362 Design of Machine Elements

The dimensions of the key are, has a corresponding recess. The diameters of the
22 x 14 x 140 mm (V) spigot and the recess are machined with more
Step VII Check for stresses in key accuracy. During the assembly, the spigot fits into
From Eq. (9.27), the recess and the two flanges are located precisely
with respect to each other. This ensures alignment
t=2M23978873.58) of the axes of the two shafts.
dbl 80 (22)(140) There are two types of rigid flange couplings-
unprotected and protected. The flange coupling
=
32.3 N/mm t< 40 N/mm shown in Fig. 9.33 is the unprotected type of
From Eq. (9.28),
coupling. The revolving bolt heads and nuts are
dangerous to the operator and may lead to accident.
4(3 978 873.58) Protected type flange coupling is shown in Fig.
80(14)140)
9.34. In this case, protecting circumferential rims
= 101.5 N/mm o , < 120 N/mm*
cover the bolt heads and nuts. In case of failure of
The design of key is safe from shear and bolts while the machine is being run, the broken
compression considerations. pieces will dash against this rim and eventually fall
down. This protects the operator against injuries.
9.21 RIGID FLANGE COUPLINGS
Protecting9
circumferential
A flange coupling consists of two flanges one rims
keyed to the driving shaft and the other to the AAR Spigot and
driven shaft as shown in Fig. 9.33. The two flanges recess
are connected together by means of four or six
bolts arranged on a circle concentric with the axes
of the shafts. Power is transmitted from the driving
A
FlangesT Bolt

Fig. 9.34 Protected Type Rigid Coupling

NN Key
--- The rigid flange couplings have the following

Driving Driven advantages

shaft ) Rigid coupling has high torque transmitting
VNPshaft
capacity.
Fig. 9.33 Unprotected Type Elange Coupling ii) Rigid coupling is easy to assemble and
dismantle.
shaft to the left side flange through the key. It is (ii) Rigid coupling has simple construction. It is
then transmitted from the left side flange to the easy to design and manufacture.
right side flange through the bolts. Finally, power The rigid flange couplings have the following
is transmitted from the right side flange to the
disadvantages:
driven shaft through the key. Since flange coupling (i) It is a rigid type of coupling. It cannot
is rigid type of coupling, provision should be made tolerate misalignment between the axes of
for precise location of the axes of two shafts. The two shafts.
mating flanges have spigot and recess for precise is free
(ii) It can be used only where the motion
location. The left side flange has a cylindrical from shocks and vibrations.
projection called spigot while the right side flange ii) t requires more radial space.
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Rigid flange couplings are widely used for
transmitting large torques.
The flange of the protected type coupling has
Outer im
Central portion
of flange
Hub
Fig. 9.35 Proportions of Rigid Coupling
function of the hub is to transmit the torque from
the shaft to the central fiange and vice versa.
The central portion of the flange has holes to
accommodate the bolts. Torque is transmitted from
one flange to the other by means of these bolts.
The outer circumferential rim is for the purpose of
safety to cover the projecting bolt heads and nuts.
Various dimensions of flanges are shown in Fig.
9.35. Many times, the dimensions of the flanges are
calculated by using standard proportions in terms
of shaft diameter. Shop-floor engineers have used
such empirical formulae for many years without
any problem. It is easy to design the coupling
using these standard proportions, because no stress
analysis is involved. The dimensions calculated by
these formulae result in robust design. The standard
proportions for various dimensions of the flange
shown in Fig. 9.35 are as follows:
(i) d,outside diameter of hub
d,22d
(i) ,= length of hub or effective length of key
=1.5 d
(ii) D= pitch circle diameter of bolts
D 3d
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Shafts, Keys and Couplings 363
three distinct regionsinner hub, central fange
with boltholes and peripheral outer rim as shown in
Fig.9.35. The hub is provided with a keyway. The
(iv) (= thickness offlanges
I=0.5 d
(v) = thickness of protecting rim
0.25 d
(vi) d,= diameter ofspigot and recess
d=1.5d
(vii) D= outside diameter offlange
D=(4d+ 21)
In the above relationships, d is the shaft
diameter.
The number of bolts ( ) is also decided from the
shaft diameter in the following way:
N=3 for shafts up to 40 mm diameter
N=4 for shafts from 40 to 100 mm diameter
N=6 for shafts from 100 to 180 mm diameter.
The analysis of rigid coupling can be done by
two different ways, depending upon the clearance
between the bolt and the hole. In the first approach,
the bolts are fitted in reamed and ground holes. In
this case, there is no clearance and the bolts are
finger tight. Therefore, power is transmitted by
means of shear resistance of the bolts. In the second
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364 Design of Machine Elements

approach, the bolts are fitted in large clearance Case II Bolts Fitted Large Clearance
holes. In this case, bolts are tightened with a pre- Holes When the bolts are fitted in large clearance
load and power is transmitted by means of friction holes, the above analysis is not applicable. In this
between the two flanges. case, the bolts are suficiently tightened with a pre
Case I Bolts Fitted in Reamed and Ground
load and the torque is transmitted from one flange
to the other by means of friction between them. For
Holes The forces acting on individual bolts due to
uniformly distributed pressure, the friction radius
transmission of the torque are shown in Fig. 9.36.
Equating the external torque with the resisting torque, Ryis given by.
2R-R
where,
M,-PxxN
2

M=torque transmitted by the coupling (N-mm)

(a)
RRR)
where, (Fig. 9.35)
(9.42)

R.Outer radius of the flange (D, /2) (mm)

P=force acting on each bolt (N)
R radius of the recess (d, /2) (mm)
D=pitch circle diameter of bolts (mm)
Assume that,
N= number of bolts.
P= initial tension in each bolt (N)
Bolt cross-section
coefficient
of friction between fanges
The friction force will be (u P, M) and the torque
is given by,
M,=u P NR, (9.43)
Flanges have complex shape and the easiest
to make the flanges is casting. Flanges are
method
usually made of grey cast iron of grade FG 200.
The bolts, keys and shaft are made of plain carbon
steels on strength criterion.
Fig. 9.36 Shear Resistance of Bolts
It should be noted that the bolts are subjected to 9.22 DESIGN PROCEDURE FOR RIGID
direct shear stress due to the force P and not torsional FLANGE cOUPLINGG
shear stress. No torque is acting about the axis of the
bolt. The force P results in only direct shear stress. The basic procedure for finding out the dimensions
The direct shear stress in the bolt is given by, of the rigid flange coupling consists of the
following steps:
(b)
() Shaft Diameter Calculate the shaf diameter by
using the following two cquations:
where,
T
shear stress in the bolt (N/mm2) M=
60x10 (kW)
d nominal diameter of the bolt (mm) 2Tn
16 M,
From (a) and (b), and

T 8M, (9.41) (ii) Dimensions of Flanges Calculate the dimen-

TDNd
Equation (941) is used to determine the nominal sions of the flanges by the following empirical
diameter of the bolts. The above analysis of the equations:
based on the assumption that the bolts are
coupling is
fitted in rimmed and ground holes. The bolts are finger
a2d
1.Sd
tight in these holes and there is no clearance between D3d
the holes and the nominal diameter of the bolts. I 0.5d

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