FLANGED COUPLING

What is coupling?
 A device that is used to connect two shafts together for

the purpose of power transmission.

General types of
couplings:
 Rigid: for aligned shafts
 Flexible: for non-aligned shaft

Rigid couplings:
Rigid couplings are aligned shaft couplings that are designed

to draw two shafts together so that no motion can occur

between them
 Types of rigid
couplings:
1-Flanged 2-Sleeve/Muff Coupling

3-Clamp/Split muff/Compression Coupling

Flexible couplings:
i. Used to join shafts that meet at a slight angle.
ii. Angle may still change while running due to vibration or

load.

Types of flexible
couplings:
1-Universal Coupling2-Bushed Pin Type Coupling
3-Olbham Coupling

Flanged Coupling:
Flange:

A flange is defined as a plate type device, normally round,

that is attached to the end of a pipe, fitting, valve or other

object to facilitate the assembly and disassembly of a piping

system.

Flange coupling:Each flange is mounted on

the shaft and keyed to it. Faces are turned up at right angle

to the axis of the shafts. One of the flange has a projected

portion and other has a corresponding recess. Two flanges are

coupled together by bolts and nuts.

Types of flange
couplings:
1-Protected type flange coupling

2-Unprotected type flange coupling

3-Marine type flange coupling

Unprotected type
flange coupling:
In this type of flange coupling each shaft is keyed to the boss

of a flange with a counter sunk key and the flanges are

coupled together by means of bolts (Generally 3,4,6 bolts are

used.)Keys are staggered at right angle along the

circumference of the shafts in order to divide weakening

effect caused by key ways.

Unprotected type
flange coupling:
The usual proportions for an unprotected type cast iron flange

couplings, are shown as follows:

Let d = Diameter of shaft or inner diameter of hub,

D = Outer diameter of hub,

 d1 = Nominal or outside diameter of bolt,

D1 = Diameter of bolt circle,

n = Number of bolts,

tf = Thickness of flange,

τs, τb, 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

1-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.

T=3.14/16×τc(D^4-d^4/D)

Here D=2d and L=1.5d

2-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.

3-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 shaft ×Radius of hub

=3.14D×tf×τc×d/2=3.14D^2/2×τc×tf

Here tf=1.5d

Therefore from the above relation, the induced shearing

stress in the flange may be checked.

4-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 D1=3, load on each bolt=3.14/4×(d1)^2 τb Total load on all

the bolts=3.14/4(d1)^2 τb×n And torque is transmitted

T=3.14/4(d1)^2τb×n×D/2

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

Now, the diameter of bolt may checked in crushing.

Area resisting crushing of all the bolts

=n×d1×tf

And crushing stress for all the bolts

=( n×d1×tf) σcb

Torque,

T=( n×d1×tf×σcb)D1/2

From this equation, the induced crushing stress in the

bolts may be checked.

 CALCULATIONS:
Statement:
Design flange coupling with diameter of shaft 60mm and

material of shaft is high carbon steel, material of key,

coupling and bolt is low carbon steel with factor of safety 2.

Data:

d = 50mm

For high carbon steel Sy = 380 MPa

For low carbon steel Sy = 300 MPa

FOS = 2

Solution:

For shaft:

Τ all = 0.4 Sy =0.4×380 = 152 MPa

Σ all = 0.9 Sy = 0.9×380 = 342 MPa

nf = T all/ Td

Td = 152/2 = 76 MPa

Tmax = pi/16 d3 Td =pi/16 (0.06) 76= 3221.64 Nm

For hub, key,bolts,:

tall = 0.4 Sy = 0.4×300 = 120 MPa

σall = 0.9 Sy = 0.9×300 = 270 MPa

nf = tall/td

td = tall/ nf = 120/2 = 60 MPa

σd = σall/ nf = 270/2 = 135 MPa

1-Design of hub:

D = 2d = 2×60 = 120mm

L = 1.5d = 1. ×560 =90mm

T = pi/16 tc[D^4 – d^4] / D

3221640 = pi/16 tc (120^4 – 60^4 )/ 120

tc = 10.13 MPa<60MPa

which is designed stress so design is safe here.

2-Design of key:

w= d/4 = 60/4 = 15 mm

t = d/6 = 60/6 = 10mm

l = 1.5d = 1.5×60 = 90m

Shear of the key:

T = tk×w×l(d/2)w
 tk = T/w×l× (d/2)

= 3221640/ 15×90×30=79.54 Mpa

Crushing of the key:

σck = 2T/ t×l× (d/2)

= 6443280/ 27000

= 238.64 MPa

3-Design for flange:

tf = 0.5 d=30mm

Resistive area=piD

T=tc.pid^2/2.tf , tc =2T/piD^2tf=4.75MPa

While for flange:

td=60MPa

It means the actual shear stress(4.75MPa) in flange is less

than designed(60MPa)so our design is in safe range.

4-Design for bolts:

D1=3d=3(60)
 =180mm

T=tb×pi/4×db^2×n×D1/2

db^2=8T/tb.pi.n.D1/2

db =19.49mm

From Market point of view 22mm or 22M.

Now,

T=σcb×n×(db×tf)×D1/2

σcb = 2T/n.db.tf.D1

=13.55 MPa<135MPa

which is designed stress so design is safe.

Objective

• The objective of this project is to

design and fabricate a Bushed-pin
type flexible coupling.
• Its function is to transmit power
between shafts that are partially
misaligned and it also absorbs
shock loads.
• It employs rubber bushes fitted
over pins that transmit torque by
means of shear resistance.
• Design will be carried out by
choosing a prime mover having an
output of 5000 W and a speed of
750 rpm.
PHOTOGRAPHIC VIEWS OF THE
COUPLING
AUTOCAD DIAGRAM OF THE
COUPLING
LIST OF COMPONENTS
USED
• INPUT FLANGE : It is keyed to the input shaft coming from the prime
mover and transmits power to the pins through the
rubber bush.

• OUTPUT FLANGE : It obtains power from the pins by means of shear

resistance, is keyed to the output shaft.

• PINS : The pins here are nothing but unthreaded bolts. They
connect the two flanges and also maintain a clearance
between the two shafts for angular misalignment.

• RUBBER BUSHES : These rubber bushes are provided to absorb shock

loads, torsional vibrations and angular misalignments.
They are provided with brass linings to reduce wear.
INPUT FLANGE

OUTPUT FLANGE
 PINS

RUBBER BUSHES
 DESIGN OUTPUT DIAGRAM
DRAWN USING AUTOCAD

DESIGN OUTPUT PARAMETERS

• SHAFT DIAMETER : 16mm
• OUTER FLANGE DIAMETER : 100 mm
• HUB DIAMETER : 30mm
• PCD of PINS : 63mm
• LENGTH OF HUB : 30mm
• PIN DIAMETER : 10mm
• LENGTH OF BUSH : 20mm
• PROTECTIVE LAYER : 12mm
THICKNESS
• NUMBER OF PINS : 4
• DIAMETER OF BUSH : 22mm
• CLEARANCE : 2mm
ADVANTAGES

• It can tolerate 0.5mm of lateral or axial misalignment and 1.5

degrees of angular
misalignment.
• Prevents transmission of shock from one shaft to the other and
absorbs vibrations.
• It can be used for transmitting high torques.
• It is simple in construction and easy to assemble and
dismantle.
• It is easy to design and manufacture the coupling.
• For the same size of shafts, flexible bush coupling has larger
number of bolts or
larger pitch circle diameter than rigid type coupling.
This reduces the force acting on the
pins and
lowers bearing pressure on the rubber bush.

DISADVANTAGES

• The cost of flexible coupling is more than that of rigid coupling

due to additional parts.
• It requires more radial space compared with other types of
coupling.
• Maximum allowable peripheral speed of the coupling is 30m/s.
 Design of shaft coupling

• Shafts are usually available up to 7 meters length due to

inconvenience in transport.
• In order to have a greater length, it becomes necessary to join two
or more pieces of the shaft by means of a coupling

• Shaft couplings are used in machinery for several purposes,

• 1.To provide for the connection of shafts of units that are
manufactured separately such as a motor and generator and to
provide for disconnection for repairs or alternations.
• 2.To provide for misalignment of the shafts or to introduce
mechanical flexibility.
• 3.To reduce the transmission of shock loads from one shaft to
another.
• 4.To introduce protection against overloads.
• 5.It should have no projecting parts

• Requirements of a Good Shaft Coupling

• 1.It should be easy to connect or disconnect.
• 2. It should transmit the full power from one shaft to the other shaft
without losses.
• 3.It should hold the shafts in perfect alignment.
• 4.It should reduce the transmission of shock loads from one shaft to
another shaft.
• 5.If should have no projecting parts.
 Types of Shafts Couplings
• 1. Rigid coupling 2. Flexible coupling
1. Rigid coupling : It is used to connect two shafts which
are perfectly aligned.
• types of rigid coupling are
• a)Sleeve or muff coupling.
• b)Clamp or split-muff or compression coupling,
• c)Flange coupling

• 2.Flexible coupling : It is used to connect two shafts

having both lateral and angular misalignment.
• Types of flexible coupling are
• a)Bushed pin type coupling,
• b)Universal coupling, and
• c)Oldham coupling

a. Sleeve or 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 (sleeve).
• It is fitted over the ends of the two shafts by means
of a gib head key, as shown in Fig.
 • The power is transmitted from one shaft to the other
shaft by means of a key and a sleeve.

• SHAFT - (d, T)
d = diameter of the shaft , T= torque
• SLEEVE – (D, L)
D= Outer diameter of the sleeve
• KEY- RED
• l= length, w= width, t=thickness

1. Design for sleeve

• The usual proportions of a cast iron sleeve coupling

• Outer diameter of the sleeve, D =2d + 13 mm

• length of the sleeve, L=3.5d

Where d = diameter of the shaft
• The sleeve is designed by considering it as a hollow
shaft.
• T=Torque to be transmitted by the coupling
• τc=Permissible shear stress for the material of the
sleeve which is cast rion.
• τc = 14 MPa.
• Torque transmitted by a hollow section
T = (π/16)×τc×(D4-d4)/D
= (π/16)×τc×D3(1-K4)
... (∵k = d / D)
• From this expression, the induced shear stress in
the sleeve may be checked

2. Design for key

• The length of the coupling key = length of the sleeve
( i.e. . 3.5d ).
• The coupling key is usually made into two parts
• length of the key in each shaft
l= L/2=3.5d/2
• After fixing the length of key in each shaft, the
induced shearing and crushing stresses may be
checked. We know that torque transmitted,

• T = l× w×τ ×(d /2)

(Considering shearing of the key)
• T = l × t/2 × σC × (d /2)
(Considering crushing of the key
 b. Clamp or Compression Coupling

• the muff or sleeve is made into two halves and are

bolted together.
• The halves of the muff are made of cast iron.
• The shaft ends are made to a butt each other
• a single key is fitted directly in the keyways of both
the shafts.
• One-half of the muff is fixed from below and the other
half is placed from above.
• Both the halves are held together by means of mild
steel studs or bolts and nuts.
• The number of bolts may be two, four or six.
• The advantage of this coupling is that the position of
the shafts need not be changed for assembling or
disassembling of the couplings

1. Design of muff

• The usual proportions of a cast iron sleeve coupling

• Outer diameter of the sleeve, D =2d + 13 mm

• length of the sleeve, L=3.5d

Where d = diameter of the shaft
• The sleeve is designed by considering it as a hollow
shaft.

• T=Torque to be transmitted by the coupling

• τc=Permissible shear stress for the material of the
sleeve which is cast iron.
• τc = 14 MPa.
• Torque transmitted by a hollow section
T = (π/16)×τc×(D4-d4)/D
= (π/16)×τc×D3(1-K4)
... (∵k = d / D)
• From this expression, the induced shear stress in
the sleeve may be checked
 2. Design for key

• The length of the coupling key = length of the sleeve

( i.e. . 3.5d ).
• The coupling key is usually made into two parts
• length of the key in each shaft
l= L/2=3.5d/2
• After fixing the length of key in each shaft, the
induced shearing and crushing stresses may be
checked. We know that torque transmitted

• T = l× w×τ ×(d /2)

(Considering shearing of the key)
• T = l × t/2 × σC × (d /2)
(Considering crushing of the key

3. Design of clamping bolts

• T =Torque transmited by the shaft,

• d =Diameter of shaft,
• d b=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.

• force exerted by each bolt (F) =(π/4) (d b2 ) σt

• Force exerted by the bolts on each side of the shaft
(F)= (π/4) (d b2 ) (σt )(n/2)
• (P )be the pressure on the shaft and the muff surface
due to the force, then for uniform pressure distribution
over the surface
• P=Force/Projected area
• P= (π/4) (d b2 ) (σt )(n/2)/(1/2)Ld

• ∴Frictional force between each shaft and muff,

F =µ× pressure × area
• F=(µ × (π/4)(d b2 )(σt )(n/2)/(1/2)Ld )
× π (1/2) d L
 • F= µ × (π2/8)(d b2 )(σt )(n)

• Torque that can be transmitted by the coupling

T=F × d/2
T=µ × (π2/8)(d b2 )(σt )(n)×d/2
• From this relation, the root diameter of the bolt (d b )
may be evaluated . µ=0.3
 c. 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
• Flange coupling are
• 1.Unprotected type flange coupling
• 2. Protected type flange coupling
• 3. Marine type flange coupling
Conclusion:

Coupling designed according to the above considerations

will be more suitable, but the modifications according to our

needs can also be made for more better results.

 AUTOMOBILE SHOP EQUIPMENT

As good workshop must have equipped undertake all types of fault

finding and Servicing jobs. The following is a list of tools and equipment
which are must in the workshop:-

1. Screw drivers.
2. Spanners, Wrenches etc.
3. Pliers.
4. Hammer
5. Chisel
6. Files
7. Hack saw
8. Drilling machine
9. Bench vice
10. Grinder
11. Measuring tools
12. Chain pulley block
13. Hydraulic jack and axle stands
14. Creeper
15. lubrication equipment
16. Battery testing and charging.
17. Electric equipment.
18. hydraulic lilt
19. Tools for treys .
20. Tyre remover
21. wheel balancing equipment
22. brake testing
23. high pressure washing equipment
24. Engine analyzer.
25. Air compressor and pressure gauge.
26. workshop manuals for popular vehicle
27. Hydraulic press.
28. Piston ring compressor.
29. Ring remover.
30. ring fitting tool
31. Piston grooves cleaner.
32. Cylinder boring machine.
33. cylinder boring machine
34. Valve facing machine.
35. Valve seat grinding equipment.
36. Chassis alignment equipment.
37. Spark plug testing and cleaning machine.
38. Steering geometry and alignment machine .
39. Connecting rod alignment machine.
40. Nozzle testing and cleaning equipment.
41. Fuel injector tester.
42. Centre lathe.
43. Fire extinguisher.
44. Electric welding set.