Rigid flange coupling

• Flange coupling is the device that is used to connect two shafts if both
the machine shafts are properly aligned to each other. Flange coupling is
used where free access is available for both the shafts.
• It is mostly used coupling, and the couplings flanges and the shafts are
bolted together.
• Rigid couplings can be manufactured from most metal materials.
• This allows Rigid couplings to be used in many applications and variable
conditions.
• It can transmit more power.

Advantages of rigid coupling

• Rigid couplings can be used in complex motion systems and provides
more torque between the shafts.
• It is also useful for better positioning as it has High torsional stiffness.
• Easy availability and Cost-efficient.
• It has precision with zero backlashes.
• Rigid couplings are used for the proper alignment and rigid
connection.
• Easy to assemble and disassemble and easy for the maintenance
operations

Selection Of Materials & Its 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 appearancebecause 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
• The silicon promotes good corrosion resistance and increase fluidity
while casting
Q. Design a rigid coupling for connecting two shafts. The input shaft
transmits 37.5 kW power at 180 rpm to output shaft through coupling. The
factor of safety for this application is 1.5. Design torque is 1.5 times the rated
torque. Select suitable materials for various parts and specify the
dimensions.
Solution :
Given- kW = 37.5 n= 180 rpm design torque = 1.5 (rated torque)
Step I- Selection of materials
• The shafts are subjected to torsional shear stress. On the basis of
strength, plain carbon steel of grade 40C8 (S yt =380 N/mm^ 2 ) is
used for the shaft. The factor of safety for the shafts is assumed to be
2.5.
• The keys and bolts are subjected to shear and compressive stresses.
On the basis of strength criterion, plain carbon steel of grade 30C8 (S
yt =400 N/mm^ 2 ) is selected for the keys and the bolts. It is assumed
that the compressive yield strength is 150% of the tensile yield
strength. The factor of safety for the keys and the bolts is taken as 2.5.
• Flanges have complex shape and the easiest

Method to make the flanges is casting. Grey cast iron FG 200 (S ut =200
N/mm^ 2 ) is selected as the material for the flanges from manufacturing
considerations. It is assumed that ultimate shear strength is one half of the
ultimate tensile strength. The factor of safety for the flanges is assumed as 6,
since the permissible stress is based on the ultimate strength and not on the
yield strength.

Step II- Permissible stresses

• Shaft

Tau= S sy (fs) = 0.5S yt (fs) = 0.5(380) (2.5) =76N/mm^ 2 (ii) Keys and bolts

Tau= S sy (fs) = 0.5S yt (fs) = 0.5(400) (2.5) =80 N/mm^ 2

σc = S yc (fs) = 1.5S yt (fs) = 1.5(400) (2.5) =240 N/mm^ 2

σ_{c} < 240N / m * m ^ 2
Step III Diameter of shafts

The design torque is given by, tau = (16M_{t})/(pi * d ^ 3) or 76= 16(2 984
155.18) pi * d ^ 3

M_{t} = (60 * 10 ^ 6 * (kW))/(2pi*n) * (1.5) = (60 * 10 ^ 6 *

(37.5)(1.5))/(2pi(180)) =2 984 * 155.18N – mm

D = 58.4 or 60 mm

Step VI Dimensions of keys From Table 9.3, the standard cross-section of the
flat key for a 60-mm diameter shaft is 18 * 11 mm. The length of the key is
equal to l_{k} Or,

L = l_{h} = 90 mm The dimensions of the flat key are 18 * 11 * 90 mm.

From Eq. (9.27), tau= 2M t dbl = 2(2 984 155.18) (60)(18)(90) = 61.4N / m *
m^2

Tau < 80N / m * m ^ 2 From Eq. (9.28), σ_{c} = (4M_{t})/(dhl) = 4(2 984
155.18) (60)(11)(90) = 200.95N / m * m ^ 2

σ_{c} < 240N / m * m ^ 2

The shear and compressive stresses induced in the key are within
permissible limits.
(3) Flanges

Tau= S sut (fs) = 0.5 S ut (fs) = 0.5(200) (6) =16.67N/mm^ 2 Taking into
consideration the service factor of 1.5,

Step V Diameter of bolts The diameter of the shaft is 60 mm. 40 < d <100 I
mm

The number of bolts is 4.

From Eq. (9.46),

D_{1} ^ 2 = (8M_{t})/(pi*DN*tau) = 8(2 984 155.18) pi(180)(4)(80) d_{1} =
11.49or * 12mm

The compressive stress in the bolt is determined by Eq .(9.47)

σ_{c} = (2M_{t})/(N*d_{1}*tD) = 2(2 984 155.18) (4)(12)(30)(180) = 23.03N /

m*m^2

Step IV Dimensions of flanges The dimensions of the flanges are as follows,

D=2d 2 (60)= 120 mm

1=1.5d 1.5 (60) = 90 mm

D = 3 * d = 3(60) = 180mm

1=0.5d=0.5(60) = 30 mm

T_{1} = 0.25 * d = 0.25(60) = 15mm

D=1.5d=1.5(60) = 90 mm

D_{0} = (4 * (d + 2t_{1})) = 4(60) + 2(15) = 270mm

The above dimensions of the flange are shown in Fig. 9.37. The thickness of
recess is assumed as 5 mm. The hub is treated as a hollow shaft

Subjected to torsional moment. From Eq. (9.44),

J = (pi(d_{h} ^ 4 – d ^ 4))/32 = (pi(120 ^ 4 – 60 ^ 4))/32 =19 85 * 175.37m * m

^ 4 r = d_{h}/2 = 120/2 = 60mm
The torsional shear stress in the hub is given by,

Tau= M t r J = (2 984 155.18)(60) (19 085 175.37) = 9.38N / m * m ^ 2

Tau < 16.67N / m * m ^ 2

The shear stress in the flange at the junction of

The hub is determined by E mathfrak q . (9.45) .

Tau = (2M_{t})/(pi * d_{h} ^ 2 * t) = 2(2 984 155.18) pi(120)^ 2 (30)

= 4.4N / m * m ^ 2

Tau < 16.67N / m * m ^ 2

Referances
[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
(Online): 2319-7064
[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)