By Dr. Liaquat /Anique Mukhtar aniquemukhtar@hotmail.com Spline Problem • 1-inch shaft transmits 7.5 hp at 1450 rpm. The shaft is made of steel. If direction is regularly reversed, design a spline so that it can’t slide under loading condition. Justify number of splines selected. Spline Design The torque capacity for SAE splines is based on the limit of 1000-psi bearing stress on the sides of the splines, from which the following formula is derived: T = 1000NRh 1. Number of Spline - N 2. Mean Radius of Spline - R 3. Spline Depth - h Spline Design Design of Keys & Couplings • Ch-13 Khurmi • Ch-7 Shigley • Ch-11 Robert L. Mott Pinning • A hole can be drilled through both the shaft and hub. • A pin can be inserted in the hole. • Types of Pins Cylindrical Pin Taper Pin Split spring Pin Pinning • Fitting as well as prevention of a cylindrical pin from falling out of the assembly is difficult. • To overcome above problem, taper or split spring pin is utilized. • Split spring pin is the most suitable pin as the hole is made slightly smaller than the diameter of the pin in this case. • The pin is press fit in the hole and requires a little force to insert the pin. Stress in Pin Shear Stress in Pin
1. Diameter of shaft - D 2. Diameter of Pin - d COUPLING Shaft couplings are used in machinery for;
1. To provide for the connection of shafts
2. To provide for misalignment of the shafts 3. To introduce protection against overloads COUPLING Types of Shafts Couplings
1. Rigid coupling a) Sleeve or muff Coupling b) Clamp or Compression Coupling c) Flange Coupling
2. Flexible coupling a) Universal or Hooke’s Coupling COUPLING Sleeve or Muff-coupling COUPLING
Steam turbine (5 KW) Keyway COUPLING MATERIALS • Aluminum offers low cost and low moment of inertia. When coated appropriately, it also boasts low coefficient of friction, good wear characteristics, and good corrosion resistance. aluminum is the best default choice for metallic coupling components.
• Stainless steel offers good corrosion resistance and high strength over a wide range of temperatures, but increases cost.
• Alloy steel and brass are worth considering when cost is the primary consideration. Flange Coupling
tf = 0.5 d COUPLING Design of Flange Coupling
d = Diameter of shaft or inner diameter of hub,
D = Outer diameter of hub, d1 = 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 τf = Allowable shear stress for the flange material i.e. cast iron, σcb and σck = Allowable crushing stress for bolt and key material COUPLING Design for hub
T 16T h = r h = D J (D − d ) 4 4
Design for key
Failure by Shearing Failure by Torsion Failure by Compression
2T r2 l= 4T l= l= dw 2w c t d COUPLING Design for flange
F F .( D / 2) = T A = π D tf f = A 2T f = D2 t f COUPLING Design for Bolts Failure by shearing
F b = A F .( D1 / 2) = T π d12 A=n 4 8T b = n D1 d12 COUPLING Design for Bolts
Failure by crushing F cb = F .( D1 / 2) = T A = nd1t f A
2T cb = n D1 d1 t f COUPLING Design for Bolts
n = 3, for d upto 40 mm n = 4, for d upto 100 mm n = 6, for d upto 180 mm
d (mm) n= +3 50 COUPLING Example-1
Design a rigid type flange coupling to connect two shafts in order to transmit torque. The input shaft transmits 20 HP at 200 R.P.M. to the output shaft through coupling. The service factor of safety is 1.5 and the design torque is 1.5 times the rated torque.
The stress values are given below.
Flange & hub (Grey cast iron) with σyt = 200MPa Shaft (Plain Carbon Steel) with σyt = 400MPa Key & bolts (Plain Carbon Steel) with σyt = 350MPa 16T tf = d/2 h = D (D − d ) 4 4
2T f = D2 t f 8T b = n D1 d12 2T cb = n D1 d1 t f
d (mm) n= +3 50 COUPLING
Example-2
Design a cast iron flange coupling for a steel shaft transmitting 50HP at 500R.P.M. and having an allowable shear stress of 40MPa. The working stress in the bolts should not exceed 30 MPa. Assume that the same material is used for shaft and key and that the crushing stress is twice the value of its shear stress. The maximum torque is 25% greater than the full load torque. The shear stress for cast iron is 14 MPa. COUPLING
Example-3
Design a cast iron flange coupling to transmit 15 kW at 900 R.P.M. from an
electric motor to a compressor. The service factor of safety may be assumed as 1.35. The following permissible stresses may be used : Shear stress for shaft, bolt and key material = 40 MPa, Shear stress for cast iron flange = 8 MPa. See You In Next Class
