Section I-C

Flexible Couplings

I-C. COUPLING INTERFACE CONNECTION

C. COUPLING INTERFACE CONNECTION 1. Shrink Fit vs. Clearance Fit a. Clearance Fit (With Keys and Set Screw s) b. Shrink Fits 2. Straight Shaft Installation a. Clearance Fits. b. Interference Fit. c. Straight Shafts With Intermediate Bushings/Locking Rings. 3. Taper Shaft Installation. a. General Discussion b. Taper Installation 4. General Installation Guidelines. 5. Rough and Semi-Finished bores. 6. Key-Fit. 7. Shrink fit effect on pilots. I-C-1 I-C-1 I-C-1 I-C-1 I-C-2 I-C-2 I-C-2 I-C-3 I-C-4 I-C-4 I-C-5 I-C-5 I-C-7 I-C-8 I-C-12

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C. COUPLING INTERFACE CONNECTION In this section w e w ill discuss coupling shaft connections. This section w ill discuss keyed and keyless shafts the next section w ill deal w ith flange connections. 1. Shrink Fit vs. Clearance Fit The question often arises as to w hen to use a clearance fit vs. interference fit. Also how much shrink should one use. It is very important to ensure a proper fit of a hub on its shaft.

a. Clearance Fit (With Keys and

Set Screw s) Generally, clearance fits w ith set screw s are used on shafts up to 4 inches. Torque is transmitted through the keys. Set screw s are usually provided over the key to minimize the play and resist moments and forces. All flexible couplings resist misalignment w ith reactionary moments and forces. The magnitude depends on the type and size of the coupling. These moments and forces are caused by friction in lubricated couplings and the flexing of material in nonlubricated couplings. These moments and forces can cause a loose hub to rock on its shaft. Fretting can occur w hich can cause failure of the shaft and/or the hub. Therefore, clearance fit applications should be limited to relatively small horsepow er applications w here the reactionary loads are usually low .

shaft and resist the moments and forces generated from unbalance and misalignment. If one tries (or w ants) to drive totally through the shrink fit w hen a key is used this can lead to hubs splitting over the keyw ays. If this is w hat one w ants then take the key out and then go to a heavier interference. Some standard couplings have hubs made from material that can not handle shrink fit or very little shrink For high horsepow er and high-speed applications (API 671 & ISO) keyless fits (straight and tapered) are commonly used. The shrink for keyless fits needs to be sufficient to handle the expected normal and transient loads. Interference rates range from 0.0015 in/in to 0.003 in/in. Below is a chart (see Figure I-C-1) that show s the maximum interference that generally can be used w ith various hubs w ith and w ithout keys. It is suggested you consult w ith the coupling manufacturing to find out the maximum shrink they recommend for their hubs. Figure I-C-1 Rules of Thum b - Material Hardness vs. Maxim um Am ount of Shrink (for Steel) Material Hardness (BHN) 110 160 250 160 250 300 330 Am ount of Shrink 0.0003 in/in 0.0005 in/in 0.00075 in/in 0.001 in/in 0.00175 in/in 0.0025 in/in 0.003 in/in Key

b. Shrink Fits
Shrink fits that conform to AGMA 9002 recommendations are usually sufficient to keep the hub from rocking on the shaft. For standard type couplings w ith keys the shrink should not exceed 0.00075 in/in. Caution must be exercised w hen specifying heavy shrinks for keyed hubs. Remember that on keyed hubs the purpose of the shrink is to keep the hub axially positioned on the Page I- C-1

yes yes yes no no no no

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Flexible Couplings

2.

Straight Shaft Installation a. Clearance Fits. This type of installation is relatively simple Rotate the shaft to position the keyw ay at 12 oclock. Install the key(s) in the shaft keyw ay(s). Coat the shaft and key w ith a thin layer of antiseize compound. Make sure that any part that w ill not slide over the coupling hub is placed back on the shaft, such as seals, carriers, and covers, and on gear couplings, the sleeves. Push the hub onto the shaft until the face of the hub is flush w ith the ends of the shaft. (Note: Some coupling hubs are not mounted flush. Check specific instructions.) If the hub does not slide onto the shaft, check the clearances betw een the bore and the shaft. In addition, check to insure that there is clearance betw een the keys at the sides of the coupling keyw ay and on top of the key (see section c-6). Lock the hub in position (usually w ith setscrew s). Make sure that setscrew s have a locking feature such as a Nylok Insert, or use locking compound. Some hubs use bolts, nuts, or other means to secure the hub in place. See the specific instructions.

b. Interference Fit.
This type of installation is the same as that for the straight shaft, w ith the exception that the hubs must be heated before they slide on to the shaft. The coupling manufacturer usually supplies information as to how to heat the hub and to w hat temperature (Figure I-C-2). For a steel hub, 1600F is required for every 0.001 in. of

interference per inch of hub diameter (0.001 in./in.). For example, a steel hub w ith a 4-in. bore and an interference of 0.003 inch requires a differential of 0.00075/0.001 x 1600F = 1200F. Therefore, if the shaft temperature is 800F, the hub temperature must be 2000F. This does not account for human factors such as cooling due to handling time, errors in measurements, and so on. As a general rule, add 50 to 750F to the calculated expansion temperatures to account for these factors. The hub should be heated in an oil bath or an oven; a torch or open flame should not be used. This could cause localized distortion or softening of the hub material. It could also cause an explosion in some atmospheres. Oil bath heating is usually limited to approximately 3500F, or under the flash point of the oil used. Special handling devices are required such as tongs, threaded rods placed in taped holes in the hub, etc. Oven heating and induction heaters offer some advantages over oil. Parts can be heated to higher temperatures (usually not exceeding 6000F) and the parts can be handled w ith heat-resistant gloves. Regardless of the method used, heat must be applied evenly to avoid distortion. This is especially important w hen using induction heaters. In any event, extreme care must be exercised w hen handling heated hubs to avoid Injury to personnel It is also important w hen mounting interference hubs to make sure that clearance exists over the top of keys; otherw ise, w hen the hub cools, it w ill rest on the key and produce high stresses in the hub that could cause it to fail.

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Figure I-C-2 Expansion Guide (Heat vs Bore)

c. Straight Shafts With

Interm ediate Bushings/Locking Rings. (see Figure I-C-3) Bushings come in tw o basic configurations: internal or external.

Although installation varies w ith bushing design, the net result is an interference fit betw een the hub and the shaft. Tightening axial screw s to draw up opposing tapered rings develops the required interference.

Figure I-C-3A Interm ediate Bushings

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Flexible Couplings

3.

Figure I-C-3B Interm ediate Bushings

Figure I-C-3C Locking Ring

Taper Shaft Installation. a. General Discussion Tapered shafts have the advantage that the interference betw een the hub and the shaft can be accomplished by advancing the hub on the shaft. Depending on the amount of interference, the hub may be draw n up w ith nuts or heating. Removal of the hub is usually easier on tapered shafts than on straight shafts. Note: The shallow tapers used in coupling applications are usually self-locking. This means that the friction forces resisting the hub advance are larger than the forces pushing the hub onto the shaft. Therefore, the only w ay to accomplish the required advance is to heat the hub before installation. Applications using tapered bores require more attention than those using straight shafts because it is easier to machine tw o cylindrical surfaces that match than tw o tapered surfaces. The hub can be overstressed if it is advanced too far on the shaft. Dirt and surface imperfections can restrain the hub advance and give the false impression that the desired interference has been reached. To determine the draw -up required for the desired interference, use the follow ing equation

Draw up(in.) =12 x

Where:

i T

i = diametral interference (in.)

T = taper (in/ft. on dia.)
Whenever possible, the area of contact betw een the bore, shaft and respective plug or ring gage should be checked w ith machinist bluing. A final Page I- C-4

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Flexible Couplings

check of the contact area betw een the bore of the hub and the shaft should be done to verify previous results. Recommended procedures can be found in AGMA 9002-A86, Bores and Keyw ays for Flexible Couplings and AGMA 9003-A91, Flexible Couplings-Keyless Fits. Fifty to 80% contact area is an acceptable range, although a minimum of 70% is the most desirable (this is especially true for hydraulically fitted hubs. If less than the required contact is achieved, lapping the bore can increase the contact area and/or the shaft w ith a lapping plug or ring made from a master plug and ring gage. It is not recommended that the master gages or shaft be used to lap the hub, as the gages could end up w ith ridges. Ridges in the hub or shaft w ill prevent proper hub installation and could cause the hub or shaft to fail because of stress concentrations. Taper Installation (1) Light interference (Under 0.0005 in./in.): When the interference is less than 0.0005 in./ in., the hub can usually be advanced w ithout heating. Although heating the hub is the most common method, the hub can usually be advanced by tightening the retaining nut or plate on the shaft. It is also common practice w hen light interference is used w ith a combination of keys and a retaining nut or plate to use a light grease or antisieze compound betw een the hub, shaft and threads on the shaft and nut. This should help facilitate installation and future removal and help prevent shaft and/or bore gauling. (2) Medium interference (Betw een 0.0005 and 0.0015 in./in.). When the interference is over 0.0005 in./in., the force required to advance the hub could become too large for manual assembly. When this occurs, the hub must be heat mounted or Page I- C-5

hydraulically mounted. Heating hubs for mounting is the most common method. Regardless of the method used, the amount of draw -up must be measured. (3) Heavy Interference (Above 0.0015 in./in.) When the interference is over 0.0015 in./in., hubs are usually heat mounted and removed hydraulically. Some users prefer to both mount and remove hydraulically. 4. General Installation Guidelines. The follow ing is recommended as a general guide w hen installing hubs on an equipment shaft: Install the hub on the shaft, insuring that the parts mate properly and are burr-free and clean. Using a depth gage or dial indicator (see Figure I-C4A) measure and record the initial reading. Remove the hub and lubricate the bore or shaft if hydraulic assist is to be used; if not, heat in oil or an oven. When using a heating method for mounting hubs, it is best to provide a positive stop, such as a clamp on the shaft, to insure proper draw -up (see Figure I-C-4B). The reason for this is that a hub advanced too far may not be removable (too much force required or not enough hydraulic pressure available to remove the hub) and normally requires that the hubs be cut off. Even if the hub can be removed, excessive advance may have caused the hub material to yield and the coupling manufacturer should be consulted before attempting to reuse the hub.

b.

Section I-C

Flexible Couplings

Figure I-C-4A Depth Gage

Figure I-C-4B Positive Stop

The hub is installed and advanced the required amount. Page I- C-6

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Flexible Couplings

The shaft nut is then properly tightened and locked in place. Locking is done w ith a tab w asher or setscrew .

5.

Rough and Sem i-Finished bores.

Most coupling manufacturers w ill supply couplings w ith rough or semi-finished bores. While this bore condition helps to reduce inventory requirements it is important that the user properly bore and key these couplings; otherw ise, the interface torque-transmission capabilities can be reduced or the coupling balance (or unbalance) can be upset. Verification of bore condition and recommendations for finished bore tolerances should be obtained from the specific coupling manufacturer. As a general guide, the hub must be placed in a lathe so that it is perpendicular and concentric to its controlling diameters. Rough Bore Example On rigid hubs the pilot and face are usually the controlling diameter and surface (see Figure I-C-5A). On flex hubs (gear and grid) the gear major diameter (OD) and hub face act as the controlling diameter and surface. [Note: Some manufacturers use the hub barrel as the controlling diameter (see Figure I-C-5B).] Semi-Finished Bore Example (Straight Bore) In this case, the finished bore should be machined using the semi-finished bore as the controlling diameter. Indicate the bore for concentricity and straightness.

Figure I-C-5 Setup for re-boring straight shafts

There are three types of errors that can occur w hen hubs are bored:

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Flexible Couplings

(1) The bore diameter is incorrect. Too much interference w ill cause installation problems and may damage the hub or shaft w hile too much clearance can produce unbalance forces that may be unacceptable to the system. (2) The bore is eccentric, but parallel to the hub axis. This can produce unbalance forces that may be unacceptable to the system (see Figure I-C-6).

(3) The bore is at an angle to the OD of the hub. In this case the misalignment capacity of the coupling is reduced (see Figure I-C-7).

Figure I-C-7 Skew ed Hub Bore

Figure I-C-6 Eccentric Hub Bore

6. Key-Fit. Most couplings must have one or tw o keyw ays cut in the hub. These should be cut generally per AGMA 9002-A86. Particular attention should be given to the follow ing: Page I- C-8

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Flexible Couplings

FIGURE I-V-8 Keyw ay Offset

FIGURE I-V-9 Keyw ay Parallelism

FIGURE I-V-10 Keyw ay Lead

FIGURE I-V-11 Keyw ay Width and Height

The fitting of keys is important to insure the proper capacity of the interface. Refer to the AGMA standards on keyw ays and keys. As a general rule, four fits must be checked:

1. The key should fit tightly in the shaft keyw ays. 2. The key should have a sliding fit (but not be too loose) in the hub keyw ay. 3. The key should have a clearance w ith the top of the keyw ay (see Figure I-C-12A). 4. The key should have chamfered corners.

Figure I-C-12 Fitted Keys

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Flexible Couplings

Properly Fitted Key

Im properly Fitted Keys

The key should be chamfered so that it fits w ithout riding on the keyw ay radii (see Figure I- C12B). A sloppily fitted key can cause the keys to roll or shear w hen Ioaded. The results of a sloppy key fit are show n in Figure I-C-12C. The forces generated by torque are at distance S, and this movement tends to roll the key and

assembly very difficult and increase the residual stresses, w hich could cause premature failure of the hub and/or shaft. A key in the keyw ay that is too high could cause the hub to split (see Figure I-C-12D). When there is too much clearance at the top or sides of a key, a path is provided for lubricant to squeeze out. For lubricated couplings, clearances betw een keys and keyw ays should be sealed w ith an appropriate sealant to prevent loss of lubricant and thus starvation of the coupling.

can cause very high loading at the key edges. On the other hand, too tight a fit w ill make Page I- C-11

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Flexible Couplings

7. Shrink fit effect on pilots. When a coupling hub is pressed on a shaft (shrink fitted), the bore expands to fit the larger shaft. Not only does the bore grow but so does any diameter directly over the bore. Therefore if the coupling has piloting fits that are directly over the shaft they too w ill grow . As a general guide, this grow th can be expressed as

G=

DB xi DH

Where: G - Grow th of pilot (in) DB = Bore Diameter (in) DH = Pilot OD (in) i = Amount of shrink (in) Compensation for this grow th must be accounted for. For outside rabbets they can grow so the assembly becomes difficult or impossible. Inside rabbet may loosen and cause unbalance problems. In the case of gear couplings the tooth tips may grow so they w ill no longer slide in the sleeve. This causes the coupling to be mechanically locked. Coupling manufacturers account for this in their designs but if one elects to buy rough-bored couplings and decides to put a heavy shrink the grow th of the hub tooth might be greater than allow ed by design and Lockup may occur.

Page I- C-12