German GUDEL coupling GUDEL model GUDEL price

GUDEL couplings utilize their mechanical design to enable continuous rotation of two shafts that are not on the same axis and have an angular misalignment, while reliably transmitting torque and motion. The most significant feature of universal couplings is their large angular compensation capability, compact structure, and high transmission efficiency. The angle between the two shaft axes varies depending on the structural type of the universal coupling, generally ranging from 5° to 45°.

GUDEL Coupling Introduction

It consists of two hubs and a thin-walled metal tube, connected by welding or bonding. Although many other materials are available, stainless steel and nickel are the most commonly used materials for the metal tube. Nickel tubes are produced using electroforming. This process begins by machining a solid mandrel into a corrugated shape, electroplating nickel onto the mandrel, and then chemically dissolving the mandrel to obtain a nickel bellows. This method allows for precise control of the bellows wall thickness and can produce thinner walls than other manufacturing methods. These thin-walled bellows give the coupling high sensitivity and rapid response, making it ideal for applications in extremely small and precision instruments.

GUDEL Coupling Features and Applications

1) Bellows couplings are backlash-free and highly sensitive. 2) High elasticity provides better equipment protection. 3) Capable of absorbing vibration and compensating for radial, angular, and axial misalignments. 4) Resistant to oil contamination and corrosion. 5) Torsionally rigid, with identical rotational characteristics in both clockwise and counter-clockwise directions. 6) Commonly used in industrial machinery such as CNC machine tools and indexing tables. The elastic element of a bellows coupling is a precision metal bellows, available in flexible and rigid series. The flexible series offers greater elasticity and is often used in micro-applications such as encoders and sensors, while the rigid series is primarily applied in servo motors and CNC machine tools (machining centers).

GUDEL Coupling Troubleshooting

Based on the coupling structure, power is transmitted from the coupling to the power output shaft (gearbox shaft) via a clamping hub assembly, and to the power input shaft via a clamp collar. Power is transmitted between the clamp end and the clamping hub end through the bellows, which are bonded to the clamping hub and clamp collar. The failure occurs at the interface between the clamp collar and the bellows. Two pre-deformation slots are machined radially into the clamp collar. The slot width is approximately 2mm. The slot on the side with the clamping screw is a through-slot in the diametrical direction but does not penetrate through to the bellows connection in the depth direction, featuring a beveled cross-section. The other slot does not extend through radially, but its longitudinal section also does not penetrate to the bellows connection, featuring a beveled cross-section. During clamping, the clamping screws are tightened to the specified torque using a torque wrench. The deformation of the clamp collar eliminates the clearance between the bore and the shaft to achieve clamping. As shown in the cross-sectional view, the presence of the two pre-deformation slots creates a weaker section, with deformation occurring primarily at these slots. The cross-sectional area is smallest at the pre-deformation slot on the side with the clamping screw, making it the weakest point. Permanent V-shaped deformation marks at the end indicate high stress in this area during clamping, exceeding the yield limit of the super-hard aluminum. According to the stress distribution diagram, once the bevel gear box and main gearbox are assembled and clamped, the stress value at the bonded interface of the pre-deformation slot on the clamping screw side is 164Mpa, with a deformation magnitude of 0.027mm. During launcher operation, the coupling is subjected to alternating composite stresses, causing even greater stress and deformation at this location. If minor defects such as voids, inclusions, or flaws exist at the bonded interface during manufacturing, micro-cracks will initiate at the defect sites within the highest stress region when the alternating stress exceeds the bond strength, forming fatigue sources. Due to stress concentration at the crack tips, the cracks gradually propagate with increasing stress cycles and prolonged exposure to constant stress. As the cracks spread, the bonded interface is progressively weakened. When the cracks reach a certain size, fatigue failure occurs. The coupling may function normally during initial testing, but as usage time increases, the cracks gradually propagate, leading to failure even under low loads. The presence of stress at the bonded joint is a potential hidden cause of failure. To avoid generating excessive stress when the coupling clamp collar is tightened, annular grooves are typically machined into the clamp collar for stress relief.

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