Tutorial # 3 (Design of Couplings)

Exercise 1:
A rigid coupling has a bore diameter of 50 mm. Four
machined bolts on a bolt circle of 125 mm diameter
and fitted in reamed holes. If the bolts are made from
the same material as the shaft, with an ultimate tensile
strength of 550 MPa and a yield point in tension of
345 MPa, determine the necessary size of bolts to have
the same capacity as the shaft in torsion.

Solution:
The shaft capacity is found from:
D3 = (16/s)Tkt
(the shaft equation for a solid shaft in torsion only).

Then: s (allowable) is the smallest of: 0.18x550 = 99 MPa

and 0.3x345 = 103.5 MPa
and the allowance for the keyway effect is 0.75
3
Then (0.05) = (16Tkt/x0.18x550xl06)(0.75)
Tkt=1.823 kNm
The coupling can be designed for kt = 1.0 or Tkt can be left as a product.
Using the case (1), which gives the most conservative design:
Tkt = s [(/4)(d2)](0.5DBC)(n)
Where:
DBC = diameter of bolt circle, m
d = diameter of bolt, m (shank diameter)
:. 1.823x103 = 0.18x550x106( /4)(d)2(0.5x0.125)x(4) -- d = 0.00968 m Here use an M10
bolt.
Using the case (2),
Tkt = (3/4) s [(/4)(d2)](0.5DBC)(n)
:. 1. 1.823x103 = 0.75x0.1 8x550(/4)(d)2(0.5x0.125)(4) -- d = 0.0112 m MI2 bolt may be
used.
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Exercise 2:
Assume that a flange coupling has the
following specifications:
Number of bolts: 6.
Size of bolts: 12 mm diameter
Preloading of bolts: 22 KN in each bolt.
Inner diameter of contact: 175 mm.
Outer diameter of contact: 200 mm.
Speed of rotation of coupling: 300 rpm.
Coefficient of friction: 0.15
Shaft diameter: 50 mm.
Shaft material, annealed steel with an ultimate tensile strength of 586 MPa and a yield point
in tension of 310 MPa.
The bolts are set in large clearance holes in the coupling.
1) Determine the maximum power capacity based upon friction such that slip occurs
between faces of contact.
2) Compare the shaft power capacity with the friction power capacity. Assume steady
load conditions and that the shaft is in torsion only.

Solution:

a) The torque capacity based on friction is:

T= F x f x Rf
Where:
F = axial force caused by bolts loading, N
f = coefficient of friction
Rf = friction radius

This assumes that the pressure is uniformly distributed.

.'. Friction power = (2x T x N)/60 = (2x T x 300)/60= 58,4 kW
b) Shaft torque capacity:

T = s x x D3/16 = [93 x l06 x 0.75 x x (0.05)3]/ 16 = 1.712 kN.m.

Where, s is the smallest of 0.18x586 = 105 MPa and 0.3x310 = 93 MPa.
Shaft power capacity = (2x T x N)/60 = (2x 1712 x 300)/60 = 53.7 kW
The coupling has greater power capacity based on friction than the shaft capacity.
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Exercise 3:
Set up the equations or relations necessary
determine:
a) the hub diameter DH.
b) the web thickness t.
c) the flange thickness h.

to

Solution:
a) The hub diameter (DH ) is established on the basis of proportions.
DH (1.75Ds to 2.0Ds)

b) The minimum thickness of the web (t) is based on:

1)-Shear of the web:
T = [s x (x DH x t)] x (DH/2)
or
t = 2Mt/(s x x DH2)
**Usually, t determined from the above equation is very small and the
difficulty of casting necessitates using a thickness much larger than calculated.
2)- Bearing of the bolts and web:
T = [B x (d x t)] x (DBC /2) x n
or
t = 2Mt/(B x d x DBC x n)
Where:
B = allowable bearing stress for the bolt or web (whichever is weaker), Pa of
the projected area.
c) The thickness of flange is based upon proportions and casting requirements.
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Exercise 4:
A flange coupling connects two 50 mm diameter lengths of commercial shafting. The
coupling webs are bolted together with four bolts of the same material as the shaft. The bolts
are set in clearance holes. The diameter of the bolt circle is 240 mm and the web thickness is
22 mm.
a) Determine the minimum bolt diameter required transmitting the same torque that the
shaft can transmit.
b) What power may be transmitted at 200 rev/min under steady state conditions?
Solution:
T = (x s x D3)/16 = (x 40 x 106 x 0.053)/16 = 981.8 N.m.
a) Bolts diameter:
1)- Based upon shear:
Assume uniform shear:
T = s x (x db2)/4 x (DBc/2) x (n/2)

981.8 = (55 x l06) x (x db2)/4 x (0.24/2) x (n/2)

db = 9.73 mm Take Ml0 bolt.
2)- Based upon bearing:
T = B x (tx db) x (DBc/2) x (n/2)
981.8 = (2 x 55 x l06) x (x db) x (0.24/2) x (n/2)
db = 1.69 mm
Thus, Take Ml0 bolts.
b) Power:
Power = x (x N)/60 = [981.8 x (x 200)/60] x 10-3 = 20.56 kW
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