ISSN: 2455-2631 © September 2019 IJSDR | Volume 4, Issue 9

MODELING AND STRUCTURAL ANALYSIS OF

RIGID FLANGE COUPLING BY UG-NX AND FINITE
ELEMENT METHOD
1C.SUBHAHAN BASHA, 2M.RAJESH, 3S.VASUDEVA RAO

1
Assistant Professor, 2Assistant Professor, 3Assistant Professor
Department of Mechanical engineering,
Gates Institute of Technology, Gooty-515401, A.P.

Abstract: A coupling is a mechanical device which is used to connect two shafts for power transmission. A shaft coupling consist a
rigid or flexible joint. Rigid joint holds both the shaft with perfectly alignment whereas flexible joint allows angular displacement
between the shaft axis. This project shows the structural analysis of flange coupling using ANSYS workbench 18.1. Grey cast Iron
and plain carbon steel is used as flange coupling material. The main objective of this paper is to verify the safe design of flange
coupling to transmit power of 25 kW by comparing theoretical and analytical result both. UG-NX10.0 software is used to create
the model of flange coupling.

Keywords: Flange Coupling, Shear stress, Crushing stress, Grey cast iron, ANSYS 18.1, UG-NX 10.0

I. INTRODUCTION
A power transmission shaft is generally provided with standard length of 8m. Longer shafts are not convenient in use and
transportation. Therefore shaft coupling is used to connect two separate shafts. It also reduces the bending and vibration produced
is the shaft system. It also reduces the transmission of shock loads from one shaft to another shaft.
Shaft couplings can be broadly classify into two groups-
1) RIGID COUPLING: When two shafts are aligned perfectly, it is known as rigid coupling. It does not permit any misalignment
to the shaft axis. Types of rigid coupling are-
a) Sleeve or muff coupling
b) Split muff or clamp coupling
c) Flange coupling
2) FLEXIBLE COUPLING: - When a coupling system provides lateral and angular misalignment to the shafts, it is known as
flexible coupling. It permits certain degree of displacement to the shaft axis. Types of flexible coupling are-
a) Bushed pin type coupling
b) Universal coupling
c) Oldham coupling

FLANGE COUPLING: - Flange coupling is generally used for heavy load application. It consists of two separate flanges mounted
on each end of the shaft. Out of which one flange has extended or projected face and other flange has a corresponding recess. It
allows bringing the shafts perfectly co-axial. The flanges are joined by nuts and bolts. Number of bolts depends upon the power
transmitted and diameter of shafts used. There are some types of flange coupling are-
a) Unprotected flange coupling
b) Protected flange coupling
c) Marine type flange coupling

II.MATERIALS AND PROPERTIES

Rigid flanges are usually manufactured by casting process technique. The commonly used material for flange coupling grey cast
iron (ferrous metal carbon % between 2.5 to 4) which is characterized by graphite flakes microstructure to have a grey appearance
because it has a good damping capacity compare to other ferrous metals. The composition of grey cast iron is 2.5-4% carbon, 1-
3% silicon and the rest is iron by weight proportion. It has less tensile strength and good shock resistance as compared to its
compressive strength. It’s mechanical Properties are controlled by the size of the graphite flakes which it has good wear resistance
and damping capacity. It also has less solidification shrinkage than other cast iron that does not easily form graphite
microstructure while grain growth during solidification. The silicon promotes good corrosion resistance and increase fluidity
while casting.

Table.1. Material Properties

Items Name Material

Shaft Plain Carbon Steel
Flange Grey Cast Iron
Key, Nuts and Bolts Plain Carbon Steel

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Fig:1 Isometric view of protective rigid flange coupling

III. DESIGN AND CALCULATION

Input parameters
Power transmit: 25 kw at 500 rpm
Assume TMax = 1.25 TMean
Allowable shear stress in shaft: 35 MPa
Allowable Tensile stress in shaft: 60 MPa
Shear stress for cast iron: 12 MPa
Allowable shear stress for key material: 35 MPa
Crushing stress for key: 60 MPa
Shear stress for bolt material: 28 MPa
Crushing stress for bolt material: 60 MPa

Calculations
I) Design torque TMax= Tmean X service factor
Service factor is assumed to be 1.25
Tmean = 60000xP
2πN
= 60000x25x1000
2πx500
= 477.464x103 N-mm
TMax = Tmean x service factor
= 477.464x103 x1.25
= 596.830 x103 N-mm
We also know that Maximum Torque Transmitted by the shaft

TMax = π τs x d3
16
596.830 x103 = π 35x d3
16
d = 44.28≈45mm.
II) Other Dimensions of the Coupling
a) Hub diameter Dh=2d=2×45=90mm
b) Hub length l=1.5d=1.5×45=67.5mm≈68mm
c) Bolt circle diameter D=3d=3×45=135mm
d) Rectangular sunk key b=d/4=12mm
h=d/6=8mm
e) Flange thickness t =0.5d=0.5x45=23mm
f) Web thickness t1 = 0.25d=12mm
g) Diameter of spigot and recess dr = 1.5d=68mm
h) Outer diameter of flange Do =(4d+2 t1)=204mm

III) Design of hub as a hollow shaft

τhub = 16 TMax / π(d0 3-di3 )
= (16x596.830x (10)3) / π (90 3- 453 )
= 4.76 N/mm2
τhub = 4.76 N/mm2 < 12 N/mm2
Hence the design of hub is safe. Since the induced shear stress for the hub material cast iron is less than permissible value.

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IV) Design for Bolts (4 bolts for shaft diameter from 40 to 100mm)
Diameter bolt d12 = 8 TMax / πDN τb
= (8x596.830x103) / (πx135x4x28)
= 10.02≈10mm
The compressive stress in the bolt is determined by
σc = 2 Mt / N d 1 t D
= (2x596.830x103) /(4x10x23x135)
= 9.6107 N/mm2
σc = 9.6107N/mm2 < 60 N/mm2
Hence the design of bolt is safe. Since the induced crushing stress for the bolt material Plain Carbon Steel is less than
permissible value.

V) Design of Key
Width = d/4=45/4=11.25 ≈12mm
Height = d/6=45/6=7.5≈8mm
Length = length of hub=68mm
Dimensions of the key = Width x Height x Length
= 12x8x68 mm.
Shear failure:
Induced shear stress in the key material
τinduced = 2 TMax / dbl
= (2x596.830x103) / (45x12x68)
=32.5 N/mm2
τkey = 32.5 N/mm2<35 N/mm2
Crushing failure:
Induced crushing stress in the key material
TMax = lx(t/2)xσck x d/2
596.830x103 = 68x(8/2)xσck x 45
σck = 48.76 N/mm2< 60 N/mm2
Hence the design of key is safe. Since the induced shear and crushing stresses in the key are less than the permissible
stresses.

Table.2. Design specifications of coupling

Part specification Dimensions in mm.
Hub diameter (Dh) 90
Hub length (lh) 68
Bolt circle diameter (D) 135
Flange thickness (t) 23
Web thickness 12
Outside diameter flange(Do) 204

Diameter of spigot and recess dr 68

Fig: 2 sketch of rigid flange coupling Isometric view

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ISSN: 2455-2631 © September 2019 IJSDR | Volume 4, Issue 9

Fig:3 Flange Design Fig:4 Shaft Design

Fig: 5 key Design Fig: 4 Nut Design

Fig: 5 Bolt Design Fig: 6 Assembly of rigid flange

coupling

IV.MESHING
There are several methods analysis software’s have been used for analyzing. In this project we are using Ansys 18.1software for
analyzing. Ansys is a leading finite element analysis software developed by ansys inc. it is use friendly graphical user interface
package. In a linear static we determine the stresses, displacements, strain and reaction in the FEM. Static analysis deals with
computation of displacement and stress due to static loads refers to loading but doesn’t cause inertial or damping effects to be
significant for consideration in the analysis.

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Fig: 7 Mesh Model of rigid flange coupling

V.ANALYSIS OF RIGID FLANGE COUPLING

According to figures shows the result of stress-strain analysis on a rigid flange coupling and the different results
Obtained with maximum and minimum values of deformation, stress and strain using Finite Element Method (FEM) in
ANSYS 18.1Workbench.

Fig: 8 Max principal stress Fig: 9 Max shear stress

Fig: 10 Total deformation Fig: 11 Normal stresses

Fig: 12 Equivalent stress Fig: 13 Shear stress in Flange

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Fig: 14 Shear stress in bolt Fig: 15 crushing stress in bolt

Fig: 16 Shear stress in key Fig: 17 crushing stress in key

VI.RUSULTS
Comparison of shear stress in hub flange

Table.3. Shear stress in hub flange

S.No Comparison Shear stress in

hub flange
1 Theoretical 12N/mm2
results
2 Analytical 16.549 N/mm2
results

Comparison of shear stress, crushing stress in bolts

Table.4. Shear stress, crushing stress in bolts

S.No Comparison Shear stress of Crushing stress of
bolt bolt
1 Theoretical 28 N/mm2 9.6107 N/mm2
results
2 Analytical results 0.9583 N/mm2 9.1999N/mm2

Comparison of shear stress, crushing stress in key

Table.4. Shear stress, crushing stress in bolts

S.No Comparison Shear stress of Crushing stress of
key key
1 Theoretical 32.5 N/mm2 48.76N/mm2
results
2 Analytical results 4.56N/mm2 42.35N/mm2

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VII.CONCLUSION
The result obtained from the analysis of the bolts and keys of a rigid-flange coupling using ANSYS workbench is better than that
of calculation using analytical method. It was found that the crushing stress for bolts and shear stress in bolts, keys obtained from
the Ansys software is less than the crushing and shear stress obtained in the theoretical calculation. Hence the results obtained from
Ansys matches theoretical calculations so the design is safe. From this comparison we can conclude that the design of coupling
done using UG-NX 10.0 is more suitable and safe.

REFERENCES
[1]V.B. Bhandari, Design of Machine Elements, ISBN: 0-07-0681791-1 (978-0-07-068179-8)
[2] Machine design by R.S.Khurmi, ISBN:978-81-219-2537-2
[3]Design and stress-Analysis of a Rigid Flange Coupling using FEM by Saurav Rajgadia Vol. 4, Issue 10, October 2015
ISSN(Online) :2319- 8753
[4]Rujuta M. Nakhale and G. K. Gattani “Design and Analysis of Coupling using ANSYS”. (IJPRET),2015; Volume 3 (9): 202-
206, ISSN: 2319-507X(IJPRET)
[5] Kondru Nagendra Babu and Dr. D Sunnel“Failure analysis of flange coupling with twodifferent materials”. (IJERT), Vol. 4
Issue 04, April-2015, ISSN: 2278-0181
[6] Shivaji G. Chavan “Stress analysis of flangedjoint using finite element method”. (IJSR), Volume 3Issue 8, August 2014, ISSN
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[7] Rujuta M. Nakhale and G. K. Gattani “Designand Analysis of Coupling using ANSYS”. (IJPRET),2015; Volume 3 (9): 202-
206, ISSN: 2319-507X
(IJPRET)
[8]. Chandra Sekhar Katta, Kamana Srinivasa Rao , Design and Analysis of flange coupling , International Journal of Professional
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[9]. Maram Venkata Sunil Reddy, C. Raghunatha Reddy, Design and Analysis of Universal Coupling Joint, International Journal
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[10].Mr. S.B. Jaiswal, Prof. M.D. Pasarkar, Failure Analysis of Flange Coupling in Industry, InternationalJournal of Emerging
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