® Failure Analysis • Installation & Maintenance
a good name in industry Freedom Disc Couplings
TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General Information . . . . . . . . . . . . . . . . . . . . . . . . . Page
Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
Detection of Disc Pack Trouble . . . . . . . . . . . . . . . . . . Page
Analysis of Failed Disc Couplings . . . . . . . . . . . . . . . . Page
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
INTRODUCTION
A disc coupling serves as a mechanical device, which
connects shafts of two separate machines and accommodates
small amounts of shaft misalignment. The purpose of this
manual is to review the areas in which disc couplings have
experienced difficulties and to identify the various types and
probable causes of failures.
N-HUB N-HUB
A D
C BE C However, the use of mirrors or a protective shield such as
GENERAL INFORMATION
A flexible disc coupling is designed for long life when
operated within the torque and alignment limits as set forth in
the catalog and installation instructions. The information
provided here may also be used for visual determination of
the condition of the disc packs.
The installation of a flexible disc coupling is critical. Various
problems could arise during mounting of the hubs and the
coupling assembly process. Burrs, dirt, and grit on either the
shaft or in the bores can cause the hubs to gall during
mounting. Poorly fitted keys can also gall and not seat
correctly.
Concentrated heat on the hubs will cause distortion. The
coupling must be properly assembled and the locknuts
tightened in accordance with the installation instructions.
Loose bolts will cause elongation of the disc bolt holes and
eventual failure of the discs or the bolts.
The most common form of failure in disc couplings is fatigue
due to excessive disc flexure. This is usually caused by poor
initial alignment of the connected machines. It also can be
brought about by operational conditions. The following
discussion presents some ideas to assure that the coupling is
operating satisfactorily.
The Falk Corporation, P.O. Box 492, Zip 53201-0492
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131
Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
(Page 1 of 4)
DETECTION
1 A disc coupling is easily inspected. Visual analysis may point
1 to possible drive system problems. Proper evaluation of the
1 disc packs and connecting parts may save considerable
1 maintenance costs and downtime. When a multiple blade disc
2 coupling starts to fail, it is usually from the outer disc of the
4 laminated pack and progresses towards the center of the
pack. See Figure 1.
Figure 1
Because of this progression, the deterioration of the disc pack
may be detected before ultimate failure.
DETECTION OF DISC PACK TROUBLE (with
guard removed and equipment not in service)
NOTE: Disc pack trouble can also be detected when the
equipment is in operation, such as with a strobe light.
plexiglass should be placed between the coupling and the
observer.
The following are some of the more evident visual inspection
criteria and recommended corrective procedures.
1. Fine line cracking starting in the outer disc, tangent to the
washer O.D. This is an indication of misalignment and can
be seen by looking at the outside edge of the disc pack.
Misalignment can be caused by any combination of the
following: angular, parallel, and axial.
2. Reddish brown color bleeding out between disc laminations
at the O.D. of the disc packs. This is an indication of
fretting and/or chemical attack of the disc material. This is
more prevalent in Type FD style disc coupling as the Type
FDP disc pack has thin shims separating the individual
discs to prevent fretting corrosion, however this may be
observed on the Type FDG/FDP packs due to chemical
attack.
3. Disc pack is wavy and dimension between flange faces is
either smaller or larger than indicated in the installation
instructions or applicable assembly drawing. This indicates
that the coupling has been installed in a compressed
condition (smaller dimension) or in an elongated position
(larger dimension). This could also indicate that the
equipment has shifted closer or further apart axially during
operation. Check for shaft thermal growth conditions.
Realign axial position of equipment so the coupling
operates with a neutral, flat disc pack.
478-980
April 2004
NEW
Installation & Maintenance • Failure Analysis ®

(Page 2 of 4) Freedom Disc Couplings a good name in industry

4. Disc packs (both ends) are wavy. One end is compressed,

and the other end is elongated. Moving the center member HOLE ELONGATION
towards the elongated end can reverse the conditions. This CRACK
is called “oil canned” disc packs. The disc pack has no
neutral center where it remains flat and parallel with the
end flanges.
This condition can be the result of:
1) Tightening the disc pack locknuts while the disc packs
are in the compressed or elongated position, such as
assembling adapter couplings in a vertical condition on
a bench. The spacer weight can compress the lower
disc pack and the adapter weight can compress the Figure 2
upper disc pack. This can also occur when installing a
spacer or floating shaft coupling in a vertical 2. Individual discs from a Type FDG disc pack or the bushing
application without supporting the spacer. unitizing the Type FDP disc pack embedded into a bolt
2) Tightening of disc pack locknuts while coupling is body is usually the result of a loose bolt or a severe torque
misaligned or other end of spool is hanging overload. See Figure 3.
unsupported.
3) Bound up bolt(s) in the bolt hole(s).
4) Damaged discs, which could be caused by abnormal
running conditions, misuse or loose bolts.
To correct “oil canned" disc packs:
1) Loosen all the disc pack locknuts. Correct the axial
spacing of the coupling as necessary with the coupling
aligned and spacer fully supported. If “oil canned”
conditions disappear, retorque locknut while coupling is
in its neutral position.
2) If (1) above is not successful, determine that all bolts,
with locknuts loose, can be turned by hand. If any bolts
are tight, the bolt holes should be cleaned out by lightly
reaming the flange so that the bolt turns by hand in the
Figure 3
hole. Reassemble and torque the locknuts while
coupling is in its neutral position.
3) If the discs in the pack are permanently deformed, A bolt failure such as in Figure 3 can also occur with a
replace the disc pack with a new one and reassemble loose bolt, which may show no apparent damage to the
the coupling. A severe torque overload, abnormal axial disc pack. Replace the bolt and disc pack. Tighten the
loads, or even loose bolts could cause this permanent locknuts to the proper torque. Try to avoid torquing the bolt
deformation. The cause of the deformation must be through the head as insufficient bolt stretch may occur and
corrected before restart. there is a possibility of galling the bolt in the bolt hole. See
The coupling, as finally assembled, should have a neutral Figure 4 for an example of a failed Type FDG disc and bolt
center where the center member is free to float axially without due to a loose bolt or severe torque overload.
snapping from one end to the other when moved by hand.

ANALYSIS OF FAILED DISC COUPLINGS

In the event of a coupling failure, a thorough investigation
should be made to determine the cause. The most common
causes of failure are improper coupling selection, improper
assembly, excessive misalignment, and corrosive attack:
1. Disc broken through the bolt hole indicates loose coupling
bolts. See Figure 2. Replace disc pack and tighten locknuts
to specified torque value. Note: Type FD bolts are “oiled” Figure 4
and Type FDG/P bolts are not.

478-980 The Falk Corporation, P.O. Box 492, Zip 53201-0492

April 2004 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
 ® Failure Analysis • Installation & Maintenance
a good name in industry Freedom Disc Couplings (Page 3 of 4)

An example of a bolt that has been embedded by a disc pack yields where a slight opening as in Figure 8 may
bushing in a Type FDP disc pack can be seen in Figure 5. be observed. This indicates improper coupling selection or
a momentary system torque overload.

Figure 5

3. Discs broken adjacent to the washer face usually indicates

excessive shaft misalignment during operation. See Figure 6.
This type of disc failure usually starts with the outer disc and
progresses inward through the disc pack. Realign equipment
and replace both disc packs. Make hot check of alignment
to assure it is within coupling misalignment capacity.
CRACK
Figure 6
4. Disc broken adjacent to washer face with fretting corrosion
present in the area of crack usually indicates excessive
shaft misalignment during operation. Also, iron oxide will
most likely be evident on the outside of disc pack. See
Figure 7.
Figure 8
If a bulged or bowed condition appears in only one
chordal section, there may be a loose bolt on one side of
the distortion. Loosen all coupling locknuts and unseat the
bolts. The bulge should release and flatten out. Retorque
locknuts. If distortion does not disappear, replace disc pack
and retorque locknuts.
Note: During normal operation, a slight opening may be
observed in the compressed leg. This should not be a
cause for concern. However, openings should not be
observed in the tensile leg.
6. Occasionally a Freedom disc coupling hub shank failure is
encountered. These failures generally consist of cracks
extending through the hub shank at a keyway corner or
through a set screw if one is used. See Figure 9.

CRACK CORROSION

Figure 7

5. The disc pack has a severe bulge near the center or is

bowed toward one flange in alternate chordal sections,
which are the compression link(s). See Figure 8. Figure 9
This condition is a result of a large torque overload
induced into the system, beyond the peak overload
capacity of the coupling. The remaining disc pack chordal
sections, tension links, will be straight and tight until the

The Falk Corporation, P.O. Box 492, Zip 53201-0492 478-980

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 April 2004
Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com NEW
Installation & Maintenance • Failure Analysis ®

(Page 4 of 4) Freedom Disc Couplings a good name in industry

It is possible to have disc coupling hubs fail over the

keyway from a combination of hoop stress produced by
an interference fit and a high tensile stress as a result of
excessive torque loads transmitted through the key.
These types of failures can also be traced to poor
installation practices, such as hubs forced onto shaft radii,
keys oversize for hub or shaft keyways, set screws being
tightened on hot hubs used for interference fits, or
excessive interference fit between shaft and hub. This type
of failure will typically occur if the conditions are right at or
near maximum published bores. In order to prevent hub
fractures, it is necessary that couplings be selected using
the proper service factor for the application based on
motor capacity. If a brake is involved in the system, then
the coupling should be selected on the brake capacity.

SUMMARY
The Falk Corporation disc couplings are designed for infinite
life. They must be properly selected, installed and aligned to
assure reliable service. Because of the design principle,
catastrophic failures are very rare. One final thing that we
would like to stress is that disc packs, bolts, and washers
cannot be substituted for “standard” off the shelf components.
The components in Falk disc couplings are made to tight
tolerances and the use of unspecified or off the shelf
components will lead to coupling failure.

478-980 The Falk Corporation, P.O. Box 492, Zip 53201-0492

April 2004 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com