What are the Differences Between Flexible Couplings? http://machinedesign.com/print/cables-connectors-enclosures/what-are-di...

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Machine Design
Jeff Kerns
Mon, 2016-04-04 10:40

With so many types of flexible couplings on the market, designers need to understand the differences between
them to ensure that they make the right selection for an application. There are six degrees of freedom (DOF) to
a ridged shaft, but four DOF are of particular concern: axial, angular, parallel, and torsional.

Misalignments will cause balancing and vibration problems responsible for shutdowns. They will also greatly
increase wear on multiple parts, such as the bearings. Flexible couplings can help offset the cost associated with
damage or increased maintenance due to ill-aligned couplings.

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New Flange Coupling Tackles Heavy-Duty Tasks

Elastomeric Couplings

Using rubber or plastic materials will accommodate some misalignment while providing vibration dampening.

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astomeric types of couplings are capable of also providing shock absorption. A popular design is the jaw
coupling. A metallic component goes on either end of the shafts to be connected and the elastomer fits between
them.

If a jaw coupling fails, its design permits torque to

continue to be transferred through the remaining
metal, albeit with a lot of shaking, vibration, noise, and
backlash. However, this might permit maintenance at
a more convenient time, building in time to prepare for
a shutdown. In addition, a keen ear, sound sensor, or
vibration monitor might work as a maintenance
detection device, because the vibration and noise
generally increases as the elastomer breaks down. All
elastomers will breakdown over time. Avoid using
elastomeric couplings in environments that will expose
it to high temperatures or UV light—operating in these
environments will reduce the coupling’s lifecycle.

Other elastomeric couplings can stop power

transmission when the materials fail. The ability to
stop power transmission upon failure can protect
equipment downstream, much like a rigid pin
coupling. A designer can calculate a specific force that
the pin should fail at, but it is more difficult with an elastomer for a few reasons. Estimating an elastomeric
coupling’s precise failing load or shock can be problematic due to the changing operational and environmental
conditions in varying applications. These changes affect the lifecycle and strength of the elastomer.

A similar idea to the jaw coupling is the disk coupling. The main difference is the flexible-disk coupling has little
or even no backlash. Its curved jointing face may require higher machining tolerances, which can increase cost.
The disk design can also reduce the shock absorption compared to the straight dental-like jointing design of the
jaw coupling. The Disk design may be more difficult to assemble. Multiple disks need to align. Other designs,
such as the jaw coupling, are often a single piece. These properties might lead to using disk couplings where
lower loads and precision are more important.

Lubricated/Non-Lubricated Couplings

Other flexible couplings, called lubricated couplings: gear grid and chain. These designs rely on a tolerance
allowance to compensate for misalignment. For example, a roller chain connecting two shafts allow for some
movement or slack in the assembly, which occurs naturally from the tolerances between components of the
chain.

This type of coupling, specifically the flexible gear design, is known for having the ability to transmit large loads.
Unfortunately, they can also be costly and typically require more maintenance, as these couplings must have
proper lubrication. Such lubricated couplings may not work well in hazardous or wash down environments.

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Non-lubricated couplings include disk, diaphragm, link, spiral wound, bellows, and beam coupling types. If
these couplings stay within the design properties, they theoretically can have an infinite life. Some are complex,
and therefore tend to be expensive. However, when compared to the costs associated with premature or fatigue
failure brought on by a misalignment, the additional cost can be justified.

Bellow Couplings

Flexible couplings are generally two hubs connected by a compliant member. The compliant member can be an
elastomer and even some soft or springy metal. Bellow couplings represent one type of flexible metal coupling.
They come in three types: formed, electroplated, and edge-welded.

Bellow couplings resist axial, parallel, and angular misalignment. Their design can be costly, though, and not
necessarily be able to handle greater misalignments than elastomeric or other flexible couplings. Such couplings
can account for misalignment while adding little to no residual stress on the connecting shaft.

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Bellows can be designed for a theoretically infinite life. Servometer published that electroplated bellows can
handle up to 100 million cycles, and end-welded bellows will survive over 3 million cycles. End-welded bellows
differ from their electroplated counterparts in their ability to handle larger outer diameters of shafts and greater
lengths between shafts. In addition, end-welded bellows offer a wider range in materials, and can be cheaper in
startup tool cost. However, depending on the volume, both formed and electroplated bellows can be competitive
price-wise despite startup tool cost.

Other differences between electroplated and formed bellows include tolerance in wall thicknesses and material
selection. Electroplating can offer more consistent wall thicknesses at 25 µm or less. This allows electroformed
bellows to be used for sensitive precise applications that require an exacting coupling. The different processes
will inherently lend themselves to different materials. For example, metals with a high modulus of elasticity may
not form easily and might better lend themselves to electroplating.

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