Design and analysis of PROTECTED FLANGE

COUPLING Solidworks 2016 and ANSYS Workbench

(Course Project)

By

HARSHIT PALIWAL- 60005140058

RAHUL PATHAK-60005140066

JINIT SHAH- 60005140086

ARMAAN VALJEE- 60005140112

Under guidance of:

PROF. RAJNARAYAN YADAV

CERTIFICATE
This is to certify that the project entitled Design of Protected
Flange Coupling using Solid works 2016 and Ansys Workbench is
a bonafide work of HARSHIT PALIWAL(60005140058), RAHUL
PATHAK (60005140066), JINIT SHAH (60005140086) AND ARMAAN
VALJEE (60005140112) submitted to the University of Mumbai in
partial fulfillment of the requirement for the award of the project
course in Bacgelor of Engineering in Mechanical Engineering.

Project Guide

(Prof. Rajnarayan Yadav)

ABSTRACT
 This project presents the Design and analysis of Protected Flange
Coupling. The following abstract using the two software mainly
Solid Works 2016 & Ansys Workbench.

This project report consist of the design of Protected Flange

Coupling followed by the design analysis in the Ansys software
and verifying from the results obtained by the software that the
design is safe and verified for practical applications considering
the mechanical and structural stresses.

TABLE OF CONTENTS
 SR. NO TITLE PAGE NO
A COVER PAGE
B CERTIFICATE
C ABSTRACT
D SUMMARY
1. INTRODUCTION
2. MANUAL
CALCULATION

3. ANSYS REPORT
4. ANSYS RESULTS
5. CONCLUSION
6. BIBLIOGRAPHY

FIGURE NO. FIGURE NAME PAGE NO.

1.

2.

3.

4.

5.

D. SUMMARY
1. INTRODUCTION
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.

Flange coupling is a type of rigid coupling in which two co-linear

shafts are connected by a projecting flat rim called flange.
These couplings are specifically designed and developed for
horizontal shaft mounted geared unit applications.

Flange Couplings find application in the following working

environments:

1. When the shafts are slightly misaligned (parallel, angular or axial)

2. When very high strength coupling is required
3. When the shafts to be connected are susceptible to shocks

Industrial Applications:
1. Designed for heavy load industrial equipment
2. Used to couple electric motors to machines
3. Used in driven shaft of a car or truck.
4. Used in extrusion presses
5. Used in elevators and conveyors

Advantages:
1. No lubrication required.
2. Fit and forget low maintenance coupling
3. Great allowable misalignments
4. Easy mounting and dismounting
5. Superior resistance to environmental conditions
6. Lower thrust load and bending moment
FIG.1: ASSEMBLY OF PROTECTED FLANGE COUPLING
 FIG 2: DIMENSIONS OF FLANGE COUPLING

2. MANUAL CALCULATION

The flange is subjected to a loading of P=25 kw at 250 rpm

 db = 8 mm

tp = 14 mm

tf = 28 mm

D = 112 mm

D1 = 168 mm

D2 = 224 mm

D3 = 123.2 mm

D = 56 mm

W = 14mm

h = 14 mm

l = 87 mm

SELECTION OF MATERIAL

A) Taking GREY CAST IRON as material for Flange-

Adequate strength
Less expensive
Ease in availability
Good machinability characteristics

For Grey Cast Iron:

ut=2.4x108 Pa
Let F.O.S. be 16.

Permissible Stresses:
 t= yt/F.O.S
t= 8.75 MPa
us = 2.25x108 Pa
= us/F.O.S = 14.06 MPa

B)Taking 35C8 as material for Shaft and Key-

Adequate strength
Less expensive
Ease in availability

FOR 35C8:
yt =5.7X108 Pa
Let F.O.S. be 4
Permissible Stresses:

t= yt/F.O.S
t = 350/4
t= 87.14 MPa
us = 0.5xyt = 175 MPa
= us/F.O.S = 43.75 MPa

C)Taking 35Ni5Cr2 as material for Nut and Bolts-

Standard bolt material
For 35Ni5CR2:
yt = 500 Mpa
Let F.O.S be 5
Permissible Stresses:
t= yt/F.O.S
t = 500/5
t = 100 Mpa

Design Torque:
 2 nT
P= 601000

2 250T
25= 601000
T= 954.93 N-m

1. Design of Shaft

max = 16 T/(3.14*d3)
d= 56mm

2. Design of key:

Selecting square key:

W=h=d/4=56/4=14mm

L=1.5d=1.5*56=84mm

Considering shearing of key,

T
2T
= d /2
= dW l
Wl

2954.93
35= 5614l

l= 87mm

Therefore, selecting largest of the two values l=87mm

3.Design Of Hub:
Length of hub, l=87mm

Outer diameter of hub, D=2d = 112mm

Checking for shear stress :

h = 16T/(D3(1-k4))

h = 3.692 MPa

Hence, the hub is safe against shear failure .

4.Design Of Flange :

Thickness of flange, tf = 0.5d = 0.5*56 = 28mm

Thickness of protective flange, tp = 0.25d = 0.25*56= 14mm

Diameter of bolt circle, D1 = 3d = 3*56 = 168mm

Outer diameter of flange , D2 = 4d = 4*56 = 224mm

Diameter of flange recess, D3 = 1.1 D = 1.1*112 = 123.2mm

The direct shear stress induced in a flange at a junction with hub

is:
T
2954930
= D/2 = 11211228
Dt

= 1.7308 Mpa

Hence, the flange is safe against shear failure.

5.Design Of Bolts:

The bolts are subjected to subjected shear stress .

Shearing Of bolts :
 T
D1/2
= ndpdp
4

8954930
50 = 6168dd

db= 7.76mm

The next standard nominal diameter is 8mm or M8

db= 8mm