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‫ ) دراﺳﺔ ﻋﻦ رﺑﻂ اﻟﻤﺤﺎور اﻟﺪوارة اﻟﻤﻴﻜﺎﻧﻴﻜﻴﺔ ﺑﺘﻘﻨﻴﺔ‬Jaw Coupling ) ‫واﻳﺠﺎد اﻟﺤﻠﻮل ﻟﻤﺸﻜﻠﺔ‬
‫ﻓﺸﻠﻬﺎ ﻧﺘﻴﺠﺔ اﻟﻜﻠﻞ‬

Technical Report · April 2022

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 ‫وزارة التعليم العالي والبحث العلمي‬

‫جامعة كركوك‬

‫كلية الهندسة – قسم الميكانيك‬

‫دراسة عن ربط المحاور الدوارة الميكانيكية بتقنية ( ‪)Jaw Coupling‬‬

‫وايجاد الحلول لمشكلة فشلها نتيجة الكلل‬

‫‪A study on connecting mechanical rotating shafts with (Jaw‬‬

‫‪Coupling) technology and find solutions for fatigue failure‬‬
‫‪problems‬‬

‫أعداد الدراسة‬
‫‪ -1‬أ‪.‬م‪ .‬بالل محمد قاسم ‪ -‬تدريسي في قسم الهندسة الميكانيكية – جامعة كركوك‬

‫‪ -2‬أ‪.‬م‪ .‬تيمور جوبان خضر ‪ -‬تدريسي في قسم الهندسة الميكانيكية – جامعة كركوك‬

‫‪1‬‬
 I. INTRODUCTION

A shaft coupling can be define as a mechanical part used for connecting two rotating
shafts used for power and torque transmission such as pumps, gears, compressors and
electric generators, the shaft that connect to the motor called drive and the other shaft
called driven. The coupling can be classified in two groups, rigid and flexible, these
classify depend on the torque requirement and alignment accuracies of the system.

During the mounting of two rotating shafts, misalignment impossible completely

became zero, fatigue failure of shafts or failure of bearings motors appear as result of
misalignment between drive and driven components. Misalignment inaccurate
generally outset due to inevitable errors of manufacturing, or it came as result caused
by working which lead to deformation of rotating components by time such as
unbalance of foundation, temperature fluctuating, flexible coupling compensate most
of misalignment problems, and absorb vibration and impact as well as torsional
moments variation, while in rigid coupling cannot absorb vibration and other problems.

There are two types of misalignment between two shafts, angular misalignment and
offset misalignment, the two types should not be more than the limited range as shown
in table (1)

Table 1: Typical Tolerances For Alignment

2
2- TYPES OF COUPLING AND THEIR APPLICATIONS

2.1 Beam Coupling

In beam coupling as shown in figure (1) the angular misalignment up to 7 degree and
parallel misalignment up to 0.025 inch limited, the coupling body consists of single or
multiple helical cuts, it used for torques below 100 inch-lbs.

Figure (1) Beam Couplings

2.2 Bellows Coupling

This kind of coupling provide high magnitude torsional stiffness, the advantage of
torsional stiffness to reduce both misalignment parallel and angular. Figure (2) shows
Bellows Couplings.

Figure (2) Bellows Couplings

2.3 Chain Coupling

The Chain Couplings angular and parallel misalignment allowances 2 degrees and
0.015 inches, it is suitable for power transmission, figure (3) shows Chain Couplings.

Figure (3) Chain Couplings

3
2.4 Jaw Coupling

In jaw coupling elastomeric spider use to join two pairs of hub as shown in figure (4),
it used for light power and motion control applications. Allowable for both parallel and
angular misalignment 0.01inch and 1 degree respectively.

Figure (4) Jaw Couplings

2.5 Diaphragm Coupling

This kind of coupling used for high power transmission and high speed operations, the
main advantage is their lack lubrication requirement, figure (5 ) shows diaphragm
coupling.

Figure (5) Diaphragm Coupling

2.6 Disc Coupling

Multiple and single or double discs stages used in disc coupling as shown in figure (6),
it is suitable for accommodate angular misalignment in power transmission and high
torque.

Figure (6) Disc Coupling

4
2.7 Gear Coupling
To overcome the spacer between shafts gear coupling gear coupling used, about 0.01-
0.02 inch in parallel misalignment while 2 degree in angular is allowable. Lubricant
used in some kind of coupling, figure (7) shows gear coupling.

Figure (7) Gear Coupling

2.8 Grid Coupling

This kind of coupling used for high torque with absorption shock and torsional
damping, figure (8) shows grid coupling. Allowable angular misalignment of about ¼
degree and parallel misalignment up to 0.30 inch.

Figure (8) Grid Coupling

2.9 Oldham Coupling

In Oldham coupling cylinder slider used instead of rectangular slider, in most of
coupling elastomer element use rather than metal, as shown in figure (9). The tolerance
of angular misalignment can be reach 5 degree.

Figure (9) Oldham Couplings

5
2.10 Schmidt Coupling

Offset shaft can be coupling by using Schmidt coupling, because it accommodate slight
misalignment, this king used in papermaking machines as shown in figure (10).

Figure (10) Schmidt Coupling

2.11 Clamping Coupling

This kind of coupling used in where alignment not concern. It is simplest type of
coupling as shown in figure (11), and it is suitable for zero- backlash devices.

Figure (11) Clamping Coupling

6
3- JAW COUPLING (Case Study)
Rubber and Polyurethane Spiders are an Essential Component of Spider Couplings, the
coupling connect to shafts for power transmission by reducing vibration, also
misalignment shafts in parallel positions and angular as well as the axial misalignment
, which is also can be used in motion control applications.

Spider couplings as shown in figure (12) are made up of three parts, spider in the center,
which is made from elastomer and two parts of metals as hub. The three parts meshes
with the lobes of spider as shown in figure (13). The torque is transmitted between the
two metals with spider.

Figure (12) Jaw Coupling

Figure (13) Spider part

The components designed to fails the spiders first, this called fail-safe, which means
that if the elastomer wears out, the hubs’ teeth will mate and the coupling will continue
to transmit torque without damaging the equipment.

7
4- THEORETICAL ANALYSES OF CHANGING MATERIAL OF SPIDER IN
JAW COUPLING

Couplings are designed using modeling software SOLIWORKS and then it is imported
to analysis software FEA SOLIWORKS for static analysis. The spider type coupling is
given a constant torque, is analyzed using FEA technique rather than mathematical or
experimental method because the mesh is made sufficiently fine around the areas of
geometric discontinuity or stress raiser. The analysis is performed using FEA with
SOLIWORKS by constraining all the degrees of freedom in the driving shaft and then
the torque is applied on the drive shaft in order to calculate the resultant stress on the
coupling Hub and Spider, results compared between two materials (Rubber and
POLYURETHANE) using the Solidworks software.

Figure (14) Standard Dimensions of Coupling Hub (All dimensions are in mm)

8
Figure (15) Standard Dimensions of Spider (All dimensions are in mm)

Figure (16) isometric view Model of Spider coupling

Figure (17) isometric view Model of coupling Hub

9
 Figure (18) isometric view Model of Spider

Figure (19) Section view of Spider coupling

4.1 PROPERTIES OF MATERIAL OF SPIDER COUPLING

Table (2) Coupling Hub Alloy Steel

NO Property Value Unit

1 Elastic Modulus 210000 Mpa
2 Poisson's Ratio 0.28 N/A
3 Tensile Strength 723.8256 Mpa
4 Mass density 7700 Kg/m^3
5 Yield Strength 620.422 MPa
6 Shear Modulus 79000 Mpa

Table (3) Spider Rubber

NO Property Value Unit

1 Elastic Modulus 6.1 Mpa
2 Poisson's Ratio 0.49 N/A
3 Tensile Strength 13.7871 Mpa
4 Mass density 1000 Kg/m^3
5 Yield Strength 9.23737 MPa
6 Shear Modulus 2.9 Mpa

10
Table (4) Spider Polytetrafluoroethylene (PTFE)

NO Property Value Unit

1 Elastic Modulus 750 Mpa
2 Poisson's Ratio 0.46 N/A
3 Tensile Strength 55 Mpa
4 Mass density 2300 Kg/m^3
5 Yield Strength 196 MPa
6 Shear Modulus 230 Mpa

4.2 ANALYTICAL DESIGN OF SPIDER COUPLING

4.1. Meshing of Spider coupling:

Use SOLIDWORK SIMULATION for a meshing of Spider Coupling. It creates
sufficient meshing as shown in figures below.

Figure (20) Meshing of Spider Coupling

4.2. Analysis:

Spider Coupling analysis for calculating Von mises Stress, STRAIN, Deformation. Test
by applying Torque = 190.5 N.m at Speed = 1500 r.p.m.

11
4.2.1- Von mises (Rubber)

Figure (21) Von mises stress of Spider Coupling

4.2.2- Strain (Rubber)

Figure (22) Strain of Spider Coupling

12
4.2.3 Deformation (Rubber)

Figure (23) Deformation of Spider Coupling

4.3.1- Von mises (PTFE)

Figure (24) Von mises stress of Spider Coupling

13
4.3.2- Strain (PTFE)

Figure (25) Strain of Spider Coupling

4.3.3- Deformation (PTFE)

Figure (26) Deformation of Spider Coupling

Table (5) Results obtained by Solidworks

Parts Material Von mises Strain Deformation Yield
Coupling stress Max Max (mm) Strength
Max (Mpa) Max (Mpa)
Coupling Alloy 3.9 0.0000532 0.00101 620.422
Hub Steel
With Rubber
Spider Rubber 3.9 0.0000532 0.00101 9.23737
Coupling Alloy 3.86 0.0000488 0.000966 620.422
Hub Steel
With PTFE
Spider PTFE 3.86 0.0000488 0.000966 196

14
5- RESULTS AND DISCUSION

In this study the shear stress and Von mises stress are studied in the driven flange of
the spider typeflexible coupling. The stress concentration for torsion and bending was
found . results,one can select the proper size for the standard type flexible coupling.
Also the mesh is made finer around thestress raiser to get accurate results and analysis
can be done in Solidworks which is more users friendly.
Results shows that maximum Von mises stress occured at the surface of intersection of
the stepped shaft and jaws Also found stress concentration in the Spider part for Rubber
and PTFE material . So by this analysis it was concluded that the maximum stress
occurs at that connecting end of the jaw and Spider.
Also, through the deformation analysis, we found a greater percentage of deformation
in rubber than PTEF material This shows us that the rubber absorption of vibration
during the start of rotation of the Coupling more than PTEF In this case the spider-type
rubber will reduce the failure Coupling Hub.

6- RECOMMENDATIONS
Connecting the rotating parts using the Jaw Coupling method is one of the most
important methods that are used to reduce vibrations between the rotating parts and in
the absence of a match between the levels of the rotating axes. The points listed below
increase the efficiency of (Jaw Coupling), increase its life and reduce its failure as a
result of fatigue.
1 - select the type of connection between the axes depending on the rotational speed of
the rotating parts.
2 - Not to exceed the tolerance between the rotating parts, according to Table No. (1).
Increasing the amount of this tolerance leads to the failure of many parts that are not
limited to (jaw coupling), for example the bearings in the system are greatly affected in
addition lead to increase in energy consumption for the system.
3 - It is necessity of having a space between the interlocking parts (jaw coupling),
which helps to reduce vibrations and sounds, especially if there is a large amount of
difference between the levels (Table No. 1) and thus leads to an increase in the life of
the rotating parts and this is what is known as (Backlash).

15
‫‪4 -There are external factors that affect on the failure of (Jaw coupling), such as a large‬‬
‫‪divaition in temperature between maximum and minimum temperature, or contact of‬‬
‫‪parts with chemicals.‬‬
‫‪5 - Suddenly increasing the torque negatively affects the life span of the rotating parts.‬‬
‫‪6 - The failure of the metal part in (Jaw coupling) leads directly to the failure of the part‬‬
‫‪(Spider).‬‬

‫التوصيات‬
‫تعتبر ربط االجزاء الدوارة بطريقة ( ‪ )Jaw Coupling‬واحدة من أهم الطرق التي تستخدم في تقليل االهتزازات‬
‫بين االجزاء الدوارة وتظهر المشاكل في حالة عدم وجود تطابق بين مستويات المحاور الدوارة ‪ .‬أن النقاط المدرجة‬
‫ادناه تعمل على زيادة كفاءة ( ‪ )Jaw Coupling‬وزيادة عمرها وتقليل فشلها نتيجة الكلل‪.‬‬
‫‪ -1‬اختيار نوع الربط بين المحاور اعتمادا على السرعة الدورانية لالجزاء الدوارة ‪.‬‬
‫‪ -2‬عدم تجاوز السماحية بين األجزاء الدوارة وحسب جدول رقم (‪ .)1‬أن زيادة مقدار هذه السماحية يؤدي الى فشل‬
‫أجزاء كثيرة ال تقتصر على ( ‪ ,)Jaw coupling‬فعلى سبيل المثال المحامل الموجودة في المنظومة تتأثر بشكل‬
‫كبير باالضافة الى زيادة استهالك الطاقة في المنظومة‪.‬‬
‫‪ -3‬ضرورة وجود مسافة بين االجزاء (‪ )jaw coupling‬المتعشقة‪ ,‬والذي يساعد على تقليل األهتزازات‬
‫واألصوات وخاصة اذا كان هناك مقدار كبير في فرق بين مستويات ( ‪ )figure 27‬وبالتالي يؤدي الى زيادة عمر‬
‫االجزاء الدوارة وهذا ما يعرف بمصطلح ( ‪.)Backlash‬‬
‫‪ -4‬هناك عوامل خارجية تؤثر على سرعة فشل (‪ )Jaw coupling‬مثل تغيركبير في درجات الحرارة بين الحرارة‬
‫العالية واألنجماد‪ ,‬أو تالمس االجزاء بالمواد كيميائية ‪.‬‬
‫‪ -5‬زيادة العزم الدوراني وبشكل مفاجئ يؤثر بشكل سلبي على العمر االفتراضي لألجزاء الدوارة‪.‬‬
‫‪ -6‬فشل الجزء المعدني في ( ‪ )Jaw coupling‬يؤدي وبشكل مباشرالى فشل الجزء ( ‪.)Spider‬‬

‫‪Figure (27) misaaligment of rotating parts‬‬

‫‪16‬‬
 REFERENCES

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Analysis of Universal Joint." IOSR Journal of Mechanical and Civil Engg 11.3
(2014): 64-69.
[3] Jaiswal, S. B., and M. D. Pasarkar. "Failure Analysis of Flange Coupling In
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[4] Prof. Salunkhe R.T., Mr. Patil N.T., Mr. Lokhande V.S., Mr. Bandelkar D.M. and
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[8] Babu, Kondru Nagendra, and Dr D. Sunnel. "Failure analysis of flange coupling
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[9] Vijaya, V. G. "Analysis of Rigid Flange Couplings." International Journal of
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