Coupling is a mechanical element that connects two shafts together to accurately

transmit the power from the drive side to the driven side while absorbing the
mounting error (misalignment), etc. of the two shafts.  

Power can be transmitted by means of various gear arrangements or drives only if the
shafts are parallel where as couplings are used when the shafts are in a straight line and
are to be connected end to end to transmit power.

Uses
Shaft couplings are used in machinery for several purposes, the most common of which are
the following.
1. To introduce protection against overloads.
2. To alter the vibration characteristics of rotating units.
3. To transmit power from driver shaft to driven shaft.
4. To connect or couple 2 components which are manufactured separately eg. output
motor shaft and generator.
5. To introduce an extra flexibility while transmitting power in case of space
restrictions.
6. To introduce protection against overloads.
7. To reduce the transmission of shock loads from one shaft to another by using
flexible couplings.

Type of Couplings
There are two basic classes of couplings:-

1. Rigid Couplings
2. Flexible Couplings

Rigid Couplings
This type of coupling has no flexibility or resilience, hence it is necessary for the shafts that
are to  be connected to be in good alignment. Rigid couplings do not accommodate
misalignment and consequently should not be used  indiscriminately.

Types of Rigid Couplings:-

1. Sleeve or Solid muff coupling

2. Half lap muff coupling
3. Clamp coupling or Split muff coupling
4. Flange coupling
1. Sleeve or Solid muff coupling : It is the simplest type of rigid coupling, made of cast
iron. It  consists of a hollow cylinder whose inner diameter is the same as that of 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 haft to the other shaft by means of a key and a sleeve. It is, therefore,
necessary that all the elements must be strong enough to transmit the torque.They are
used where the shafts don’t require any alignments and load capacity is light to
medium duty.

2.Half Lap Muff coupling

In this coupling, ends of the shafts overlap each other for a short length equal to D. An axial
taper of about 3 mm is given on the overlapping faces which prevents shaft from slipping
axially. Since the torque is transmitted by the overlapping ends, a hollow saddle key is
enough to prevent muff from sliding. Muff size is of diameter 2D and length 3D.
3.Clamp coupling (split muff coupling)
Clamp coupling is sometimes called a compression coupling or a ribbed coupling. Clamp
coupling is a modification and an improvement of the sleeve coupling. This coupling is made
in two parts which are machined to fit the shaft and are finished off around the periphery
and on both ends. The two halves of the coupling are clamped tightly against the surface of
the shaft ends by through bolts and the entire torsional moment is transmitted entirely by
friction.

4. Flange coupling
A flange coupling usually applies to a coupling having two separate cast iron flanges. Each
flange is mounted on the shaft end and keyed to it. The faces are turned up at right angle to
the axis of the shaft. One of the flange has a projected portion and the other flange has a
corresponding recess. This helps to bring the shafts into line and to maintain alignment. The
two flanges are coupled together by means of bolts and nuts. The flange coupling is adopted
to heavy loads and hence it is used on large shafting. The flange couplings are of the
following types:-

a) Unprotected type flange coupling

b) Protected type flange coupling
c) Marine type flange coupling

a) Unprotected type flange coupling:- In an unprotected type flange coupling each

shaft is keyed to the boss of a flange with a counter sunk key, and the flange are
coupled together by means of bolts. Generally, three, four or six bolts are used. The
keys are staggered at right angle along the circumference of the shafts in order to
divide the weakening effect caused by key ways. 
b) Protected type flange coupling:- In a protected type flange coupling the
protruding bolts and nuts are protected by flanges on the two halves of the coupling,
in order to avoid danger to the workman.

c) Marine type flange coupling:- It is so called because this type of coupling is

generally used for marine engines. In a marine type flange coupling, the flanges are
forged integral with the shafts. The flanges are held together by means of tapered
headless bolts numbering from four to twelve depending upon the diameter of shaft.
Flexible Couplings
It is nearly impossible completely to eliminate all chance misalignment between the shafts
of separately built machines, and such misalignment of shafts always leads to eventual
failure of bearings or fatigue failure of shafts. The relative position of the connected shafts,
inaccurate at the outset due to inevitable errors of manufacturing, is in course of time
aggravated by deformations caused by the working load, temperature fluctuations, the
uneven sinking of foundations or supports, etc. In such cases ineffective rigid couplings are
replaced by flexible couplings. Therefore the purpose of a flexible coupling is to allow for
imperfect alignment of two joining shafts, or to absorb impact from the fluctuation of
torsional moment or of angular speed.

These couplings are rigid under torsion, but, allow the correction of errors in the alignment
of drive shafts. They are widely used in the fields of robotics or automatisms, because they
are excellent for very accurate system piloting. They are also known as "precision
couplings".

Type of Flexible Couplings:

Some of flexible couplings are as following-

1. Oldham Coupling
2. Universal Joint Couplings
3.Bushed Pin type coupling
4. Jaw coupling
5. Bellows coupling
6. Gear coupling
 1. Oldham Coupling
Oldham can be used for any velocities and loads and cause small additional loads and
bearings.
The special advantage of this coupling is that it can be used for shafts which are not in
alignment but whose axes are parallel up to the extent of 0.05 times the shaft diameter. By
using this type of coupling minor axial alignment of shafts can be compensated.

The coupling consists of two flanges keyed or screwed to the respective shafts and the
flanges have the slots on the face surface. A cylindrical piece called disc with a tongue
running across each flat is present The tounges are at right angles to each other.

The Oldham joints allow rotational movement between two parallel shafts, placed near to
each other.
(Parallel mis-alignment). It is made up of two hubs, and a disk, which has two grooves, at
right angles to each other.
During rotation, the grooves in the hubs slide into the grooves in the disk, thus correcting
the mis-alignment.

The result of this is that the drive shaft and driven shaft turn at the same speed. The
transmission is then said to be 'homokinetic'
The attachment to the shafts is done in one of two ways with fixing screws at right angles to
each other, or, by a clamp fitting.

In the case of fixing screws, a flat section must be machined into the shaft, when using a
clamp fixing, the max. torque must be checked, (possible slipping of the shaft if the torque is
too high in comparison to the shaft diameter.

2. Universal Flexible Couplings/ Hooke's Couplings:

 In cases where the angular or offset misalignment of the shaft reaches values which cannot
be accommodated by flexible couplings, a different type, known as Hooke’s coupling or
universal Flexible coupling can be applied to good advantage. It is named after Robert
Hook , who developed the device. The universal coupling is used for two shafts whose
center lines form a large angle , as 5 to 15 degrees, or even 30 degrees. The joint itself has
no torsional flexibility nor can it accommodate any parallel misalignment. 
This coupling is widely used in agricultural machinery, machine tools and automobiles. It
consists of two fork mounted on the shaft end, either with the help keys or screwed on the
shaft ends. There is a center piece through which pass two pins whose axes are at right
angles to each other.

3. Bushed Pin Type Coupling (Flexible Flange Coupling):- 

This coupling is an upgraded version of flange coupling. The only difference between them is
the usage of rubber bushings. Slightly thick rubber bushings are designed so that the studs or
bolts perfectly fit inside it and bushing fits perfectly inside the holes provided.
The major advantage of using this coupling is that it can be  used for slightly misaligned shafts .
The rubber bushings add a certain amount of flexibility to the coupling which also  helps to
absorb shocks and vibrations . In the various designs this type of flexible coupling is
extensively used, especially where the driving and driven units are mounted on a common
base plate, where excessive misalignment is not likely, for example, a prime mover
connected to a generator, a compressor connected to an electric motor, an electric motor
connected to a centrifugal blower etc

4. Jaw Type Coupling

A jaw coupling is a type of general purpose power transmission coupling that also can be used
in motion control (servo) applications. It is designed to transmit torque (by connecting two shafts) while
damping system vibrations and accommodating misalignment, which protects other components from
damage. Jaw couplings are composed of three parts: two metallic hubs and an elastomer insert called
an element, but commonly referred to as a "spider". The three parts press fit together with a jaw from
each hub fitted alternately with the lobes of the spider. Jaw coupling torque is transmitted through the
elastomer lobes in compression.
The elastomer of the spider can be made in different materials and hardness, which allows the user to
customize the coupling to best serve their application. Considerations for elastomer selection include
ability to dampen vibration, ability to handle misalignment, operational temperature range, speed of
equipment, and chemical conditions,
 4. Bellows coupling:

These couplings link a torsional rigidity, high torque, mis-alignment and high rotational
speeds. They are light in weight, they have a large range of applications and they are very
good value for money.

They are made up of two hubs which are mounted on the shafts, and a bellows, which whilst
being rigid under torsion, has the flexibility in a longitudinal sense to correct any mis-
alignments. The bellows is welded onto the hubs. These couplings are capable of very high
rotational speeds. At high speed, the least eccentricity would lead very high levels of
vibration which could be detrimental to the system as a whole.
5. The gear coupling is another modified version of the flange coupling. In gear
coupling, the flange and hub are different parts assembled together  instead of a
single part as in flange coupling.
The hubs are externally splined but they are so thick and deep that you can regard
them as gear teeth. Also the flanges have internal teeth. The gear ratio is 1:1 and
are meshed together. The single joint gear couplings are limited to lower angular
misalignments.
Application- 
Gear couplings are used for heavy-duty applications where requirement of torque
transmission is higher.