Design and manufacturing of a new type torque connection

Torque connection (coupling) is termed as a device used to connect two shafts to each other at their ends for the purpose of transmitting power. The couplings can be divided into two main groups, first is rigid coupling second type is flexible coupling. Rigid coupling used to connect two shafts which are perfectly aligned and flexible coupling used to join two rotating parts and allow some degree of misalignment. The flexible coupling also falls into two main categories: Material Flexing and Mechanical Flexing. The material flexible types obtain their flexibility from stretching or compressing a resilient material or from the flexing of thin metallic discs. The mechanical flexing couplings accept misalignment from rocking, rolling or sliding of metal surfaces. In this thesis, design and simulation of a modified coupling was studied. Design of coupling was conducted by solid modeling CAD software (SOLIDWORKS 2018). After preparing the 3D model in SOLIDWORKS, the numerical analysis was obtained with the use of ANSYS 16.2 software. Manufacturing of each part of the new design was explained in details. Comparisons made between the new design and standard flange coupling with respect to load capacity and misalignment. The new design is an attempt to reach a better performing coupling. By combining the two types of the main categories: Material Flexing and Mechanical Flexing type of couplings, increasing the critical part's area to decrease the stress that may be occurring, giving some parts the ability to slide and with the presence of the resilient material, high misalignment and high torque capacity with more reliability were obtained.