DME-1 COUPLINGS

Shear stress in shaft=τ s

Shear stress in bolt= τ b
Shear stress in key = τ k
Crushing or bearing or compressive stress in key= σ k
Crushing or bearing or compressive stress in key ¿ σ b

1. If shear and crushing stress of shaft , bolt and key is

given, consider the given values for solving the problem

2. Since crushing of bolt is not given in the question.

Consider crushing stress is twice the shear stress of bolt.
σb=¿𝝉b×2

3.shear (𝝉K )and crushing stress¿ )of the bolt is not

given. Hence consider bolt and key material is same
4.Assume efficiency Ƞ=75%
5. If service factor is given (Example:-Service factor
1.35),The maximum torque TMAX=T× Service factor

6. IF any condition given-The maximum torque is 20%

greater than mean torque or full torque(T).
100+20
TMAX =T × 100 = 1.2T
Example:- The maximum torque is 15% greater than
mean torque or full torque(T).
100+15
TMAX =T × 100 = 1.5T
7.The maximum torque is 1.5 times the mean torque.
TMAX =1.5 T
8.If angle of twist θ,Length( 20 diameter(L=20d) is
given, Find out shaft diameter based on rigidity besides
strength method.
Select highest value among them.
9.Modulus of Rigidity(G) or shear stress of any material
is not given ,select the value from DDHAB Chapter
1.Engineering materials.
9.G for Mild steel =80000N/mm2 or MPa

Given data

Power P=15KW

=15*1000=15000W

Speed n=1200 rpm

𝝉f =30MPa
𝝉s=𝝉k=𝝉b=75MPa

𝝈𝒄 =150MPa

1.Torque transmitted by the coupling

9550∗P 9550∗15000
Torque,T= n = 1200 = 119375Nmm (EQN
19.3 c)
T=Tmax=119375Nmm
2.Diameter of shaft
π
T= 16 ×𝒅³×Ƞ× 𝝉S eqn 19.2

Assume Ƞ =75%=0.75
π
119375= 16 ×𝒅³×0.75× 75

119375*16= π *d3*0.75*75

119375∗16
d3 = π∗0.75∗75 =10813.87
d =22.11mm
From DDHAB PAGE NO 14.19,TABLE 14.6
Standard diameter of shaft d=25 mm
3.Bolt circle diameter,D1=2d+0.05 in m (Eqn 19.12 a)
=2d+50 in mm
=2*25 +50=100 mm
4.Design of Hub
Diameter of hub= D2=1.5 d+25( eqn 19.13 a)
D2=1.5*25+25=62.5mm
Length of hub= l=1.25d+18.75 = ( eqn 19.14 a)
l=1.25*25+18.75 =50 mm
5.Design of flange
Outside diameter of flange =D=2.5d +75
D=2.5*25 +75=137.5mm
Thickness of flange t=0.5d=0.5*25=12.5mm
Check for flange
D2
Tmax =t×𝝅×D2×𝝉f × 2 EQN 19.6
62.5
119375=12.5×𝝅×62.5×𝝉f × 2
119375*2 =12.5×𝝅×62.5×𝝉f ×62.5
119375∗2
𝝉f= 12.5∗π∗62.5∗62.5 =1.55 MPa

INDUCED SHEAR STRESS OF FLANGE IE 1.55 N.MM2 IS LESS THAN

ALLOWABLE SHEAR ie 3MPa
𝝉f in <3𝑴𝑷𝒂
Hence design of flange is safe.
6.Design of bolt
Number of bolt,i=20d+3 d in m=70mm=70/1000=0.07
20*0.025 +3 =3.5 = 4 consider even number for number of bolts
Diameter of Bolts
Torque transmitted through the bolts
πd 1² D1
Tmax = i 4 * 𝝉b*
2

πd 1² 100
119375= 4 4 * 75*
2

d 1 =3.19mm
Standard pitch Diameter of bolt from table 18.7 d1=3.54mm
Hence selected bolt size is M4

Check for bolt

Based on Crushing or bearing stress
D1
Tmax =i d1 t 𝝈𝒄 2
100
119375=4*3.54*12.5* 𝝈𝒄 2

𝝈𝒄=30.4MPa
INDUCED crushing STRESS OF bolt ie 30.4MPa IS LESS THAN
ALLOWABLE crushing stress ie 150MPa
7.Design of Key
Page No 17.6,table 17.3
According standard diameter of shaft d=25,which comes between 65-70mm
dia..
Width of key B =8mm
Height of keyH=7mm
Length of key= more than length of hub=50 =55mm
Check for key
2∗Tmax
Width of key b= τk∗l∗d eqn 19.50
2∗119375 x
8= τk∗55∗25
2∗119375
τk = 8∗55∗25 =21.7MPa

4∗Tmax
Height of key h= σk∗l∗d eqn 19.51

4∗119375
7= σk∗55∗25
 4∗119375
σk = 7∗55∗25 =49.6 MPa

INDUCED crushing and shear stress of bolt ie 49.6 MPa & 21 MPa are
LESS THAN ALLOWABLE crushing and shear stress ie 150MPa and 75MPa.

Given P=90kw=90*1000=90000w
Speed n=250rpm

𝝉s =40MPa
θ = 1°
L=20d
𝝉b=30MPa
Since crushing of bolt is not given in the question. Consider crushing stress
is twice the shear stress of bolt.
σb=¿𝝉b×2 =30×2=60 MPa
Here shear (𝝉K )and crushing stress¿ )of the bolt is not given. Hence
consider bolt and key material is same
𝝉K=30MPa,
σ k =60MPa
Assume efficiency Ƞ=75%
1.Torque transmitted by the coupling

9550∗P 9550∗90000
1. Torque,T= n = 250 = 3438000Nmm (EQN
19.3 c)
2. 2.Diameter of shaft
π
T= 16 ×𝒅³×Ƞ× 𝝉S eqn 19.2
Assume Ƞ =75%=0.75
π
3438000= 16 ×𝒅³×0.75× 40
3438000*16= π *d3*0.75*40
3438000∗16
d3 = π∗0.75∗40 =

3438000∗16
d =3
√ π∗0.75∗40
=83.5mm

1
584 ×Tmax × L
Based on rigidityd= ( Gθ ) 4
page 14.4 eqn 14.17

Assume Modulus of rigidity of steel G=80000MPa

θ =1°
L=20d

584 ×3438000 ×20 d 14

d= ( 80000∗1 )
584 ×3438000 ×20 d 14
d= (
80000∗1 )
584 ×3438000 ×20 d
d4 ¿ 80000∗1

584 ×3438000 ×20

d3 ¿ 80000∗1

584 × 3438000× 20
d= 3
√ 80000∗1
=79.47 mm

Considering highest value of shaft diameter,d=83.5mm

From DDHAB PAGE NO 14.19,TABLE 14.6
Standard diameter of shaft d=85mm

3.Bolt circle diameter,D1=2d+0.05 in m (Eqn 19.12 a)

=2d+50 in mm
=2*85 +50=220mm
4.Design of Hub
Diameter of hub= D2=1.5 d+25( eqn 19.13 a)
D2=1.5*85+25=152.5mm
Length of hub= l=1.25d+18.75 = ( eqn 19.14 a)
l=1.25*85+18.75 =125 mm
5.Design of flange
Outside diameter of flange =D=2.5d +75
D=2.5*85 +75=287.5mm
Thickness of flange t=0.5d=0.5*85=42.5mm
Check for flange
Since shear stress of flange is not given,Take shear stress of grey cast iron
ASTM CLASS 20,from table 1.3,τ f=27-39. τ f=35MPa
D2
Tmax =t×𝝅×D2×𝝉f × 2 EQN 19.6
152.5
3438000 =42.5×𝝅×152.5×𝝉f ×
2

3438000∗2 =42.5×𝝅×152.5×𝝉f ×152.5

3438000∗2
𝝉f= 42.5 × π ×152.5 ×152.5 =2.21 MPa
Induced 𝝉f ¿ 35 MPa ..Hence Design of flange is safe.

6.Design of bolt
Number of bolt,i=20d+3 d in m=85mm=85/1000=0.085
20*0.085 +3 =4.7 = 6 consider even number for number of bolts
Diameter of Bolts
Torque transmitted through the bolts
πd 1² D1
Tmax = i 4 * 𝝉b* 2

πd 1² 220
3 438000 =6 4 * 30* 2

3438000 × 4 × 2 = 6× π × d 1² ×30×220
3 438000× 4 ×2
d 12 =
6 × π ×30 ×220

3438000 × 4 ×2
d1= √ 6 × π × 30 ×220 =14.868 mm
Standard pitch Diameter of bolt from table 18.7 d1=15.02mm
Hence selected bolt size is M16
Check for bolt …. 𝝉b=30MPa
σb=¿𝝉b×2 =30×2=60 MPa

Based on Crushing or bearing stress

D1
Tmax =i d1 t 𝝈𝒄 2 l=t
220
3438000 =6*15.02*42.5* 𝝈𝒄 2

3438000 × 2=6*15.02*42.5* 𝝈𝒄×220

3 438000 ×2
σc=
6∗15.02∗42.5× 220
=8.16 MPa

Induced crushing stress of the bolt ie 8.16 MPa ¿ 60 MPa ..Hence

Design of bolt is safe.
7.Design of Key
Page No 17.6,table 17.3
According standard diameter of shaft d=85,which comes between 75-85mm
dia..
Width of key b =22mm
Height of keyh=14mm
Length of key= more than length of hub(125mm),=130mm
Check for key
2∗Tmax
Width of key b= τk∗l∗d eqn 19.50
2∗3 438000
22= τk∗130∗85
2∗3 438000 0
τk = 22∗130∗85 = 28.28MPa

4∗Tmax
Height of key h= σk∗l∗d eqn 19.51

2∗3 438000
14= σk∗130∗85

2∗3 438000
σk = 14∗130∗85 =44.47 MPa
Induced τ k (28.28)<30 N/mm2
Inducedσk (44.47)<80 N/mm2
Hence Design of key is safe.

Given P=100kw=100*1000=100000w
Speed n=250rpm

𝝉s =4ON/mm2
θ = 1°
L=20d
𝝉b=13N/mm2
𝝉f=14 N/mm2
𝝉k= 𝝉b=-40 N/mm2
σ k =σ b=80 N/mm2 (crushing stress=bearing stress=compressive stress)

1.Torque transmitted by the coupling

9550∗P 9550∗100000
1. Torque,T= n = 250 = 3820000Nmm (EQN
19.3 c)
2.Diameter of shaft
π
T= 16 ×𝒅³×Ƞ× 𝝉S eqn 19.2

Assume Ƞ =75%=0.75
π
3820000= 16 ×𝒅³×0.75× 40
3820000*16= π *d3*0.75*40
3820000∗16
d3 = π∗0.75∗40

3 820 000∗16
d =3
√ π∗0.75∗40
=86.56mm

1
584 ×Tmax × L
Based on rigidityd= ( Gθ ) 4
page 14.4 eqn 14.17

Assume Modulus of rigidity of steel G=80000MPa

θ =1°
L=20d

584 ×3 820 000 ×20 d 14

d= ( 80000∗1 )
584 ×3 820 000 ×20 d 14
d= (80000∗1 )
584 ×3 820 000 ×20 d
d4 ¿ 80000∗1

584 ×3 820 000 ×20

d3 ¿ 80000∗1

584 × 3 820 000× 20

d= 3
√ 80000∗1
=82.31 mm

Considering highest value of shaft diameter,d=86.56mm

From DDHAB PAGE NO 14.19,TABLE 14.6
Standard diameter of shaft d=90mm

3.Bolt circle diameter,D1=2d+0.05 in m (Eqn 19.12 a)

=2d+50 in mm
=2*90+50=230mm
4.Design of Hub
Diameter of hub= D2=1.5 d+25( eqn 19.13 a)
D2=1.5*90+25=160mm
Length of hub= l=1.25d+18.75 = ( eqn 19.14 a)
l=1.25*90+18.75 =131.25 mm
5.Design of flange
Outside diameter of flange =D=2.5d +75
D=2.5*90 +75=300mm
Thickness of flange t=0.5d=0.5*90=45mm
Check for flange
D2
Tmax =t×𝝅×D2×𝝉f × 2 EQN 19.6
160
3820 000 =45×𝝅×160×𝝉f ×
2

3 820 000∗2 =45×𝝅×160×𝝉f ×160

3 820 000∗2
=2.11N/mm2
𝝉f= 4 5 × π ×1 60 ×1 60

Induced 𝝉f (2.11) ¿ 14 N/mm2 ..Hence Design of

flange is safe.

6.Design of bolt
Number of bolt,i=20d+3 ,d in m=90mm=90/1000=0.09
20*0.09 +3 =4.8 = 6 consider even number for number of bolts
Diameter of Bolts
Torque transmitted through the bolts
πd 1² D1
Tmax = i 4 * 𝝉b* 2 eqn 19.4
πd 1² 230
3 820 000 =6 4 * 13* 2

3820000 × 4 ×2 = 6× π × d 1² ×13×2 3 0
3 820000 × 4 ×2
d 12 =
6 × π × 13 ×2 3 0

3 820000 ×4 ×2
d1= √ 6 × π × 13× 23 0 =23.286 mm
Standard pitch Diameter of bolt from table 18.7 d1=23.05mm
Hence selected bolt size is M25

Check for bolt

Based on Crushing or bearing stress

 D1
Tmax =i d1 t 𝝈𝒄 2 l=t eqn 19.5
230
3820000 =6*23.05*45* 𝝈𝒄 2

3820000 ×2=6*23.05*45* 𝝈𝒄×230

3 820000 ×2
σc=
6∗23.05∗4 5 ×2 3 0
=5.34 N/mm2

Induced crushing stress of the bolt ie 5.34 ¿ 80 MPa ..Hence Design

of bolt is safe.
7.Design of Key
Page No 17.6,table 17.3
According standard diameter of shaft d=90,which comes between 85-95mm
dia..
Width of key b =25mm
Height of keyh=14mm
Length of key= more than length of hub(131.25mm),=135mm
Check for key
2∗Tmax
Width of key b= τk∗l∗d eqn 19.50
2∗3 820000
25= τk∗13 5∗90
2∗3 438000 0
τk = 25∗13 5∗90 = 26.12MPa

2 Tmax
Height of key h= σk∗l∗d eqn 19.51

2∗3 820 000

14= σk∗13 5∗90

2∗3 820000
σk = 14∗130∗85 =44.91MPa

Induced τ k (26.12)<30 N/mm2

Inducedσk (44.91)<80 N/mm2
Hence Design of key is safe.
Given data

Power P=15KW

=15*1000=15000W

Speed n=900rpm

𝝉f =8MPa
𝝉s=𝝉k=𝝉b=40MPa

𝝈b= 𝝈k =80MPa
Service factor 1.35

1.Torque transmitted by the coupling

9550∗P 9550∗15000
Torque,T= n = 900 = 159166.67Nmm (EQN 19.3 c)
Tmax= T × Service factor=159166.67× 1.35 =214875.0045 Nmm

2.Diameter of shaft
π
T max= 16 ×𝒅³×Ƞ× 𝝉S eqn 19.2

Assume Ƞ =75%=0.75
π
214875.0045= 16 ×𝒅³×0.75× 40

214875.0045*16= π *d3*0.75*40

214875.0045∗16
d3 = π∗0.75∗40
 214875.0045∗16
√
d= 3
d =33.16
π∗0.75∗40

From DDHAB PAGE NO 14.19,TABLE 14.6

Standard diameter of shaft d=35 mm

3.Bolt circle diameter,D1=2d+0.05 in m (Eqn 19.12 a)

=2d+50 in mm
=2*35+50=120mm
4.Design of Hub
Diameter of hub= D2=1.5 d+25( eqn 19.13 a)
D2=1.5*35+25=77.5mm
Length of hub= l=1.25d+18.75 = ( eqn 19.14 a)
l=1.25*35+18.75 =62.5 mm
5.Design of flange
Outside diameter of flange =D=2.5d +75
D=2.5*35 +75=162.5mm
Thickness of flange t=0.5d=0.5*35=17.5mm
Check for flange
D2
Tmax =t×𝝅×D2×𝝉f × 2 EQN 19.6
77.5
214875.0045 =17.5×𝝅×77.5×𝝉f × 2

214875.0045∗2 =17.5×𝝅×77.5×𝝉f ×77.5

214875.0045∗2
=1.30 MPa
𝝉f= 17.5× π × 77.5× 77.5

Induced 𝝉f (1.30) ¿ 8MPa ..Hence Design of flange is

safe.

6.Design of bolt
Number of bolt,i=20d+3 ,d in m=35mm=35/1000=0.035
20*0.035 +3 =3.7 = 4 consider even number for number of bolts
Diameter of Bolts
Torque transmitted through the bolts
πd 1² D1
Tmax = i 4 * 𝝉b* 2 eqn 19.4
πd 1² 120
214875.0045 =4 4 * 40* 2

214875.0045 ×4 ×2 = 4× π × d 1² ×40×120
 214875.0045× 4 × 2
d 12 =
4 × π × 40× 120

214875.0045 × 4 ×2
d1= √ 4 × π ×40 × 120 =5.34 mm
Standard pitch Diameter of bolt from table 18.7, d1=5.35mm
Hence selected bolt size is M6

Check for bolt

Based on Crushing or bearing stress

D1
Tmax =i d1 t 𝝈𝒄 2 l=t eqn 19.5
120
214875.0045=4*5.35*17.5* 𝝈𝒄 2

214875.0045 ×2=4*5.35*17.5* 𝝈𝒄×120

214875.0045 ×2
σc=
4∗5.35∗17.5 ×120
=9.56 MPa

Induced crushing stress of the bolt ie 9.56 ¿ 80 MPa ..Hence Design

of bolt is safe.
7.Design of Key
Page No 17.6,table 17.3
According standard diameter of shaft d=35,which comes between dia..
Width of key b =10mm
Height of key h=8mm
Length of key= more than length of hub(62.5mm),=65mm
Check for key
2∗Tmax
Width of key b= τk∗l∗d eqn 19.50
2∗214875.0045
10= τk∗65∗35
2∗214875.0045
τk = 10∗65∗35 = 18.89 MPa

2 Tmax
Height of key h= σk∗l∗d eqn 19.51
 2∗214875.0045
8= σk∗65∗35

2∗214875.0045
σk = 8∗65∗35 =23.61MPa

Induced τ k (18.89)<40 N/mm2

Inducedσk (23.61)<80 N/mm2
Hence Design of key is safe.