Selecting the Right Gear

Coupling for Your

Application
Before We Start
q  This webinar will be available afterwards at
www.designworldonline.com & email

q  Q&A at the end of the presentation

q  Hashtag for this webinar: #DWwebinar

Moderator Presenter

Miles Budimir Paul Konkol

Design World Altra Ameridrives Gear Couplings
 Design World Webinar

Selecting the right gear

coupling for your application

April 29, 2015

 What is a Coupling ?

A Flexible Coupling is a machine part that transmits

rotating power from one shaft to another while
accommodating misalignment and axial displacement
between the two shafts.
 Basic Coupling Functions

The basic functions of a flexible coupling:

•  Transmit power
•  Accommodate misalignment
•  Compensate for shaft end movement
DRIVEN DRIVER
Transmit Torque

While allowing for:

Misalignment

Axial Movement
 Coupling Terminology
• Torque: The tendency of a force to cause or change • Flexible Element: The part of a coupling which
rotational motion of a body, calculated by multiplying Force and provides flexibility. There are 3 main categories:
distance. Defined more fully in the Torque section below. Mechanical, Metallic, and Elastomeric.
• Misalignment: The state of being not in alignment. • Sleeve: A gear coupling component with internal teeth.
Alignment is generally defined as the state where opposing • Hardware: The nuts, bolts, washers, etc., which are
equipment shaft centerlines are coaxial. For machinery and
used to attach the various coupling components together.
couplings, it is the proper orientation of mechanical parts to
obtain minimal wear and/or dynamic forces. • Clearance Fit: A condition where the hub bore
diameter is equal to or larger than the shaft diameter.
• Hub: The coupling component which is machined for
mounting on a shaft. • Interference Fit: A condition where the hub bore
diameter is equal to or smaller than the shaft diameter.
• Spacer: A removable center member that provides a
specified axial shaft separation. • Pilots:A surface that positions a coupling component,
subassembly or assembly.
• Distance Between Shaft Ends (DBSE): The
distance from the face of one shaft to the face of the next shaft. • Key: A mating torsional load transmitting member placed
in a groove in both shaft and hub.
• Shaft: The revolving cylindrical bar, the centerline of which is
also the center of rotation for the components to which it is • Keyway: The axial groove in the hub that holds the key
attached, through which torsional power is transmitted or in the proper location.
delivered.
• Bore: Cylindrical or conical holes in hubs of couplings with
axes coincident with the rotational axis of the coupling.
 Basic Torque Calculation

Torque = Power x Unit Constant

Speed

•  in-lb. = HP x 63025 / RPM

•  Nm = kW x 9554 / RPM

•  HP/100 RPM = HP x 100 / RPM

 Torque

HP transmitted x 63,025 x Service Factor

=
RPM
 Service Factors
Service  Factors  are  a  multiplier  to  the  calculated  torque  when  selecting  a  
coupling.  
•  Selection  Torque  =  Calculated  TQ  x  SF
•  Note:    Different  coupling  types  and/or  manufacturers  recommend  different  service  
factors  for  similar  operating  conditions.    Always  check  your  catalog

CLASS SMOOTH STEADY MODERATE MEDIUM HEAVY EXTRA HEAVY EXTREMELY HEAVY

DRIVER
TYPE

HIGH STARTING
MOTOR OR MOTOR OR MOTOR OR MOTOR OR TORQUE MOTOR
TURBINE TURBINE TURBINE TURBINE OR ENGINE ENGINE ENGINE

- SOFT START WITH STEADY - ABOVE AVERAGE - MILD SHOCK LOADING - EXTREME SHOCK
- NORMAL STARTING LOADS - HIGH STARTING TORQUE - HEAVY SHOCK LOADING
LOAD LOAD STARTING LOADS ENGINES WITH SMOOTH LOADING
- SLIGHT TORQUE - MEDIUM TO HEAVY LOAD - LIGHT TO MODERATE
TYPE - CENTRIFUGAL - MODERATE LOAD LOADING - HEAVY REVERSING WIDE
VARIATIONS VARIATIONS REVERSING
EQUIPMENT VARIATIONS - EXTREME RELIABILITY TORQUE VARIATION

SERVICE
FACTOR 1.0 1.5 2.0 2.5 3.0 3.25 4.0
 Types of Misalignment

Angular
Misalignment

Parallel Offset
Misalignment
Misalignment

Parallel offset

Angular misalignment

Combination of both
 Types of Misalignment

•  Axial Misalignment or End Float

o  Some couplings will limit shaft movement, others will not
o  Sometimes limited end float (LEF) devices may be added
to a coupling
 A.  Small amount
•  Thermal growth
•  Bearing float
Axial Movement B.  Large amount
•  Axial adjustment
•  Operational shifting
 Coupling Categories and Types

Mechanical

Gear Chain Grid UJoint

Elastomeric Metallic

Shear Compression Disc Diaphragm

Miscellaneous

Pin & Bushing Spring Slider Block

 Mechanical

UJoint

Gear

Chain

Grid
 Elastomeric

Shear

Compression
 Metallic

Disc

Diaphragm
 Couplings Cover a Wide Range

Price

Form-Flex®
Gear
Grid Modify/MTO
Dura-Flex®
Sure-Flex®
L-jaw Make to Stock
Performance
So, which is the right coupling for my application?
 Types of Couplings & Application Requirements
Coupling Gear Spindle Grid U Joint Elastomeric Elastomeric Disc Diaphragm
Characteristics Shear Compression
Lubrication Yes Yes Yes Yes No No No No
Backlash Med High Med None None Low None None
Overhung Med High Med High High High Low Low
Moment
Unbalance Med High High High High High Med Low
Bending High High Med High Low Med Med Med
Moment
Axial Force High High Med High Low Med Med Med

Torsional High High Med High Low Med High High

Stiffness
Damping Low Low Med Low High Med Low Low

Coupling selection based on application needs

 +++ = BEST
++ = BETTER
$$$ = HIGHEST
$$ = LOWER Costs and Benefits
+ = GOOD $ = LOWEST

Coupling  Types
Elastomeric  -­‐‑  Shear Elastomeric  -­‐‑  Compress      
Tire Block Sleeve Jaw Curved-­‐‑Jaw Block   Gear Disc Grid
 

                   

 
Criteria

N   N   N   N   N   N   Y   N   Y  
   Lubrication
   Ease  of  Installation  ++ +++   +++   +++   +++   +++   +   +   +  

   Fail  Safe N   N   N   Y Y Y N N   N
   Misalignment  Rating  +++ +   ++   +   +   +   ++ +   +  
   Purchase  Cost  $$   $   $   $   $   $   $$$   $$$   $$  
   Maintenance  Cost N   N   N   N   N   N   Y   N   Y  
   Replacement  Cost  $$   $   $   $   $   $   $$$   $$$   $$  
++ +++ +++ +++ +++ ++ + + +
   Installation  Cost/Time
   Life    ++   +   ++ +   +   +   +++   +++   ++

   Torsional  Stiffness Low High Low High High High Highest Highest Low
 Why Select a Gear Coupling?
Coupling Gear Spindle Grid U Joint Elastomeric Elastomeric Disc Diaphragm
Characteristics Shear Compression
Lubrication Yes Yes Yes Yes No No No No
Backlash Med High Med None None Low None None
Overhung Med High Med High High High Low Low
Moment
Unbalance Med High High High High High Med Low
Bending High High Med High Low Med Med Med
Moment
Axial Force High High Med High Low Med Med Med

Torsional High High Med High Low Med High High

Stiffness
Damping Low Low Med Low High Med Low Low

Gear Coupling is selected because it is torque dense, has axial capacity

independent of angular misalignment, large bore capacity, and long life.
Why a Gear Coupling?

•  High torque

•  High misalignment

•  Axial capacity
 Basic Gear Coupling Parts

Flange Nuts & Bolts Sleeve

Lube Plugs
O-ring Seal

Hub
 How a Gear Coupling Transmits Torque
Torque is transmitted on
the flank or face of the
gear tooth

Major Diameter Sleeve

Piloting
 Gear Tooth Design
•  Gear teeth are either
straight or crowned

•  Clearance in gear mesh

allows for misalignment

•  Crowned tooth allows for

greater misalignment,
higher torque capacity,
less backlash
 Crowned or Fully Crowned Gearing

A) Flank (Face)

B) Tip (and Root)

C) Chamfer
How a Gear Coupling Works

When everything is
“perfectly” aligned
all teeth share the
load equally
How a Gear Coupling Works

As you misalign, fewer and fewer

teeth are in contact
Ratings are based on the torque
that can be transmitted at a given
misalignment
Reduce your misalignment,
increase your ratings
Fully Crowned Gearing Allows for
Max Misalignment
Fully Crowned Gear Reduces
Backlash and Vibration
 Gear Couplings Require Lubrication

Original gear couplings 75+

years ago were filled with oil for
lubrication
A metal labyrinth seal and
centrifugal force kept the gear
mesh lubricated
 O-ring Seal

Buna-N O-ring seals keep

contamination out, and lubricant in.

Designed to accommodate
temperatures up to 250°F.

Viton seals are available for

temperatures up to 550°F. O-ring Seal

Clean grease of the proper amount and type will give

longest life
 Recommended Grease

Suggested grease by manufacturer and operating conditions

 Gear Coupling Standards

•  Flange Diameter is standard for manufactures

•  Shrouded or Exposed bolt pattern is standard
•  Allows for Identification & Half-to-Half Interchangeability
 Standard AGMA Nomenclature Size 1 ½ to 7
Size Mfg.  K Mfg.  F Mfg.  A O.D. #  SB  Bolts #  EB  Bolts

1-­‐‑1/2 1-­‐‑1/2H 1015 201.5 6.00” 8 8

2 2H 1020 202 7.00” 10 6
2-­‐‑1/2 2-­‐‑1/2H 1025 202.5 8.38” 10 6
3 3H 1030 203 9.44” 12 8

7 7H 1070 207 20.75” n/a 16

•  Measure flange O.D.

•  Count the bolts O.D.

•  Step in ½ sizes
 Special Coupling Functions
Many couplings today are special made to order
and incorporate other special features.
§  Allow for axial travel §  Tune a system out of a torsional
§  Maintain sleeve bearing motor critical
rotor position (Limited End Float or §  Support the rotor of a generator or
LEF) other radial load (single flex)
§  Allow for extended DBSE §  Electrically insulate the driver
§  Protect Equipment from overload from the driven equipment
§  Dampen vibration and reduce §  Measure output torque of driven
peak or shock loads equipment
§  Electrically insulate the driver §  Support axial loads on vertical
from the driven equipment installation
§  Incorporate a brake disc or drum §  Support other PT Components
§  V-Belt Drive, Fluid Drive, Clutch, etc.
 Special Coupling Functions
Application Data Form to gather all information
important to the installation
§  HP, speed, DBSE, shaft sizes,
SF, temperature, etc.
§  What is currently being used?
§  Drawings of existing
application
§  What changes have been
made since original
installation?
§  What operational problems
are there?
§  Special documentation
BORES, FITS AND HUB MOUNTING
 Hub to Shaft Fits
•  Slip or Clearance Fits
o  Hub bore is always larger than shaft OD

•  Press or Interference Fits

o  Hub bore is always smaller than shaft OD
 Clearance Fits

•  Use for Low Speeds

o  1800 to 3600 RPM max
•  Requires set screws and keyway
o  Worse for balance
•  Low HP ranges
o  Generally 250 HP and under
•  Smaller Shaft Diameters
o  Generally 3 3/8” or less
•  Risk of Fretting
 Interference Fits
•  Light: under .0005 in/in
o  Must use a key – minimal interference will slip under heavy load
o  AGMA Standard A86
o  Hub mounting: Heating necessary
o  Stresses are usually not an issue
•  Medium: ~.0005 - .0015 in/in
o  Usually tapered shaft and some keyless fits
o  AGMA standards A86 & A91
o  Hub mounting: Must be heated or hydraulically mounted
o  Stresses may need to be checked
•  Heavy: ~over .0015 in/in
o  Keyless fits
o  AGMA Standard A91
o  Hub mounting: Heating necessary
o  Stresses need to be checked
AGMA Fit Tables
 Interference Fit Calculations

•  Steel expands .0006”/inch of diameter per 100°F temp rise

•  Heat the hub to expand bore by 150%+ of the interference
•  Example: 5” dia. shaft with .004” interference
•  5” dia. x .0006” = .003” expansion per 100°F temp rise
•  .004” x 150% = minimum .006” growth
•  .003”/100°F x 2 = .006” bore growth = min 200°F temp rise
•  At 70°F temp, need to heat hub to at least 270°F
Ø  350°F is recommended, even heat distribution, less that 600°F
 Interference Fit Hub Installation
•  Calculate the correct temperature rise
•  Make sure bore and shaft are clean and free
of burrs
•  Plan how you will handle the heated hub
•  Heat hub thoroughly – if not heated through,
hub may cool, shrink and bind before
completely on the shaft
•  Shield shaft and seals from over-heating
when you install the hub
•  Quickly and safely position the hub on the
shaft and allow it to cool
 Metric vs. English Shaft Specification
Inch Shafts
•  Standard AGMA tolerances
•  Square keys
•  Half in hub / half in shaft

Inch Keyways
Metric Shafts
•  Various Metric standards DIN Standards
•  Rectangular keys
•  Keyway depth per metric standards
•  Overkey dimension for keyway depth

Metric Keyways
Fitting of Keys

1.  Tight Fit in Shaft Keyway

2.  Sliding Fit in Hub Keyway
3.  Clearance over Top of Key
4.  Chamfered Key Corners
Interference Fit with Key
 The proper gear coupling
selection and design will give
you the maximum
misalignment capacity &
maximum torque capacity for
the longest life in your
application.
 Questions?
Miles Budimir Paul Konkol
Design World Altra Ameridrives Gear Couplings
mbudimir@wtwhmedia.com Paul.konkol@ameridrives.com
Twitter: @DW_Motion
Thank You
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