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

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 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 Bachelor of Engineering in Mechanical Engineering.

Project Guide

(Prof. Rajnarayan Yadav)

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 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.

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 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

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FIGURE NO. FIGURE NAME PAGE NO.

1. 8

2. 9

3. 15

4.

5.

5
D. SUMMARY

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 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

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FIG.1: ASSEMBLY OF PROTECTED FLANGE COUPLING

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FIG 2: DIMENSIONS OF FLANGE COUPLING

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 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

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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

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Permissible Stresses:
t= yt/F.O.S
t = 500/5
t = 100 Mpa

Design Torque:

2
P=
601000

2250
25=
601000

T= 954.93 N-m

-------------------------------------------------------------------------------------------

1. Design of Shaft

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

---------------------------------------------------------------------------------------------------------

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 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,

/2 2
= =

2954.93
35=
5614

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.

-------------------------------------------------------------------------------------------------------------

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 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:

/2 2954930
= =
11211228

= 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:

1/2
=
4

8954930
50 =
6168

db= 7.76mm

The next standard nominal diameter is 8mm or M8

db= 8mm

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3. ANSYS REPORT

FIG.3: 3-D Model of Flange

FIG.4: 3D Model of Key

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 FIG.5: 3D model of Shaft

FIG.6: Assembly of Protected Flange Coupling

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 4. ANSYS RESULTS

1. EQUIVALENT STRESS (FLANGE):

FIG.6: Equivalent stress

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2. TOTAL DEFORMATION (FLANGE) :

FIG.7: Total Deformation

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3. EQUIVALENT STRESS (SHAFT)

FIG.8: Equivalent Stress

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4. Total Deformation (Shaft)

FIG.9: Total deformation

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5.Total Deformation (KEY)

FIG.10: Total Deformation

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Material Data
Gray Cast Iron
TABLE 14
Gray Cast Iron > Constants
Density 7.2e-006 kg mm^-3

Coefficient of Thermal Expansion 1.1e-005 C^-1

Specific Heat 4.47e+005 mJ kg^-1 C^-1

Thermal Conductivity 5.2e-002 W mm^-1 C^-1

Resistivity 9.6e-005 ohm mm

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 5. CONCLUSION

As per the objective of the project, first the parts of the Protected
Flanged Coupling were designed manually using empirical and designing
procedures and selecting the materials according to standard use. It was
then verified doing manual calculations that the design was indeed safe.
The design was then recreated in Solidworks and from there imported to
Ansys for further analysis. It was found that on applying all the loads the
design turned out to be safe as per the software too. Also it became easy
to identify the regions of maximum stress and minimum stress from the
results obtained from Ansys analysis so that if needed further design
changes can be made to reduce stress concentration.
During the course of this project we learned the principles of designing
and mainly to analyze components using Ansys software. Also we
learned qualities of team work, punctuality and hard work.

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 6. Bibliography

R.S. KHURMI, A Textbook MACHINE DESIGN.

Design Data Book by Mahadevan.

H.S. Manohar, Finite Element Method, First edition.

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