SWC315 cardan shafts with couplings

SWC315 cardan shafts with couplings,www.timothyholding.com

Product Details SWC315 cardan shafts with couplings Material:35CrMo and 20CrMnTi Largely used in rolling mills,Pipe straighteners,Steel mill,tube mill,Continuous casting machinery,Paper machines ,Piercing mills,Bridge cranes,Steckel mill,Punchers,Roller conveyor, Rotating furnace,Mining machinery and other heavy duty machinery . SWC315 cardan shafts with couplings,www.timothyholding.com SWC315 cardan shafts with couplings,www.timothyholding.com Contact Name:August Mobile Phone:+86-13758897904 E :august@timothyholding.com Web：www.timothyholding.com Address：55# Jinshi Road ,Lecheng Industrial Park,Yueqing City,Zhejiang provice,China

 

Material Requirements and Specifications for Gear Couplings

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Material Requirements and Specifications for Gear Couplings

The internal structure of gear couplings is complex, requiring specific materials to meet the torque and rotational speed demands. Commonly used materials include 42CrMo and Grade 45 forged steel. These materials are selected for their wear resistance: higher material hardness improves wear resistance, enhances torque capacity, and extends the service life of the coupling.

42CrMo Steel used in gear couplings is an ultra-high-strength steel characterized by:

· High strength and toughness,

· Good harden-ability with minimal deformation during quenching,

· Absence of noticeable temper brittleness,

· High fatigue resistance and multi-impact resistance after quenching and tempering treatment,

· Excellent low-temperature impact toughness,

· Superior creep strength and enduring high-temperature performance.

For heat treatment, surface hardening after quenching and tempering is typically applied to optimize its mechanical properties.

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Causes of Drum Gear Coupling Failures

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Drum Gear Coupling , www.timothyholding.com

Causes of Drum Gear Coupling Failures

1. System Design & Integration Issues

· Unbalanced Shaft System Compatibility:
Components in the drive train (e.g., diesel engines, gearboxes, shafts, and highly elastic couplings) must be mutually complementary in design and application. Sub-optimal integration or low manufacturing precision in any component may compromise the entire system.

o Example: In marine applications, improper alignment between the main engine and propulsion system accelerates coupling wear.

2. Mechanical Overload & Misalignment

· Damper Subsidence in Prime Movers:
Subsidence of the main engine's vibration damper induces shaft misalignment, generating additional torsional loads.

o Consequence: Excessive heat buildup in highly elastic couplings leads to thermal stress fractures.

· Insufficient Compensation Capacity:
Despite their angular displacement tolerance, drum gear couplings may fail under unanticipated combined loads (e.g., simultaneous axial, radial, and angular stresses).

3. Operational & Maintenance Factors

· Improper Usage:

o Overloading beyond rated torque.

o Frequent starts/stops or reverse operations in non-design conditions.

· Environmental Neglect:

o Contamination (dust, moisture) entering unsealed lubrication cavities.

o Failure to replace degraded lubricant, accelerating tooth surface wear.

4. Industry-Specific Challenges

· Broad Application Scope:
Widely used in heavy industries (metallurgy, mining, etc.), couplings face diverse operational stresses.

o Risk: Misapplication in high-speed or ultra-precision scenarios beyond their design limits.

Key Takeaway:
Drum gear coupling failures often stem from systematic design flaws, mechanical over-stress, or operational oversights. Regular alignment checks, load monitoring, and adherence to lubrication protocols are critical for longevity.

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Application Scope of GICL & GIICL Series Drum Gear Couplings

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Application Scope of GICL & GIICL Series Drum Gear Couplings

1. Overview

Drum gear couplings (rigid flexible couplings) consist of internal gear rings and flanged half-couplings with external teeth, both sharing identical tooth counts. The external teeth are categorized as straight teeth or drum-shaped teeth. Compared to straight-tooth designs, drum-shaped teeth enable:

•Larger angular displacement tolerance

•Improved tooth contact conditions

•Enhanced torque transmission capacity

•Extended service life

2. Technical Features of GICL/GIICL Series

•Optimized for low-speed, heavy-load conditions

•Robust construction with high misalignment compensation (axial, radial, angular)

•Sealed lubrication system to minimize wear and ensure stable performance

3. Key Applications

GICL/GIICL series couplings are widely used in industries requiring reliable heavy-duty power transmission, including:

•Metallurgy: Rolling mills, blast furnace equipment

•Mining: Crushers, conveyors, hoisting systems

•Material Handling: Cranes, winches, heavy-duty transporters

•Petrochemical: Pumps, compressors, agitators

•General Machinery: High-torque drives in manufacturing and processing systems

4. Industry Advantages

•Durability: Designed to withstand harsh environments (shock loads, vibrations, temperature variations).

•Versatility: Suitable for both horizontal and vertical shaft configurations.

•Maintenance Efficiency: Modular design simplifies inspection and replacement.

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The processing steps for drum gear couplings

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 drum gear couplings,www.timothyholding.com

What are the processing steps for drum gear couplings ?
Drum gear couplings are generally processed through turning and milling operations (CNC milling ensures higher precision). Keyways can be machined via wire cutting or broaching.

Processing Methods:
Typical manufacturing steps include turning, milling, gear hobbing, and gear shaping. The tooth surfaces undergo high-frequency quenching. For higher performance requirements, die forging is used to shape the coupling before machining. Some couplings are formed using cast steel or cast iron, followed by machining.

drum gear couplings,www.timothyholding.com

Technical Overview:
Drum gear couplings fall under the category of flexible-rigid couplings. They consist of internal gear rings and flanged half-couplings with external teeth. The external teeth are either straight or drum-shaped. Compared to straight-tooth couplings, drum-shaped teeth allow for greater angular displacement, improve tooth contact conditions, enhance torque transmission capacity, and extend service life.

Key Advantages:

1. High Load Capacity: The carburizing and quenching treatment of the drum-shaped tooth surfaces significantly increases load-bearing capacity.

2. Reduced Wear: When forced oil lubrication is applied, tooth surface wear decreases dramatically (to approximately 10% of that with grease lubrication). Circulating oil also dissipates heat generated by rolling mills and gear friction, preventing degradation of the material’s allowable contact stress.

3. Durability: Under normal conditions, tooth breakage is avoided, meeting the demands of continuous rolling mill operations.

4. Axial Flexibility: The design accommodates axial displacement during rolling mill operation, enabling easy expansion and contraction.

5. Operational Benefits: Safe, clean, and efficient performance.

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Coupling Functions in Transmission Systems

 Coupling Functions in Transmission Systems

1. Shaft Connection &     Torque Transmission

• Flexible couplings with elastic elements compensate for axial,      radial, and angular misalignment.

2. Overload Protection

• Types: Pin-type, friction, magnetic particle, centrifugal,      hydraulic.

3. Vibration Damping

• Compensates for misalignment caused by machining errors,      load-induced deformation, and thermal effects.

High-Speed Grinding Applications　

• Stiffness and power in     grinding systems are critical for high-speed operations.

• High-speed spindle units are     key components in grinding machines.

• Grinding     wheels require high strength and optimal abrasive performance.

• Cooling systems are     essential for high-speed grinding efficiency.

  

  drum gear coupling ,https://www.timothyholding.com

Key Takeaways

• Couplings     are vital for misalignment compensation and vibration     reduction.

• Material     selection, forging precision, and heat treatment directly impact     performance.

• Sealing     technology ensures longevity in harsh environments.

• High-speed     applications demand rigid yet flexible coupling solutions.

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Application and Considerations for Couplings in Rolling Mills

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Application and Considerations for Couplings in Rolling Mills

1. Application of Couplings in Rolling　Mills

Couplings are critical transmissioncomponents in rolling mills, connecting the motor, reducer, and work rolls totransmit torque and accommodate misalignment. The most commonly used typesinclude:

• Gear Couplings: Widely     adopted due to their high torque capacity (standardized for <1000 kN·m     in China) and ability to handle slight angular/radial deviations.

• Elastic Sleeve Pin Couplings: Used in some mills for their compact size and heavy-load     capability, suitable for low-speed, high-torque applications. However,     they are being phased out and should be avoided in new designs.

  

2. Key Considerations

• Axial Load Resistance: Gear     couplings in rolling mills often endure heavy axial loads, which may shear     the sealing end cover screws, damage seals (causing oil leaks), and     accelerate gear wear. Solution: Increase screw diameter in     heavy-duty designs.

• Precision & Balancing: For high-speed applications (e.g., roll shafts), couplings must be     dynamically balanced to minimize vibration.

• Obsolescence Risk: Avoid     outdated designs like elastic sleeve pin couplings unless necessary for     legacy systems.

3. System Integration

Rolling mills consist of a prime mover(motor), transmission (couplings, gearboxes), and actuators (rolls). Propercoupling selection ensures efficient power transfer, reduces downtime, andextends equipment life.

Note: Regular maintenance (e.g., lubrication, sealinspection) is essential to prevent failures in harsh rolling mill conditions.

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Translation Rationale:

• Structure: Organized     into clear sections for technical readability.

• Terminology: Uses     industry-standard terms (e.g., "dynamic balancing,"     "angular/radial deviations").

• Conciseness: Combines     related ideas (e.g., axial load effects + solutions) for efficiency.

• Warnings: Explicitly     flags phased-out components to align with the original text’s intent.

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Drum Gear Coupling Models, Standards, and Performance Overview

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Drum Gear Coupling Models, Standards, and Performance Overview

1. GICL Series (JB/T8854.3-2001)

· Model: GICL

o Application: Connects two horizontally aligned shafts with angular misalignment compensation.

o Rated Torque: 0.8–3,200 kN·m

o Operating Temp.: -20°C to +80°C

· Model: GICLZ (Extended Shaft Version)

o Application: Same as GICL but for longer shaft distances.

o Rated Torque: 0.8–3,200 kN·m

o Operating Temp.: -20°C to +80°C

2. GIICL Series (JB/T8854.2-2001)

· Model: GIICL

o Application: Horizontal shaft connection with angular and radial displacement compensation.

o Rated Torque: 0.4–4,500 kN·m

o Operating Temp.: -20°C to +80°C

· Model: GIICLZ (Extended Shaft Version)

o Application: Long-distance shaft connections with misalignment tolerance.

o Rated Torque: 0.4–4,500 kN·m

o Operating Temp.: -20°C to +80°C

3. GCLD Series (JB/T8854.1-2001)

· Model: GCLD

o Application: Connects motors to machinery with angular misalignment compensation.

o Rated Torque: 1.12–50 kN·m

o Operating Temp.: -20°C to +80°C

4. NGCL Series (JB/ZQ4644-97)

· Model: NGCL (Brake Wheel Type)

o Application: Horizontal shaft connection with integrated braking system.

o Rated Torque: 355–100,000 N·m

5. TGL Series (JB/T5514-91)

· Model: TGL

o Application: General-purpose shaft connection with elastic displacement compensation.

o Rated Torque: 10–2,500 N·m

o Operating Temp.: -20°C to +80°C

6. WG Series (JB/ZQ4186-97)

· Model: WG

o Application: Heavy-duty horizontal shaft connections with angular misalignment compensation.

o Rated Torque: 710–1,250,000 N·m

o Operating Temp.: -20°C to +80°C

7. WGC Series (JB/T7002-93)

· Model: WGC

o Application: Vertical shaft connections.

o Rated Torque: 0.71–160 kN·m

8. WGT Series (JB/T7004-93)

· Model: WGT (With Intermediate Shaft)

o Application: Long-distance horizontal shaft connections.

o Rated Torque: 0.71–1,250 kN·m

9. WGP Series (JB/T7001-93)

· Model: WGP (With Brake Disc)

o Application: Horizontal shaft connections with brake disc (diameter: 315–1,000 mm).

o Rated Torque: 0.71–160 kN·m

Summary Table

Model	Standard	Torque Range	Key Feature	Temp. Range
GICL	JB/T8854.3-2001	0.8–3,200 kN·m	Basic horizontal shaft coupling	-20°C to +80°C
GICLZ	JB/T8854.3-2001	0.8–3,200 kN·m	Extended shaft version	-20°C to +80°C
GIICL	JB/T8854.2-2001	0.4–4,500 kN·m	High torque, angular compensation	-20°C to +80°C
GCLD	JB/T8854.1-2001	1.12–50 kN·m	Motor-machinery connection	-20°C to +80°C
NGCL	JB/ZQ4644-97	355–100,000 N·m	Brake wheel integrated	-
WG	JB/ZQ4186-97	710–1,250,000 N·m	Heavy-duty industrial use	-20°C to +80°C
WGC	JB/T7002-93	0.71–160 kN·m	Vertical shaft connection	-

Selection Guidelines

· For high torque & heavy loads: GIICL or WG series.

· For motor connections: GCLD series.

· For braking systems: NGCL or WGP series.

· For vertical shafts: WGC series.

Proper selection based on torque, alignment, and environmental conditions ensures optimal performance and longevity. Always refer to manufacturer specifications for detailed installation and maintenance requirements.

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