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Coupling Failure Analysis -

Jaw Couplings (includes hub
& spider photos)

Coupling Sizing Torque -

How to Quickly Calculate
(inclusive of Service Factor)

Gear Coupling Tutorial - Part II:

Configurations

Why a Grid Coupling -

Jaw couplings are an incredibly robust and popular solution for transmitting torque between two
Features & Benefits, Design
shafts. With tens of millions of applications currently running around the world using jaw couplings, Basics, and Element
this coupling type is one of the most trusted power transmission devices on the planet... however, Options
like almost anything else, they can and do fail. When they do, whatever the application is and
whatever corner of the world you may be in, it is important to be able to quickly understand why the
coupling failed... as well as what needs to be done to ensure your application is safely up and Clearance vs Interference
running as soon as possible. Fit Couplings - Which Hub
Fit is Better?
Fortunately, not only are jaw couplings robust, cost effective,
popular, and straight forward to use… but they are also fairly straight
forward to trouble shoot if/when they fail. The reason jaw couplings
are straight forward to trouble shoot is because jaw coupling failures API 671 Coupling Standard
often leave behind a telltale “signature”. (These "signatures" are why
coupling application engineers are particularly quick to request Cutting Keyways -
photographs when trying to root cause a failure with a client.) Broaching, Keyseating,
Wire-Cut EDM, Shaping, &
This post will explore the most common jaw coupling "signature" failure modes, and hopefully help Milling
you get started in identifying and correcting any jaw coupling failures you may come across. All
failures discussed in this post will fall into one of five categories: normal wear, torque overload
failure, misalignment failure, environmental failure, or vibration failure.
How to Install an
(Note: This post does not address manufacturer quality failures, such as casting defects or poor Interference Fit Coupling
elastomer quality. It is important to remember that interchangeable products do not mean
equivalent quality, so it is important to source your couplings from a trusted industry leader.)

Should you care to learn more about jaw coupling basics before carrying on with failure modes,
please check out: Jaw Coupling Overview - Features & Benefits, Design Basics, and Element What do Lovejoy jaw
Options. coupling numerical sizes
stand for?

Normal Wear

The image at the top of the page (and at right) is actually an

example of normal even elastomeric jaw coupling spider Coupling Answers Archive
wear for a coupling that is operated in one direction only.
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The wear is even and linear, indicating that misalignment
does not appear to be an issue with this specific ▼
▼ 2014 (70)
application. ►
► December (20)
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► November (18)
When a jaw coupling runs in one direction, only every other spider leg is put under compression. (If
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the application were to run in both directions, called a reversing load, you would expect to see

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similar wear on every leg of the spider.) Jaw coupling spider materials hold the
key to solv...
While this wear pictured is to be expected, this coupling Bellows Couplings – Flexibility and
spider has worn to the point where it does need to be Accuracy for M...
replaced. As a general rule, you should replace a spider Rolled Key Example in a Coupling Hub
when at least one of the elastomeric legs have compress or
Shaft Inspection Prior to Coupling
worn down to 75% of their original thickness Installation
What is Static and Dynamic Alignment?
And how fast does it take for the coupling spider to be
compressed to 75%? Unfortunately, this cannot be Maintenance Procedures for Couplings
calculated as it is entirely application specific. The Top Reason for a Coupling Failure
environment, peak torques, selected service factor, Sizing a Coupling – Pay Attention to the
misalignment, system vibrations, starts/stops... will all play Driver!
a role in determining how long it takes for the spider to compress to 75%.
Should I rotate shaft keyways 180° apart
when inst...
Bonus Suggestion: If you are running an application in only one direction, and discover wear on
Shaft Keyway Damage
your spider similar to the one pictured above (3 legs compressed 25% or more)... if you don't have
a replacement spider readily available, you can rotate the spider one leg rotation (moving the 3 Square Bores, Hollow Shafts, and a
Sausage Stuffer!
uncompressed legs into the position the 3 compressed legs were), and continue running the
application until your replacement spider arrives. Can I Rebore Sintered Iron Coupling
Hubs?
Powdered Metal 101 for Mechanical
Overload Failure Power Transmissi...
API 671 Coupling Standard
When sizing and selecting a coupling it is always important to identify the appropriate service factor
API 610 Standard - Coupling Highlights
for the given application, and include it when calculating the coupling sizing torque. (For a great
tutorial on how to calculate coupling sizing torque, check out: Coupling Sizing Torque - How to Coupling Failure Analysis - Jaw
Couplings (include...
Quickly Calculate.)
Jaw Coupling Overview - Features &
Benefits, Desig...
Overload or over-torque occurs when the coupling is subjected to peak torque load(s) in excess of
the calculated coupling sizing torque (which, again, if you don't understand... please click the link Coupling Guards - OSHA Requirements
above). This can happen because the coupling was undersized (usually the case), or because Oversizing couplings? - Three Reasons
something terribly wrong and unexpected happened in the system. In the case of the coupling You Should R...
being undersized, it is important to not just replace the failed coupling, but to go through the Clearance vs Interference Fit Couplings -
selection process again... selecting a coupling that meets the necessary requirements of the Which Hu...
application. Five Tips to Getting 3D Coupling CAD
Models (When ...
So what does an overload failure look like? Well... when something is pushed to the point of failure, ATEX Couplings - What They Are, And
something is going to fail... and, in the case of flexible jaw couplings, the weak point is the Why They Matter
elastomeric spider or insert. Pictured below is a classic jaw coupling overload failure. When the Diaphragm vs Disc vs Gear Couplings -
overload occurs, the legs of the jaw hub will pinch/shear off the spider legs under compression. Who, What, W...
(Please jump back up to the "normal wear" section above if you don't understand why only 3 of the Active Coupling Bore and Keyway
6 spider legs would have sheared in the example below.) Standards - What A...
How to Install a Coupling

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► September (7)

Other Useful Links

Lovejoy, Inc. Website

Find a Lovejoy Coupling Distributor
Couplings.com (Coupling Installation
Videos)
Mechanical Power Transmission
Association (MPTA)
Power Transmission Distributors
Association (PTDA)
European Power Transmission Distributors
Jaw couplings are fail-safe by design (meaning they can continue to run after a failure), and this is Association (EPTDA)
because, even after the elastomeric spider legs are sheared away... the metallic hubs will interlock National Fluid Power Association (NFPA)
and continue to transmit torque. This is not a good long term condition for a system, but can be a
Fluid Power Distributors Association
useful feature during short term cases of emergency. The metallic jaw hubs will rub and wear away (FPDA)
on each other (without lubrication), so quickly identifying the root cause of the failure (which may Hydraulic Institute
be an undersized coupling) and replacing the element and/or coupling is important.

While straight jaw spider overload failures generally take the form of complete shear (pictured
above and below left), curved jaw couplings can show spider overload failures either in complete
leg shear off (like straight jaw) or in "squared off" spider legs (pictured below right).

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Though fail-safe by design, when jaw couplings are hit with a large enough over-torque, jaw
coupling hubs can and do fail catastrophically. (This would a good time to remind you that OSHA
requires coupling guards for all flexible coupling applications. Please be safe.)
When a jaw coupling hub fails catastrophically, it will typically fail
either by shearing at the jaw legs (pictured at right), or by crack
open between the inside bore and outside diameter of the hub
(generally along the keyway, as pictured below). Coupling hubs
generally cracking along the keyway because there is less metal
between the keyway and the outside diameter of the hub than at
any other spot of the inner bore. The keyway is the weak link,
and, specifically, the corners of the keyway are the weakest link
inside the keyway. This failure mode is common to a large
number of coupling types, and generally referred to as a
"keyway burst".

The two pictures above represent a classic "keyway burst". The burst occurred at the corner of the
keyway, with the crack then being mirrored 180 degrees from that keyway corner on the other side
of the hub. (The picture at left also highlights that the crack split through the setscrew hole. With
clearance fit bores, a set screw hole generally needs to be inserted over the keyway, making the
keyway just that much more of a weak link.)

Misalignment Failure

Second only to transmitting torque, flexible couplings are designed to accommodate for system
misalignment. Couplings are designed and rated to handle a certain amount of angular, parallel,
and axial misalignment... but users do not always stay within these published ratings. The tell tail
sign that misalignment is causing premature jaw coupling is that the jaw coupling spider is wearing
unevenly... either at an angle or not across the full face of the spider legs. Spider "dust" may also
be present in coupling or coupling guard.

The spider legs under compression (shown at right) look like pizza wedges. This is a classic
misalignment issue, so replacing the coupling alone will not address the underlying misalignment
that is present in the application. The two shafts connected to the coupling must be either realigned
(preferable), or a different coupling that can handle the misalignment needs to be selected.

(Note: Misalignment is very hard on a power transmission system, including on the system's
bearings, and can lead to premature system failure. It should be minimized whenever possible...

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irrespective of if the coupling can
handle it or not. A future post will cover
shaft alignment in depth, but using a
dial indicator kit is a cost effective
approach for aligning couplings...
especially when they come paired with
a free calculation app. Laser alignment
systems can be even more precise,
but are generally much more
expensive.)

Environmental Failure

The two primary environmental issues

that cause jaw coupling failure are
temperature related (above or below
the rated temperature of the
elastomer), or chemical related (where
the elastomer is not compatible with a
chemical present in and around the
coupling).

On temperature... pushing an
elastomer outside its rated
temperature range, can and will lead to
premature spider failure. While these
failures can look similar to an over-
torque, if caught early enough, they
can also be identified by cracks in the
elastomeric spider's legs. (Hint: If no
suitable spider can be found to handle
the temperature of the system,
consider looking into all metallic
couplings... which are broadly
summarized in this article: Flexible
Coupling Basics - A Quick Primer).

On chemical failures... if an
elastomeric spider is in contact with
chemicals that it is not compatible with,
the spider will generally rapidly
deteriorate and fail, sometimes
breaking off in pieces. Coupling
manufacturers will generally include
compatibility guidelines in their
catalogs for each elastomer material
relative to traditional chemicals that a
coupling may come in contact with.

If you know you coupling is going to

be in regular contact with a fluid, it is
important that you check the
manufacturers catalog to ensure
compatibility and/or call the
manufacturer to confirm if their catalog
does not include such information.

Ensuring temperature and chemical

compatibility are two of the top ten
factors for selecting a coupling, and
should never be minimized or ignore.

Vibration Failure

Vibration failures are one of the easiest to identify, but can be a bit challenging to overcome. As
seen in the photos at right, in this failure mode, the spider legs heat up and melt from the inside
out... extruding or "oozing out" elastomeric material once the outside of the elastomer is finally
compromised.

What causes this failure is a heat buildup in the spider caused by the spiders attempt to absorb
damaging high natural frequencies in a system, generally caused by a reciprocating engine (diesel,
gas, natural gas, liquid propane), pump, or compressor. These system natural frequencies can

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wreak havoc on a system (and coupling spiders), and there
is actually an entire class of couplings (known as torsional
couplings) designed specifically to tune a system above or
below the system's natural frequency.

Torsional couplings are generally much more expensive

than jaw couplings. Because it is possible that a jaw
coupling can (by the use of its elastomeric element) play
the role of a torsional coupling (tuning the system above or
below its natural frequency)... many users will try to insert a
jaw coupling in the place of a true torsional coupling.

Unfortunately, if/when the jaw coupling is not able to

effectively tune the system above or below its natural
frequency, the elastomeric element will overheat (failing to
dissipate all the heat being created as it attempts to
absorbing/dampening the natural frequency vibrations)...
leading to the elastomeric spider oozing.

When this type of torsional failure is seen the "right

response" is to contact your coupling manufacturer and
request a torsional analysis for your application. The
manufacturer will ask you for a number of pieces of
information on your system, run some calculations, and
offer you a specific torsional coupling designed specifically
to tune your system out of harm's way. This solution will
almost certainly cost significantly more than the jaw
coupling it replaced.
The "alternative response" (which may or may not work,
and could take a considerable amount of time) is to start
buying and trying different jaw coupling variations, hoping
for the best. With a bit of luck, the changes will lead to the
system being tuned away from the systems natural
frequencies. (Changes that may work include changing the
hardness of the spider, going harder or softer, or changing
the size of the coupling, up or down, of course taking care
not to undersize or significantly oversize the coupling.)

Ultimately, using a jaw coupling as a "poor man's torsional

coupling" is an inexact science that could prove to be a cost
savings if you are patient and can afford the time. Jaw
coupling really are not ideally suited to serve this function,
but they can work. Oozing indicates "it not working", so you
need to try something different. Just replacing the spider
with a like spider will not fix a torsional vibration problem.

Still Have Questions?

If this article did not help you better understand a jaw coupling failure and you still have questions,
please give us a call or send us an email (with photos) so we can help you trouble shoot further.

Alternatively, if this article was helpful for... we'd love to know that as well, so please leave us a
note at the bottom of the page.

And if you liked this article, but you'd like to get a "second opinion" from another source... we
recommend you check out the Mechanical Power Transmission Association's Common Causes of
Jaw Coupling Failure publication. (Note: We are an active part of this association, and did play a
significant role in drafting the document. You will find its advice to be largely similar to this post,
though certainly presented in a much more formal manner.)

For a deeper dive into jaw couplings, we recommend reading: Jaw Coupling Overview -
Features & Benefits, Design Basics, and Element Options.

For further information on coupling failures, we also recommend reading:

Gear Coupling Tutorial - Part V: Failure Analysis (with photos)
Grid Coupling Failure Analysis (includes photos)
Coupling Peak Torque Failure at Keyway
Top Reason for a Coupling Failure

Posted by Elliot Wilson at 8:12 AM

Labels: broke coupling, coupling failure, cracked coupling, damaged coupling, destroyed coupling, jaw coupling, jaw
coupling failure, jaw failure, lovejoy failure, spider failure

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6 comments:

Unknown October 14, 2014 at 3:25 AM

Sound advice indeed. jbj Techniques have a useful chart to help in these circumstances
http://www.jbj.co.uk/couplingelementchart.html
Reply

Elliot Wilson October 15, 2014 at 12:35 AM

Thanks for the props James, and best regards to you and the rest of your jbj Techniques team (a
very knowledgeable Lovejoy distributor) across the pond in the UK.

Reply

James October 24, 2015 at 11:18 AM

Why would love joy on a log splitter get VERY hit. Any help ??

Reply

Replies

Elliot Wilson October 26, 2015 at 12:37 PM

James, assuming the heat is coming from the coupling (and not an external source)...
shaft misalignment would be the culprit. When subject to misalignment, the elastomeric
flexing "spider" is designed to accommodate it (to its catalog ratings), but, in doing so,
absorbs energy which is then transferred into heat. By minimizing shaft misalignment,
you will minimize the amount of heat generated in the coupling... allow your system to
run more efficiently... and likely get more life out of your elastomeric flexing "spider"
element.

Unknown November 25, 2015 at 10:00 AM

This site is great! This article is very helpful. Thank You.

This article mentions that a future post will cover shaft alignment in depth. Did that
happen? Have you ever obtained vibration data to support determining life of a spider
when there is some amount of misalignment, i.e. "if vertical ips p/k is above 0.1 ips,
your life is estimated at....?". Mignt not be possible but there might be enough data to
try. On the flip side, you can always take more data than you have answers for! haha.
Thanks again.

Elliot Wilson November 25, 2015 at 8:31 PM

Hi CJames K, and thanks for the feedback! Given your level of understanding on the
topic... we have not taken what you would consider a deep dive into shaft alignment...
though we have hit on the topic in 3 or 4 lighter posts like the following one comparing
dial and laser alignment (http://www.couplinganswers.com/2014/12/shaft-laser-
alignment-3-benefits-over.html). Regarding testing, we actually do quite a bit of testing
in our test lab to simulate all types of environments... but spider life (or any coupling
life) is notoriously difficult to predict because (as I'm sure you know) so many
environmental factors (which generally are not static) come into play. If you are a
reliability guy... we certainly advocate laser or dial indicator alignment
(http://www.couplinganswers.com/2014/10/top-reason-for-coupling-failure.html), and if
you are an OEM or end user and would like further follow up with one of our
application engineers, please don't hesitate to holler (http://www.lovejoy-
inc.com/support/).

Reply

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