1.

0 TITLE
1.1 SHAFT COUPLINGS

2.0 CONTENTS
CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Title Content Objective Introduction Theory Procedure Problem Statement & Solution PAGES 1 2 3 4 5-6 7-8 9-13
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8.0 9.0 10.0

Conclusion Suggestion Reference

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3.0 OBJECTIVE

The objective of shaft alignment is to increase the operating lifespan of rotating machinery. To achieve this goal, machinery components that are most likely to fail must operate within their design limits. Since the components that are most likely to fail are the bearings, seals, coupling, and shafts, accurately aligned machinery will achieve the following results ...
Reduce excessive axial and radial forces on the bearings to insure longer

bearing life and rotor stability under dynamic operating conditions. Minimize the amount of shaft bending from the point of power transmission in the coupling to the coupling end bearing. Minimize the amount of wear in the coupling components. Reduce mechanical seal failure. Maintain proper internal rotor clearances. Eliminate the possibility of shaft failure from cyclic fatigue.

4.0 INTRODUCTION
Shaft and coupling must have adequate torsional strength to transmit torque and not be over stressed. Shaft must sustain a combination of bending and torsional loads. Two shafts join together by the way of a coupling for the purpose of transmitting power. Couplings connect motors to pumps, to gearboxes, to fans, to

compressors, to turbines, and a host of other machines that require power by means of a rotating shaft. For shaft coupling alignment to occur, the two shafts must rotate on the same centerline. In this condition the coupling enables a smooth and efficient transmission of power from the powered-shaft to the shaft being powered.

5.0 THEORY
5.1 SHAFT 5.1.1 Types of shafts : i) ii) Transmission Shafts Machine Shafts

5.1.2 Material For ordinary shafts is mild steel. When high strength is required, and alloy such as nickel, nickel chromium or chrome-vanadium steel is used. 5.1.3 Transmission Shaft A. Standard sizes 25 60 mm with 5 mm steps 60 110 mm with 10 mm steps 110 140 mm with 15 mm steps 140 500 mm with 20 mm steps B. Stresses in shafts i) ii) iii) Sheer stress Bending stress Stresses due to combined torsional and bending loads

C. Maximum Permissible Working Stresses For Transmission Shafts Maximum permissible working stresses in tension or compression: @ 112 N/mm (1120 kgf/cm) for shaft without allowance

for keyways @ 84 N/mm (840 kgf/cm) for shafts with allowance for keyways [May be taken as 60% of elastic limit in tension but no more than 36% of ultimate tensile strength] Maximum permissible sheer stress @ 56 N/mm (560 kgf/cm) for shaft without allowance for keyways @ 42 N/mm (420 kgf/cm) for shaft with allowance for keyways [May be taken as 30% of elastic limit in tension but no more than 18% of ultimate tensile strength] 5.2 RIGID COUPLING Used to connect 2 shafts which are perfectly aligned 5.2.1 Types of Rigid Coupling i) Flange Coupling ii) Clamp / Compression Coupling 5.2.1.1 Flange Coupling Usually applied to a coupling having to separate cast iron flange. Each flange mounted on the shaft end and keyed to it. An adopted to heavy load is used on large shafting Types: i) Unprotected type ii) Protected type iii) Marine type 5.2.1.2 Clamp / Compression Coupling

 Shafts end are made to a butt each other and single key is fitted directly

in the keyway of bold shaft. May be used for heavy duty and moderate speeds Advantages the position of shaft need not to be changed far assembling or disassembling of the coupling.

6.0 PROCEDURE
6.1 Design for flange coupling 6.1.1 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.

T=

/16

fsc ( D d /D )
4 4

The outer diameter of hub is usually taken as twice of the diameter of shaft. Therefore from the relation, the induced shearing stress in the hub may be checked. The length of hub ( L ) is taken as 1.5d. 6.1.2 Design for key The key is designed with usual proportion and the checked for shearing and crushing stresses. The material of the key is usually the same as that of shaft. The length of key is taken equal to the length of hub. 6.1.3 Design for flange The flange at the junction of the hub is under shear while transmitting the torque. Therefore the torque transmitted

T=

. D . tf . fsc

x D/2

Or T = circumference of hub x thickness of flange x shear stress of flange x radius of hub.

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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. 6.1.4 Design for bolts The bolts are subjected to shear stress due torque transmitted. The number of bolts ( n ) depends upon the diameter of shaft and the pitch circle diameter of bolts ( D1) is taken as 3d. We know that ;

Load on each bolts =

/ 4 ( d ) fsb
1 2

Total loads on all bolts =

/ 4 ( d ) fsb x n
1 2

And torque transmitted, T =

/ 4 ( d ) fsb
1 2

D1 / 2

From the equation, the diameter of bolts ( d1) may be obtain. 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 ) fcb
1

Therefore, torque =

( n . d1 . tf . fcb ) D / 2

From this equation, the induced crushing stress in the bolts may be checked.

7.0 PROBLEM STATEMENT & SOLUTION

Design a unprotected type of cast iron flange coupling for a shaft transmitting 11.19 kW at 500 r.p.m. The following permissible stresses may be used: shear stress for shaft, bolt and key material crushing stress for bolt and key shear stress for cast iron diameter of shaft maximum allowable stress for shaft with allowance for keyways

= 40 N/mm = 80 N/mm = 8 N/mm = 50 mm = 42 N/mm2 Km

1.0 1.5 to 2.0 1.5 1.5 to 2.0 2.0 to 3.0

Nature of load
1. Stationary Shafts (a) Gradually applied load (b) Suddenly applied load 2. Rotating shafts (a) Gradually applied load (b) Suddenly applied load with minor shock (c) Suddenly applied load with major shock

Kt
1.0 1.5 to 2.0 1.0 1.5 to 2.0 1.5 to 3.0

Table 1: Recommended values of Km and Kt

1. Design for hub T= r d = 50mm d/2 = r = 25 J P = /32 (50)4 = 613,592 m4 = 2N/60 = 52.36 Nm = T = P/ = 11,190/52.36 = 213.7 N/m 213.7 613592 = 20 _ = 3.48 X 10-4 25 = 3.48 X 10-4 (25) = 8.707 X 10-3 = 8.7 N/mm Since the induce d shear stress in the hub is less than the permissible value of 42 N/mm2 , therefore the design for hub is safe.
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2. Design for key Since the crushing stress for the key material is twice its shear stress, therefore a square key may be used. From table , we can fine for a 50 mm diameter shaft, Width of key, = 16mm Ans And thickness of key, t = =16mm Ans The length of key (t) is taken equal to the length of hub. ... l = L = 16mm 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), 895000 = l..sk X d/2 = 75 X 16 X sk X 50/2 = 30,000 sk sk = 895 000/30 000 = 29.8 N/mm

...

Considering the key crushing.We know that the maximum torque transmitted (Tmax). 895000 = l X t/2 X ck X d/2 = 75 X 16/2 X ck X 50/2 = 15 000 ck ck = 895 000/15 000

...

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= 59.6 N/mm Since the induced shear and crushing stresses in key are less then the permissible stresses, therefore the design for key safe. 3. Design for flange The thickness of the flange (t) is taken as 0.5 d. ... t = 0.5 X 50 = 25 mm Let us now check the induced shear stress in the flange, by considering the flange at the junction of the hub in shear. We know that the maximum torque transmitted (Tmax), 895 000 = D X sc X t 2 = (100) X sc X t 2 = sc X 25 = 392 750 sc . .. sc = 895 000/392 750 = 2.3 N/mm Since the induced shear stress in the flange is less than the permissible value of 42 N/mm, therefore the design for flange is safe.

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4. Design for bolts

Let d1 = Nominal diameter of bolts. Since the diameter of shaft is 50mm, therefore let us take the numbers of bolts, n =4 and pitch circle diameter of bolts D1= 3d = 3 X 50 = 150 mm The bolts are subjected to shear stress due to the torque transmitted. We know that the maximum torque transmitted (Tmax) 895000 = __ (d1)2 sb X n X _D1_ 4 2 2 = __ (d1) 30 X 4 X 150 4 2 2 = 7070 (d1) 2 (d1) = 895000 7070 = 126.6 or d1 = 11.25 mm Other proportions of the flange are taken as follow : Outer diameter of the flange , D2 = 4 d = 4 X 50 = 200 mm

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8.0 CONCLUSION

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9.0 SUGGESTION

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10.0 REFERENCE
http://www.maintenanceresources.com/referencelibrary/align ment/importance.htm http://www.vibralign.com/alignment-coupling http://en.wikipedia.org/wiki/Coupling http://images.search.yahoo.com/search/images? p=shaft+coupling&ni=64&b=181&fr=yfp-t-701&fr2=pivweb&tab=organic http://www.brighthubengineering.com/machine-design/43237shaft-couplings-types/ http://www.thepipefittings.com/rigid-coupling.html http://www.monition.com/coupling-alignment.html http://shaft-alignment.net/index.html http://www.unionmillwright.com/shaft.html http://thealignmentblog.com/blog/2012/10/22/practice-perfectshaft-alignment/

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