, Print ,

Fig. 1. A typical gear-tooth-style steel coupling

Clearance And InterIerence Coupling Fits
Written bv Tom Bishop, P.E., Electrical Apparatus Service Association (EASA)
Wednesdav, 12 Mav 2010 10.31
Check out these tips on when to use and how to determine tolerances with your coupling arrangements.
Couplings Ior connecting shaIts (shown in Fig. 1) can be placed in two categories: keyed
and keyless. Similarly, the Iits oI couplings to shaIts can be categorized as clearance or
interIerence. A keyless coupling arrangement will always have an interIerence Iit, while a
keyed arrangement may have either a clearance or an interIerence Iit. This article will
Iocus on determining when to use a clearance or an interIerence Iit, and how to obtain the
tolerances Ior the resulting Iit. Since we are dealing with existing shaIts and couplings, the
category oI keyed or keyless has already been established and will not be considered.
Clearance versus interference fits
The lower the power rating (actually the lower the transmitted torque), the greater the
probability oI using a clearance Iit between coupling and shaIt. Conversely, higher power
and torque usually requires an interIerence Iit. Further, as the power and torque
requirements become very high, it is more common to Iind that keyless Iits are required.
Note that the terms "lower," "higher" and "very high" are all relative, with no guideline
levels associated with them.
The questions that oIten arise are on when to use a clearance Iit versus an interIerence Iit,
and what tolerance range to use Ior the applicable clearance or interIerence. We'll proceed
Irom applications where a clearance Iit can be used, to those requiring progressively
greater interIerence Iits. A general rule oI thumb: There's little risk with having more interIerence than necessary, while there's more risk in
having less.
Clearance fit (keys and setscrews)
Keyed clearance Iit couplings are most Irequently used on lower-power applications with shaIts under about 2.5 in (about 65 mm). A visual
indicator that the Iit is clearance rather than interIerence is that set screws are usually provided over the key when a clearance Iit is used (see
Fig. 2). The set-screw location "A" oI Fig. 2 is more common, but some manuIacturers use location "B." Be sure to remove set screws beIore
trying to remove a coupling. Table I reIlects clearance Iits used Ior NEMA-Irame-size motor shaIts.
The design principle oI the clearance Iit is that the torque is transmitted through the key, minimizing any sliding oI the coupling on the shaIt.
Whether a clearance Iit is acceptable depends on the torque to be transmitted, the coeIIicient oI Iriction used, the dimensions oI the hub and
operating speed. II the torque Iorces or misalignment are excessive, the coupling hub may rock and become loose, leading to Iretting. Evidence
oI this condition will be a Iine rust-colored powder at the ends oI the coupling Iits, oIten with visible wear to one side oI the key and/or
keyway.
+f10f2012 Clearance And !nterference Coupling .
mt-online.comf.f1505-clearance-and. 1f+
Interference fit (keys)
Keyed interIerence Iit couplings are commonly used Ior applications up to a Iew thousand horsepower/kW, and speeds up to or slightly above
10,000 rpm. The interIerence Iit standard Ior most couplings made oI medium-carbon steel are 0.00050-0.00075 in/in (mm/mm) interIerence up
to 1800 rpm and 0.00075-0.00100 in/in (mm/mm) over 1800 rpm. Table II reIlects interIerence Iits used Ior NEMA-Irame-size motor shaIts.
The purpose oI the interIerence Iit with a keyed shaIt is to axially locate the coupling hub and resist Iorces associated with unbalance and
misalignment. A Irequently used reIerence Ior keyed-coupling interIerence Iits is ANSI/AGMA 9002-B04.
Interference fit (keyless)
For high-horsepower/kW and high-speed applications, ANSI/AGMA 9003-B08 or equivalent Iits (straight and tapered) are commonly used.
The interIerence Ior keyless Iits needs to be adequate to withstand expected normal and transient loads. Common keyless interIerence Iits range
Irom 0.0015 in/in (mm/mm) to 0.0020 in/in (mm/mm). The Brinell hardness oI the hub material is a signiIicant Iactor in keyless coupling Iit.
Typical Iits Ior various Brinell hardness (BH) steels are: 0.00175 in/in (mm/mm) Ior 250 BH, 0.0025 in/in (mm/mm) Ior 300 BH and 0.0030
in/in (mm/mm) Ior 330 BH.
+f10f2012 Clearance And !nterference Coupling .
mt-online.comf.f1505-clearance-and. 2f+
Coupling bore and key
The key is a critical element in successIul transmission oI torque. The bore and keyway in a coupling hub should be checked beIore installation.
Bores should have surIace Iinishes oI 63 to 125 microinches (1.6 to 3.2 micrometers) and must not be eccentric or skewed. II a bore is machined
eccentric to the hub axis, the coupling eccentricity may cause vibration. A coupling bore machined askew to the centerline axis will increase the
misalignment Ior which the coupling, shaIt and bearings must compensate. The keyway should be cut square and centered to the shaIt.
The Iit oI the key is critical in assuring suIIicient capacity oI the shaIt-to-coupling hub interIace. Be sure to check that the key Iits tightly in
the shaIt keyway; that the key has a sliding Iit (but not be too loose) in the coupling hub keyway; and that the key has a clearance oI 0.003 to
0.020 in (0.08 to 0.51 mm) with the hub keyway at the top oI the key.
The key should have chamIered corners so that it Iits in the keyway without riding on the keyway radii. A loosely Iitted key can roll or shear
when heavily loaded and provide a path Irom which coupling lubricant can leak. Conversely, too tight a Iit will make assembly diIIicult and
increase residual stresses, possibly resulting in premature Iailure oI the coupling hub and/or shaIt. A key that is too high in the keyway also
could cause the coupling hub to Iracture.
Coupling heating
Steel coupling hubs require an increase oI 160 F degrees (90 C) Ior every mil (0.001 in or 0.025 mm) oI interIerence divided by the hub inside
diameter. For example, a steel hub with a 2.125 in-bore with an interIerence oI 0.0015 in will require an increase oI 1.5/2.125 x 160 113 F
degrees (63 C). Thus, iI the shaIt temperature is 70 F (21 C), the hub temperature must be at least 183 F (84 C). This does not account Ior
potential cooling due to handling time, so as a general rule add about 60 F degrees (33 C) to the calculated expansion temperature to account Ior
these Iactors. In this example the target temperature would be 243 F (117 C). II the calculated target temperature exceeds 350 F (177 C), check
with the coupling manuIacturer to be certain the required temperature will not aIIect the coupling hub integrity.
The hub should be heated on an induction-type bearing heater or in an oven; a torch should not be used. Use oI a torch or open Ilame could
cause distortion or a reduction in hardness and strength oI the hub material. BeIore installing the coupling hub, make certain that the inboard
and outboard ends have been identiIied. Removal and reinstallation oI an incorrectly installed coupling hub will be diIIicult or impossible at the
installation location. Also, make certain that the grease seals are in place and not damaged beIore installing the coupling covers.
Dynamic balance
Don't simply assume that a new coupling is dynamically balanced. Not all couplings are pre-balanced by the manuIacturerand some are not
designed to be balanced. Check with the coupling manuIacturer or supplier to determine iI a new coupling has been Iactory balanced. A good
practice is to measure vibration levels aIter replacing a coupling (whether or not it has been balanced) to conIirm that the levels are within
acceptable limits. The length oI the key will aIIect the balance. To determine the correct key length, add the length oI the shaIt keyway to the
length oI the coupling-hub keyway and divide by two.
Lubrication
The grease used Ior couplings is not the same as that used in electric motors. Be sure to use a coupling grease equivalent to that speciIied by the
coupling manuIacturer. Lubricant should be replenished when the motor alignment is periodically checked, and the customer should typically
replenish the coupling grease on an annual basis. MT
Tom Bishop is a technical support specialist Ior EASA, headquartered in St. Louis, MO. Telephone: (314) 993-2220.
+f10f2012 Clearance And !nterference Coupling .
mt-online.comf.f1505-clearance-and. 3f+
For more info, enter 01 at www.MT-freeinfo.com
+f10f2012 Clearance And !nterference Coupling .
mt-online.comf.f1505-clearance-and. +f+