Flexible Couplings

By

Ghulam Jillani
JDL Rotary

March 26, 2020 1

 Presentation Outline
• Introduction 3
• Coupling Categories 7
• Coupling Interface Connections 10
• Gear Couplings 14
• Disc Couplings 26
• Diaphragm Couplings 36
• Elastomeric Couplings 49
• Information To Coupling Vendor 54
• Coupling Characteristics For Pumps 55
• Comparison of Pump Couplings 56
• References 58
March 26, 2020 2
 Coupling Functions

1- Transmit Power

2- Accommodate Misalignment

 Coupling means Flexible Coupling

March 26, 2020 3

 Coupling Functions
3- Compensate For End Movement

Besides these basic functions,couplings are sometimes required to

do the followings :
 Dampen vibration & reduce peak or shock loads
 Position a rotor of a motor
 Be used to tune a system out of a torsional critical.

March 26, 2020 4

 Misalignment

1- Parallel or Offset

2- Angular

3- Combined

March 26, 2020 5

 Causes Of Misalignment

 Installation (Human) Errors

 Thermal Growth

 Worn Bearings

 Settling Bases / Foundations

 Dynamic Twist Of bases under load ( Soft Foot )

March 26, 2020 6

 Coupling Categories (Based On Functions)

 Mechanical Element ( Lubricated)

Transmits torque through a lube film.Accommodates
misalignment by rolling or sliding of loose fitting parts.

Gear Coupling Grid Coupling

March 26, 2020 7

 Coupling Categories
 Metallic Element ( Non-Lubricated)
Transmits torque through compression & tension of metal.
Accommodates misalignment through deflection of metal.

Disc Coupling Diaphragm Coupling

March 26, 2020 8

 Coupling Categories
 Elastomer Element ( Non-Lubricated)
Transmits torque through compression or shear of
elastomer or both. Accommodates misalignment through
deflection of elastomer.

Elastomeric Jaw Elastomer Couplings

Coupling

March 26, 2020 9

 Coupling Interface Connections
Attaching coupling to machinery on either end can be
flanged or a hub mounted on the shaft.

API 671 allows either method by specifying the responsibility

for flange dimensions and by specifying fits on hub type
mounting.

March 26, 2020 10

 Coupling Interface Connections
1- Clearance Fit ( With Keys & Set Screws)
Clearance Fits with set screws are used on shafts up
to 4 inches.Torque is transmitted through the
keys.Clearance fit applications should be limited to
small horsepower applications where reactionary
loads are usually low.

2- Shrink Fits
Shrink Fits that conform to AGMA 9002
recommendations are usually sufficient to keep the
hub from rocking on the shaft.
For high horse power & high speed applications (API
671 & ISO) keyless fits (Straight & Tapered) are
commonly used.
March 26, 2020 11
 Coupling Interface Connections

Rule Of Thumb----Material Hardness vs Max.Amount of Shrink

For Steel
Recommended procedures can be found in AGMA 9002-A86
‘Bores & Keyways for Flexible Couplings & AGMA 9003-
A91’Flexible Couplings-Keyless Fits.

March 26, 2020 12

 Coupling Interface Connections

Intermediate
Bushings

Tapered Hub Shaft Installation

Locking Ring
March 26, 2020 13
 Gear Couplings

Gear Couplings consist of two hubs

with external teeth on a two or one
piece sleeve. These are used for
medium to large applications
generally over 100 hp. They have
torque capacities up to 54,000,000
lb-in and bore capacities to 45
inches. The gear teeth must be
lubricated to minimize wear. Gear Coupling

March 26, 2020 14

 Gear Couplings
Construction Of A Typical Gear Coupling

March 26, 2020 15

 Gear Couplings
Sleeve
Hub Teeth

Basic Design Features Of Gear Couplings are:

1- Double Engagement or Full Flex
2- Single Engagement or Semi Flex

March 26, 2020 16

 Gear Couplings
Double Engagement Gear Coupling

1 Flex Hub 2 Sleeve 3 Inside O

Ring
4 Outside O Rings 5 Nuts & Bolts

March 26, 2020 17

 Gear Couplings
Single Engagement Gear Coupling

1 Flex Hub 2 Sleeve 3 Inside O Ring

4 Outside O Rings 5 Nuts & Bolts 6 Rigid Hub

March 26, 2020 18

 Gear Couplings
Continuous Sleeve Design

March 26, 2020 19

 Gear Couplings
Spacer Design

Spacer

March 26, 2020 20

 Gear Couplings
Operating Principles
Gear Coupling transmits torque & accepts misalignment by the
meshing and movement of gear teeth.
In effect each set of gear teeth
provides an angular pivot. The
amount of permissible angle is a
function of backlash & tooth form.
Backlash

March 26, 2020 21

 Gear Couplings
Design Considerations

Improved Tooth Design

 Straight /Crowned
 Amount Of Backlash
 Pressure Angle Of tooth

A Flank Crowning
B Tip Crowning
C Chamfer Crowning

March 26, 2020 22

 Gear Couplings
Design Considerations
2- Material
 Type Of Material Alloy Steel Min.Rockwell C 45,Titanium Alloy
Surface Hardening Nitriding Tooth Surfaces

3- Lubrication
 Grease Lube –Most Common

 Continuous Oil Lube –High Speed Drives

 Batch oil Lube –Usually Low Speed
 Non-Lube ---Non Metallic Sleeve Tooth (Nylon Coupling)

March 26, 2020 23

 Gear Couplings
Continuous Oil Lubrication
Oil is injected into the coupling in the form of oil jets on to the
collecting lips or rings. Oil is injected at one end in the coupling
& exit from the other end. Oil viscosity 2100-3600 SSU at 100F
can be used successfully at high speeds.

March 26, 2020 24

 Gear Couplings
Advantages
 High Torque Capacity ( Torque To OD Ratio)

 High Torsional Stiffness

 Accommodates large misalignment with most axial displacements
 Economical

Disadvantage

 Needs Lubrication / Regular maintenance

March 26, 2020 25

 Disc Couplings
The disc coupling transmits torque by a
simple tensile force in disc elements
between alternating driving & driven bolts
on a common bolt circle. These are
generally used on applications over 100
hp. They have continuous torque
capacities up to 4,000,000 Lb-in and bore
capacities to 15.5 inches.

March 26, 2020 26

 Disc Couplings
Operating Principle Disc

Misalignment is accommodated
by the flexing of the elements
between the adjacent bolts. The
elements must be thin to be
flexible. Stacks of elements
provide parallel load paths and
the diameter of the bolt circle is
an indicator of the amount of
torque to be carried. The
amount of misalignment is
related to the chord length
between bolts and the thickness
of the discs & disc packs.
Alternating Attachment Fasteners

March 26, 2020 27

 Disc Couplings
Operating Principle
The thin element has both tensile
stresses & cyclic bending imposed
on the element so that a fatigue
life analysis is required. Once the
fatigue life is determined, an
infinite life coupling can be
designed to keep the loading
below the fatigue limit.
The amount of misalignment
available is a function of the
bending that can be
accommodated while under
tension. The unit will allow limited
axial movement.
March 26, 2020 28
 Disc Couplings
Disc Shapes/Profiles

March 26, 2020 29

 Disc Couplings
Disc Shapes/Profiles

March 26, 2020 30

 Disc Couplings
Terminology
Disc Stainless Steel Flexible Disc
> ( 0.012’’ To 0.015 Thick )
(0.3 to 0.38 mm)
Disc Pack Unitized Pack made up
of several disc
Link The disc section b/w bolt holes
Scallop Optimized Disc Profile,
Thickest near bolt holes

March 26, 2020 31

 Disc Couplings
Closed Coupled Type

March 26, 2020 32

 Disc Couplings
Spacer Type

March 26, 2020 33

 Disc Couplings
Spacer Type

March 26, 2020 34

 Disc Couplings
Advantages

• No maintenance – No Lubrication

• Designed For Infinite Life

• Good Inherent Balance
• Zero Backlash
• Low reactionary forces as compared to gear
couplings
Disadvantages
• Less tolerant for extreme misalignments

• Less axial float & large dia. as compare to gear couplings

March 26, 2020 35

 Diaphragm Couplings
Diaphragm Couplings that utilize
a single or a series of
diaphragms for the flexible
members. The torque
transmission path through the
diaphragm members is in the
radial direction,from the outer
dia. to the inner dia. or vice Diaphragm Coupling
versa.Load from operating torque
is seen as a shear stress on the
diaphragm member.
March 26, 2020 36
 Diaphragm Couplings
Types Of Diaphragm Couplings

Single Diaphragm

Couplings that use a single diaphragm for the flexing

member,The deflection of the outer dia. relative to the inner
dia. is what occurs when the diaphragm is subjected to
angular & axial misalignment.

Axial displacement attempts to stretch the diaphragm,which

results in a combination of elongation and bending of the
diaphragm profile.

March 26, 2020 37

 Diaphragm Couplings
Types Of Diaphragm Couplings

Single Diaphragm

Diaphragm

March 26, 2020 38

 Diaphragm Couplings
Types Of Diaphragm Couplings

Multiple Diaphragms

Multiple diaphragms accommodate misalignment somewhat

differently.They use multiple thin plates/diaphragms that are
made to be wavy from OD to ID. They react similarly to the
contoured (Single) diaphragms under misalignment except that
they unfold the wavy profile of the diaphragms instead of
stretching the diaphragm.

March 26, 2020 39

 Diaphragm Couplings
Types Of Diaphragm Couplings

Multiple Diaphragm

Diaphragm

March 26, 2020 40

 Diaphragm Couplings
Diaphragm Profiles
Contoured Or Tapered
A contoured diaphragm coupling typically uses a single
diaphragm for flexible member,the plate has a contoured or a
wavy profile,which usually has a variable thickness from OD to
ID to provide optimum stress condition.

Contoured

March 26, 2020 41

 Diaphragm Couplings
Diaphragm Profiles
Convoluted & Flat Profile
A convoluted and flat profile diaphragm couplings typically
uses multiple diaphragms that have a wavy profile or other
modified profile.All types attach the flexible member to other
components with bolts,splines or welds and both transmit
torque in the same manner.

Flat Profile-Spokes Welded Design

Convoluted

March 26, 2020 42

 Diaphragm Couplings
Types Of Diaphragm Couplings

Diaphragm

Diaphragm With Integral Flange

March 26, 2020 43

 Diaphragm Couplings
Types Of Diaphragm Couplings

Single Diaphragm Spacer Coupling

March 26, 2020 44

 Diaphragm Couplings
Types Of Diaphragm Couplings

Multiple Diaphragm Spacer Coupling

March 26, 2020 45

 Diaphragm Couplings
Types Of Diaphragm Couplings

Cross Section

Multiple Diaphragm Spacer Coupling

March 26, 2020 46

 Diaphragm Couplings
Material Considerations

Diaphragms are made of high strength materials.Some are

corrosion resistant ( 15-5/17-4 PH ), Others use high quality 4300
steel or other alloy and coat the diaphragms for corrosion
protection.Some diaphragms are shot peened to reduce residual
stresses that are imposed on manufacturing process & to prevent
the development of surface crack initiation points.

March 26, 2020 47

 Diaphragm Couplings
Advantages

• No Limitation on torque.

• Higher axial & angular misalignment.

• No frictional fretting on parts.

• Diaphragms are designed to act like a fuse, failing in torsion.

Disadvantages

• High Costs

• Large Size as compare to gear couplings.

March 26, 2020 48

 Elastomeric Couplings
Elastomeric element couplings come into
two basic types.
Shear Types
These are generally found on
applications under 100 hp. They have
torque capacities up to 450,000 lbs-in Tyre
and bore sizes to 11 inches. The Coupling
elastomer (Polymer, Plastic, Natural
Rubber) transmits torque through shear.
Compression Types
The compression type usually used on
applications over 100 hp. They have
torque capacities up to 20,000,000 lbs-in
& bore to 34’’.The elastomer transmits
torque through compression.
Jaw Coupling

March 26, 2020 49

 Elastomeric Couplings
The compression type of elastomer
coupling transmits torque by inserting
elastomeric material between axially
protruding intermeshing teeth of two hubs.
Parallel offset misalignment is accepted
via compressive distortion of elastomeric
material.
Angular misalignment is accepted via
sliding or distortion of the elastomer
Jaw Coupling
material and method of securing to hubs.
The elastomeric member, typically called
as spider, is made up of Buna N,
Urethane & NBR. The jaw hubs are of
sintered iron or cast iron.
March 26, 2020 50
 Elastomeric Couplings

Jaw Coupling with Clamp Jaw Coupling With Ring & Groove

Metallic Ring prevents expansion of element

Clamp is actually used under centrifugal force & is placed in a groove
to restrict movement of cut in centre of element.
element under
centrifugal force & is
fastened with hubs.

March 26, 2020 51

 Elastomeric Couplings
The Shear type elastomeric
coupling transmits torque through
an elastomeric cylindrical type tube
which is attached to each hub via
various methods such as clamping,
bonding to metallic members which
are then bolted to the hubs or by
intermeshing teeth. The design
accepts misalignment through
deflection & deflection of element
and also through sliding if Tyre Coupling
elastomeric member is attached to
the hubs through the use of
intermeshing teeth.

March 26, 2020 52

 Elastomeric Couplings
Different Types Of Shear Couplings

Tyre
Coupling

Spacer Design Clamped Donut Type

March 26, 2020 53

 Information To Coupling Vendor
Purchaser must supply following information to coupling vendor
for proper selection of coupling.

Referenced From An Article By KopFlex Published in WorldPumps, Nov,2004

March 26, 2020 54

 Coupling Characteristics For Pumps
Qualitative Coupling Characteristics Required For Most
Pumping Applications

Referenced From An Article By KopFlex Published in WorldPumps, Nov,2004

March 26, 2020 55

 Comparison Of Pump Couplings (1/2)

Referenced From An Article By KopFlex Published in WorldPumps, Nov,2004

March 26, 2020 56

 Comparison Of Pump Couplings (2/2)

Referenced From An Article By KopFlex Published in WorldPumps, Nov,2004

March 26, 2020 57

 References:
 Flexible Couplings Presented at Sixteenth International Pump User
Symposium By Jon R Mancuso ( E.M., KopFlex, EPT USA)
 Related Websites
 Vendor Websites e.g; EPT, Flexibox, Rexnord, Ameridrives,
Falk & TBWoods
 Different Research Papers Available At EPT Website
 Article From World Pumps dated Nov.,2004

March 26, 2020 58