FLANGE COUPLING

A PROJECT REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR CONTINUOUS EVALUATION OF INTERNAL MARKS
IN DESIGN OF MACHINE ELEMENTS, ME503

SUBBMITTED BY
ROCKY DUBEY 177040341

ASSIGNED BY
DR. NIRMAL KANTI DAS
PROFESSOR OF DEPARTMENT OF MECHANICAL ENGINEERING.

DATED:

BENGAL COLLEGE OF ENGINEERING AND TECHNOLOGY

DURGAPUR
DEPARTMENT OF MECHANICAL ENGINEERING
 CERTIFICATE

I do hereby certify that the work being presented in this Mini-Project Report entitled “Flange
Coupling”, in partial fulfillment of the requirements for continuous evaluation of internal marks
in Primary Manufacturing Technology,ME-503, submitted to the Department of Mechanical
Engineering, Bengal College of Engineering and Technology, Durgapur, is an authentic record
of my own work carried out during a period from / 11 /2019 (5th semester) under the
guidance of DR. NIRMAL KANTI DAS ,professor, of Department of Mechanical Engineering.
The matter presented in this Report has not been submitted by me elsewhere.

Date:

--------------------------
Signature of Student
Rocky Dubey
Roll No:177040341

This is to certify that the above statement made by the student is correct to the best of my
knowledge.

-----------------------------
Signature of Teacher
DR. Nirmal Kanti Das ,Professor of Department of Mechanical Engineering.

Countersigned

---------------------------------
Signature of HOD (ME)
DR. Nirmal kanti Das, Professor of Department of Mechanical Engineering.
 ACKNOWLEDGEMENT

I would like to express my deep sense of gratitude to Dr. Nirmal Kanti Das, Department of
Mechanical Engineering, Bengal College of Engineering and Technology, Durgapur, for his
generous and commendable guidance, help and useful suggestions towards successful
completion of this mini-project.

Date:

--------------------------
Signature of Student
Rocky Dubey
Roll No:177040341
 ABSTRACT
A coupling is a device used to connect two shafts together at their
ends for the purpose of transmitting power. Rigid flange coupling
are designed for heavy loads or industrial equipment. When joining
shafts within a machine, mechanics can choose between flexible
and rigid couplings. The connecting methods for flange couplings
are usually very strong because of either the pressure of the
material or the sometimes hazardous nature of materials passed
through many industrial piping systems. This project deals with
stress analysis of rigid flange couplings subjected to Static loads
using ansys. The design of flange coupling will be done in SOLID
WORKS PREMIUM SOFTWARE 2014. To obtain computer solution
ANSYS will be used.
 TABLE OF CONTENTS
CONTENTS PAGE NUMBER
 Introduction. 01
 Types Of Couplings: 02-03
 Sleeve Coupling.
 Clamp Or Split-Muff OR
Compression Coupling.
 Flange Coupling.
 Coupling Maintenance And Failure. 03-04
 Checking The Coupling Balance. 04
 Materials And Its properties. 04-05
 Protected Type Flange Coupling: 05
 Advantages.
 Unprotected Type Flange Coupling: 05-06
 The Usual Proportional for an
Unprotected Type Flange
Coupling.
 Marine Type Flange Coupling: 06-07
 The Usual Proportional for an
Marine Type Flange Coupling.
 Advantages.
 Disadvantages.
 Introduction to Composites. 07-08
 Basic Concepts Of Composites
Material.
 Fibres
 Matrix.
 Classification Of Composites
Materials.
 Advantages Of Composites.
 Limitations Of Composites.
 Application of Composites
Materials.
 Preperation Of Aluminum Silicon carbide. 09
 Introduction To Solid works. 09
 Modeling of Flange Coupling in
Solid works.

 Conclusion. 10
 References. 11
INTRODUCTION : Flange Coupling is a driving coupling between rotating
shafts that consists of flanges one of which is fixed at the end of each shaft, the
two Flanges being bolted together with a ring of bolts to complete the drive.

A flange coupling meant to bring two

tube ends together in a flush, sealed
manner. This two-piece coupling unit
consists of a keyed receiving side for the
flanged end to be fastened to, so it may
be married to the opposing tube end,
which also has a flanged end. Each
flange has either a male or female coupler opening so that when the two ends
are brought together, they are aligned without causing resistance or drag in the
material being passed through them. This male or female coupling method also
creates a stable connection that is resistant to shifting, keeping the flange
coupling sturdily in place.

Flange couplings are typically used in pressurized piping systems where two
pipe or tubing ends have to come together. The connecting methods for flange
couplings are usually very strong because of
either the pressure of the material or the
sometimes hazardous nature of materials passed
through many industrial piping systems. High
thread count nut and bolt connections are used
to secure the flange couplings in place. These
nuts and bolts are usually made from tempered
steel or alloys to provide enduring strength and the ability to be tightened to
the utmost level to ensure the piping system doesn’t leak at any flanged
junction. Most flange couplings utilize four, six, or up to 12 bolt assemblies.
Types of couplings:

Sleeve coupling: A sleeve coupling consists of

a pipe whose bore is finished to the required
tolerance based on the shaft size. Based on the
usage of the coupling a keyway is made in the
bore in order to transmit the torque by means of
the key. Two threaded holes are provided in order to lock the coupling in
position.

Clamp or Split Muff or Compression coupling: It is also known as

split muff coupling. In this case, the muff or sleeve is
made into two halve sand are bolted together as shown
in Fig. The halves of the muff are made of cast iron.
The shaft ends are made to a butt each other and 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 nuts are recessed into the bodies of the
muff castings.

Flange coupling: Coupling is a device used to connect the shafts together

for the purpose of transmitting power and torque. Generally, couplings are
used for connection of shafts unit that are
manufactured separately. Such as motor and
generator; electric motor and centrifugal pump etc.
Due to the inconvenience in transportation of shaft of
greater length, it becomes necessary to join two or
more shafts by means of coupling. The shafts that
are connected by coupling should be easy enough to
assemble and dismantle for the purpose of repair and alterations. The severe
failure due to shearing of bolts head, key head, nuts and other projecting parts
may cause accidents. So, it should be covered by giving suitable shape to the
flanges or by providing guards. The shaft to be connected by the coupling may
have collinear axes, intercepting axes or a parallel axes with a small distance in
between them. The flange coupling is further classified into two types; Rigid
and Flexible Coupling. Rigid flange coupling consists of two separate grey cast
iron flanges. One keyed to the driving shaft and the other to the driven shaft by
means of nuts and bolts arranged on a circle concentric with the axes of the
shafts. There are two types of rigid flange couplings; Protected and Unprotected
rigid flange coupling. In a protected rigid flange coupling, a protective
circumferential rim covers the nut and bolt head. So in any case of failure of
bolts during operation, broken piece of bolt will dash against this rim and
eventually fall down, protecting the operator from any possible injuries. In
unprotected rigid flange coupling such protective circumferential rim is absent.
So, in any case of failure of bolts, it may hit and harm the operator.

Coupling maintenance and failure: Coupling maintenance is generally

a simple matter, requiring a regularly scheduled inspection of each coupling. It
consists of:

 Performing visual inspections, checking for signs of wear or fatigue, and

cleaning couplings regularly
 Checking and changing lubricant regularly if the coupling is lubricated.
This maintenance is required annually for most couplings and more
frequently for couplings in adverse environments or in demanding
operating conditions.
 Documenting the maintenance performed on each coupling, along with
the date.

Even with proper maintenance, however, couplings can fail. Underlying

reasons for failure, other than maintenance, include:
  Improper installation
 Poor coupling selection
 Operation beyond design capabilities.

The only way to improve coupling life is to understand what caused the failure

 Abnormal noise, such as screeching, squealing or chattering

 Excessive vibration or wobble
 Failed seals indicated by lubricant leakage or contamination

Checking the coupling balance: Couplings are normally balanced at the

factory prior to being shipped, but they occasionally go out of balance in
operation. Balancing can be difficult and expensive, and is normally done only
when operating tolerances are such that the effort and the expense are
justified. The amount of coupling unbalance that can be tolerated by any
system is dictated by the characteristics of the specific connected machines
and can be determined by detailed analysis or experience.

Material And Its Properties: Rigid flange is usually manufactured by

casting as it consists of projection and recess. The commonly used material for
flange coupling is grey cast iron which is characterized by graphitic
microstructure causing fracture of the material to have a grey appearance. It is
one of the most commonly used form of cast iron and the widely used cast
material based on casting properties. Most alloys of Ironcontain2.5-4% carbon,
1-3% silicon and the rest is iron by weight proportion. It has less tensile
strength and shock resistance as compared to its compressive strength. Its
mechanical properties are controlled by the size and morphology of the
graphite flakes which deflect a passing crack and initiate counter less new
cracks as the material breaks due to which it has good wear resistance and
damping capacity. It also experiences less solidification shrinkage than other
cast iron that does not form a graphitic microstructure during casting process.
The silicon promotes good corrosion resistance and increase fluidity while
casting. It also offers good weld ability.

Protected type flange coupling: In this type of coupling the bolts head
and nuts are covered by projecting
circumferential rims. In case of
failure of bolts while the machine
is being run, the broken piece will
dash against this rim and
eventually fall down. This protects
the operator from injuries. The
construction of unprotected and protected flange coupling is exactly identical
except the protective rim.

It has following advantages:- 1. It can tolerate 0.5 mm of lateral misalignment

and 1.50 of angular misalignment.

2. Prevents transmission of shock from one shaft to another.

3. Can transmit high torque.

4. Simple in construction easy to assemble and dismantle. Adv. are also

associated with this like, the cost of flexible coupling is more, requires more
redial distance etc.

Unprotected type flange coupling: In an unprotected type flange

coupling, each shaft is keyed to the boss of a
flange with a counter sunk key and the
flanges are by means of bolts. Generally,
three, four or six bolts are used. The keys
staggered at right angle along the
circumference of the shafts in order to divide
the by keyways.
The usual proportions for an unprotected type cast iron flange couplings,
are as follows: If d is the diameter of the shaft or inner diameter of the hub,
then D = 2 d

Length of hub, L = 1.5 d Pitch circle diameter of bolts,

Outside diameter of flange, D2 = D1 + (D1 – D) = 2 D

Thickness of flange, if = 0.5 d

Number of bolts = 3, for d = 4, for d up to 100 mm = 6, for d up to 180 mm

Marine type flange coupling: In a marine type flange coupling, the

flanges are forged integral with the shafts The flanges are held together by
means of tapered headless bolts, numbering from four to twelve depending
upon the diameter of shaft.

The other proportions for the marine type flange coupling are taken as
follows:

Thickness of flange = d / 3

Taper of bolt = 1 in 20 to 1 in 40 Pitch circle diameter of bolts,

D1 = 1.6 d Outside diameter of flange,

D2 = 2.2 d

Advantages: 1. It is cheap

2. It is simple in structure

3. More efficiency

4. Maintenance is not required.

Disadvantages:
It cannot be de-engaged in motion.

Flange coupling cannot transmit power between two non linear shafts.

Introduction to composites:

Composite materials have been widely used to improve the performance of

various types of structures. Compared to conventional materials, the main
advantages of composites are their superior stiffness to mass ratio as well as
high strength to weight ratio. Because of these advantages, composites have
been increasingly incorporated in structural components in various industrial
fields. Some examples are helicopter rotor blades, aircraft wings in aerospace
engineering, and bridge structures in civil engineering applications. Some of
the basic concepts of composite materials are discussed in the following section
to better acquaint ourselves with the behavior of composites.

Basic Concepts of Composite Materials: Composite materials are

basically hybrid materials formed of multiple materials in order to utilize their
individual structural advantages in a single structural material. The
constituents are combined at a macroscopic level and are not soluble in each
other

Fibres: Fibres are the principal constituent in a fibre reinforced composite

material. They occupy the largest volume fraction in a composite laminate and
share the major portion of the load acting on a composite structure.

Matrix: In a composite material the fibres are surrounded by a thin layer of

matrix material that holds the fibres permanently in the desired orientation
and distributes an applied load among all the fibres. The matrix also plays a
strong role in determining the environmental stability of the composite article
as well as mechanical factors such as toughness and shear strength.
Classification of Composites: A material composed of 2 or more
constituents is called composite material. Composites consist of two or more
materials or material phases that are combined to produce a material that has
superior properties to those of its individual constituents. The constituents are
combined at a macroscopic level and or not soluble in each other.

Advantages Of Composites: The advantages of composites over the

conventional materials are: High strength to weight ratio, high stiffness to
weight ratio, high impact resistance, better fatigue resistance, Improved
corrosion resistance, Good thermal conductivity, Low Coefficient of thermal
expansion. As a result, composite structures may exhibit a better dimensional
stability over a wide temperature range, high damping capacity.

Limitations Of Composites: The limitations of composites are:

Mechanical characterization of a composite structure is more complex than
that of a metallic structure, the design of fiber reinforced structure is difficult
compared to a metallic structure, mainly due to the difference in properties in
directions, the fabrication cost of composites is high, rework and repairing are
difficult, they do not have a high combination of strength and fracture
toughness as compared to metals and they do not necessarily give higher
performance in all properties used for material selection.

Applications of Composite Materials: Aerospace: Drive shafts,

rudders, elevators, bearings, landing gear doors, panels and floorings of
airplanes,

payload bay doors, remote manipulator arm, high gain antenna, antenna ribs
and struts etc.

Marine: Propeller vanes, fans & blowers, gear cases, valves &strainers,
condenser shells.
Preparation of aluminum silicon carbide:

Preparation of Aluminium-Silicon
Carbide Composite Casting is probably
one of the most ancient processes of
manufacturing metallic components.
The metal matrix composite used in
the present work is prepared by the
stir casting method. For the preparation of the Aluminium silicon carbide
composite by using stir casting mass basis ratio of 100:2.5, 100:5, 100:7.5,
and 100:10 are taken. Fig. illustrates the raw materials and samples of
Aluminium Silicon Carbide material. Aluminium alloy in the form of ingots is
used. The metal ingots are cleaned and melted to the desired super heating
temperature of 750o C in graphite crucibles. Fig. shows schematic set up for
stir casting technique.

Introduction to solid works

Solid works mechanical design automation software is a feature-based,

parametric solid modeling design tool which advantage of the easy to learn
windows TM graphical user interface. We can create fully associate 3-D solid
models with or without while utilizing automatic or user defined relations to
capture design intent.

Modeling of flange coupling in solid-works :

Designing dimensions:
Flange:

Shaft:

Flange Coupling:
 Conclusion
 Flange coupling is designed and analyzed in step-wise manner

 Flange coupling is modeled in solid works 2014

 The model designed in solid works is imported to ansys workbench

 Analysis is done in ansys work bench

 Different materials are applied

 Such as aluminum silicon carbide, grey cast iron are applied and stress,
strain deformations of respective materials is noted

 From the structural analysis results stresses generated in aluminum silicon

carbide is high compared to grey cast iron but obtained stress is within the
critical stress.

So main advantage of using composite is it reduce the weight of the component

and withstand maximum applied loads.
 REFERENCES

[1] Coupling Wikipedia, https://en.wikipedia.org/wiki/Coupling

[2] V.B. Bhandari, Design of Machine Elements,ISBN: 0-07-0681791-1 (978-0-

07-0681798) Design of IC Engine Component, Page no. 356368

[3] 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)

[4]Cast iron: https://en.wikipedia.org/wiki/Cast_iron, Plain carbon steel:

http://saajsteel.com/?page_id=1802

[5] Praveena S,Lava kumar M and Sreekanth Reddy S “Modeling and Structural
Analysis of Disc Brake” (IJIRSET), Vol. 3, Issue 10, October 2014, ISSN: 2319-
8753

[6] A. Belhocine, C.-D. Cho, M. Nouby, Y. B. Yi and A. R. Abu Bakar “Thermal

analysis of both ventilated and full disc brake rotors with frictional heat
generation” (Applied and computational mechanics 8 (2014) 5-24, Received 3
march 2014; received in revised form 27 June 2014

[7] Prof. Salunkhe R.T., Mr. Patil N.T., Mr. Lokhande V.S., Mr. Bandelkar D.M.
and Mr. Patil R.D. “ Design, Modelling, Analysis of Propeller Shaft and
Couplings” (IJST), Issue 3 volume 5, Sep.Oct. 2013, ISSN 2249-9954

[8] Siraj MohammadAli Sheikh “ANALYSIS OF UNIVERSAL COUPLING UNDER

DIFFERENT TORQUE CONDITION “(IJESAT), Volume-2, Issue-3, 690 – 694,
ISSN: 2250–3676