Continuation…

COUPLINGS
MACHINE DESIGN & SHOP PRACTICE

“Satisfaction lies in the effort, not the attainment.

Full effort is full victory.”
- Mahatma Gandhi
 COUPLINGS

Couplings
• Are used to connect
sections of shafts or
to connect the shaft
of a driving machine
to the shaft of a
driven machine.
 ANALYSIS OF COUPLINGS
COUPLING ELEMENT FAILURE MODE STRESS FORMULA
𝟐𝐓
Shearing of key 𝐒𝐬 =
𝐰𝐋𝐃𝐬
KEY
𝟒𝐓
Compression of key 𝐒𝐜 =
𝐭𝐋𝐃𝐬
𝟐𝐓
Shearing of bolts 𝐒𝐬 = 𝛑
𝟐
𝟒 𝐛 𝐧𝐛 𝐃𝐁𝐂
𝐝
BOLTS Compression 𝟐𝐓
between bolt and 𝐒𝐜 =
𝐝𝐛 𝐭 𝐟 𝐧𝐛 𝐃𝐁𝐂
flange
𝟐𝐓
FLANGE Punching shear 𝐒𝐬 =
𝛑𝐭 𝐟 𝐃𝐡
COUPLINGS Problem 22

Two shafts are connected by a flange

coupling. The coupling is secured by 6
bolts, 20 mm in diameter on a pitch circle
diameter of 150 mm. If torque of 120 N-m
is applied, find the shear stress in the
bolts.
A. 0.85 N/mm2 C. 0.85 Pa
B. 0.85 kPa D. 0.95 Pa

Ans: 𝟎. 𝟖𝟓 𝐌𝐏𝐚
COUPLINGS Problem 23

A flanged coupling has an outside

diameter of 200 mm and connects two 40
mm shafts. There are four 16 mm bolts on
a 140 mm bolt circle. The radial flanged
thickness is 20 mm. If the torsional stress
in the shaft is not to exceed 26 MPa,
determine the shear stress in the bolts if
uniformly distributed
A. 1.2 MPa C. 4.3 MPa
B. 2.9 MPa D. 5.8 MPa
Ans: 𝟓. 𝟖 𝐌𝐏𝐚
COUPLINGS Problem 24

Two short shafts having identical

diameters of 38.1 mm and rotating at 400
rpm are connected by a flange coupling
having 4 bolts with a 100 mm bolt circle.
The design shearing stress of the bolt is
12 N/mm2 and the design compressive
stress of the flange is 15 N/mm2 . How
thick should the flange be in mm?
A. 11.51 mm C. 12.49 mm
B. 13.60 mm D. 15.65 mm
Ans: 𝟏𝟏. 𝟓𝟏 𝐦𝐦
COUPLINGS Problem 25

A flange coupling is to be designed, using

25-mm diameter bolts at a distance of 152
mm from the center of the shaft. Allowable
shearing stress on the bolt is 103 MPa. If
the shaft is to transmit 5,800 hp at a speed
of 1,200 rpm, how many bolts are needed
in the connection?
A. 2 C. 4
B. 3 D. 5
Ans: 𝟓 𝐛𝐨𝐥𝐭𝐬
SPRINGS, FLYWHEELS
MACHINE DESIGN & SHOP PRACTICE

“Satisfaction lies in the effort, not the attainment.

Full effort is full victory.”
- Mahatma Gandhi
 SPRINGS

• A spring is defined as an elastic body, whose

function is to distort when loaded and to
recover its original shape when the load is
removed.
• To cushion, absorb or control energy due to either
shock or vibration;
• To apply forces, as in brakes, clutches and spring-
loaded valves;
• To control motion by maintaining contact between
two elements;
• To measure forces;
• To store energy.
 TERMS IN COMPRESSION SPRINGS

• Solid Length
• When the compression
spring is compressed until
the coils come in contact with
each other.
𝐋𝐬𝐨𝐥𝐢𝐝𝐬 = 𝐧𝐭 𝐝𝐰

• Free Length
• The length of the spring in
the free or unloaded
condition.
𝐋𝐟𝐫𝐞𝐞 = 𝐧𝐭 𝐝𝐰 + 𝛅𝐦𝐚𝐱 + 𝐧𝐭 − 𝟏 𝐱 𝟏𝐦𝐦

𝐋𝐟𝐫𝐞𝐞 = 𝐧𝐭 𝐝𝐰 + 𝛅𝐦𝐚𝐱 + 𝟎. 𝟏𝟓𝛅𝐦𝐚𝐱

 TERMS IN COMPRESSION SPRINGS

• Spring index. The spring index is defined as the ratio

of the mean diameter of the coil to the diameter of the
wire.
𝐃𝐦𝐞𝐚𝐧 𝐃𝐨 − 𝐝𝐰
𝐂= =
𝐝𝐰 𝐝𝐰

• Spring rate. The spring rate (or stiffness or spring

constant) is defined as the load required per unit
deflection of the spring.

𝐖 𝐅
𝐤= =
𝛅 ∆𝐱
 TERMS IN COMPRESSION SPRINGS

• Pitch. The pitch of the coil is defined as the axial

distance between adjacent coils in uncompressed
state.
𝐋𝐟𝐫𝐞𝐞 𝐋𝐟𝐫𝐞𝐞 − 𝐋𝐬𝐨𝐥𝐢𝐝
𝐩= = + 𝐝𝐰
𝐧𝐭 − 𝟏 𝐧𝐭
 TERMS IN COMPRESSION SPRINGS
End Connections for Compression Helical Springs

End type 𝐧𝐭𝐨𝐭𝐚𝐥 𝐋𝐬𝐨𝐥𝐢𝐝 𝐋𝐟𝐫𝐞𝐞

Plain ends n (n+1) dw np + dw
Ground ends n ndw np
Squared ends n+2 (n+3)dw np + 3dw
Squared & Ground ends n+2 (n+2)dw np + 2dw
ANALYSIS OF COMPRESSION SPRINGS
F
F

dw

F Dm
Dm F
 ANALYSIS OF COMPRESSION SPRINGS
Maximum Torsional, Direct Shear Stress & Curvature of wire

𝟖𝐅𝐃𝐦 𝟖𝐅𝑪
𝐒𝐬 = 𝐊 𝐰 = 𝐊𝐰 𝟐
𝛑𝐝𝟑𝐰 𝛑𝐝𝐰

Where:
𝟒𝐂−𝟏 𝟎.𝟔𝟏𝟓
𝐊𝐰 = +
𝟒𝐂−𝟒 𝐂

𝐊𝐰 = 𝐊𝐒𝐊𝐂
Note:
𝐊 𝐬 − 𝐒𝐡𝐞𝐚𝐫 𝐬𝐭𝐫𝐞𝐬𝐬 𝐟𝐚𝐜𝐭𝐨𝐫
𝐊 𝒄 − 𝐬𝐭𝐫𝐞𝐬𝐬 𝐜𝐨𝐧𝐜𝐞𝐧𝐭𝐫𝐚𝐭𝐢𝐨𝐧 𝐟𝐚𝐜𝐭𝐨𝐫 𝐝𝐮𝐞 𝐭𝐨 𝐜𝐮𝐫𝐯𝐚𝐭𝐮𝐫𝐞
 ANALYSIS OF COMPRESSION SPRINGS
Deflection of Helical Springs of Circular wire

𝟖𝐅𝐃𝟑𝐦 𝐧 𝟖𝐅𝐂 𝟑 𝐧
𝛅= 𝟒
=
𝐆𝐝𝐰 𝐆𝐝𝐰
 ANALYSIS OF COMPRESSION SPRINGS
Energy Stored in a Helical Spring or Circular Wire

𝟏 𝟏 𝟏 𝟐
𝐄 = 𝐅𝛅 = 𝐅∆𝐱 = 𝐤 ∆𝐱
𝟐 𝟐 𝟐

Note : When a load (say P) falls on a spring through a height h,

then the energy absorbed in a spring is given by:
Work done by the Load P = Energy absorbed by the Spring
𝟏 𝟐
𝐏 𝐡 + 𝛅 = 𝐤𝛅
𝟐
 ANALYSIS OF COMPRESSION SPRINGS
Springs in Series
𝛅 = 𝛅𝟏 + 𝛅𝟐
𝟏 𝟏 𝟏
= +
𝐤 𝐤𝟏 𝐤𝟐

Springs in Parallel
𝐅 = 𝐅𝟏 + 𝐅𝟐
𝐤 = 𝐤𝟏 + 𝐤𝟐
 SPRINGS

• Leaf springs (also known as flat springs) are

made out of flat plates.
• The advantage of leaf spring over helical
spring is that the ends of the spring may be
guided along a definite path as it deflects to act
as a structural member in addition to energy
absorbing device.
• Thus the leaf springs may carry lateral loads,
brake torque, driving torque etc., in addition to
shocks.
SPRINGS
ANALYSIS OF LEAF SPRINGS
 ANALYSIS OF LEAF SPRINGS
Bending Stress on Leaf Springs
𝟔𝐅𝐋
𝐒𝐛 =
𝐧𝐬 𝐛𝐭 𝟐
Deflection of Leaf Springs
Multiple Leaves (same Length)
𝟒𝐅𝐋𝟑
𝛅=
𝐧𝐬 𝐄𝐛𝐭 𝟑
Multiple Leaves (graduated Length)
𝟔𝐅𝐋𝟑 𝐒𝐛 𝐋𝟐
𝛅= 𝟑
=
𝐧𝐠 𝐄𝐛𝐭 𝐄𝐭
 ANALYSIS OF LEAF SPRINGS
Bending Stress on Leaf Springs
Multiple Leaves (diff sizes)
𝟏𝟖𝐅𝐋
𝐒𝐬 =
𝐛𝐭 𝟐 𝟐𝐧𝐠 + 𝟑𝐧𝐟

Deflection of Leaf Springs

Multiple Leaves (diff sizes)

𝟏𝟐𝐅𝐋𝟑
𝐒𝐬 =
𝐄𝐛𝐭 𝟑 𝟐𝐧𝐠 + 𝟑𝐧𝐟
SPRINGS Problem 1

A coiled spring with 1¾ in. outside

diameter is required to work under load of
140 lb. Wire diameter used is 0.192 in.,
spring is to have seven active coils, and
the ends are to be closed and ground.
Determine the safe shearing stress and
the unit deflection. Assume G equal to 12
million psi and mean radius to be 0.779 in.

Ans: 𝟏. 𝟖𝟏𝟕 𝐢𝐧
SPRINGS Problem 2

A high alloy spring having squared and

ground ends and has a total of 16 coils
and modulus of elasticity in shear of 85
GPa. Compute the Wahl factor. The spring
outside diameter is 9.66 cm and wire
diameter is 0.65 cm.

Ans: 𝟏. 𝟏𝟎
SPRINGS Problem 3

Compute the maximum deflection of a 22

coils helical spring having a load of 120
kgs. The spring is squared and ground
ends with modulus of elasticity in shear of
80 GPa, outside diameter of 8 cm and wire
diameter of 8 mm.

Ans: 𝟐𝟏𝟒. 𝟓 𝐦𝐦
SPRINGS Problem 4

The load on a helical spring is 1600-lb and

the corresponding deflection is to be 4-in.
Rigidity modulus is 11 million psi and the
maximum intensity of safe torsional stress
is 60,000 psi. Design the spring for the
total number of turns if the wire is circular
in cross section with a diameter of 5/8 in.
and a center line radius of 1 1/2 in. The
spring is squared and ground ends.

Ans: 𝟐𝟐 𝐜𝐨𝐢𝐥𝐬
SPRINGS Problem 5

All four compression coil spring support

one load of 700 kg/mm. All four springs
are arranged in parallel and rated same at
0.609 kg/mm. Compute the deflection in
mm.

Ans: 𝟐𝟖𝟕 𝐦𝐦
SPRINGS Problem 6

A Mercedes Benz gas engine valve spring

is to have a mean diameter of 3.81 cm.
The maximum load it will have to sustain is
45.45 kg with corresponding deflection of
1.27 cm. The spring is to be made of
tempered steel wire. Since the material is
to be subjected to repeated loading, and
fatigue must be considered, a low working
stress of 2280 kg/sq.cm. will be used.
Determine the size of wire.
Ans: 𝟎. 𝟔𝟑𝟓 𝐜𝐦
SPRINGS Problem 7

A body weighing 1000 lb falls 6 inches and

strikes a 2000 lb per in spring. The
deformation of the spring is:

Ans: 𝟑 𝐢𝐧
SPRINGS Problem 8

Determine the width and thickness of the

leaves of a six-leaf steel cantilever spring
13 in. long to carry a load of 375 lb with a
deflection of 1¼ in. The maximum stress
in stress in this spring is limited to 50,000
psi.

Ans: 𝐭 = 𝟎. 𝟐𝟐𝟓 𝐢𝐧, 𝐰 = 𝟏. 𝟗𝟑 𝐢𝐧

 FLYWHEELS

• A flywheel used in machines serves as a

reservoir which stores energy during the period
when the supply of energy is more than the
requirement and releases it during the period
when the requirement of energy is more than
supply
 FLYWHEELS

Coefficient of Fluctuation of Speed

• The ratio of the maximum fluctuation of speed to the
mean speed.

𝐍𝟏 − 𝐍𝟐 𝟐 𝐍𝟏 − 𝐍𝟐
𝐂𝐟 = =
𝐍𝐦 𝐍𝟏 + 𝐍𝟐
𝛚𝟏 − 𝛚𝟐 𝟐 𝛚𝟏 − 𝛚𝟐
𝐂𝐟 = =
𝛚𝐦 𝛚𝟏 + 𝛚𝟐
𝐯𝟏 − 𝐯𝟐 𝟐 𝐯𝟏 − 𝐯𝟐
𝐂𝐟 = = Note:
𝐯𝐦 𝐯𝟏 + 𝐯𝟐 𝐍𝟏 + 𝐍𝟐
𝐍𝐦 =
𝟐
ANALYSIS OF FLYWHEELS
 ANALYSIS OF FLYWHEELS
Energy Stored by the Flywheel (Kinetic Energy)

𝟏 𝟐
𝐊𝐄 = 𝐈𝛚𝐦
𝟐
∆𝐊𝐄 = 𝐈𝛚𝟐𝐦 𝐂𝐟 = 𝐦𝐤 𝟐 𝛚𝟐𝐦 𝐂𝐟 = 𝐦𝐂𝐟 𝐯𝐦
𝟐

𝟏 𝟐 𝟐
𝟏 𝐖𝐅 𝟐
∆𝐊𝐄 = 𝐦 𝐯𝟏 − 𝐯𝟐 = 𝐯𝟏 − 𝐯𝟐𝟐
𝟐 𝟐 𝐠
Where:
WF = WArms + WHub + WRim

𝐖𝐑𝐢𝐦 = 𝛄𝐕𝐑𝐢𝐦 = 𝛄 𝛑𝐃𝐦 𝐭𝐛

 ANALYSIS OF FLYWHEELS
Energy needed to punch a hole Power Requirement

𝟏 𝐄
𝐄 = 𝐅𝐦 𝐭 𝐩 = 𝐅𝐭 𝐩 𝐏=
𝟐 𝐭𝐢𝐦𝐞
From:
𝐅 𝐅
𝐒𝐬𝐮 = =
𝐀𝐬 𝛑𝐝𝐡 𝐭 𝐩

𝟏
𝐄 = 𝐒𝐬𝐮 𝛑𝐝𝐡 𝐭 𝟐𝐩
𝟐
 ANALYSIS OF FLYWHEELS
Stresses induced in Flywheel arms

Tensile Stress
𝟐
𝐒𝐭 = 𝛄𝐯𝐦
Bending Stress
𝐌 𝐓
𝐒𝐛 = = 𝐑−𝐫
𝐙 𝐑𝐧𝐚𝐫𝐦𝐬 𝐙
 ANALYSIS OF FLYWHEELS
From Machinery’s Handbook
Pressure (Force) Required for Punching
• General Equation Note:
Steel/Iron – 50,000 psi
𝐏 = 𝑨𝒔 𝐒𝐬 = 𝛑𝐝𝐡 𝐭 𝐩 𝐒𝐬 Bronze – 40,000 psi
Copper – 30, 000 psi
• Steel Material Aluminum – 20, 000 psi
Zinc – 10, 000 psi
𝐏 = 𝐝𝐡 𝐭 𝐩 × 𝟖𝟎 Tin/lead – 5000 psi
• Brass Material Conversion:
1 ton = 2000 lbs
𝐏 = 𝐝𝐡 𝐭 𝐩 × 𝟔𝟓
Note: (For non- circular hole)
𝟏
𝐝𝐡 = 𝐏𝐡
𝟑
FLYWHEEL Problem 9

A flywheel weighing 457 kg has radius of

375 mm. How much energy in N -m does
the flywheel loss from 3.0 rev/sec to 2.8
rev/sec?

Ans: 𝟏𝟒𝟕𝟐 𝐍 − 𝐦
FLYWHEEL Problem 10

A flywheel weighing 6 kN has a mean

diameter of 90 cm. The maximum speed
of the flywheel is 7 rev/sec slowed down to
4 rev/sec during the shearing process.
Determine the energy released by the
flywheel.

Ans: 𝟖𝟐𝟒𝟏 𝐤𝐠 − 𝐦
FLYWHEEL Problem 11

A flywheel rotates at 220 rpm slowed down

to 65 % of its revolution during the three –
fourth second punching portion of the
cycle. Compute the angular acceleration of
the flywheel in radian per second squared.

Ans: −𝟏𝟎. 𝟕𝟓𝟏 𝐫𝐚𝐝/𝐬 𝟐

FLYWHEEL Problem 12

A flywheel has a diameter of 1.5 m, and

mass of 800 kg. What torque in N-m, is
needed to produce an angular
acceleration of 100 revolutions per minute,
per second?

Ans: 𝟐𝟑𝟓𝟔
FLYWHEEL Problem 13

A cast iron flywheel with a mean diameter

of 36 inches changes speed from 300 rpm
to 280 rpm while it gives up 8000 ft-lb of
energy. What is the coefficient of
fluctuation.

Ans: 𝟎. 𝟎𝟔𝟗
FLYWHEEL Problem 14

What would be the weight of a flywheel in

kg if the weight of the rim is 3 times the
sum of the weight of the hub and arms.
Given the outside diameter and inside
diameter to be 24 in and 18 in respectively
and the rim width is 4.5 in. (assume steel
flywheel)

Ans: 𝟏𝟓𝟐. 𝟗𝟓 𝐤𝐠
FLYWHEEL Problem 15

A flywheel has a mean diameter of 4 ft and

is required to handle 2250 ft-lb of kinetic
energy. The flywheel has a width of 8 in.
Normal operating speed is 300 rpm and
the coefficient of fluctuation is to be 0.05.
Find the weight of the rim assuming that
the arms and hub are equivalent to 10% of
the rim weight.

Ans: 𝟑𝟑𝟑. 𝟔𝟗 𝐥𝐛𝐬

FLYWHEEL Problem 16

A shearing machine requires 150 kg-m of

energy to shear a steel sheet, and has a
normal speed of 3 rev/sec, slowing down
to 2.8 rev/sec during the shearing process.
The flywheel of the machine has a mean
diameter of 75 cm and weighs 0.0155
kg/cm3. The width of the rim is 30 cm. If
the hub and arms of the flywheel account
for 15% of its total weight, find the weight
of the flywheel.
Ans: 𝟒𝟓𝟕 𝐤𝐠
FLYWHEEL Problem 17

A punch punches a 1-in diameter hole in a

steel plate ¾ inch thick every 10 sec. The
actual punching takes 1 sec. The ultimate
shear strength of the plate is 60,000 psi.
The flywheel of the punch press has a
mass moment of inertia of 500 in-lb-sec2
and rotates at a mean speed of 150 rpm.
What is the horsepower required for the
punch operation?

Ans: 𝟖. 𝟎𝟒 𝐡𝐩
FLYWHEEL Problem 18

What pressure is required for punching a

hole 3 inches in diameter through 1/4 inch
steel stock?

Ans: 𝟔𝟎 𝐭𝐨𝐧𝐬
FLYWHEEL Problem 19

What pressure is required for punching a

1.5 inch square hole in a 1/4 inch thick
plate steel?

Ans: 𝟒𝟎 𝐭𝐨𝐧𝐬
FLYWHEEL Problem 20

What pressure is required for punching a

1.5 inch by 2 inch rectangular hole in a
1/4 inch thick brass?

Ans: 𝟑𝟕. 𝟗𝟐 𝐭𝐨𝐧𝐬