Universal joints can be the most efficient and cost effective method of driving mill rolls including applications in high-impact reversing roughers and Steck! mils. Design and selection of universal joints for rolling mi James H. Paluh, Manager—Engineering, Industial Products, Gary R. Hil ternational, Eri ‘Construction Co., Worcester, Mass. ‘THE application of universal joints has significantly ‘nereased in steel and aluminum rolling mills. It is gener- ally known that the most unique feature of universal Joints is misalignment eapabilitios of 15° or greater. While ‘his is significantly higher than the 6” capability of gear ‘couplings and spindles, there are other advantages for the high torque loads and almost continuous operation of today’s miilly, Universe) joints resist lubrication loss and contamination in harsh environments beeause of their bearing and seal design. Simplicity and ease of ubrieation, ‘can significantly reduce maintenance time. When com: pared to other types of high-angle couplings, universal Joints operate with neghble backlash and radial clear- ‘ance that can improve product quality, Selection and retrofitting procedures of universal joints {for mill gear spindles are discussed in this article, inelud- ing a review of operating characteristics, bearing life, length compensating features, roll end support design and ‘maintenance requirements, Background Universal joints are defined as a mechanical device that can transmit torque and/or rotational motion from one shaft to another af fixed or varying angles af intersection of the shaft axes. They aro categorized by their motion cher- acteristics as a single joint, which can be nonuniform or uniform. A uniform or constant velocity (CV) universal joint assembly transmits motion with an angular velocity ratio, of unity between input and output members. The device commonly referred to a8 a universal joint transmits motion ‘with various ratios of instantaneous angular velocity botween driving and driven members when operating at angles grester than O° and only a single joint is used. The average angular velocity is unity. ‘This type of universal Joint is normally reforrod to as either a Cardan or Hooke ‘universal joint Fig. 1), Placing two universal joints in tan- dem with proper phasing allows the velocity fluctuations of the first joint to be cancelled by the second joint, allowing for a constant output speed equal to the input speed. SS aXe ae \ aa Ce " Sales Manager—Mil Products, Ameridrives Pa,, and Thomas C. Woltkowski, Project Engineet—Research and Development, Morgan Historical evidence indicates the Grosks invented the universal joint approximately 300 B.C. The name Cardan ‘wes derived from the sixteenth century Ttalian mathe- matician Geronimo Cardano, who utilized a sizailar mechanism to suspend a ship's compass horizontal, regardless of the ships movement. During tho seven teenth century, Robert Hocko made the first application of a universal joint to a rotating shaft im a clock anve.! ‘The development of the automobile accelerated the refine nent of universal joints. Other uses include: marine; rail- ay: alerats gitar; and industrial appintions pared to high angle, low torque automotive applies tions, industrial applications, such as rolling mills, require high ‘torques and relatively low operating angles for uni- ‘yersal joints, Historically, the most common type of spin- dle used to drive rolling mill rolls were wobbler cozplings (ig. 2 and slippers (Fig. 3), Wobblers are typically east pods and are not sealed to prevent lubricant leakage Heavy metal to metal contact produces high wear and ‘high noise levels. A slipper coupling has the same rotating, characteristics as « universal joint. Infact, a shaft can be made with a Cardaa joint at one end and a slipper at the other. The slipper clements are normally made from bronze and, more recently, nonmetallic ‘materials, Slippers wear through repotitive sliding of loaded metal to ‘metal interfaces, Excessive tolerances inherent in the design cause lose of concentricity.2 These characteristics ‘can contribute to product flawe resulting from mill chat- tor. Additionally, lubricant is not contained and, in some ages, must be continuously supplied, ‘The inherent disadvantages of wobblere and slippers com- bined with market demand for greater productivity and improved quality of rolled products led to the application of ~ WES 7 Fig. 2— Wobbler couning. Fig. 8 — Sipser couping‘crowned gear tooth spindles (Fig. 4). Higher operating Speeds tues and misalignment capablities in rolling is were possible with goared spindles, They provide con- stant angular selocty at micalinmont angles and mint mize vitration, Generally, seale are used to minimize the eakage of lubricant. The high hardness and controlled ‘crown of the gear teeth provide efficiencies, longer life and greater value than found in wobblers and slippers. Fig. 4 — Mit goor opine Advantages of universal joint Universal joints have always been recognized for their inherent advantage of, large misalignment capebilities upward of 15° compared to @ maximum of approximately 6 for typical gear-type spindles. In recent years, research improvements in design and manufueture have con- tributed to substantial inerenson in fhe torque capability of “universal joints, Achievement of power transmission den- sities that allow universal joints to meet rolling mill diam- ster limitations has increased their competitiveness with gear spindles. Today, U-jints are generally available with ower densities equal to or groater than geared spindles, specially when operating Taisaligament angles exceed MP, The advantages of universal joints include: + Consistent operating characteristics. 4 Redced harklach and ronan ‘+ Reduced maintenance. + Elimination of poseible mill chatter. + Lower operating costs Opceating characteristic U-jeints utilize a crose and bearings instead of engaging gear teeth for the flex- ing component, Gear spindle teeth are constantly sliding and wearing during their operational life, which can have significant effects uu Ue life nnd capacity of Ge gear spindle. ‘Ucjoint bearings rll and have minimal and relatively pre- diciable wear daring their operating life, ‘The torque capacity of gear spindles decreases as mis: alignment increasos because fewer teeth are in full con- tact to share the land. Ujint torque capacity is not significantly influenced by ‘the misalignment angle, and reduction in bearing life is statistically predictable regardless of operating angle Backlash and runout — Goar spindles, by design, must have 0.020 to 0.100 in. of backlash in order to flex—this backlash ineresses as the spindle woars. ‘U;joints typically have leas than 0.008 in. of backlash, wthich door nat increaan wntil afar eamplate henring ure. Gear spindles typically have 0,020 to 0.080-in. runout as a result of heat treatment distortion (which will increase due to wean). ‘U-jointe are aoscmbled with virtually no radial runout. Maintenance — Gear spindles should be lubricated ‘weekly for optimum life. U-joints typically require only monthly retubrication (Table D. Gear spindles typically expel small amounts of contami- nated greaze ae a result of We ‘Since bearing seals are not subjoctod to evcontric loading rogardless of operating angle, U-joint seals have long ser- vie life and expel comparatively little grease, Mill chatter ~ The use of gear-type spindles can, under ‘certain conditions, provide a vibration forcing function that cetuss mil chatter and resultant produc quality defects.6* Operating costs — Life expectancy for Tjaints is 9 to 6 timos that of gear spindles (leas change-out frequency}. Initial cost of U.joints is generally 1.6 to 1.8 times the cost of gear spindles, Additional cost reductions include: tmaintenance and repair, lubricant quantity, and clean-up TABLE} Typical 7-stand hot finishing mill with 26-in. 00 geer spindles and U-joint lubrication man-hours Coupingbvcwlon) Manis ‘Totaling, Tota cow sand he 2 Sareea a8 3 eo e0 ome 2 4 rm era 88 saan TABLE Typical 7-stand hot finishing mill with 26-In. 00 gear spindles and Ujolnt lubrleaton quan- ty and clean-up costs ‘Coupling Lubreant, Latrewtons, Lbieant® Lubrowton Tota petit am clamp 2 ska ore ae Biom 1 2 vem "Sets, Fiona Universal joint designs Cardan joints for industrial applications consist of vari- ations using a erose and bearing design. All designs (except for plain or composite bearing types) tranamit torque through anti-friction bearings, two forged or cast yokes and a forged cross member. Heavy-duty lip seals That are not subject to eccentric loading prevent lubri- cant leakage and contamination. This allows aporation in contaminated atmospheres such es caster applicn- tions. Since crowned rollers ate typically used, the Usoint life can be statistically determined. Hardened precision tolerance raceways are used with the bearing- ‘tool rollora for optirnum life. ‘Mill universal joints cam be categorized as one of the fol- lowing five types: * Closed eye 1-piece) yoke design (Fig. 5)~-A 1-pioco yoko surrounds the bearing housing. + Split yoke design (Fig. 6)—Yokes are split axially to produce a I-piece bearing housing with a solid bearing end cap whose yoke halves are held together with a Ue bolt during assembly, shipping ‘and instellation. After mill assembly, tho halvos are held together by the bolted connection to the drive shaft flange. + Split bearing eye (Fig. 7)—Bearing bores are split {nto two sections and retained by & combination of serrations and boltsCtosed-aye (1-pace) yoko. Be Fig. 7 — Splt-baaring eye. ‘Black type (Fig. 8)—Bearing housings are belted to ‘yokes with face keys, I-piece bearing housing bore. + Composite plain bearing—Only design without roller bearings. Bearings are generally made of « nonferrous material such as selflubricating com- posite (used on low speed, highly contaminated, ‘high temperature applications such as steel eon- tinuous slab eaating machines) The 1pice jokes have the advanlage of wo mainbenunce requirement to verify if bolted connections have loosened and elimination of precision matching of components for ‘equal bearing loading. Corrosion issues associated with Salle Dearing eye dati ave alo svulded The pace ‘yokes and block type designe were developed to increase Ihe eros trunnion Slometer and trae coset of the U. Jain vile allowing for aston. Spltcyoke designe are Mingus aince the Ue but i not Used for lrgue tensa sion or retention of yoke components after installation. All designs have the option of splined center sections to allow for length compensation for axial travel and align- tent changes during operation. Splines ean be hardened, {Spically by mitiding, or applications wi frequen axial Perel Ii enntor one Pepin write ay the yokes or flanged to allow for more economical replace- ment sparing of U-joint parts. It is not uncommon to tnachine integral face pace or Spotl spline vet baleen {he flange face (Fig and 10 Yon high load application, Selection eriterla Torque requirements — The first step in selecting a Cardan shaft is determining the maximum torque to be transmitted (see subsequent section: Special considera- tions for reversing roughers and Steckel mills for addi tonal considerations). The maximum torque should take {nto account the maximum prime mover torque including inortial effocts from the prime mover when decelerating during overloads, The prime mover torque is generally considered as being unequally split through the pinion stand in the range of 40 to 674 to allow for unequal torque Toading of the mill rolls. ‘This application torque is adjusted by applying the appropriate service factoris) in accordance with the joint ‘manufacturer's recommendation. The resultant selection torque is compared to either: the U-joint’s endurance or fatigue torque rating for reversing applieations; or the Fig. 10 —Ratial face spline.| -way or pulsating fatigue torque rating for nonreversing applications. Both ratings are based on the material rength of the shaft. The I-way torque rating is typically 15 times the reversing fatigue torque rating, ‘Next, compare the ‘maximum peak torque to the peak torque rating ofthe Ujoint selected. The peak torque rating is typically based on the yield strength capacity af ‘the joint. I'the pak operating torque occurs on a frequent bosis, brinelling ofthe bourings is possible. This will short- ‘ea the hie of the bearings. The Ujoint manufacturer should be consulted for eonfirmation of proper sizing forthe case of frequently oceurring high momentary load applications, ‘The final torque analysis involves the calculation of bear- ‘ing life, whieh is unigue for U-joints when compared ta ‘other types of spindles. Each manufactures’ technical it- ‘erature will provide an equation with constants for caleu- lating the bearing B-10 life in hours. B-10 life is defined as the life exceeded hy 90% of a large sampling of bearings. ‘The actual average bearing life is four to five times the 'B-10 life for a large number of identical bearings operating under identical conditions.® This is similar to the ealeula- tions used by roller bearing manufacturers except the B-10 life for universal joint bearings is based on oscillating rmotion of the truxinions, B-10 fife is « function of trans mitted torque, rotational speed and misalignment angle ‘The torque used for analysis is usually the application torque, although for certain applications, such as diesel engine drivers, the U-joint mamufacturer may recommend using a selection torque that includes service factors. A rule of thuta is to target a minimum B-10 life of 5000 hr. ‘Since bearing life can he statistically analyzed, for appli- cations where the torque, speed and operating angle vary predictably during a typical load eycle, a duty cycle ean be determined. First, the load cycle must be analyzed and divided into groups of fixed combinations of torque, spoed and operating angle. These groups represent percentages of the total operating time of the load cyele. Life expectan- cy can then be ealeulated using Miner's Rule, which takes {nto account the cumulative effect resulting from operat- ing at varying conditions. The total life expectancy is eal- cclated using the following equation: 1 Na, Ns, i Na Na, Nm Tq” Ey! Ley fraction of total time at operating condition 1 life expectancy at operating condition I, hr fraction of total time at operating condition Lm = life expectaney at operating eandition Rotational speed considerations Cardan shafts have unique angular velocity charaeteris- ‘ics that are dependent on the operating misalignment angle when compared with gear spindles. At the aame time, long and/or high speed joint center sections have dif- ferent bending or lateral critical speed limitations based on the acceleration and deceleration of the center section. ‘As a general rule for most mill applications, critical speed is not a concern for spoeds less than 300 rpm. ‘As a Usjoint driving yoke rotates in misalignment, the driven yoke alternately rotalos faster and slower than the Griving yoke twice during each revolution in a sine wave pattern. However, the average velocity is the samme for the driving and driven yoke. Accordingly, if the driving yoke rotates one revolution, the driven yoke rotates one revolu- tion. As a result of the nonuniform motion of a single ‘U-joint, most spindle applications require placing two uni- versal joints in tandem, If the misalignment angles at both ends of the shaft are equal and properly phasod to be in the same plane, the velocity Quetuations of the first, U- Jeint are cancelled by the yecond joint. Proper phasing: Tequires not only equal operating angles of the joints, but that all sections of the U-joint lie in one plane and the in- board yokes of the center section must be in the same plane (Fig, 11). Acceleration and deceleration or inertial excitation will still occur, but only to the intermediate shaft. Although this mass acceleration variation is not rypleally a concern for spindle speeds lest than 860 rpm, the U-joint supplier should he consulted for the meximur, speed and misalignment angle allowable based on the ‘mass acceleration limitations, Tr the Ujoints at the opposite ends of a connecting spin- dle are not at equal misalignment angles, the velocity. ‘variations wil not be cancelled and the output shaft will pulsate or vibrate. As the difference in misalignment angles increases, the greater the vibration and torsional, excitation. An out of phase condition will effect product speed and transfer fluctuating loads to the U-joints on “other stands, ‘The critical speed of a spindle assembly is that speed at ‘which excessive vibration amplitudes set in. It is a func. lion of the natural froqueney of the shaft assembly. The ‘maximum operating speed should he sufficiently below the critical bending speed. The effect of the secondary couple ‘occurring twice per revolution is to create @ eritical speed at approximately half the lateral critical speed. Again, this is not normally w concern for typical mill speeds. The Int- ‘eral eritieal speed is a function of the intermediate shaft tube diameter, wall thickness and effective length. The lat- cal critical speed can be provided by the U-joint manufac- turer of estimated from the following equation: 4.53210° [D2 sD?) EF Interal eritical speed, rpm D, = shaft tubo outside di, in. Dj = shatt tube inside dia,, in. L’ = effective shaft length = centerline to centerline of flex element, in, Fig. 11 — Correct phasing requiramants,‘The allowable operating speed should not excood 75% of the lateral critical speed nor be within +154 of half the lateral eitical speed to avoid unacceptable vibrations and reducing the life of the parts. Universal joint unbalance forces are related to part eccentricities and rotational speed squared. Unbalance is caused by manufacturing processes in components, such as casting voids and accumulation of part toleranes, and mating part clearances. As a general rule, balancing isnot required for speeds under 800 rpm. At speeds over 300 pm, the U-joint supplier should be contacted for balanc- ing recommendations. Maximum bending moment — During U-joint opera- tion, bending moments occur inthe connecting shafts a8 a function of the operating misalignment angle and driving torque. This bending moment causes a load on the sup- porting bearings that is periodic with to complate eyelos per revolutions of the shaft. The bending moment is always in the plane of the ests of the yokes. The maxi- num value of the bending moment is given by: Me Ttand where ‘Mf = maximum bending moment T = operating torque & = operating angle,” For a gear spindle, the bending moment is generated from the driving torque and operating misalignment angle and frictional loading between the teeth and ‘moment generated from displacement of the load frem its conter: Typically, n gear spindle wil generate 2 to 8 times the bending moment of a U-joint, A comparison of gear spindle to U-joint bending moments is provided by TABLE Ill Bending moments for 26-in. OD gear spindle and Ujoint “Gouging Toraun Operating Pith Felon ending ‘cb “fngle”_clan._confclont _ mover ab. ‘Geer 8185000225 teas‘ nae Int_negao0 2.25 WAN 24000 Ta oi appcabe Axial travel requirements and axial forces — Gear spindles are designed to accommodate angular misalign- ‘ment and small changes in axial travel length by having. their hubs traverse within or pullout in the sleeves. However, U-joints are required to have a clearance fit in, ‘the connected equipment (such as the roll end adapter) or a spline travol section in the intermediate chaft. A clear- ance or slip fit allows the roll end to pull out under mis alignment. The amount of pull-out required can be caleulated from: Pullout = CL(A ~ 008 = operating misalignment angle, Axial travel of the U-jint telescopic spline under torque results in axial forces being applied to the support bear- ings. Those forces are a fanction of the spline eaefficient of friction, operating torque, operating angle and spline pitch diauneter, The wxial force can be calculated by: = coefficiont of friction (0.10 to 0.16 for lubricated steel on steel) @_ = operating angle,* PD = spline pitch diameter ‘The same equation is used for gear spindle force with a length compensa ing spline. For spindles without jength compensating splines, the some equation ie apliable trap thet the pitch diamter of She cowed gearing ted The lager pitch diameter would reduce the axial {ovees proportionally. Universal joint support considerations, Roll change aupport i an important consideration in the application of universal joints. In new installations, the ‘ill builder takes the support requirement inta nosonnt the eating’ ofthe mal dos The univeral joint and roll end hub must be held nearly horizontal during the roll change procedure so thatthe rll ends ean be eas ‘ily engaged with and disengaged from the spindle hub. Gear spindles aro commonly supplies with spring loaded ‘rust buttons to support the rol end adapter ding ral changes (Fig, 4). When the roll neck is removed from the spindle hub, the spring force drives the sleeve assembly ‘ont it locks ageinat the hab while the spindle is sup. Ported on its intermediate shat Retrofitting a gear spindle with a U-joint is often a rel- atively simple job in mills where there is an existing spindle support. In this ease, the existing epindle supe port can often be sed ass with angle limiters attached ‘to the universal joints, or the spindle support mecha- niem ean be modified t9 support the intermediate shaft fand roll end adapter simultaneously. Spring packages Gig. 12) are designed for milly with relatively sumall operating angles and an existing intermediate shaft support. The springs aro not in contact during normal operation. When the roll end is removed, the yoke is permitted to misalign to a Inrger than eperating.angle ‘that atill permits the roll end to engage the adapter chamfer. Tn mills that are being retrofitted with a U-joint where there is no spindle support, there are a variety of ‘mechonical methods that can be used to support the spindle during roll changes. Methods of support range from techniques as simple as slinging the epindle from ‘an overhead crane to building spindle support devices Fig. 12 — Spring angie liter,Fig. 13 — Ujoint support mechanism, Because of existing equipment, each installation usually requires a diferent design..An example of @ eustom epin- dle support is shown in Fig. 13. Hydraulically operated U-joint angle limiters ean be used to hold a small angle in a mill where large spindle angularity is required during operation. Hydraulic angle limiters (Hig. 14) utilize a small hydraulic cylinder built into the yoke. Before a roll change, the cylinder is ener- ized and extended to support the universal joint. and roll hhub in the horizontal position. This technique is particu larly useful on mills where the owner di i existing spindle carriers, and not add additional capital equipment to capture the roll end of the universal joint during roll changes. oll En Hub Shaft Ena Yoko Fell Et Yoko Shaft Flange Hydkaule Cylinder Fig. 14 —Hydrauie angle lertor Special considerations Applicability — Universal joints sre particularly well- suited for the rity requirements of reversing rougher and mill applications, The rolls of these mills aro usually powered by two separate direct-drive ‘motors that are speed synchronized by the mill control system, The mills are required to operate through a rela- tively large range of angularity. A range from 5° to 2° dur- ing a single schedule is common, Angularity in excess of 6° is not recommended in these application: Due to the motor avarload capshiliting built into thee mills, and the low minimum speed of the motors, it is, ‘more appropriate to consider the torque density of the application rathor than the power density. Motors for ‘these applications normally have a current limit setting between 220 and 250% of the nameplate motor rating. ‘When the overload tactors and minimum motor speeds are taken into account, the designer ean be faced with an 8000 or 10,000-hp mill motor that can produce 1.5 mil- lion ft-lb of torque at current limit, and is capable of gen- crating toraue spikes in excess of 2.0 million 1b. This torque must be transmitted through @ universal joint that has smaller diameter than the discard diameter of ‘the work roll, Experience has shown that a properly designed and maintained universal joint spindle ia well suited for thaxe applicatins. Compated to finishing stand applications, these types of ‘ills run relatively slowly, The faster Stockel mills rarely ‘exceed 120 or 140 rpm. Accordingly, dynamic balancing of spindle components is not normally required. Size selection — Size selection for reversing roughers and Steckel mills requires careful consideration of ll ‘operating conditions. Bocause of the overload capabilities, using catalog toraue ratings are usually not usefel and ean be misleading, When designing a mechanical drive system for these types of mills itis recommended that the ‘Uyoint manufacturer be contacted as early aa possible in the design process. The two mein factors that usually Astermine the final U-joial sising are: minimim work roll diameter, and who is specifying the U-jint? ‘To abtain the maxirmur ponsible reductions per pass mill, designers (particularly on Steckel mils) specify the work rolls as small in diameter as possible. The question of how ‘to got the required torque to the work rolls is usually a ec~ ‘ondary consideration. As a result, the discard diamotor of the work rolls is, in many cases, the deciding factor when choosing the size of the universal joints, atleast for the roll end U-jint, Often, the spindle designer finds that a uni- versal Joint that 1s, for example, 900 mm. dia may be roquired to meet the desired overload criteria. However, the diseard size of the work rolls for the mill is 860 mm. ‘The swing diameter of the roll end joint must be equal to or less than 850 mm. This does not adversely affect the ‘functionality of the mill, Itonly means that the service life ofthe universal joint bearings will be shortened. ‘The party that specifies the U-joint also influences the final size selected. Because ofthe objective of end ners to minimize capital expenditures on new projects, new mills are typically built with the smallest spindles adequate for the application, In many cases, the universal joint size that {8 required ot the roll end is also used at the ‘motor end, even though the allowable size on the motor ond are usuaily considered acceptable, and the mill builder reduces the initial ‘expense to the end user by using the same size universal joint on both ends of the spindle.Fig. 15 — Reversing mill apptcation, For the ease of retrofits, spindle specifications are often, driven by maintenanee considerations. In these eases, it is normal to seo U-joint assemblies with roll end joints that are nearly the same diameter as the minimuin roll diameter, but with much larger universal joints on the motor end of the spindle. Some maintenance groups have decided that itis easier to remove a univorsal joint from the roll end of the shaft and pull it through the mill stand rather than remove the entire spindle, which ‘would have included the motor-side U-joint. In these cases, they have chosen to retrofit the motor end of the spindles with a considerably larger universal joint where the maintenance intervals are often 86 to 60 months. ‘This combination results in a reduction in overall mgin- tenance expense. Universal joint tife in reversing roughers and Steckel mills — The service Iie of universal joni tn roughing and Steckel mila 38 a funetion of maximum motor load, and mill operating and maintenance practice, Another factor is the torque amplification factor (TAF) that the spindles are subjected to, TAF is the ratio of ‘torque that would be measured with a strain gate on the spindle shaft as compared to the theoretical torque pro- duced by the motor. This number is always greater than tunity. On tight, well maintained and properly operated mills the TAF usually ranges from 1.1 to 14, The TAF can be in excess of 1.7 during some passes for milla that are poorly maintained and/or not properly operated. ‘Experience has shown that the average torque thet 9 universal joint is subjected to during service does not usu- ally deterinine the life of the universal joint in a reversing, mill. Spindle lifa is ultimately determined by the number of high magnitude torque spikes that it experiences. The failure mode of a properly designed and maintained uni- ‘versal joint will be the fatigue failure of the U-joint bear- ings. Reducing the number and magnitude of shock loads imposed upon che U-joine’s bearings is the best way Uo maximize their service life In general, if the roll end and motor end U-joints are of equal size,’ roll side universal joints tend to require ‘more maintenance attention than motor side ‘Torque spikes are often higher at the roll end and, in the ease of the bottom spindle, the U-joint- must work in a eascade of coolant. In general, a service interval of 12 ‘to 24 months can be expected for the roll end U-joint. As previously mentioned, this mumbor is heavily influenced oy the discard size of the work rolls. If the motor end U-joint is sized appropriately, 36 to 60-month mainte- nance intervals can be achieved. A maintenance inter- val ig defined as the interval between bearing replacement. ‘Tubrication intervals for universal joints in reversing roughers and Steckel mills should be moro frequent than in other applications because of the extremely high unit loads and tighter bearing tolerances, Where U-joints in ‘other applications should be lubricated approximately once a month, U-joints in these applications should be lubricated evety one o two waeks. Installation of modern universal joint spindle in a reveraing ill — The following is an ove view of a spr dle design in a fictitious reversing mill. The design is, illustrated in Fig. 18, Even though the mill is fictitious, all, the features discussed are currently in service: ‘© Rolland rmniwarasl joint slightly emallar than work roll discard diameier—For a reversing rougher or Steckel mill, this results in an estimated service interval of 12 to 24 months. ‘+ Dual guidance hub on the work roll—This feature ‘liminates loping commen on older Ujoint designs, ‘Liner plates in rol] hub—This feature facilitates set-up of proper clearances between roll and spin- le hub to be maintained, thereby helping to reduce TAF. ‘+ Hollow shafl—This dasign results in # shaft with, high stiffness and reducod weight, which ean lead to elimination of spindle carriors whon usod in conjunction with dual guidance roll hubs. ‘+ Motor end joint with 50% more eapacity than roll end—hese larger universal joints are sized for ‘maintenance interval of 36 to 60 months. ‘Summary Tn today’s global market, universal joints can he an eff- cient, cost-effective mothod of driving mill rolls. Research and ‘provements in design and manufacture have enabled universal joints to become a popular choice for few mills, but viable retrofit for existing slipper end gear spindles. Universal joints have achieved successful opera- fion in virtually every type of mill drive including high Impact reversing rougher and Steckel mills. As environ- ‘menial eoncorns continue to inerease and the cost of waste disposal Guch as lubricants) and preventive maintenance centinues to inerease, Usjints could become even more cost effective in the future. REFERENCES 1, Polgister, F, M., “Cardan Universal Joints Applied To Stes! ‘Mill Drives," ATSR Year Book, 1969, pp 216-229. 2 Kamil, N., and Okuda, H,, “Universal Joints Applied To Hot Strip Mil Drive Lines,” AISE Yaar Book, 1975, pp 478-482. 8, Keller, N,, and Lesonick, M.S, “Vibration Analysis of Stand, £72 of Wheeling Pittsburgh's 60-In. Hot Strip Mil” AISE Year Book, 1980, pp 208-210. 4. Keller, N, “Spindln Inenlvement in Raling: Mil Vihention * AISE Year Book, 1992, pp 985-840, ', Shipley, J. Mechanical Engineering Design, 3rd ed, MeCraw- Hl, 197, 6. Spotts, M., Design Of Machine Elemente, 5th ed., Prentice- Hall, 1078, 2Clutches & Brakes CCeniric Clutch Products PO Box b68 ‘Woodbridge Ny USA 07095 0668 Tel 732 634 1761 Fax 732 6340793 ‘unwa?ceritigciutch com Inqustial Cstch Products PO Box 118 Waukesha Wi USA $3187 0118 Tel 414 S47 3357 Fax 414 547 2949 Marland Clutch Products PO Box 308 {2 Grange Usa 60525 0308 Tel 708 352 3330 Fax 708382 [403 ‘yewvezmarland.com Cente” Centritugal Clutches Trig-O-Matic” Overload Release Clutches Vari Torque” Overtoad Release Air Clutches Series H Mechanical and Pneumatic Oveqoad Release Clutches ‘Ameriguard* Torque Limiting Clutches ‘Mode! LKB Low Inertia Clutches & Brakes ‘Model CBA/CBH Combination Clutch/Brake Model HC, HBA, HAS Oil Cooled Clutches & Brakes Marland Backstops CECON* Clutches CEBMAG Clutches. 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