MANUFACTURING OF FLANGE COUPLING

COUPLING :

• A coupling is a device used to connect two shafts together at their ends

for the purpose of transmitting power. The primary purpose of couplings
is to join two pieces of rotating equipment while permitting some degree
of misalignment or end movement or both
TYPES OF COUPLING:
Rigid coupling.
Flexible coupling.
Sleeve or muff coupling.
Split muff coupling.
Flange coupling.
Gear coupling.
Universal joint (Hooke’s joint)

• Oldham coupling
FLANGE COUPLING MANUFACTURING
PROCESS :
• STEP:1 SELECTION OF MATERIAL

• STEP:2 MATERIAL INSPECTION

• STEP:3 2D AND 3D DRAWING

• STEP:4 DESIGN CONSIDERATION AND CALCULATION

• STEP:5 MATERIAL CUTTING

• STEP:6 FLANGE FORGING

• STEP:7 HEAT TREATMENT

• STEP:8 FORGING ROLLING

Raw Material:
• High durability, strength, and resistance to a
variety of non-supporting situations are
guaranteed by stainless steel flanges (SS),
which are of superior grade. With this step,
the system regulates the quality of all
external supplies by the material’s raw
material test certificate.
 Material Inspection:

• Ensuring the quality of raw materials and

components used to make a product before
production begins is known as incoming
quality control (IQC). Before doing a first item
or production inspection, you can control for
quality using an incoming inspection
 DESIGN CONSIDERATIONS:

Considering a standard motor with Power = 37.5 kW and RPM = 180.

Assuming design torque to be 1.5 times the rated torque.
• Hub diameter, dh = 2d = 2* 60 = 120 mm.
• Hub length, lh = 1.5d = 1.5 *60 = 90 mm.
• Bolt circle diameter, d = 3d = 3* 60 = 180 mm.
• Flange thickness, t = 0.5d = 0.5* 60 = 30 mm.
• Web thickness, t1 = 0.25d = 0.25 *60 = 15 mm.
• Diameter of spigot and recess, dr = 1.5d = 1.5 *60 = 90 mm.
• Outside diameter of flange, d0 = 4d + 2t1 = 4* 60 + 2 *15 = 270 mm.
• Hub diameter D = 2 X d = 2 X 85 = 170mm.
• B) Length of hub = 1.5 X d = 1.5 X 85 = 127.5mm≈130mm.
• C) Key dimensions b = 22mm; h = 14mm (from reference table).
• D) Flange thickness tf= 0.5d = 0.5 X 85 = 42.5m.
 Material Cutting
• The bolt hole and water line are processed, and
the center plate’s internal diameter of the disc
and the inner diameter of the flange with the
processing amount is straight cut out.

• The resultant flange is known as a cut flange,

and its outer diameter is constrained to the width
of the center plate.
 Flange Forging:
• Compared to cast flanges, forged flanges typically
contain less carbon and are less likely to corrode.
Better mechanical qualities, a thicker structure,
and a more streamlined shape are all features of
forgings. The benefit of a forged flange is that its
inner system is homogeneous and devoid of
damaging flaws like holes and casting presences
 Heat Treatment:
•The speed of total forging cooling is the slowest,
followed by standardized cooling and lowering
cooling while the flange undergoes heat
treatment. A flange is continuously connected
throughout the process. Heating molten salts in a
vacuum can be protected by coating or packaging
techniques.
 Forging Rolling:
• A metal item is shaped using opposing rolls in
the forging process known as roll forging.
Roll forging is categorized as a metal forging
process, not a rolling process, even though it
uses rollers to create the material’s
deformation. Only a section of the roll’s edge
currently has the forging geometry necessary
to forge metal components
Applications of Flange Couplings:
Flange couplings are used in medium to heavy-duty applications. They find applications in a wide range
of industries, including:
Industrial Machinery: Flange couplings are commonly used in pumps, compressors, conveyors, and other
industrial machinery to transmit power efficiently and reliably.
Marine Engineering: They are crucial in marine propulsion systems, connecting the engine’s output shaft
to the propeller shaft.
Automotive Industry: Flange couplings are used in drivetrain components, such as the connection between
the transmission and the driveshaft.
Aerospace: In aircraft and spacecraft, flange couplings are employed to connect various rotating
components, ensuring precise and secure power transmission.
• Energy Sector: Power plants, both traditional and renewable, utilize flange couplings to connect
turbines, generators, and other equipment.
Advantages of Flange Couplings
Flange couplings offer several advantages, making them a preferred choice in many applications:
High Torque Transmission: Flange couplings are designed to handle high levels of torque, making them
suitable for heavy-duty applications.
Precise Alignment: The bolted design of flange couplings ensures precise alignment of shafts, reducing wear
and tear and extending the life of connected components.
Vibration Dampening: They are effective at dampening vibrations, which is crucial for machinery and
vehicles to operate smoothly and quietly.

 Ease of Maintenance: Flange couplings are relatively easy to install and maintain, thanks to their simple
design.