Topology optimization of rigid flanged couplings using finite element analysis

A Coupling is a device which is responsible for the operative power transmission between two shafts rotating at particular rpm. Coupling is used to connect two different shafts at their end and can slip or fail depending upon the torque limit. It is the crucial part of any power transmission and may last for very long time if designed and maintained properly. The present study of this paper is to reduce the stress that acting on the bolts by making it uniform strength coupling. The stress in the threaded part of the bolt will be higher than that in the shank. Hence a greater portion of the will be absorbed at the region of the threaded part which may fracture the threaded portion because of its small length. An axial hole is drilled at the center of the bolt through the head as far as thread portion such that the stress in the bolt is uniformly distributed along the length of the bolt. The present study of this paper is to reduce the maximum shear stress by selecting a suitable material for flange coupling. For this purpose, modelling of the rigid-flange coupling is carried out in Solidworks and analysed in ANSYS Workbench. Objective is to design a flanged coupling to connect the drive shaft of a 10 kW Kirloskar diesel generator operating at a rated speed of 1500 rpm to an alternator. The above specifications show a maximum torque transmission of 63.662 Nm. A standard shaft of ∅︀25 mm is used, and the analysis for basic rigid flange is done, including varying the materials. From the results obtained, the existing design is modified to reduce the weight and improve performance.