CONTENTS

Chapter-1_________________________________________________4

 Abstract
 Introduction
 Aims And Objectives

Chapter-2____________________________________________________6

 Literature Review
 Concept Of A Flange coupling
 Application Of Flange coupling
 Types Of Flange coupling

Chapter-3_______________________________________________________12

 Methodology
 Description Of The Flange Coupling
 Selection Of Material For The Coupling

Chapter-4

 Conclusion
 Reference
 Scope O Future Work
 CHAPTER-1
 ABSTRACT :
A Coupling is a device which is responsible for the operative power transmission between two
shafts rotating at particular RPM. Coupling is used to connect two different shafts at their end
and can slip or fail depending upon the torque limit. It is the crucial part of any power
transmission and may last for very long time if designed and maintained properly. The present
study of this paper is to reduce the stress that acting on the bolts by making it uniform
strengthens. The stress in the threaded part of the bolt will be higher than that in the shank.
Hence a greater portion of the will be absorbed at the region of the threaded part which may
fracture the threaded portion because of its small length. An axial hole is drilled at the center of
the bolt through the head as far as thread portion such that the stress in the bolt is uniformly
distributed along the length of the bolt.

 INTRODUCTION:
Flange Couplings, The two-piece coupling unit comprises of a keyed receiving side for the
flanged end to be secured to, so it might be married to the opposing tube end, which additionally
has a flanged end.
Every flange has either a male or female coupler opening so when the two ends are united, they
are adjusted without causing resistance or drag in the material being gone through them.
This male or female coupling technique likewise makes a stable connection that is impervious to
moving, keeping the flange coupling sturdily set up.
Flange couplings are normally utilized in pressurized piping systems where two pipes or tubing
closes need to meet up.
The associating methods for flange couplings are generally solid due to either the weight of the
material or the occasionally dangerous nature of materials went through numerous modern
piping systems.
High thread count nut and bolt connections are utilized to verify the rib couplings set up. These
nuts and bolts are generally produced using tempered steel or compounds to give suffering
quality and the capacity to be fixed to the most extreme dimension to guarantee the piping
system doesn’t leak at any flanged junction.
Most flange couplings use four, six, or up to 12 bolt assemblies.
Advantages of flange couplings:
 High torque transmitting capacity.
 Easy to assemble and dismantle.
 Simple in construction.
 Easy to design and manufacture.

Disadvantages of flange couplings:

 It can’t tolerate misalignment between the axes of two shafts.
 It is utilized just where the motion is free from shock and vibrations.
 It requires more radial space. Rathi Couplings is the Best Manufacturer and Brand of
Flange Coupling in India.

 AIMS AND OBJECTIVES:

 AIM:

The aim of the project is to design and modeling of an unprotected type flange coupling
will be use to connect a water pump and an alternator moving at a particular torque
without failure.

 OBJECTIVES:

1. To design an unprotected type flange coupling that will connect a water pump and
an alternator.

2. To design a flange couple that will take care of misalignment

3. To design a coupling that will operate effectively and efficiently on a giving

power.

4. Checking for failure:

 Due to induced shear stress of the material

 Due to induced crushing stress of the material

5. Checking whether the design is safe or not

CHAPTER-2
 Literature Review:
 This chapter gives the background for up-coming sections.
It is an assessment of the present state of the wide and complex fields of coupling and
machine tool chatter.
Also, this chapter reviews what has been done in the past in the area of nonlinear
dynamics of metal cutting process.
This observation leads to the study of mutual dependency among relatively independent
components which is referred as coupling.
Coupling between signals is quantified by conventional methods such as relative phase
relations, coherence analysis, or cross-correlation.
However, these tools are linear and assume that individual components have additive
mutual influences, rather than nonlinear multiplicative interactions.

 CONCEPT OF FLANGE COUPLING

Flange Coupling is the standard forms of couplings, which are most extensively used. Flange
coupling is a sort of connector between turning chutes that have two arrangements of flanges.
Flanges are fitted or provided at the end of shafts. The flanges are tightened together by means of
a number of nuts and bolts. One of these flanges or chutes is fixed at the end of each shaft.
During activities and operations, couplings guarantee that there is no interference of shafts. In
any case, a few couplings have torque constraints, and it can fail or disengage the shafts when a
similar limit surpasses past a specific point.
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

Keys:
Keys are machine elements used to prevent any kind of relative rotational movement between a
mounted shaft and the parts mounted on it.
For making the joint, keyways or grooves are cut on the surface of the shaft and in the hub of the
part to be mounted.
The mounting at an intermediate location on the shaft, the key is firmly placed in the keyway of
the shaft and then the part to be mounted is slid, until it gets fully engaged.

Types of Flange Coupling:

The need for coupling arises after you purchase a heavy working costly pump and motor for it
because they both need to be connected and ensured to be maximum utilized while providing
protection at the same time.
It is unavoidable to couple both the shafts, and it would be simple in the event that they could be
flawlessly aligned, and shafts never moved because of the vibration of the machines.
Generally, there are three types of flange coupling; they can be classified as protected flange
coupling, unprotected flange coupling and marine flange coupling.

Unprotected Flange Coupling:

In an unprotected flange coupling, each shaft is entered in the main flange with a security key
that modifies into the keyways of both the shafts and furthermore the essential flange of the
machine. The flanges are consolidated with the assistance of screws and bolts.

It consists of two similar discs called flanges. Each flange is keyed to needs of shafts to be
coupled. To secure both the flanges together, both the flanges have four to six holes to receive
the bolts. When these flanges are bolted together, they form a rigid joint between the two shaft
ends.

In these kinds of coupling, three to six screws are utilized to affix the flanges. Keyways may
cause a debilitating impact on the flange coupling by making a gap. To moderate the equivalent,
the keys are balanced at the correct point along the perimeter of the shafts.
Different applications of couplings:

 Couplings are an important part of any machinery.

 They form the main and integral part of the rotation mechanism of any electrical and
industrial machinery.
 Every coupling should be considered with planning and thought.
 Different types of couplings are available and the selection is based on the particular
amount of torque required or the torque weight ratio.
 Rathi Coupling is one such manufactures variety of couplings of very supreme quality,
designs and efficiency.
Coupling maintenance and failure

Coupling maintenance requires a regularly scheduled inspection of each coupling. It consists of:

 Performing visual inspections

 Checking for signs of wear or fatigue
 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.[12]
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.[12]
External signs that indicate potential coupling failure include:

 Abnormal noise, such as screeching, squealing or chattering

 Excessive vibration or wobble
 Failed seals indicated by lubricant leakage or contamination.[12]
 CHAPTER-3

METHODOLOGY OF FLANGE COUPLING

Selection of Material For Coupling:

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 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 can tolerate 0.5 mm of lateral misalignment and 1.5o of angular misalignment.
 Prevents transmission of shock from one shaft to another Can transmit high torque
 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

Description Of Flange Coupling:

Flange coupling is a sort of connector between turning chutes that have two arrangements of

flanges. Flanges are fitted or provided at the end of shafts. The flanges are tightened together by

means of a number of nuts and bolts. One of these flanges or chutes is fixed at the end of each

shaft.

 Design of Flange Coupling:

Consider a flange coupling as shown in Fig. 1 and Fig. 2.

Let d = Diameter of shaft or inner diameter of hub,

D = Outer diameter of hub,

d1 = Nominal or outside diameter of bolt,

D1 = Diameter of bolt circle,

n = Number of bolts,

tf = Thickness of flange,

τs, τb and τk = Allowable shear stress for shaft, bolt and key material respectively

τc = Allowable shear stress for the flange material i.e. cast iron,

σcb, and σck = Allowable crushing stress for bolt and key material respectively.

The flange coupling is designed as discussed below :

1. Design for hub

The hub is designed by considering it as a hollow shaft, transmitting the same torque (T) as
that of a solid shaft.

T = π/16 × τc { (D^4 – d^4) / D }

The outer diameter of hub is usually taken as twice the diameter of shaft. Therefore from
the above relation, the induced shearing stress in the hub may be checked.

The length of hub (L) is taken as 1.5 d.

2. Design for key

The key is designed with usual proportions and then checked for shearing and crushing stresses.

The material of key is usually the same as that of shaft. The length of key is taken equal to the
length of hub.

3. Design for flange

The flange at the junction of the hub is under shear while transmitting the torque. Therefore,
the troque transmitted,

T = Circumference of hub × Thickness of flange × Shear stress of flange × Radius of hub

= π D × tf × τc × D/2 = {(πD^2) / 2} × τc × tf

The thickness of flange is usually taken as half the diameter of shaft. Therefore from the
above relation, the induced shearing stress in the flange may be checked.

4. Design for bolts

The bolts are subjected to shear stress due to the torque transmitted. The number of bolts
(n) depends upon the diameter of shaft and the pitch circle diameter of bolts (D1) is taken as 3 d.
We know that

Load on each bolt = π/4 d1^2 τb

∴ Total load on all the bolts = π/4 d1^2 τb × n

and torque transmitted, T = π/4 d1^2 τb × n × D1/2

From this equation, the diameter of bolt (d1) may be obtained. Now the diameter of bolt may
be checked in crushing.
We know that area resisting crushing of all the bolts

= n × d1 × tf

and crushing strength of all the bolts

= (n × d1 × tf ) σcb

∴ Torque, T = (n × d1 × tf × σcb ) D1/2

From this equation, the induced crushing stress in the bolts may be checked.