Consideration About Elastic Couplings Modeled in CATIA

URDEA Mihaela1,a, BUTNARIU Silviu2,b

1
Transilvania University of Braşov, Technological Engineering and Industrial Management,
Manufacturing Engineering Department, B-dul Eroilor nr. 29, 500036, Romania
2
Transilvania University of Braşov, Mechanical Engeneering,
Automotive and Transport Engeneering Department, B-dul Eroilor nr. 29, 500036, Romania
a
urdeam@unitbv.ro, bbutnariu@unitbv.ro

Keywords: Elastic shaft coupling, Vulkan coupling, CATIA, finite element, FEM.

Abstract. This paper refers to an elastic shaft coupling named Vulkan coupling, with its general
behavior. Vulkan shaft couplings link two shafts in diesel-engine and electric drives. They are
simple from the construction point of view, are easily mounted and dismounted. Parts and assembly
modeling, preprocessing, processing and post processing can be performed using all leading CAD
tools, like CATIA. The main goal of this work is to generate a finite element model for a Vulkan
coupling, using FEM Solid (FMD). For the demonstration, a Vulkan coupling with a torque of 350
Nm has been chosen. At the end of the modeling with finite element, it results that, for intermediate
coupling elements with mechanical material properties very different from those of steel
components, MEF analysis with rubber parts only is to be preferred. The other components can be
simulated using the virtual rigid elements.

Introduction
Couplings are machine parts; they perform the connection between two consecutive elements of
a kinematic chain. The coupling element transmits the torque between rigid coupling components
which are situated concentrically one inside the other. Their purpose is to transmit rotational
movement and torque without changing the law of movement. They have a great variety of
constructive shapes. Couplings must ensure: security; small size; easy installation and removal, to
be balanced statically and dynamically, to ensure high durability [1].
Couplings can be divided into mechanical couplings, hydraulic and electromagnetic couplings.
Mechanical couplings are classified as permanent and intermittent couplings. Permanent coupling
could be fixed or mobile coupling and these mobile can be rigid or elastic coupling.
An elastic shaft coupling named also flexible coupling has an annular disk-shaped coupling
component made in part of elastic rubber material. This coupling element transmits the torque
between rigid coupling components which are situated concentrically one inside the other. The
elastic element includes reinforcement rings embedded in the elastic rubber material in the area of
the marginal zones of the coupling element [1].

Fig. 1. Vulkan coupling

Vulkan coupling is an elastic coupling with a rubber sleeve, sectioned in order to reduce the cost
of execution. This rubber bandage are mounted in parallel, the centrifugal forces are taken over by
the upper clamping area. The torque is uniformly distributed on the two rubber bandages. This
coupling transmits torque higher than Periflex coupling to the same dimensions (Fig. 1).
Elastic couplings provide good absorption of shocks and vibrations, with a high storage capacity
of shock energy, due to the large volume of elastic element. Moment of torsion is transmitted by
friction. Flexible couplings are designed to transmit torque while permitting some radial, axial, and
angular misalignment. These couplings can accommodate angular misalignment up to a few
degrees and some parallel misalignment. Elastic couplings have however disadvantages: lower
durability, low levels of torque [1].

Vulkan coupling
This paper refers to elastic couplings especially to Vulkan couplings, with their general behavior
and with a large variety of designs. Vulkan coupling is a flexible coupling for misalignment
problems, with a rubber sleeve mounted in parallel. They are in a wide variety of shapes, sizes and
features (Fig. 2). These couplings provide the ideal solution for pleasure boats, for elastically-
mounted engines.

Fig. 2. A few Vulkan couplings shapes [3]

For finite element analysis, the Vulkan assembly modeled in CATIA is preferred (Fig. 4). CATIA
is not a specialized tool for Meshing and analysis, but CATIA has a user friendly platform for
carrying out any FEM analysis. CATIA Analysis is an integral part of CATIA. The analysis
specifications are an extension of the part and assembly design specifications, and the analysis is
performed directly on the CATIA geometry [4].
The Advanced Meshing Tools workbench for CATIA includes FEM Solid (FMD) to generate
finite element models for complex solid parts.

Fig. 4. The CAD model for Vulkan coupling

Steps for finite element analyzing using FEM – first analysis

Finite Element Analysis essentially consists of the following 3 steps: Pre-processing, Processing,
Post-processing.
 Preparing the assembly for analysis
(Pre-processing). After modeling each
CAD component model, for assembling,
geometrical constraints, axis coincident
for all components, flat contact surfaces
between all pairs of pieces were
performed. In addition to this, there were
established coincidences for all
cylindrical surfaces, were screws will be
mounted [2] (Fig. 5).
The material components, for static
analysis with finite element, are very
important. In the Library Material
Catalog, metallic material has been
Fig. 5. Vulkan coupling, with all constrains, modeled in
chosen from the group of steels (Steel) CATIA
for 6 components. Similarly rubber material for non-metallic components is assigned.
For generating the finite element model Static Analysis case is used.
Restraints (Processing). The next step is to define the rigid parts of the couplings part, the
restraints and the moments. Virtual rigid components are to be used for simulating the existence of
related parts (shafts and keys), thus: for main semi coupling - sliding pivot to the inner cylindrical
surface (hole) (Fig. 6), for driven semi coupling - sliding pivot to the inner cylindrical surface (hole)
and Clamp joint for keyway (fastening) (Fig. 7).

Fig. 6. Conductor coupling parts Fig. 7. Driven coupling parts

The basic stress consists of a torque applied to the main coupling, through the parallel keyway
assembly. One can use a virtual rigid element that simulates a key assembly activated by a torque of
350 Nm (Fig. 8).
The coupling assembly has Coincidence and Contact constrains. In the hypothesis that there isn’t
any sliding between the rubber and steel parts in contact (washer, main coupling, housing), the
constraints type Surface Contacts were converted into Fastened Connection Property elements
(Fig. 9).

Fig. 8. Virtual rigid element for keyway Fig. 9. Fastened Connection Property elements
 Meshing is an essential step in Finite Element Analysis. The final solution always depends on the
quality of the mesh used during computation. OCTREE Tetrahedron Mesh set the size of the mesh
for every component.
The mesh values represent; Size: for choosing the size of the mesh elements, Absolute sag:
Maximal gap between the mesh and the geometry and Element type: for choosing the type of
element. To begin, automatic settings of the finite elements sizing are used (Size = 13.512 mm,
Absolute sag = 2.512 mm).
Once these parameters
are defined, the coupling can
be analyzed by clicking on
the compute icon. The
Compute command
calculates the unknown
parameters. It is selected
initially Mesh only for
identifying the first error and
for viewing the mesh model.
The node and the element
numbers can be seen (Fig.
10). Fig. 10. Compute - Mesh Only
For static analysis, all results are
important, such as Deformation, Von Mises stress, Principal stress, Displacements and Precision.
After computation the following results for Von Mises stresses (Fig. 11 a) and displacements are
obtained (Fig. 11 b).

a b
Fig. 11. Von Mises stress and Displacements

Post-processing discussions. Due to the large differences between the properties of the coupling
materials component (steel and rubber), in case of analysis based on FEM, the results are less
conclusive. The deformations and the internal tensions of rubber parts can’t be observed, only the
maximum values of the half coupling in the keyway area. For this purpose it is preferred a new
model for analysis that uses only rubber sleeves, the other steel components will be replaced by
virtual rigid elements.
On the other side, it is observed that the maximum displacement is at the outer surfaces level,
corresponding to a maximum angular phase shift of approximately 33o, between the main coupling
and the driven coupling, to a maximum tension (350 Nm).
Analysis model for rubber sleeve - second analysis. In order to resolve this analysis virtual
rigid elements that simulate the other elements of the coupling have been constructed. This analysis
model can be viewed in Fig. 12.
 Various analyzes were performed,
considering the finite elements with sizes
becoming smaller and smaller. There can be
notice a convergence of the results with the
ones obtained by using the parabolic edge
tetrahedral finite element (Fig. 13).
The results show areas of maximum tension
for rubber sleeves, areas where the first flaw
appear. This may suggest modifications and
optimizations of the sleeves shape by Fig. 12. New model for rubber sleeve
thickening of maximum stress areas, so as to
reduce the risk of cracks.

Fig.13. The finite analysis for rubber sleeve

Final conclusions for FEA

For intermediate coupling element with mechanical material properties very different from those
of steel components (sleeves, bushings, rubber, plastics) is preferred MEF analysis only with rubber
parts, the other components being simulated through the virtual rigid elements.
It can be observed that the values of some analysis results are different, depending on the type
and size of the selected finite elements. Thus, for the tetrahedral finite elements with straight edges,
the results converge to a limit, simultaneously with the decreasing of the finite element, thus the
increasing of the finite elements number. In the case of selecting EF tetrahedral parabolic edges, the
results are almost unchanged once the finite elements are resized.
Regarding of the results obtained for displacements, they are equivalent in the two types of
analysis.

References
Reference to a book:
[1] I., Draghici, I., Achiriloaie, Calculul şi construcţia cuplajelor, Editura Tehnicǎ Bucureşti (1978).
[2] Gh,.L., Mogan, S., L,. Butnariu, Analiza cu elemente finite ȋn inginerie. Aplicații practice ȋn
CATIA, Transilvania University of Brașov (2007).
Other references:
[3]http://www.vulkan.com/en/vulkan_couplings/shipbuilding/pleasure_boats.htm, accessed: 20.01.
2014.
[4]http://mbi-wiki.uni-wuppertal.de/wp-content/uploads/2011/06/Grid-generation-and-analysis-
using-Catia-V5.pdf, accessed: 17.02.2014