Coupling Manufacturing Process

Coupling Manufacturing Process

Couplings fall under the category ofgeneral mechanical components, used to connect two shafts (drive shaft and driven shaft) in a mechanical system, transmitting torque through rotation. Inhigh-speed, heavy-duty power transmission, some couplings also providebuffering, vibration damping, and improved dynamic performance of the shaftsystem.

A coupling consists of a cold-assembled section that connects the driveand driven shafts.

In shaft-driven mechanical systems,couplings are commonly used as connecting elements. Most power machinery islinked to working machines via couplings. By the late 20th century, couplingproducts had rapidly developed both domestically and internationally. For mostdesigners, selecting the right coupling to meet machine requirements fromvarious options with different performance characteristics has always been achallenge in product design.

Common types of couplings include:

• Plum     blossom (jaw) couplings

• Diaphragm     couplings

• Oldham     (cross-slider) couplings

• Gear     couplings

• Universal     joints

• Star-shaped     elastic couplings

• Flexible     (elastomeric) couplings

Forging Process

Forging can be categorized into manualfree forging and mechanical free forging.

• Manual free forging has low     production efficiency and high labor intensity, making it suitable only     for repairs or small-scale, simple production.

• In     modern industrial production, mechanical free forging has     become the primary method, playing a crucial role in heavy machinery     manufacturing.

Material Requirements for Coupling　Forgings:

• Must     come with inspection certificates.

• Material     substitution requires buyer approval and written documentation.

• Forgings     must be produced using hydraulic presses or sufficiently powered forging     hammers.

• Adequate     forging ratios must be maintained to ensure uniform microstructure.

• The     forging axis should align with the ingot’s central axis.

• Forgings     can be made from ingots or billets; scale forging is permitted but     requires separate heat treatment.

WZL Standard Crane Drum Coupling

Post-Forging Heat Treatment

• Pre-heat treatment is     performed to refine the forging’s microstructure and improve     machinability.

Rough Machining

• Before     heat treatment, rough machining is conducted, leaving minimal machining     allowance.

Performance Heat Treatment

• Quenching and tempering are     applied to achieve required mechanical properties.

Post-Treatment Machining

• After     passing mechanical property tests, forgings are machined to dimensions and     surface roughness specified in supplier drawings.

• If any     surface exceeds rework limits, stress relief is mandatory.

Stress Relief Treatment

• Stress     relief temperature must be 30°C below final tempering temperature,     followed by slow cooling.

• If     stress relief exceeds this limit, mechanical retesting is required.