Sanjivani Rural Educational Society’s

SANJIVANI COLLEGE OF ENGINEERING ACAD-F-15 K

(An Autonomous Institution)
Kopargaon – 423 603, Maharashtra.

Academic Year: Revision : 00

2024-25
CIA PROJECT-BASED ACTIVITY REPORT Dated : ________
Date of Preparation
Department : Department of Mechanical Engineering : __________
Course Code &
Year/Sem: I
Name:

Activity Title: Design and analysis of Flexible Bushed Pin Coupling.

Submitted by:

Roll No PRN No Name of the Student Signature

21 UME22F1114 Sanap Pratiksha Radhakrishnan
26 UME22M1030 Dighe Sujit Gahininath
32 UME22M1036 Gagare Harshal Dhondiba
43 UME22M1045 Gite Sandip Annasaheb
68 UME22M1090 Mhalunde Ketan Gopinath

Dr. P. M. Patare

Course Incharge

ACTIVITY REPORT 1
 Rubrics for Project-Based Activity: (15 Marks)
Criteria Weightage Criteria Needs Improvement Meets Expectation Exceeds Expectation
(Level 1) (Level 2) (Level 3)

A (3 Marks) Initiative and Requires motivation Works satisfactorily Can work independently
Creativity and assistance to with assistance without assistance. Able
complete the work Satisfactory translation to translate idea with
Minimal translation of of idea and good presentation
idea and unsatisfactory presentation
presentation
B (5 Marks) Teamwork Team did not The team worked well The team worked well
collaborate or together most of the together to achieve
communicate well. time, with only a few objectives. Each member
Some members would occurrences of contributed in a valuable
work independently, communication way to the project. All
without regard to breakdown or failure data sources indicated a
objectives or priorities. to collaborate when high level of mutual
A lack of respect and appropriate. Members respect and
regard was frequently were mostly respectful collaboration.
noted. of each other
C (5 Marks) Contribution Completion of the Filled a design Published a design
For research / project work (Patent) OR (Patent) OR
Publication Submitted a paper to Presented a paper in
journal / conference conference OR
OR Published a paper in
Submitted to project journal OR
competition Participated in project
competition
D (2 Marks) Submission of Not punctual and Not very punctual but Punctual in submission
record submit incomplete maintains fairly good of record in a satisfied
record record manner

ACTIVITY REPORT 2
 Project-Based Activity (15 Marks)

Roll No of Initiative and Teamwork Contribution Submission Total Marks

the Creativity (5 Marks) For research / of record (15 Marks)
Students (3 Marks) Publication (2 Marks)
(5 Marks)

21

26

32

43

68

ACTIVITY REPORT 3
Abstract :

This report presents the design and analysis of a flexible bushed pin coupling, a critical
component in mechanical power transmission systems. The study employs finite element
analysis (FEA) to optimize the coupling's design, minimizing stress concentration and vibration
amplitude. The optimized design achieves enhanced mechanical performance, misalignment
accommodation, and reduced stress concentration.
The flexible bushed pin coupling is an innovative solution for connecting rotating shafts while
accommodating misalignment, reducing shock, and damping vibrations. This introductory
section provides an overview of the coupling's structure, material selection, and its importance
in mechanical power transmission systems. By combining flexibility with structural integrity,
the flexible bushed pin coupling serves as a reliable and durable component in various
industrial applications, such as heavy machinery and automotive systems. The introduction sets
the stage for a detailed exploration of its design principles, operational benefits, and
analysis methods.
The flexible bushed pin coupling is a critical component in mechanical power transmission,
designed to connect rotating shafts while accommodating misalignment, damping vibrations,
and absorbing shock. This coupling uses flexible bushings around pins, allowing for slight
movements that mitigate wear on connected shafts. Its structure and materials make it suitable
for industrial applications requiring both strength and flexibility, such as in manufacturing,
automotive, and heavy machinery.

ACTIVITY REPORT 4
Introduction:
Bush pin type flange coupling is used to connect of shafts which having a small parallel
misalignment, angular misalignment or axial misalignment. This is a modification of the
protected type flange coupling which has pins (covered by rubber or leather bushes) and it
works with coupling bolts. Generally it is used to assemble electric motors and machines.

In the engines there is a cylindrical flange coupling to union assembled parts. The sensitive
piece is a flange to the parameters like moment, torque, etc. Normally the coupling problems
treated as a beam theory. As we know in mechanical engineering the coupling is used for
connection of two shafts to transmit the power. In gear unit applications the rigid coupling is
designed especially for this purpose.

The parameters that effect to the flange and nut-bolts deformation are force and contact
stiffness factor. To study effect of parameters like normal stiffness, the pretension force and
friction coefficient under external loads the simulations of model bolted joint were carried out,
ANSYS 14 software used for this simulation. To obtain accurate results we need a predefined
process in this program. In flanged and nut-bolted jointed we can see the force and stress have
direct proportional relation.

In this study, the flanged join is modeled and simulated by using Solidwork v. 2016 .the finite
element analysis procedure required in Solidwork simulation is presented as a predefined
process to obtain accurate results. For the first procedure the coupling is designed as a solution
of the given example which finds the dimensions for the main coupling body and its parts, the
simulation is applied on the designed coupling by using Solidwork model designer and
solidwork Simulation add-on for better results on the main stress and deformation areas that
obtained from main acting forces, as a results from the solution of the problem. The procedure
is also aims improving the coupling performance and reducing the stress by applying different
bushes with different materials, for this study only (Rubber, Brass, Aluminum and solid pin
alone) is used for the test.

Flexible bushed pin coupling is designed to connect two shafts that may be subject to slight
misalignment. This type of coupling utilizes a series of bushings that allow for flexibility and
dampening of shocks between connected shafts. It is widely used in power transmission
systems to transmit torque while accommodating angular and parallel misalignments, often
arising due to installation imperfections or operational vibrations.

ACTIVITY REPORT 5
Block diagram:
Design Process of Flexible Bush Pin Coupling

Material Selection of Flexible Bush Pin Coupling From MIDC Kopargaon

Measure The Dimensions Of Flexible Bush Pin Coupling

Create 3D Model In SolidWork Sofware

Fig.1.1 Drafting of Flexible Bush Pin Coupling (Part sheet).

ACTIVITY REPORT 6
 Fig.1.1 Drafting of Flexible Bush Pin Coupling (Assembly Sheet).

Analysis Of Flexible Bush Pin Coupling

Material Selection

Meshing

Apply Boundary Condition

Calculate Equivalent Stress And Total Deformation

ACTIVITY REPORT 7
Application:
Flexible bushed pin couplings are widely used in various applications where misalignment,
shock, and vibrations are prevalent. Typical applications include:

• Heavy Machinery: Used in conveyors, compressors, and crushers where alignment issues and
shock loads are common.

• Automotive Transmissions: In vehicles for reducing vibrations and ensuring smooth power
transfer between the engine and wheels.

• Pumps and Compressors: Helps dampen vibrations and accommodate alignment issues in
fluid handling equipment.

• Power Generation: Connect turbines to generators or other mechanical equipment to transfer

torque with minimal vibration.

• Marine Applications: Used in propulsion systems, especially in high-vibration and

misalignment scenarios.

Wind Turbines: Used in wind turbine power trains to connect the gearbox to the generator,
where it helps to dampen vibrations from wind fluctuations and accommodates shaft
misalignment due to tower sway.

• Material Handling Systems:

Deployed in conveyor systems, especially in mining and material processing, where the
coupling absorbs impact from variable loads and prevents misalignment due to long
shaft connections.

• Textile Machinery: In textile equipment, flexible couplings are used to reduce vibration
in high-speed operations, leading to smoother operations and extending the lifespan of
the machinery.

• Food Processing Equipment: Used in mixers, grinders, and conveyors in food

processing plants, where shock absorption and alignment flexibility are crucial due to
frequent operational starts and stops.

ACTIVITY REPORT 8
Working principle:
The Flexible Bushed Pin Coupling consists of two hubs, typically made of metal, each
attached to one of the shafts. These hubs are connected using several pins with rubber or
polymer bushings, which provide flexibility to the coupling. The bushings act as a buffer
between the pins and the hubs, helping absorb shocks and vibrations.
Torque Transmission: When torque is applied to one shaft, it is transmitted through the metal
hubs and the pins, which connect to the other hub and transmit torque to the second shaft.2.

2. Components
Two Coupling Hubs: These are mounted on the shafts to be connected.
Pins and Bushes: Pins connect the two hubs, and each pin is surrounded by a bushing that
provides flexibility.
Bushing Material: Typically rubber or polyurethane, this provides elasticity, damping, and
absorbs shocks.

3. Advantages
Misalignment Compensation: Can accommodate slight axial, radial, and angular
misalignment.
Shock and Vibration Absorption: The bushings reduce shock and vibration transmission,
protecting both the coupling and shafts.
Low Maintenance: Due to fewer metallic parts in contact, these couplings require minimal
maintenance.
Ease of Installation and Removal: The simple design makes it easy to install and maintain

4. Limitations
Limited Misalignment Tolerance: Suitable only for minor misalignments.
Load Capacity: Not ideal for high-torque or heavy-duty applications, as the bushings may
wear out over time.
Limited Temperature Range: Bushings can degrade under high temperatures, limiting the
application in extreme environments.

5. Design Considerations

When designing a Flexible Bushed Pin Coupling, consider:

Torque Rating: The maximum torque the coupling can handle without bushing deformation
or failure.
Misalignment Allowance: Ensure that expected misalignments in the application are within
the coupling’s permissible range.
Material Selection for Bushings: The material should be selected based on the application's
temperature range, load conditions, and environment.
Number and Size of Pins: More pins provide higher torque capacity but may reduce
flexibility.

6. Analysis of Flexible Bushed Pin Coupling

Analysis typically involves:
Stress Analysis of Pins and Bushings: Determine the stress on each pin and the deformation
of bushings due to torque and misalignment.

ACTIVITY REPORT 9
Simulation/Analysis:

Modeling the Components :

Flange:

• Outer Diameter of Flange: Ø132 mm

• Thickness of Flange: 15 mm

• The flange serves as a connection between the shaft and the coupling and may be
integrated into the hub.
• Design using Extrude Boss/Base and Revolve Boss/Base features. Create a circular
flange shape with holes for the bolts to pass through.

Nut and Bolt:

• Bolt Diameter: M12 (Ø12 mm)

• Number of Bolts: 4 bolts (as indicated)

• Bolt Circle Diameter (PCD): Ø90 mm

• The nut and bolt assembly are used to fasten the coupling to the shaft or housing.
• Use Insert Components to bring in standard Nut and Bolt components from the
SolidWorks Toolbox or create your custom design.
• Ensure the nut and bolt sizes are appropriate for the shaft and flange holes (e.g., M10
or M12).

Key:

Typically, for a 30 mm bore, a key dimension would be :

• Width: 8 mm
• Height: 7 mm
• Length: Same as bore length (40 mm)

• The key is used to prevent the coupling from slipping on the shaft by transferring torque.
• Design the key as a rectangular block that fits into a keyway (groove) on the shaft and
hub.
• Use the Extrude Boss/Base tool for the key and the Cut Extrude tool to create the
keyway on the shaft and coupling hub.

ACTIVITY REPORT 10
Fabric Bush (Flexible Element):

• Bush Hole Diameter: Ø55 mm

• This dimension corresponds to the smaller central hole seen in the front view.

• The fabric bush (or flexible bushing) acts as the shock-absorbing, vibration-damping
element in the coupling.
• Design the bushing as a cylindrical part with the desired inner and outer diameters. The
material should be rubber or elastomer, and the geometry should allow it to fit snugly
between the pins and the hubs.

Shaft:

• Shaft Bore Diameter: Ø30 mm

• Length of Bore: 40 mm (on each coupling half)

• Design the shaft as a simple cylindrical part. You will have two shafts: one for the
input and one for the output.
• Use the Extrude Boss/Base feature to create a cylindrical shape. Add any additional
features, such as a keyway or threads, using Cut Extrude.

Washer:

• Outer Diameter of Washer: Ø55 mm

• Inner Diameter of Washer: Ø30 mm (to match the shaft bore diameter)

• Thickness of Washer: 3 mm

• Washers are used under the nuts to distribute the load.

ACTIVITY REPORT 11
Assembly of Components :

Insert Parts into Assembly:

• Use the Insert Components tool to place the modeled components into an Assembly
file.
• Start by inserting the Shaft components into the assembly, followed by the Flanges,
Bushes, Pins, Key, and Bolts.

Mate Components:
• Use Mate features to correctly position and orient the components:
• Concentric Mate for shafts, ensuring that the hub and bushings align with the
shaft.
• Coincident Mate for flat surfaces (e.g., flange against shaft or washer against
nut).
• Distance Mate for the correct spacing between parts (e.g., between the washers,
nut, and flange).
• Mate with a Key: Use Mate for the key to fix it in the keyway on the shaft and
the coupling hub.

Assembly Constraints:
• Bolts and Nuts: Mate the bolts and nuts with Concentric Mate for the bolt and
hole and Mate the nut to ensure it tightens the coupling.
• Ensure that all parts are properly constrained and positioned before proceeding
to the simulation stage.

Fig:Assembly Drawing

ACTIVITY REPORT 12
Analysis In Ansys:
Create or Import Geometry:
• CAD Modeling: Model the coupling in a CAD software (like SolidWorks) or create
the geometry directly in ANSYS DesignModeler.
• Components to model:
• Hubs: Cylindrical components that connect to the shafts.
• Pins: Cylindrical pins that hold the bushings in place.
• Bushings: Flexible elements typically made from elastomeric materials
like rubber.
• Shafts: Two shafts that will be connected by the coupling.
• Bolts, Nuts, and Washers: For fastening the coupling to the shafts.
• Import Geometry: If the parts are created in an external CAD tool (SolidWorks,
CATIA, e
• c.), use File > Import to bring them into ANSYS Workbench.

Stress Distribution:

• Identify areas where stress exceeds material limits (especially around the pins and
bushings, as these areas can be prone to wear and failure).
• Review the Von Mises stress and max principal stress results to ensure that no
component is overstressed.

Deformation:

• Look at the total displacement of the bushings, shafts, and pins under torque and
misalignment conditions. Ensure that the bushings deform elastically without exceeding
their limits.
• Check that no permanent deformation occurs in the bushings under loading.

Fig:Total Deformation

ACTIVITY REPORT 13
 Fig: Equivalent stress

ACTIVITY REPORT 14
Conclusion:
The analysis of the "Bush Type Flexible Coupling" was conducted through simulations in both
SolidWorks and Ansys to evaluate its structural performance under typical operational loads.
The following points summarize the findings and insights:

1. Stress Distribution:

• The simulation results indicate that the highest stress concentrations occur around the bolt
holes and the keyway. This is expected due to the applied torque and the load transferred
through the bolts and the key.

• The flexible bushes effectively reduce the stress transferred to the coupling hubs, indicating
that the bush design helps in dampening vibrations and compensating for minor misalignments
between the shafts. Deformation and Displacement:

• The deformation of the coupling assembly was within acceptable limits. The bush exhibited
minor deformations, which allowed for some flexibility while maintaining the alignment
between the connected shafts.

ACTIVITY REPORT 15
ACTIVITY REPORT 16