Design of Machine Members-I Unit-8

Lecture Notes - 65
1. Unprotected type flange coupling
coupling. In an unprotected type flange coupling, as shown in
Fig.1,, each shaft is keyed to the boss of a flange with a counter sunk key and the flanges are
coupled together by means of bolts. Generally, three, four or six bolts are used. The keys are
staggered at right angle along the circumference of the shafts in order to divide the
weakening effect caused by keyways.

Fig.1 Unprotected Type Flange Coupling.

The usual proportions for an unprotected type cast iron flange couplings, as shown in
Fig.1, are as follows:
If d is the diameter of the shaft or inner diameter of the hub, then Outside diameter of hub,
D=2d
Length of hub, L = 1.5 d
Pitch circle diameter of bolts, D1 = 3d
Outside diameter of flange,
D2 = D1 + (D1 – D) = 2 D1 – D = 4 d
Thickness of flange, tf = 0.5 d
Number of bolts = 3, for d upto 40 mm
= 4, for d upto 100 mm
= 6, for d upto 180 mm
Design of Machine Members-I Unit-8
Lecture Notes - 65
2. Protected type flange coupling
coupling. In a protected type flange
ange coupling, as shown in Fig.2
Fig.2,
the protruding bolts and nuts are protected by flanges on the two halves of the coupling, in
order to avoid danger to the workman. The thickness of the protective circumferential flan
flange
(tp) is taken as 0.25 d.. The other proportions of the coupling are same as for unprotected type
flange coupling.

Fig.2. Protected Type Flange Coupling.

3. Marine type flange coupling.
coupling In a marine type flange coupling, the flanges are forged
integral with
ith the shafts as shown in Fig.3.
Fig.3

Fig.3. Solid Flange Coupling or Marine Type flange coupling.

Design of Machine Members-I Unit-8
Lecture Notes - 65
The flanges are held together by means of tapered headless bolts, numbering from four to
twelve depending upon the diameter of shaft. The other proportions for the marine type
flange coupling are taken as follows:
Thickness of flange = d / 3
Taper of bolt = 1 in 20 to 1 in 40
Pitch circle diameter of bolts, D1 = 1.6 d
Outside diameter of flange, D2 = 2.2 d
Design of Flange Coupling
Consider a flange coupling as shown in Fig.1 and Fig.2.
Let d = Diameter of shaft or inner diameter of hub,
D = Outer diameter of hub,
D1 = Nominal or outside 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 respectively
τc = Allowable shear stress for the flange material i.e. cast iron,
σcb, and σck = Allowable crushing stress for bolt and key material respectively.
The flange coupling is designed as discussed below:
1. Design for hub
The hub is designed by considering it as a hollow shaft, transmitting the same torque (T) as
that of a solid shaft.

The outer diameter of hub is usually taken as twice the diameter of shaft. Therefore from the
above relation, the induced shearing stress in the hub may be checked.
The length of hub (L) is taken as 1.5 d.
2. Design for key
The key is designed with usual proportions and then checked for shearing and crushing
stresses. The material of key is usually the same as that of shaft. The length of key is taken
equal to the length of hub.
3. Design for flange
Design of Machine Members-I Unit-8
Lecture Notes - 65
The flange at the junction of the hub is under shear while transmitting the torque. Therefore,
the torque transmitted,
T = Circumference of hub × Thickness of flange × Shear stress of flange × Radius of
hub

The thickness of flange is usually taken as half the diameter of shaft. Therefore from the
above relation, the induced shearing stress in the flange may be checked.
4. Design for bolts
The bolts are subjected to shear stress due to the torque transmitted. The number of bolts (n)
depends upon the diameter of shaft and the pitch circle diameter of bolts (D1) is taken as 3 d.
We know that
Load on each bolt

Then, Total load on all the bolts

And torque transmitted,

From this equation, the diameter of bolt (d1) may be obtained. Now the diameter of bolt may
be checked in crushing.
We know that area resisting crushing of all the bolts = n × d1 × tf
And crushing strength of all the bolts = (n × d1 × tf ) σcb
Torque,

From this equation, the induced crushing stress in the bolts may be checked.
References:
1. Machine Design - V.Bandari .
2. Machine Design – R.S. Khurmi
3. Design Data hand Book - S MD Jalaludin.
Design of Machine Members-I Unit-8
Lecture Notes - 66
Problem: Design a cast iron protective type flange coupling to transmit 15 kW at 900 r.p.m.
from an electric motor to a compressor. The service factor may be assumed as 1.35. The
following permissible stresses may be used :
Shear stress for shaft, bolt and key material = 40 MPa
Crushing stress for bolt and key = 80 MPa
Shear stress for cast iron = 8 MPa
Draw a neat sketch of the coupling.

Solution. Given: P = 15 kW = 15 × 103 W; N = 900 r.p.m. ; Service factor = 1.35 ; τs = τb = τk

= 40 MPa = 40 N/mm2 ; σcb = σck = 80 MPa = 80 N/mm2 ; τc = 8 MPa = 8 N/mm2.
The protective type flange coupling is designed as discussed below:
1. Design for hub
First of all, let us find the diameter of the shaft (d).
( ). We know that the torque transmitted by
the shaft,

Since the service factor is 1.35, therefore the maximum torque transmitted by the shaft, Tmax
= 1.35 × 159.13 = 215 N-m
m = 215 × 103 N-mm
N
We know that the torque transmitted by the shaft (T),
(

We know that outer diameter of the hub,

D = 2d = 2 × 35 = 70 mm Ans.
And length of hub, L = 1.5 d = 1.5 × 35 = 52.5 mm Ans.
Let us now check the induced shear stress for the hub material which is cast iron. Considering
the hub as a hollow shaft. We know that the maximum torque transmitted (T
( max).

Then, τc = 215 × 103/63 147

1 = 3.4 N/mm2 = 3.4 MPa
Since the induced shear stress for the hub material (i.e.
( . cast iron) is less than the permissible
value of 8 MPa, therefore the design of hub is safe.
2. Design for key
Design of Machine Members-I Unit-8
Lecture Notes - 66
Since the crushing stress for the key material is twice its shear stress (i.e. σck = 2τk ), therefore
a square key may be used. From DDB, we find that for a shaft of 35 mm diameter,
Width of key, w = 12 mm Ans.
And thickness of key, t = w = 12 mm Ans.
The length of key ( l ) is taken equal to the length of hub.
Then, l = L = 52.5 mm Ans.
Let us now check the induced stresses in the key by considering it in shearing and crushing.
Considering the key in shearing. We know that the maximum torque transmitted (Tmax),

Then, τk = 215 × 103/11 025 = 19.5 N/mm2 = 19.5 MPa

Considering the key in crushing. We know that the maximum torque transmitted (Tmax),

Σck = 215 × 103/ 5512.5 = 39 N/mm2 = 39 MPa.

Since the induced shear and crushing stresses in the key are less than the permissible stresses,
therefore the design for key is safe.
3. Design for flange
The thickness of flange (tf) is taken as 0.5 d.
Then, tf = 0.5 d = 0.5 × 35 = 17.5 mm Ans.
Let us now check the induced shearing stress in the flange by considering the flange at the
junction of the hub in shear.
We know that the maximum torque transmitted (Tmax),

τc = 215 × 103/134 713 = 1.6 N/mm2 = 1.6 MPa

Since the induced shear stress in the flange is less than 8 MPa, therefore the design of flange
is safe.
4. Design for bolts
Let d1 = Nominal diameter of bolts.
Since the diameter of the shaft is 35 mm, therefore let us take the number of bolts,
n=3 and pitch circle diameter of bolts,
D1 = 3d = 3 × 35 = 105 mm
Design of Machine Members-I Unit-8
Lecture Notes - 66
The bolts are subjected to shear stress due to the torque transmitted. We know that the
maximum torque transmitted (Tmax),

(d1)2 = 215 × 103/4950 = 43.43 or d1 = 6.6 mm

Assuming coarse threads, the nearest standard size of bolt is M 8. Ans.
Other proportions of the flange are taken as follows:
Outer diameter of the flange,
D2 = 4 d = 4 × 35 = 140 mm Ans.
Thickness of the protective circumferential flange,
tp = 0.25 d = 0.25 × 35 = 8.75 say 10 mm Ans.
References:
1. Machine Design - V.Bandari .
2. Machine Design – R.S. Khurmi
3. Design Data hand Book - S MD Jalaludin.