Beruflich Dokumente
Kultur Dokumente
Submitted in
Machine Design Practice-II
On
“Design of Rigid Flange Coupling”
In Mechanical Engineering (6th Semester)
1
Design and Calculations
Step-I: Preliminary Sketch
2
Step-II: Selection of Materials and Input Parameters
Shaft Material: Mild Steel
Coupling Material: Cast Iron
Material for Bolt and Key: Mild Steel
Power transmit: 75 kW at 200 rpm
Allowable shear stress in shaft: 45 N/mm2
Allowable shear stress for key material: 45 N/mm2
Crushing stress for bolt and key: 160 N/mm2
Shear stress for bolt material: 30 N/mm2
Shear stress for cast iron: 8 N/mm2
Step-III: Calculation
1. Design Torque
Td = Nominal Torque x Service Factor
Service factor is assumed to be 1.25.
6
P ower × 60 × 10
N ominal T orque = 2π × rpm
Or d = 79.71 or 80 mm
Based on Rigidity Criterion,
584×T d ×l
d4 = G×Ө , or d= 50.88 or 52 mm
Taking the higher value, d= 80 mm
3
3. Other Dimensions of the Coupling
i. Hub Diameter, dh = 2d = 160 mm
ii. Hub Length, lh = 1.5d = 120 mm
iii. Bolt Circle Diameter, D = 3d = 240 mm
iv. Flange Thickness, t = 0.5d = 40 mm
v. Thickness of Protective Rim, t1 = 0.25d = 20 mm
vi. Diameter of Spigot and Recess, dr = 1.5d = 120 mm
vii. Outside diameter of Flange, Do = 4d+2t1 = 360 mm
4. Design of Hub as Hollow Shaft
16T d ×dh
τhub = 4 4 = 5.93 MPa < τCI (=8MPa)
π(dh −d )
5. Design of Bolts
n= Number of bolts= 4
Td × 2
Ftb = n×D = 9325.48 N
Shear Failure of bolts:-
πdb 2
Ftb = 4 × τb
db = 19.89 or 20 mm (M20 bolts)
Crushing Failure of bolts:-
F tb
σc = t ×db = 11.65 MPa (<160 MPa)
6. Failure of Key
Key Dimensions: b = 22 mm and h = 14 mm
Length of Key, lk = length of hub = 120 mm
Td
Tangential Force, F tk = d/2 = 111905.82 N
F tk
Shear Stress, τ = b×lk = 42.38 MPa (< 45 MPa)
4
F tk × 2
Crushing Stress, σ = h × lk = 133.22 MPa (< 160 MPa)
Analysis
There are several methods analysis software’s have been used for analyzing. In this
project, we are using Ansys software for analyzing. Ansys is a leading finite
element analysis software developed by Ansys inc. it uses a friendly graphical user
interface package. In a linear static, we determine the stresses, displacements,
strain and reaction in the fem. The static analysis deals with the computation of
displacement and stress due to static loads refers to loading but doesn’t cause
inertial or damping effects to be significant for consideration in the analysis.
The material used here is grey cast iron, the Poisson’s Ratio of grey cast iron is
0.28 and Young's Modulus is 1.1e+005 Mpa
5
Figure 2: Mesh Model of the coupling
6
S. No. Comparison Shear Stress of Crushing Stress
Bolts (MPa) of Bolts (MPa)
1 Theoretical Results 30 160
2 Analytical Results 17.684 123.24
Table 3: Comparison results of bolts
7
References
1. “Design of Machine Elements” by V. B. Bhandari.
2. Maleev and Hartman’s “Machine Design in SI Units”, edited by O.P.
Grover.