analyzing the performance of these devices we shall be
interested in know the following terms

Di= Inner diameter of cone,

Do = Outer diameter of cone,
Dm = mean diameter of cone,
µ = Semi cone angle or pitch cone
angle or face angle,
P = Intensity of normal pressure at
contact surface,
μ = Coefficient of friction,
Fa = Axial force

54
Conti…

A. Uniform pressure Theory (p – constant):

55
Conti…
B. Uniform wear theory (pr = constant)

56
Conti…
Example1:- The contact surface in the cone clutch have an
effective diameter of 80mm. The semi angle of the cone is
15degree and the coefficient is 0.3. Find the torque required to
produce slipping of the clutch if the applied axial force applied
is 200N. The clutch is employed to connect an electric motor
running uniformly at 900rpm with a flywheel which is initially at
rest. The flywheel has a mass of 14Kg and its radius of gyration
is 1600. calculate the time required for the flywheel to attain
full speed and also the energy lost in slipping of the clutch.

t = 3.64 second 57
 END OF CHAPTER TWO

What is What is is
coupling? clutch?

CHAPTER THREE
BRAKE

58