GENERAL INFORMATION Locking is the rigid coupling of two or more elements which, in the absence of a coupling device, would otherwise be free to rotat

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1 data sheets available upon request

2 GENERAL INFORMATION Locking is the rigid coupling of two or more elements which, in the absence of a coupling device, would otherwise be free to rotate or effect an axial movement. Statistically locking is typical of the connection between a shaft with a cylindrical section and hubs of various shapes and types, like for example a gear wheels, pulleys, cams and various levers. Locking is therefore used in a whole series of kinematic chains that have been designed for the transmission of mechanical power. Numerous locking methods are available, each more sophisticated than the last as the power transmitted using the couplings increased as the accuracy of the tools used to produce them improved. The systems in most widespread use today are without doubt those based on the use of keys, tabs and pins, due of their design and construction simplicity. For specific requirements use is also made of systems based on splined profiles, tapered shafts and hubs and other various combinations. Notwithstanding the advance of technology, the system that still remains unsurpassed is that known as shrinking on, as it unites the precision of the transmission of motion with the high power that can be transmitted by a friction coupling. Despite this their use is not very widespread as it is still today the system that is most difficult to manufacture as particular care must be taken in the design and production stages. MAV Locking Devices are the result of a study of the advantages offered by this system which retains the high quality of the coupling, facilitates the design stage and contributes to the lowering of manufacturing costs due to the vast range of types and standard sizes available. Most requirements can today be satisfied by the use of MAV Locking Devices, but where particular requirements must be satisfied, MAV SpA is ready to support the designer with special locking device systems. 1-KEY 2-TANG 3-WOODRUFFKEY 4-TANGENTIALKEY 5-TAPERED PIN 6-SPLINES EXAMPLES OF TRADITIONAL COUPLING SYSTEMS operates on the head and therefore requires particularly precise and expensive adjustment. It has the tendency to cause irregularity in the hub. operates on the sides and is normally machine produced and is less expensive, but because of its lower precision it easily becomes loose causing noise and possible shearing. difficult to manufacture, used where it is necessary to eliminate play and where used for kinematic couplings it is subject to vibrations. transmits high kinematic torque subject to impacts and movement inversions. It is expensive and complicated to manufacture. not easy to assemble and dismantle. It is used where the torques produced are not very high and where axial forces may be present. expensive, suitable where frequent fitting and dismantling takes place or where axial movement must be left free. The traditional systems above listed all have in common the disadvantage that there is a contact between the shaft and hub that is not able to transmit motion on its own. It is therefore necessary to use an intervening element which requires further work to make the housing for the element, and consequently higher costs. Examples of traditional coupling systems

3 COUPLING USING TRADITIONAL SYSTEMS In the majority of cases manufacturing costs are high because the various parts must undergo several machine processes (turning, milling, slotting, grinding, etc.) with a consequent increase in accessory time and movement between machines which increase production times. The parts to be coupled must often be assembled with adjustment operations and the use of highly specialized labour. ASSEMBLY DISMANTLING PLAY BREAKAGE Normally assembly is not difficult, provided that there is no need for preset angular or longitudinal timing between the transmission elements, for example in the case of cams. In this case the precision of the work must be excellent and often the costs make themselves felt. Often this operation is complex, mainly due to the seizure or oxidization of the contact surfaces, and requires special tools that are not always readily available or are difficult to use in certain situations. It is unusual for the coupling to be completely free of play, and also in this case, in time, impacts or alternating motion could prejudice operational safety. The presence of slots in the shaft and hub could trigger fatigue failure, especially if the coupling is subject to variable forces. These are normally difficult to predict and often lead to the over sizing of components. COUPLING USING MAV LOCKING DEVICES CALCULATION TIMING PROCESSING ASSEMBLY DISMANTLING PLAY Calculations for the coupling are simplified by the use of the values indicated in tables. These do not require any further elaboration because the data indicated is calculated with sufficient safety margins. It is normally enough to know with accuracy what maximum torque or axial thrust values the locking device will be subject, especially in the case of large masses in movement where high inertial kinetic energy values are generated. Locking devices do not require any timing operations and allow the maximum freedom and flexibility in the timing of the kinematic chain. One of the essential characteristics of locking devices is that all the intermediate processing stages are eliminated as normally only turning operations are required which respect tolerances from H7/ h7 to H11/h11. Surface finishing is that which can normally be achieved with good turning operations and grinding is only recommended in the rare cases where fatigue failure is a possibility. The possibility of using high processing tolerances and the absence of an adjustment stage means that assembly is very simple. Locking devices only require that the screws are tightened correctly using a torque wrench. No special tools are required as the locking device, after it has been dismantled using the extraction holes where the same screws used for mounting are inserted, frees the hub and shaft. The pressures generated when the locking device is fitted are enough to guarantee against the occurrence of rusting at the point of contact. During the assembly phase play is eliminated automatically, in both a radial and longitudinal sense and any tolerance errors in the turning of the shaft and hub are also recovered. BREAKAGE The absence of slots in the shaft and hub are a guarantee of the greater durability of the coupling with regards to fatigue failure. The sizing of the elements takes into consideration the pressures that act upon the shaft - coupling and hub - coupling interface. These often reach high values which, in rare cases, may require the use of special materials. Although MAV Locking Devices have an higher unit compared to traditional coupling systems, they eliminate the main defects. Their use allows a number of savings which can be summed up as follow: reduced calculation time for the technical office reduction in processing time due to the lower number of machining operations required reduced use of raw and semi-processed materials reduction in the cost of storage with the use of unified components longer longlife and precision of the coupling. Designers should take these elements into consideration during the study of the application, even if at first sight this might also mean a radical change in way one thinks of and sees the coupling. The use of MAV LOCKING DEVICES requires a "dynamic" approach to design, which might be encouraged by a good knowledge of this type of locking device. MAV, with almost fifteen years of experience, is available to anyone who would like to learn more about these concepts or those who require more detailed information than those contained in this catalogue. The company s design and calculation computer systems are also available

4 - 6 - CALCULATIONS AND VERIFICATIONS To choose the most suitable locking device for each application, the designer can make use of the following calculations. USE PARAMETERS The exact calculation of the power to be transmitted and the type of elements in the kinematic chain (e.g. helical or spur gears ) gives an indication of the transmissible torque (Mt) and the possible axial force (Fax) to be transmitted. The size of the shaft mainly depends on these values, as well as any standardization requirements. The formula commonly used to determine the diameter of a solid shaft (d) subject only to transmissible torque is the following: N 9549 N ) Mt t = 2) Mt t = n n where: Mt t = theoretical transmissible torque (Nm) - N = power expressed in kw in 1) and in Hp in 2) - n = rpm Mt 3 t ) d = k t where: d = shaft diameter (mm) - k t = unit safety load (N/mm 2 ) LOCKING DEVICE SELECTION The diameter of the shaft and the value of transmissible torque is calculated using the following formula: 2 2 d 4) Mt c = Mtt + Fax t 2000 where: Mt c = composite transmissible torque (Nm). With Fax t = 0, Mt c = Mt t Fax t = theoretical axial force (N) d = shaft diameter (mm) Once the calculation has been made one proceeds with the choice of the type of locking device required, on the basis the (Mt c ) values lower or equal to the (Mt) values in the catalogue, and also on the basis of any requirements like concentricity, perpendicularity, absence of axial movement etc. To facilitate this choice the table at page no. 3 indicates the main characteristics of MAV locking devices. HUB VERIFICATION After choosing the locking device it is necessary to check the minimum external diameter (Dem) of the hub which must be able to withstand the stresses caused by the high pressures generated by the locking device. Obviously this verification is purely static and only concerns the stresses generated by the locking device. Table at page no.8 has been produced using the following formula which gives the relationship between the external hub diameter (Dem) and internal diameter (D) on the basis of various specific pressures (Pm), the values of the utilisation coefficient (C) and the various yield strength values (Rs 0,2 ) of several types of commonly used materials. Rs0,2+ Pm C 5) Dem D Rs 0,2 Pm C where: Dem = external hub diameter (mm) - Rs 0,2 = Yield strength for a permanent elongation of 0,2% (N/mm 2 ) - Pm = specific pressure on hub (N/mm 2 ) The value of tangential stress (s te ) on the external diameter (Dem) of the hub is calculated using: 2 Q D 6) σ te = 2 Pm 7) Q = 1 Q Dem where: s te = unitary tangential stress on the external diameter (N/mm 2 ) The elastic deformation of the hub is calculated according to: D Q 8) ΔDem = 2 Pm E 1 Q where: DDem= hub deformation (mm) - E = modulus of elasticity (for steel N/mm 2 ) CALCULATION OF TRANSMISSIBLE TORQUE OF AN ELEMENT LOCKED ON TO THE HUB When the locking device is used to lock an element positioned outside the hub the final transmissible torque depends on the residual pressure in the hub - element interface. This pressure is actually the difference between the pressure developed by the locking device on the hub and that absorbed by the resistance of the hub itself during the deformation necessary to take up the play determined by the tolerances used between hub and the external element. The value can be calculated using the following formula: Clm 1 Q 9) Pdm = E 10) ΔPme = Pm Pdm 2 D Q where: Pd m = pressure for hub deformation (N/mm 2 ) - Cl m = play between hub and drive element (mm) - DPm e = residual pressure (N/mm 2 )

5 This value is used to calculate the pressure than can be used and the transmissible torque to it related. The following formulas are valid where the modulus of elasticity (E) of the material of locked element and the hub are the same: 2 2 Q t Do D 11) Pu = ΔPme 1 12) Q 2 t 1 Q t Dem = Do Nem Dem μ 13) N em = Pu Dem π H1 14) Mt em = where: Pu = usable pressure (N/mm 2 ) Do = usable external diameter of the locked element (mm) Dem = external hub diameter (mm) D = external locking device diameter (mm) Mt em = transmissible torque from the locked element on to the hub (Nm) N em = radial force m = friction coefficient (0,12 for steel on steel with lubrication) H1 = width of locking device - hub contact face (mm) It is clear that the final transmissible torque depends mostly on the type of materials used to construct the hub and locked element (and as a consequence on the relative modulus of elasticity and friction coefficient) as well as on the play in the coupling and the thickness of the hub. It is therefore task of the designer to find an organic relationship between these values and apply a suitable safety coefficient. If these configurations are used the contemporaneous use of a hollow shaft is inadvisable. HOLLOW SHAFT VERIFICATION If the locking device is used in a configuration with a hollow shaft, the characteristics of the shaft are verified using the following formulas: Rs0,2 2 Pa C 2 Pa 15) d ia d 16) σti = Rs 0,2 1 Q where: d ia = the internal diameter of the hollow shaft (mm) d = the external diameter of the hollow shaft (mm) Pa = the pressure on the external diameter of the shaft (N/mm 2 ) s ti = unitary tangential stress on the internal diameter of the hollow shaft (N/mm 2 ) 2 dia 17) Q = 2 Pa d 18) Δdia = d E ( 1 Q ) where: Dd ia = the deformation of the hollow shaft (mm) CALCULATION OF TRANSMISSIBLE TORQUE FROM A LOCKED SHAFT IN A HOLLOW SHAFT Obviously it is possible to use the residual pressure inside a hollow shaft to lock another drive shaft, in order to obtain torque transmission between three elements. As in the previous case the transmissible torque depends on play,on the thickness of the hollow shaft and on the materials used and their friction coefficient; the transmissible torque is calculated using the following formulas: Cla 19) Pd a = E ( 1 Q) 20) ΔPa1 = Pa Pda 2 d Nia dia μ 21) Nia = ΔPa1 dia π H1 22) Mtia = with: Pd a = pressure for the deformation of the hollow shaft (N/mm 2 ) DPa 1 = usable residual pressure (N/mm 2 ) Mt ia = transmissible torque from the drive shaft (Nm) N ia = radial force (N) H1 = the width of the locking device - shaft contact face (mm) The values of the deformations of the shaft and hub placed under the very high pressures generated by the locking device, demonstrate the need of a careful analysis about the position of any bearings in order to avoid undesired and dangerous preloading. It is also important to verify that the values of the tangential stress (s ti and s te ), as well as those of the specific pressures (Pm) and (Pa) are not higher than the value of (Rs 0,2 ) for the materials used for the shaft and hub. If this should occur it is necessary to select a locking device that is longer so that the pressures generated are lower. EXAMPLE Please note that there is no need to increase the diameter of the shaft, something that is necessary if the usual locking systems are used due to the presence of slots. This fact is of particular importance due to the large savings that can be made in raw materials, especially with regards to larger diameters. Purely as an example let us suppose that we need to transmit a power of 100 kw at 600 rpm, the diameter of the torque verified shaft is: ) Mt 1590Nm 24) d 3 t = = = 43,27mm with a safety yield point of 100 N/mm 2. We can select a MAV 1061 x 75, locking device, which transmits a torque of 1620Nm, with a shaft that has a diameter of mm and a total coupling length of 42 mm. If a key system was used the table shows that the recommended size would be 14 mm in width and 9 mm in height. continue to page no.9-7 -

6 HOW TO CALCULATE THE MINIMUM OUTER DIAMETER OF THE HUB The following table is useful to the designer to quickly calculate the external hub diameter (Dem) on the basis of different yield strength values (Rs 0,2 ), different values of specific pressure on the hub (Pm) and the utilization coefficient (C). The values shown are equivalent to the (Dem/D) relationship. For values greater than 2,5 it is considered more economic to change the series of locking device or type of material used for the hub. Dem / D Yield point Rs 0,2 of the material of which the hub is made Pm C ,00 2,45 2,08 1,87 1,73 1,63 1,56 1,50 1,45 1,41 1,38 1,35 1,33 1,31 1,29 1,27 1,26 1,25 1,24 1, ,80 1,91 1,73 1,61 1,53 1,46 1,41 1,37 1,34 1,31 1,29 1,27 1,25 1,24 1,22 1,21 1,20 1,19 1,18 1,18 0,60 1,58 1,48 1,41 1,36 1,32 1,29 1,26 1,24 1,22 1,21 1,20 1,18 1,17 1,16 1,15 1,15 1,14 1,13 1,13 1,00 2,32 2,04 1,86 1,73 1,64 1,57 1,51 1,47 1,43 1,40 1,37 1,35 1,33 1,31 1,29 1,28 1,26 1, ,80 2,09 1,86 1,71 1,60 1,53 1,47 1,42 1,38 1,35 1,33 1,30 1,28 1,27 1,25 1,24 1,22 1,21 1,20 1,19 0,60 1,67 1,55 1,47 1,41 1,36 1,33 1,30 1,27 1,25 1,23 1,22 1,20 1,19 1,18 1,17 1,16 1,16 1,15 1,14 1,00 2,24 2,00 1,84 1,73 1,65 1,58 1,53 1,48 1,45 1,41 1,39 1,36 1,34 1,32 1,31 1,29 1, ,80 2,32 2,00 1,81 1,69 1,60 1,53 1,47 1,43 1,39 1,36 1,34 1,31 1,29 1,28 1,26 1,25 1,24 1,22 1,21 0,60 1,77 1,62 1,53 1,46 1,40 1,36 1,33 1,30 1,28 1,26 1,24 1,22 1,21 1,20 1,19 1,18 1,17 1,16 1,16 1,00 2,49 2,17 1,97 1,83 1,73 1,65 1,59 1,54 1,50 1,46 1,43 1,40 1,38 1,36 1,34 1,32 1, ,80 2,17 1,93 1,78 1,67 1,59 1,53 1,48 1,44 1,40 1,37 1,35 1,32 1,30 1,29 1,27 1,26 1,25 1,24 0,60 1,88 1,70 1,59 1,51 1,45 1,40 1,36 1,33 1,30 1,28 1,26 1,25 1,23 1,22 1,21 1,20 1,19 1,18 1,17 1,00 2,38 2,12 1,95 1,83 1,73 1,66 1,60 1,55 1,51 1,47 1,44 1,41 1,39 1,37 1,35 1, ,80 2,38 2,07 1,88 1,75 1,66 1,59 1,53 1,48 1,44 1,41 1,38 1,35 1,33 1,31 1,30 1,28 1,27 1,26 0,60 2,00 1,79 1,66 1,56 1,50 1,44 1,40 1,36 1,33 1,31 1,29 1,27 1,25 1,24 1,22 1,21 1,20 1,19 1,18 1,00 2,30 2,08 1,93 1,82 1,73 1,66 1,61 1,56 1,52 1,48 1,45 1,43 1,40 1,38 1, ,80 2,24 2,00 1,84 1,73 1,65 1,58 1,53 1,48 1,45 1,41 1,39 1,36 1,34 1,32 1,31 1,29 1,28 0,60 2,14 1,89 1,73 1,62 1,54 1,48 1,43 1,40 1,36 1,34 1,31 1,29 1,27 1,26 1,24 1,23 1,22 1,21 1,20 1,00 2,52 2,24 2,05 1,91 1,81 1,73 1,67 1,61 1,57 1,53 1,49 1,46 1,44 1,41 1, ,80 2,43 2,13 1,94 1,81 1,71 1,64 1,58 1,53 1,49 1,45 1,42 1,39 1,37 1,35 1,33 1,31 1,30 0,60 2,32 2,00 1,81 1,69 1,60 1,53 1,47 1,43 1,39 1,36 1,34 1,31 1,29 1,28 1,26 1,25 1,24 1,22 1,21 1,00 2,42 2,19 2,02 1,90 1,81 1,73 1,67 1,62 1,57 1,54 1,50 1,47 1,45 1, ,80 2,29 2,06 1,90 1,79 1,70 1,63 1,57 1,53 1,49 1,45 1,42 1,40 1,38 1,36 1,34 1,32 0,60 2,13 1,90 1,76 1,65 1,57 1,51 1,46 1,42 1,39 1,36 1,34 1,32 1,30 1,28 1,27 1,25 1,24 1,23 1,00 2,35 2,14 2,00 1,89 1,80 1,73 1,67 1,62 1,58 1,54 1,51 1,48 1, ,80 2,48 2,19 2,00 1,87 1,77 1,69 1,62 1,57 1,53 1,49 1,46 1,43 1,40 1,38 1,36 1,34 0,60 2,27 2,00 1,83 1,71 1,62 1,56 1,50 1,46 1,42 1,39 1,36 1,34 1,32 1,30 1,28 1,27 1,26 1,25 1,00 2,54 2,29 2,11 1,98 1,88 1,80 1,73 1,68 1,63 1,59 1,55 1,52 1, ,80 2,34 2,11 1,95 1,84 1,75 1,68 1,62 1,57 1,53 1,49 1,46 1,43 1,41 1,39 1,37 0,60 2,44 2,11 1,91 1,78 1,68 1,60 1,54 1,49 1,45 1,42 1,39 1,36 1,34 1,32 1,30 1,29 1,27 1,26 1,00 2,45 2,24 2,08 1,96 1,87 1,80 1,73 1,68 1,63 1,59 1,56 1, ,80 2,52 2,24 2,05 1,91 1,81 1,73 1,67 1,61 1,57 1,53 1,49 1,46 1,44 1,41 1,39 0,60 2,24 2,00 1,84 1,73 1,65 1,58 1,53 1,48 1,45 1,41 1,39 1,36 1,34 1,32 1,31 1,29 1,28 This chart shows the values and characteristics taken for the mentioned formulas. The utilization coefficient (C) values are valid for all locking devices. Should the designer need to use hubs that are different from those shown, he or she must take account of the most similar form and worst case conditions. DDem/2 L 1 = L L 1 = 2L L 1 > 2L Pm Pa L L L Dd ia /2 d ia d D Dem C = 1 C = 0,8 C = 0,6

7 continue from page no.7 This would take the diameter of the shaft, including the material of the key slot, to 49 mm, while the length of the key would be about 53 mm. It is therefore possible to suppose that the coupling width would be about 60 mm. In the first case the shaft material weighs about 0,5 kg while in the second case it is about 0,9 kg. The savings in terms of cost and the volume of the rotating mass, without forgetting the concentricity characteristics, definitely favour locking device coupling. To calculate the internal diameter of a hollow shaft, the designer must use, in the relative formula, a utilisation coefficient value(c) of 0,8, which is valid for most cases, i.e. for a shaft length equal to or greater than twice the width of the internal ring of the locking device in the area under pressure (Pa). In other cases it is recommended that the value 1 be used. The use of hollow shafts with shrink disks is becoming ever more widespread, especially in costly applications. A good example of this is that of speed reducers where the coupling is provided by shrink disks. Due the combination of hollow shaft and shrink disk it is possible to lock a drive shaft and external hub contemporaneously, thereby eliminating the rigid joints that were once necessary, therefore providing great savings in space and weight of the assembled units. FURTHER ELEMENTS FOR CALCULATION OF LOCKING DEVICE CHARACTERISTICS As we have already seen, all the characteristics of locking devices ( Mt - Fax - Pa - Pm) are directly proportional to the Ma Fv Ma Fv Ma Fv sum of the force expressed by each screw (Fv) and the M friction coefficient (m) that results between the various parts M in contact. In the case of assemblies subject to special M M conditions, for instance in the presence of thin walled hubs and torque values lower M than the maximum transmissible, it could be necessary to reduce the locking torque M of the screws (Ma) in order to reduce the pressure generated by the locking device M (Pa and Pm) and at the same time the transmissible torque. The first fundamental M value for the following calculation is the force generated by each screw (Fv) of the M type DIN 912 tightened to a certain torque value: the beside table lists these values M according to the screw class ( ). The calculations are based on a M friction coefficient for slightly oiled screws equal to about m M v» 0,14. M M As mentioned in other parts of this catalogue too, the friction coefficient used is m = 0,12 which corresponds to the condition of a contact between steel and steel with light lubrication, while in the case of dry assembly a higher value should be used, m = 0,15. In reality, the friction generated by a locking device after assembly is much higher (from 1,5 to 3 times greater) as the starting friction must be considered. Due to this a safety factor is automatically included in the calculation. However, due to the great difference in parameters relative to each application (factors of form, vibration, utilisation coefficient, overloading etc.), it is not possible to establish these factors beforehand, therefore the calculations do not take them into account. FITTING SEVERAL UNITS ARRANGED ONE BEHIND THE OTHER no. of units In applications where several units are fitted one behind the other (n), where access to the locking screws is only Series possible from one part, the total transmissible torque (Mt t ) is not an integral multiple of the units used. The total value should be reduced by a factor of (f RS ) according to the chart on the left, using the formula: ,80 0,75 0, ,77 0,62 0,50 Mt t = n x Mt x f RS ,80 0, , ROTATIONAL BENDING MOMENT This is a crucial factor for sizing the parts when a radial load caused by pulleys, gear wheels or the weight of 4061 = 35% components etc., is applied completely outside the centre line of the locking device. A typical case is that of conveyor belt drums where the traction force of the belt causes a bending moment between the shaft, locking 1008 = 32% device and drum base. In practise this bending moment acquires in succession a negative and positive value with = 29% each rotation and for this reason it is designated "rotational bending". MAV locking devices are an excellent = 28% choice to solve this problem correctly. On the basis of many heavy duty applications on highly stressed drums 2005 = 22% and studies carried out by independent institutions, we have determined the admissible bending moment percentage in respect to the transmissible torque in the catalogue. RADIAL LOAD CENTERED ON THE LOCKING ASSEMBLY This type of load, which is generally found in pins, axles or other similar connections, generates pressure that can be expressed as the relationship between the load itself and the area of the shaft affected the locking device. This pressure is added up and then subtracted from the pressure (Pa). For correct sizing, therefore, the resulting value of (Pa) must never be lower than or equal to zero, or be greater than the yield strength of the materials used. CONCLUSIONS In recent times there has been a large number of new types of application in very different fields, due to a different approach to the study of power transmission based on the widespread use of locking assemblies. Therefore the designer should not just consider locking devices to be just an alternative to the usual coupling systems, but as an element on which to base a more modern construction concept, with evident cost savings. The need for production and storage cost reduction has caused companies to bring their design philosophies up to date, through the use of standardised or pre-assembled components and the exploitation of modern machine tools. We firmly believe that locking devices are well suited to this type of philosophy, and are frequently used as the starting point for a complete re-examination of a large part of manufacturing systems. In conclusion it must be mentioned that the substitution or elimination of certain processes, like for example various types of welding, can also have a positive effect on environmental pollution control or reduction, a factor which all modern companies should take into account. screw - 9 -

8 MAV 4061 series self centering very high transmissible torques MAV 1008 series self centering high transmissible torques T SECTION CLAMPING DEVICES This family of devices represents the high top of MAV range: the transmissible torques, in relation to diameter size, are among the highest along with maximum coupling precision. These devices consist of a set of screws one front cone, one rear cone and an outer ring made of one piece only with an internal rear traction ring. The front cones have three sets of holes: one set is threaded and the other two are smooth sided. The former holes are used during assembly to stop the internal ring from moving, and during removal, where the screws on the flange of the outer ring act as extractors. The second set of holes are those through which the tightening screws pass and are recognizable because the first and last are closest to the cut. In correspondence to the holes there are other smooth sided ones in the flange of the outer ring and threaded holes in the internal rear traction ring. The third set is also made up of smooth sided holes which in this case are threaded in correspondence to the flange of the external ring: during assembly these are used to insert several screws to hold the rings in position and, during removal, to push and free the rear cone. These locking devices have been designed so that it is not necessary to use different tools during assembly and removal operations. The same screws are used and the rings also act as extractors. The only tool needed is an appropriately sized torque wrench. The utilization characteristics (transmissible torque and transmissible axial force) are in fact directly proportional to the sum of the pull of the screws and, as a consequence, the tightening torque (Ma). Therefore great care should be taken while tightening these screws in a crosswise pattern. Incorrect assembly or insufficient screw tightening could cause the coupling to slip under load with the consequent seizure of the locking device. Installation and removal instruction... page no.11 Samples of assembling...page no.13

9 INSTALLATION and REMOVAL instructions 1008 & 4061 series INSTALLATION Locking assemblies are supplied ready for installation. However, if for some reason they have to be disassembled, make sure that in addition to lined-up slits in all collars, near and far-side clamp collars are not reversed. They are assembled correctly only if there are no holes or threads behind taps in clamp collar item [2]. Likewise, there must be no threads behind taps in center collar item [3] as illustrated in fig The frictional torque capacity of these devices is based on a coefficient of friction of μ=0,12 for slightly oiled screws, taper, or shaft and bore contact areas. 1 - Make sure shaft and bore contact areas are clean and slightly oiled. 2 - Loosen all screws by minimum 2 turns and transfer at least 2 screws to push off threads in clamp collar item [2] and center collar item [3] in order to disengage tapers for easy installation of locking assembly (see fig. 1). 3 - After installation of locking assembly, relocate locking screws used for separation of collars. Locking Devices MAV MAV1008 Metric Sizes Inch Sizes Screws DIN 912 class 12.9 Torque Ma (Nm) 24x 55to 35x 60 1 to1-7/16 M x 75 to 65 x /2 to2-9/16 M x 110 to 90 x /8 to 3-5/8 M x 145 to 120 x /4 to 4-3/4 M x 180 to 160 x /16 to 6 M x 235 to 260 x /2 to 8 M x 355 to 340 x425 M x 455 to 600 x695 M Fig Hand tighten connection and assure that collar item (2) is parallel with face of part to be attached to shaft. 5 - Use torque wrench and set it approximately 5% higher than specified tightening (Ma). Torque screws in either a clockwise or counter clockwise sequence, using only 1/4 turns (it is not necessary to tighten in a diametric pattern) for several passes until 1/4 turns can no longer be achieved. 6 - Still apply overtorque for 1 to 2 more passes. This is required to compensate for a system-related relaxation of locking screws since tightening of a given screw will always relax adjacent screws. Without overtorquing an infinite number of passes would be needed to reach specified tightening torque. 7 - Reset torque wrench to specified torque and check all locking screws. No screw should turn at this point, otherwise repeat step "6" for one or more times. It is not necessary to recheck tightening torque after equipment has been in operation. NOTE: For installations subjected to extreme corrosion, the slits in clamp collars item [2] and [4] as well as in center collar item [3] should be sealed with a suitable caulking compound or otherwise. REMOVAL ( refer to Fig. 2 and Fig. 3 ) IMPORTANT! Make sure ends of locking screws used for removal are ground flat and ends are slightly chamfered to eliminate damage to screw and collar threads during push-off. A - Check to assure that axial movement of clamp collars necessary for release of connection is not restricted. B - Remove all locking screws and trasfer some into all push-off threads in clamp collar item no.[2]. C - Release collar no. [2] by progressively tightening all push-off screws. Typically, the push-off screws appear to be completely tight after just one pass of tightening without any noticeable separation. Although it seems that screws can not be tightened further, several more rounds of torquing in a clockwise (or counter clockwise) sequence actually more push-off force to the system and ultimately release part of the front collar. Afterwards, only the screws which are still tight, should be tightened further until complete dismountling is achieved. D - Transfer locking screws used for dismounting of collar no.[2] to all pushoff threads in center collar item no.[3]. Release collar no.[4] by repeating procedures outlined in step number 3. WARNING: it is important not to use Molybdenum Disulfide, e.g. Molykote, Never-Seeze or similar lubricants in any locking assembly installation Fig Fig. 3

10 H3 H2 H1 SELF CENTRING VERY HIGH TORQUES Through cone Threaded cone Ø d Ø D class 12.9 DIN912 - UNI H4 DIMENSIONS SCREWS SPECIFICATIONS d x D H1 H2 H3 H4 n. Size Ma Mt Fax Pa Pm 24 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M Outer "T" ring Ma screw tightening torque Nm Mt transmissible torque (with Fax = 0) Nm Fax axial force (with Mt = 0) kn Pa specific pressure on the shaft N/mm 2 Pm specific pressure on the hub N/mm 2 MAV4061 series is the high top product of MAV product range. Classical examples of application for this series MAV4061 are the locking of flywheels on mechanical presses, turbine rotors, and rolling mill cylinders. The fields of application of MAV1008 series are those where special requirements must be satisfied, with large masses in movement in particular environments. A typical example is the locking of large drums (see right-top sketch) for conveyor belts or rolling mills where use of this locking device is more advantageous in respect to others as it unites good transmissible power, small size and good resistance to rotational bending. MAV1008 series is offered where MAV4061 high performances are required but with lower torque values to be transmitted or as an alternative to traditional locking devices (of which it mantains same inner and outer diameters) or the use of several locking devices of other series (e.g. MAV 2005) coupled together. It is recommended that great care been taken with the assembly in order to take advantage of the characteristics offered by this product such as, concentricity, perpendicularity, the distribution of tangential forces, particular resistance to rotational bending when used with long shafts that are loaded at their ends. It is also recommended that care be taken during removal (see page no.11) of the locking device to clean and oil it, so that the timing of the rings is not changed which would later cause problems for the future removal of the device. ORDER EXAMPLE For a shaft d=70 mm, hub D=110 mm and a transmissible torque value lower than or equal to Nm specify: LOCKING DEVICE MAV x 110 or For a shaft d=200mm, hub D=260 mm and a transmissible torque value lower than or equal to Nm specify: LOCKING DEVICE MAV x 260

11 H3 H2 H1 SELF CENTRING HIGH TORQUES Through cone Threaded cone Ød ØD class 12.9 DIN912 - UNI5931 H4 DIMENSIONS SCREWS SPECIFICATIONS d x D H1 H2 H3 H4 n. Size Ma Mt Fax Pa Pm 70 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M NOTE: This series of locking device (MAV1008) is used for particular applications, especially in the field of drums for conveyors and rolling mills (see right-top sketch). MAV SpA has more than ten years of experience in this sector and is specialized in the design of locking devices, based on datas supplied by the customer, that are able to complete satisfy even the most particular requirements. Furthermore, on request, it is possible to manufacture locking devices larger than those shown in the above tables. using MAV1008 series outer T-ring 1008 Top: Locking of a conveyor belt drum using MAV1008 locking device. The use of this series allows a reduction of the diametr of the shaft in order to reduce the rotational bending. Bottom: Contemporaneous locking of the slow shaft and slow wheel in a high power reduction gear using two MAV4061 locking device. using two MAV4061 series

12 CLAMPING DEVICES WITH SHOULDER FLANGES All of the clamping devices of this family are self centering and are suitable for medium-high torque applications. MAV1062, MAV6901 and MAV6903 feature a slight axial movement (which will be in the order of tenths of a millimeter) of the hub when the screws are tightened. Where a perfect axial positioning is required it is reccomended using one of the other series (MAV1061, MAV3061, MAV3062, MAV3063, MAV5061, MAV6902). Correct mounting (see page no.15) provides excellent results in terms of concentricity and perpendicularity. These series of MAV locking devices are composed of an internal flange, an external ring (or flange on MAV5061) and a set of screws class 12.9 (DIN912- UNI5931). The internal flange has two distinct set of holes. The first are smooth sided through which the screws are used to lock the coupling are inserted. The second set of holes are threaded and used during removal operations. The same screws are used for installation and removal operations (see page no.15); this means that there is no need for different tools in the two stages, all is required is a good torque wrench. Installation and removal instruction...page no.15 Samples of applications... page no.17, 19, 21, 22 MAV 1061 series MAV1062 series MAV 5061 series MAV 6903 series MAV series MAV 6901 series MAV 6902 series Note: The high pressure values (Pa) and (Pm) by all MAV locking devices developed are a good guarantee against formation of rust; this further facilitates removal operations.

13 INSTALLATION and REMOVAL instruction 1061, 1062, , 6901, 6902, 5061, 6903 series INSTALLATION The locking devices are supplied ready to be installed. The transmissible torque of this system is calculated with a friction coefficient of μ= 0,12 with slightly oiled screws, tapering and hub. 1 - Unscrew all the locking srews by at least two or three turns and transfer at least three symetrically opposite in the extraction holes of the flange of the internal ring, in order to separate the two rings to make the insertion of the locking assembly into its housings in the hub and shaft easier. 2 - Reposition the screws in the tightening holes 3 - Progressively tighten the screws in several passes in a crosswise pattern until the tightening torque (Ma) shown in the catalogue is reached. The screws close to the cut in the internal ring should be tightened last, so that deformation is not caused to the ring. NOTE: To compensate for settling of adjacent screws, it is recommended that a last tightening pass is made with a slightly higher (3 to 5%) torque (Ma) than the one shown in the catalogue. 4 - After the installation is terminated, check the tightness of the screws in a clockwise and anticlockwise direction to ensure that none can be unscrewed by applying the torque (Ma) shown in the catalogue. If this is not the case repeat the procedure of point no. 3. No further checks are necessary after the assembly has entered into operation. REMOVAL A -Unscrew all the screws moving them the amount necessary in the extraction holes present in the flange. B -Separate the rings by progressively tightening the screws in a crosswise pattern, keeping in mind that the screws adjacent to the cut are tightened last. WARNING: it is important not to use Molybdenum Disulfide, e.g. Molykote, Never-Seeze or similar lubricants in any locking assembly installation

14 H4 H3 H2 H1 SELF CENTRING MEDIUM-HIGH TORQUES flange cone class 12.9 DIN912 - UNI5931 Ø d Ø D Ø D DIMENSIONS SCREWS SPECIFICATIONS d x D D 1 H1 H2 H3 H4 n. Size Ma Mt Fax Pa Pm 14 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M Ma screw tightening torque Nm Mt transmissible torque (with Fax = 0) Nm Fax axial force (with Fax = 0) kn Pa specific pressure on the shaft N/mm 2 Pm specific pressure on the hub N/mm 2 MAV1061 and MAV1062 series have the same technical lay-out (inner and outer diameters, number and size of screws, etc.); the only dimensional difference between the two is the outer diameter of the internal flange (see above); infact on MAV1061 series it is larger than the diameter of the rear cone thus forming a shoulder for the hub, with two important results: 1/ the small axial displacement of the hub in respect to the shaft during assembly is eliminated. 2/ Where possible, the perpendicularity of the hub in respect to the shaft is improved. Correct mounting (see page no.15) provides excellent results in terms of concentricity and perpendicularity, the values of which are maintained within the range 0,015 and 0,03 mm on MAV1061 and between 0,025 and 0,045mm on MAV1602 series. MAV1061 locking device is particularly suitable for those applications where the maximum radial and axial positioning accuracy is required, with medium to high transmissible torque, as is the case in the coupling of helical gear wheels, pinion gears, tapered gear wheels and cams. These two series are an excellent alternative to MAV2005 locking device and improves some characteristics while maintaining same inner and outer diameters. The accuracy of these locking devices also make them particularly suitable for all those sectors where, due to high rotation velocity, the presence of eccentricity even if modest, could be damaging, for example in the case of turbines and large ventilators. Removal instruction (see page no.15). NOTE: tighten the screws of MAV1062 to the same values (Ma) of MAV1061 is also possible: the values Mt, Fax, Pa e Pm will increase proportionally. In this latter case the locking device dimension H3 must be completely embedded within the hub in order to avoid possible bendings of the inner flange of the locking device. ORDER EXAMPLE For a shaft with d=70 mm and a hub with D=110 mm and a transmissible torque value lower than, or equal to, 4730 Nm indicate in the order: Locking Device MAV x 110

15 H4 H3 H2 H1 SELF CENTRING MEDIUM-HIGH TORQUES flange cone class 12.9 DIN912 - UNI5931 Ø d Ø D 1062 DIMENSIONS SCREWS SPECIFICATIONS d x D H1 H2 H3 H4 n. Size Ma Mt Fax Pa Pm 14 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M Ma screw tightening torque Nm Mt transmissible torque (with Fax = 0) Nm Fax axial force (with Fax = 0) kn Pa specific pressure on the shaft N/mm 2 Pm specific pressure on the hub N/mm 2 MAV technical informations and examples are available on MAV Internet site at the following address: Send us your enquiries at: info@mav.it Lever assembly using a MAV1061 locking device. Maximum concentricity and perpendicularity in respect to the shaft is guaranteed, avoiding the precentering bushes needed for example with MAV 2005 locking device. MAV can produce clamping elements for shaft diameter from 6mm up to 1000mm. Almost all series are also available in inch sizes. Pieces in stainless steel are manufactured on request. MAV can design and calculate any application of clamping elements. ORDER EXAMPLE For a shaft with d=40 mm and a hub with D=65 mm and a transmissible torque value lower than, or equal to 1110 Nm indicate in the order: Locking Device MAV x

16 H4 H3 H2 H1 SELF CENTRING MEDIUM-HIGH TORQUES flange cone Ø d min Ø d max Ø D Ø D1 class 12.9 DIN912 - UNI series DIMENSIONS SCREWS SPECIFICATIONS d x D H1 H2 H3 H4 D1 n. Size Ma Mt Fax Pa Pm 14 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M Ma screw tightening torque Nm Mt transmissible torque (with Fax = 0) Nm Fax axial force (with Fax = 0) kn Pa specific pressure on the shaft N/mm 2 Pm specific pressure on the hub N/mm 2 These series (MAV3061, MAV3062 and MAV3063) of locking devices have been designed to satisfy the requirement of using units pre-assembled or united on shafts of different diameters, as is the case with sheaves or gear pulleys. It often happens that, depending on the size of the pulley and the number of sheaves etc., the size of the shaft can be different. In this case user has normally two options: 1/ In case of small numbers, acquire solid hub pulleys and drill the holes to the required diameter and cut the seat for the tab. 2/ In case of large numbers, acquire pulleys that have already been prepared with the consequent increase in costs. However the user must still cut the notch for the tab on the shaft. In view of increasing standardization in the field of transmission components, MAV has taken upon itself, in cooperation with the main pulley manufacturers, to design and produce MAV series. Thanks to the standardization of the external diameter (D) it is possible to speed up production by using standard pulleys rather than "made to measure", which provides further benefits for warehouse management and costs. Apart from these important savings, the application gains all the benefits offered by the coupling precision of the locking devices in this series. Correct fitting (see page no.15) provides excellent results in terms of concentricity and perpendicularity, the values of which are maintained within the range 0,015-0,03 mm. This means that the MAV3061, MAV3062 and MAV3063 series of locking devices are particularly suitable for those assemblies where the maximum radial and axial positioning accuracy is required, with medium to high transmissible torque. The accuracy of these locking devices also make them particularly suitable for all those applications where, due to high rotation speed, the presence of eccentricity even if modest, could be damaging (e.g. heavy pulleys that act as a flywheel) ORDER EXAMPLE Eg.: With a shaft diameter d=30 mm, the following three different coupling's solutions are possible: 1 st GROUP with D = 55 mm MAV x55 (where dimension D is both the outer diameter of the locking device and pulley's bore) 2 nd GROUP with D = 65 mm MAV x65 (where dimension D is both the outer diameter of the locking device and pulley's bore) 3 rd GROUP with D = 80 mm MAV x80 (where dimension D is both the outer diameter of the locking device and pulley's bore)

17 H4 H3 H2 H1 SAMOSTŘEDÍCÍ STŘEDNÍ KR.MOMENT vnitřní příruba objímka vnější příruba Ø d Ø D Ø D1 Ø D2 třída12.9 DIN912 - UNI5931 Rozměry Šroub Tlak d x D H1 H2 H3 H4 D1 D2 n. Size Ma Mt Fax Pa Pm 6 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M MAV1061 MAV5061 Příklad použití motáže s CONFIXEM MAV 5061 a MAV první je použité pro malý otvor pro pastorek, druhé pouzdro je standartní montáž. Přičemž je zaručena absence axiálního posuvu během fixace na na hřídel jež je nežádoucí kvůli tlaku který by mohl poškodit ozubení pastorku Ma kroutící moment pro dotažení šroubů Nm Mt přenášený kroutící moment ( s Fax=0) Nm Fax axiální síla (s Fax =0) kn Pa flak na hřídel N/mm 2 Pm tlak na posuv (zdvih) N/mm 2 CONFIX MAV 5061 se používá je navržen pro aplikace, kde v náboji je malý prostor pro upínací pouzdro a jiné typy nelze použít. Při dotahování se hlavní objímka nepatrně axiálně posunuje na náboji, zatímco upínací pouzdro je v místě je v místě upevňování zablokované a současně dochází k zlepšení kolmosti uchyceného pouzdra k ose hřídele. Správných výsledků instalace upínacího dosáhneme křížovým utahováním šroubů v rozsahu 0,015 mm - 0,03 mm zdvihu při jednom kroku dotažení. Tím získáme správné vystředění a kolmosti pouzdra. Toto znamená, že tento typ upínacího pouzdra je zvláště vhodný tam, kde je požadována maximální přesnost axiálního a radiálního umístění jako základní spoj přiněmž poměr mezi jmenovitým průměrem a průměrem hřídele relativně malý ( válcovitý a šikmý pastorek, pružné spojky,vačky. Upínací pouzdra CONFIX MAV 5061 jsou tedy vhodná pro střední a malé zatížení, nejčastěji v odvětví automatizace strojů (textilní, balící stroje, kde se používají malé průměry nosných hřídelí a kde přenášené síly nejsou moc vysoké. Nestandardní průměry jež se nenacházejí v tabulce jsou dodání na poptávku. Pokyny pro montáž a demontáž viz str.15 CONFIX MAV se vyrábí pro průměry od 6 do 1000 mm nejen v metrické, ale i palcové soustavě. Na poptávku lze vyrobit i nerezové provedení. Jsme připraveni podílet se na vývoji a produkci upínacích elementu na vaši aplikaci. PŘÍKLAD OBJEDNÁVKY Pro hřídel s průměrem d =50 mm a otvorem s D=65 mm přenášející kr.moment menší nebo roven 2060 Nm zadání : CONFIX MAV x

18 H4 H3 H2 H1 SELF CENTRING MEDIUM-HIGH TORQUES flange cone class 12.9 DIN912 - UNI5931 Ø d Ø D DIMENSIONS SCREWS SPECIFICATIONS d x D H1 H2 H3 H4 n. Size Ma Mt Fax Pa Pm 18 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M Ma screw tightening torque Nm Mt transmissible torque (with Fax = 0) Nm Fax axial force (with Fax = 0) kn Pa specific pressure on the shaft N/mm 2 Pm specific pressure on the hub N/mm 2 MAV6901 and MAV6902 series keep the same main characteristiscs of MAV1062 and MAV1061 series but have been specifically designed for use where greater transmissible torque (Mt) values are present and where lower specific pressures are allowed by the shaft and/or the hub. Infact the dimensions (H1-H2-H3-H4) of these locking devices are greater than those of the similar MAV1062 and MAV1061. The concentricity characteristics are the same while resistance to rotational bending is slightly improved. During fitting MAV6901, a small axial movement of the hub might occurs. Should this displacement, which will be in the order of tenths of a millimeter, not be acceptable, it is possible to use MAV6902 where a spacer has been added to eliminate the axial movement. In this way the flange has a fixed stop that is connected to the shaft and onto which the hub can rest while the locking device is being tightened with the result that, apart from eliminating axial movements, the orthogonality of the assembled parts is improved.the higher axial friction of the external ring respect to the hub causes a slight reduction of the transmissible torque and axial force values when compared to MAV6901. Correct fitting, where the screws are tightened in a crosswise pattern, highlights the excellent concentricity characteristics of these locking devices: values of 0,02 0,04 and 0,015 0,03 respectively for MAV6901 and MAV6902. In cases where the assembled parts might be subject to particularly aggressive agents (eg.: high humidity with the presence of abrasive dust) it is recommended that consideration be given to the use of the MAV 1008 locking device that has been specifically designed for this kind of applications, or that the locking device is protected by a flange that makes the housing watertight and which can be connected using extraction holes (see example drawing in the top of next page). Installation and removal instructions (see page no.15). ORDER EXAMPLE For a shaft with d=130mm and a hub with D=180 mm and a transmissible torque value lower than, or equal to, Nm would you please indicate in your order: LOCKING DEVICE MAV x 180

19 H4 H3 H2 H1 SELF CENTRING MEDIUM-HIGH TORQUES flange cone class 12.9 DIN912 - UNI5931 Ø d Ø D Ø D 1 DIMENSIONS SCREWS SPECIFICATIONS d x D H1 H2 H3 H4 n. Size Ma Mt Fax Pa Pm D 1 18 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M spacer 6902 Ma screw tightening torque Nm Mt transmissible torque (with Fax = 0) Nm Fax axial force (with Fax = 0) kn Pa specific pressure on the shaft N/mm 2 Pm specific pressure on the hub N/mm 2 using MAV6901 series SAVING ON STOCK VOLUMES! MAV6902 series is just a combination of MAV6901 and a spacer: order them separately to save on stock volumes. How to order the spacer to make MAV x110: spacer for MAV x110 using MAV6902 series

20 H4 H3 H2 H1 SELF CENTRING MEDIUM-HIGH TORQUES outer flange inner flange class 12.9 DIN912 - UNI5931 Ø d Ø D 6903 DIMENSIONS SCREWS SPECIFICATIONS d x D H1 H2 H3 H4 n. Size Ma Mt Fax Pa Pm 20 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M Ma screw tightening torque Nm Mt transmissible torque (with Fax = 0) Nm Fax axial force (with Fax = 0) kn Pa specific pressure on the shaft N/mm 2 Pm specific pressure on the hub N/mm 2 MAV6903 series has been designed for a specific purpose: to obtain, during locking of the element, an axial force that can be used to lock other elements (e.g. bearings) adjacent to hub. This is made possible by using a configuration similar to MAV1062 with the screws mounted on the opposite side od the locking element. As a consequence it is possible to exploit the movement of the external ring and therefore that of the locked hub, in respect to the internal ring and shaft. This hub movement, transmitted to nearby elements through flanges or spacers, means a locking force along the axis of the shaft (with values similar to that provided by the sum of the forces generated by each of the screws). MAV6903 maintains all the characteristics of precision and easy installation and removal operations of other locking devices, as well as maximum concentricity, good transmissible torque values and excellent hub to shaft perpendicularity. A typical example of an assembly is shown in the figure (bottom-left), where the locking of the flywheel also allows the axial locking of the corresponding bearing. This allows savings in space and intermediate operations while the usual cover used to lock the bearing can be avoided or sized to be used as a dust cover or oil splash guard. It is clear that in that case the thrust flange must be appropriately prepared, however the work required will be less than that for long and large sized shafts. This type of locking device can also be constructed to the drawings of the customer to match special requirements. Installation and Removal instruction (see page no.15). MAV can produce devices for shaft diameter from 6mm up to 1000mm. Almost all series are also available in inch sizes. Pieces in stainless steel are manufactured on request. MAV can design and calculate any application of clamping elements ORDER EXAMPLE For a shaft with d=70 mm and a hub with D=110 mm and transmissible torque value lower than, or equal to, 4730Nm indicate in the order MAV x 110 LOCKING DEVICE

21 MAV 2005 series no axial displacement while fixing not self locking high transmissible torques MAV 3003 series reduced thickness of the device not self locking CLAMPING DEVICES FOR GENERAL PURPOSES This family of clamping devices are probably the most wellknown and used ones and millions of examples have been manufactured. These series (MAV2005 and MAV3003) are used in a huge number of applications in the mechanical field. Are not self-centering and therefore require centering face between hub and shaft to align the two. Machining tolerances required on shaft and hubs for MAV2005 series are h11 for shaft diameters and H11 for hub bores. Machining tolerances required on shafts and hubs for MAV3003 series: diameters shaft hub's bore up to 38mm h6 H7 bigger h8 H8 Note: the pressures developed by all of MAV locking devices in the locking area are enough to provide protection against rust at the contact point, but particular attention should be paid to the protection of the area covered by the centring face where it is possible for rust to form, thereby removal operations might be difficult. Installation and removal instruction... page no. 25, 27 Samples of assembling... page no. 24, 25, 27

22 H3 H2 H1 Through cone vnější kroužek Ø d Ø D DIN912 UNI d x D H1 H2 H3 n. Size Ma Mt Fax Pa Pm 18 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M sh vnitřní kroužek Threaded cone Tuto sérii výrobce doporučuje použít pro údržbu nebo za účelem náhrady. U nových konstrukcí je dobré se přesvědčit zda nelze použít CONFIX MAV 1061 nebo Both outer and inner rings are cut along a generatrix so that they have maximum radial deformation flexibility. The front cone has a set of smooth sided holes necessary for the insertion of the screws; these holes lead to a set of threaded holes in the rear cone. Under the silver screw heads there is a set of smooth sided holes [sh] are partially threaded and are used during removal operations (see page no.25). These screws are in the next larger size to those used for assembling. Centering face must have a width enough to support the hub during assembly and, generally speaking, it should not be less than twice the width of the locking device housing in the hub. The configuration of MAV2005 locking devices is so that normally during assembly there is not any axial movement of the hub. After tightening with a torque wrench, the screws should normally only be subjected to 1 2 x 1 centering face their static load and therefore it is necessary to carefully check the sizing of long shafts where rotational bending might occur. The values of the camber should fall within the range 0,30 0,35 per thousand and if the centering face is not enough, the screws might be further stressed with problem of fatigue breakage. The values (Mt-Fax-Pa-Pm) are already calculated with an in built safety coefficient which depends on the dimensions of the locking device. For a shaft with d=70mm and a hub with D=110mm and a transmissible torque value lower than, or equal to, 5600 Nm, indicate in the order: LOCKING DEVICE MAV x110

23 INSTALLATION and REMOVAL instructions 2005 series INSTALLATION The designer must take into account the tolerances for the diameters required by these types of locking devices during the drawing stage of the application. Normally these are in range of H7/h7 - H11/h11. The housing in the hub must be sized so that the locking device can be contained within a margin of 1-2 mm in length, to facilitate assembly. Furthermore a centring face must be provided to allow alignment between shaft and hub, as the locking device is not self-centring. The roughness of the housings must be equal to or less than (Ra=3,2) to attain a correct friction coefficient of (μ=0,12). In the coupling calculation, the designer must also consider the fact that the locking device generates high pressures which could cause the radial deformation of the shaft or the hub. It is therefore necessary to check the tolerances for the fitting of other organs (like rolling bearings) close to the locking device to avoid any possible overloading. Before assembly the hub and shaft must be carefully cleaned and oiled. Normally the locking device is ready for use but it is suggested that it should be dismantled and cleaned to remove any excess of the protective coating used. Reassemble after oiling the rings and screws. The characteristics of the locking device and especially the friction coefficient, have been calculated for assembly with oiled parts. MOLYBDENUM BISULPHIDE BASED LUBRICANTS SHOULD NOT BE USED On re-assembling the locking device do not tighten the screws, and leave the rings loose. After fitting the hub to the shaft insert the locking device and start with a modest tightening of the screws following a crosswise pattern so that most of the play is taken up, but still leaving a small degree of freedom. At this point proceed with the accurate axial positioning of the locking device and if required with radial timing (cams, levers etc.). Continue tightening all the screws, again with a normal spanner and again following a crosswise pattern, while carrying out any checks required. When the screws are fully tightened and the assembly is locked, make a final positioning check and complete the tightening of the screws using an appropriately calibrated torque wrench. The transmissible torque is directly proportional to the sum of the pull of each screw, which depends on the tightening torque (Ma) indicated in the catalogue. At this point the installation is over. REMOVAL The tapering of this type of locking device is not self-locking therefore, after the locking screws have been loosened, a few light taps with an hammer on the heads of the screws should separate the rings almost automatically. Using MAV 2005 it might be necessary to proceed with the extraction of the so called through cone using two or three screws or threaded bars of one size larger than the locking screws, which are inserted in the holes provided for this purpose. These are indicated by the same number of screws of a different colour. The application of a light traction force, perhaps using a flange or extractor, will release this ring and completely free the elements that make up the assembly. Use of a MAV 2005 locking device to repair an assembly where the key has sheared, ruining the shaft. Turning is required to remove the seat of the key. A sleeve that has been cut lengthways is then added to return the shaft to its nominal diameter and provide the housing for the locking device in the hub. Assembly of a cylinder for a drier using a MAV 2005 locking device. The locking device allows the contemporaneous locking of the gear wheel, allowing the use of a commercial tube and by eliminating welding provides easy removal. Where long cylinders are used it is necessary to check for rotational bending

24 H h NOT SELF CENTRING LOW TORQUES flange locked on the hub inner ring flange locked on the shaft ØD Ød DIMENSIONS SPECIFICATIONS X d x D h H Ca Cb Mt Fax Pa Pm x 9 3,7 4, , x 10 3,7 4, , x 11 3,7 4, , x 12 3,7 4, , x 13 3,7 4, , x 15 3,7 4, , x 16 3,7 4, , x 18 5,3 6, , x 19 5,3 6, , x 20 5,3 6, , x 21 5,3 6, , x 22 5,3 6, , x 24 5,3 6, , x 25 5,3 6, , x 26 5,3 6, , x 28 5,3 6, , x 30 5,3 6, , x 32 5,3 6, , x 35 5,3 6, x 36 5,3 6, x 40 6,0 7, x 42 6,0 7, x 44 6,0 7, x 45 6,6 8, x 48 6,6 8, x 52 8,6 10, x 55 8,6 10, x 57 8,6 10, x 62 8,6 10, x 64 10,4 12, x 68 10,4 12, x 71 10,4 12, x 73 10,4 12, x 79 12,2 14, x 80 12,2 14, x 84 12,2 14, x 91 15,0 17, x 96 15,0 17, x101 15,0 17, x106 15,0 17, x114 18,7 21, x124 18,7 21, x134 18,7 21, x148 25,3 28, x158 25,3 28, x168 25,3 28, x178 25,3 28, x191 30,0 33, x201 30,0 33, x211 30,0 33, x224 34,8 38, outer ring Ca assembling load N Cb locking load N Mt transmissible torque (with Fax = 0) Nm Fax axial force (with Mt = 0) N Pa specific pressure on the shaft N/mm 2 Pm specific pressure on the hub N/mm 2 The last three columns (X) of the table, show the minimum distance (mm) between thrust flange and shaft or hub with the screws not tightened. These values depend on the number of elements used and are calculated so that once the locking is complete, a small play remains to guarantees a stable coupling. The value (X) under load must never be equal, or lower, to zero. MAV3003 locking X element is made of two rings coupled together along a tapered surface. To fit this system, user must use a flange to transmit the thrust force of the screws to the rings designed according to his own requirements. Note: if the flange is fixed to the hub, a slight axial displacement is possible when the screws are tightened. Part of the overall thrust of the screws is absorbed by the load (Ca) necessary to the elastic deformation of the rings to eliminate play caused by the coupling tolerances. This force becomes progressively more important with the reduction of the diameters, so that the smaller rings are splitted to set the value (Ca = 0). Each increase of the thrust of the screws over the value (Ca) causes an increase in the transmissible torque. Therefore two values are identified: the first (Ca) is the assembly load on the rings while the second (Cb) is the load proportional to the transmissible torque and, as consequence, to the specific pressure on the shaft (Pa). The values in the table have been calculated for a pressure of (Pa = 120 N/mm 2 ). For verification, users can look at the table relative to the relation chart (Dem/D) showed at page no.8, that has been calculated on the basis of the pressure (Pm) and a yield strength of (Rs 0,2 ). Note: it is possible to fit more elements in series to increase the transmissible torque (see page no.9).

25 VERIFICATIONS The designer, during the design phase of the application, must take the recommended coupling tolerances into account, which influence the pre-loading of the ring 7 assembly (Ca) using the formulas: d + D d 7 1) dm = 2) QIR = 7 2 d dm Cla d Clm 3) QOR = ( ) ( 1 QOR ) D 4 ) Pma = E 1 QIR 5 ) Pmm = E m D 2 d dm 2 D QOR dm 7 d 7 m dm 6) Pma Pmm Ca = Pma k 7) Pma < Pmm Ca = Pmm k 7 d D where: d m = locking element average diameter mm d = locking device internal diameter mm 7 D = locking device external diameter mm P 7 ma = pressure to zero shaft play (Cla) N/mm 2 7 P mm = pressure to zero hub play N/mm 2 Cl a = overall internal ring/shaft play mm 7 Cl m = overall external ring/hub play mm E = modulus of elasticity (for steel = ) N/mm As can be seen the assembly pre-loading value (Ca) is calculated on the higher value between (P ma ) and (P mm ) and the form coefficient (k) which has a value of 7 1,12 up to x13 then 1,05 up to x35 and 1 for larger diameters Table 1 - Tolerances Table 2 - Moltiplication factor 7 7 INTERVAL D 3003 d 3003 d shaft D hub N. of elements d 38 mm E7 f7 h6 H7 x Mt 1 1,56 1,86 2,03 2,13 7 d > 38 mm E8 e8 h8 H The table 1 shows the tolerances on which the calculations for the determination of the assembly pre-loading is based. The relationships that link the locking load 7 of the coupling (Cb) to the transmissible torque (Mt) and the specific pressure on the shaft or hub (Pa) and (Pm), are the following: C C N d μ b b 8) N = 9 ) tanα = 0, 3 10 ) tan ς = μ = 0, 11) Mt = 7 tan( α + ς) + μ tanα + 2 μ ) Pa = N π d h 13 ) Pm = N π D h where: N = radial load (N) a = angle of taper (degree) 7 7 m = frictional coefficient Mt = transmissible torque (Nm) 7 Pa = specific pressure on shaft (N/mm 2 ) Pm = specific pressure on hub (N/mm 2) Should it be necessary to use several locking elements in series it must be kept in mind that the resulting transmissible torque (Mt) is not directly proportional to 7 the number of elements as the load (Cb) falls progressively due to the friction generated by each ring. The value of the resulting transmissible torque is calculated 7 7 using the following formula which demonstrates that it is does not make economic sense to couple more than three or four elements: 7 Q tanα 14) 0W = 0W 15) 9 = U tanα + 2 μ 7 7 Assembly operations involve the same procedures used for normal locking devices. Prepare the housing in the hub and shaft and check that the roughness is not 7 greater than (Ra=0,8) so that the friction coefficient is not modified to any great extent. Carefully clean and oil and then proceed with the assembly of the parts, 7 tightening the bolts in a crosswise pattern. Final tightening of the bolts must be made using an appropriately calibrated torque wrench so that the loads (Ca) and 7 7 (Cb) are respected. A further check must be made regarding the distance (X) between the flange and the hub or shaft. This distance must never be equal to zero 7 or be reduced to a very small value. The value of the locking torque depends on the type and number of screws used and therefore on the sum of the single load 7 7 of each bolt from which is subtracted the load necessary for the ring assembly. The table at page no.9 groups together the single load values for three types of screw 7 TCCE UNI DIN 912, assuming an assembly with oiled screws with a friction coefficient of 0, ) Cb = n Cu Ca where: Cb = locking load (N) Cu = unitary force of the screw (N) Ca = assembling load (N) Application of a labyrinth seal on grinding machine shaft using MAV 3003 locking elements. Assembly and positioning are made much easier. Locking of the seal and flange of a pneumatic cylinder using MAV 3003 locking elements. The hole of the flange and the end of the shaft must be coupled accurately. The rings of the locking element are cut to fully exploit their expansion capacity.

26 MAV series Provide an high capacity mechanical interference fit with all the positive features of conventional interference fits, but eliminating installation and removal problems. Permit simple axial and angular hub timing. Offer extremely concentric and well balanced connections ideal for high speed applications. Available in light, medium and heavy duty series to meet any requirement with just a single unit. MAV 1204 series NEW! Rigid coupling for shaft to shaft connections. Compact design. High transmissible torque values. Possibility of connection of shafts of different diameters. Easy and fast installation and removal operations. MAV 1004 series Rigid coupling for shaft to shaft connections. Possibility of connection of shafts of different diameters. Easy and fast installation and removal operations. SHRINK DISCS - OUTER CLAMPING DEVICES - RIGID COUPLINGS This family of MAV devices did born to connect two shafts: MAV2008, MAV2108 and MAV2208 series provide locking between a standard shaft and an hollow shaft. The main applications for these series are in the field of gear-boxes, speed-reducers, etc. The operation of the MAV2008, MAV2108, MAV2208, MAV1204 and MAV1004 series of locking devices, which is based on heat shrink-fit principles, exploits the pressure in the hollow shaft interface generated by the coupling of the conical cones which are assembled through the bolts. All these devices consist of a set of bolts, one front cone, one rear cone and one inner ring.

27 NEW! RIGID COUPLING HIGH TORQUES ØD ØIv Ød class 10.9 DIN931 - UNI5737 inner ring rear cone d x D DIMENSIONS H2 H3 H4 H1 SCREWS SPECIFICATIONS H1 H2 H3 H4 I v n. Size Ma Mt Fax 15 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M MAV can supply MAV1204 and MAV1004 rigid coupling series in larger or intermediate sizes to those shown in this catalogue, as well as couplings according to clients specifications. Pa s e front cone checked. The screws should not tighten further. If this is not the case repeat the operation from point no Ma screw tightening torque Nm Mt transmissible torque (with Fax=0) Nm Fax axial force (with Mt=0) kn Pa specific pressure on the shaft N/mm 2 s e equivalent stress on the outer ring N/mm 2 The rigid coupling MAV1204 represents an evolution of the series MAV1004 (see page no.34). It is a rigid coupling used to couple two shafts of equal or differing diameters. The main advantages of this series versus the previously designed MAV1004 are: - More compact design (therefore smaller dimensions and masses). - For the same shaft diameter the transmissible torques are higher (between 70% and 400% more capacity). - Locking through hexagonal head screws (DIN931- UNI5737) allows smaller access room and radial access is possible. By modifying the internal ring in the appropriate manner (special rigid coupling, with availability and prices on request), or if the end user adds a reduction sleeve, it is possible to connect shafts that have different diameters. This further increases the application of this coupling. In this case, it must be taken into account that the transmissible torque is directly proportional to the smaller diameter of the two shafts. Once again we stress the importance to check the final torque setting of the screws, upon which the final capacity of the connection depends. INSTALLATION 1 - Before assembly ensure that the tolerances of the two shafts, which must fall within the range h7 - h9, are not too dissimilar. 2 - Carefully clean the parts which should then be light-ly oiled. It is recommended that MOLYBDENUM BISULPHIDE based products are not used to lubricate the shafts. 3 - Assemble the parts paying attention to the alignment of the shafts and the necessity of any angular timing. 4 - Tighten the screws cross-wise using a normal spanner and at the same time check the parallelism of the rings. 5 - The last two passes should be done clockwise or anticlockwise using a torque wrench calibrated at 3-4% more than the torque shown in the catalogue. The torque should later be set to the correct value and the tightness of each bolt REMOVAL: Loosen the screws by three or four turns only. DO NOT remove locking screws completely. The rings should now separate if they are assisted by light taps with an hammer

28 X H2 H1 e SHRINK DISC STANDARD SERIES tolerance h8 rear cone ØD ØIv Ød Ød 1 Ød alb class 10.9 DIN931 - UNI DIMENSIONS H3 H4 SCREWS SPECIFICATIONS front cone d alb d x D H1 H2 H3 H4 Iv d 1 e n. Size Ma X Mt Fax Pm P alb x ,8 22, M x ,5 24, M x ,5 26, M x ,5 28, M x ,5 30, M x ,5 33, M x ,5 33, M x ,5 33, M x ,0 36, M x ,0 36, M x ,5 43, M x ,5 43, M x ,0 48, M x ,0 48, M x ,5 56, M x ,5 56, M x ,0 57, M x ,0 57, M inner ring Ma screw tightening torque Nm Mt transmissible torque (with Fax=0) Nm Fax axial force (with Mt=0) kn Pm specific pressure on the hub N/mm 2 Palb specific pressure on the shaft N/mm 2 X clearance for torque wrench mm Pressure value (P alb ) is calculated using a number of known parameters as follow detailed: - the taper of the connection. - The friction coefficient between the rings with contact surfaces lubricated using molibdenum disulphide based products. - The sum of the traction force on the bolts, tightened to the torque value shown in the catalogue and lubricated using Molikote BR2 type grease in order to get a friction coefficient value lower than 0,1. - The force necessary to eliminate play in the connection between the shaft and hollow shaft, taking into consideration that the contact surfaces must have a total roughness (Rt) that is not more than 0,016mm. Given the value of (P alb ) the value of the transmission moment (Mt) and axial force (Fax) are calculated. The friction coefficient between the shaft and hollow shaft which are calculated as being equal to or over 0,15 (steel on steel). The designer must take into account the forces to which the shafts are subject, as well as the forces generated by the transmission of the torsional moment, with the possible co-presence of axial forces or bending moments and also the pressure that determines the locking of the elements. NOTE: The values Mt and Fax shown on Shrink Discs charts, refers to the maximum clearances admitted as per table at top page no.31. The values (Mt and Fax) increase as much as the respected tolerances are closer. MAV can manufacture all Shrink Discs series in larger or intermediate sizes to those shown in the catalogue, as well as coupling flanges according to customers specifications.

29 ORDER EXAMPLE For a shaft diameter dalb= 95mm the outer diameter of the hollow shaft will be 130mm, therefore the required clamping will be ordered as: MAV x215 Toll/2 Dd / 2 INSTALLATION MAV Shrink Discs series must not be dismantled before use to ensure that the grease used to lubricate the friction surfaces and the bolts is not removed. It is sufficient to clean the internal ring bore of any traces of grease. If it is necessary to dismantle the Shrink Discs or re-use it after servicing the connection, it is necessary to replace the layer of grease using one of the following products to avoid changing in calculated coefficients: Molikote 321 R or Molikote G Rapid and, for the bolts Molikote BR2. Before assembling the parts, the operator must carefully clean and degrease the bore of the hollow shaft and the surface of the shaft using a normal solvent. At this stage the Shrink Disc is positioned and the shaft inserted, being careful not to use too much force to avoid causing a possible seizure. Bolt tightening takes place in two stages: first tighten three or four equally spaced bolts to about half the torque values shown in the catalogue in order to verify that front and rear collars remain concentric and parallel, then tighten all the bolts to the torque values reccomended in a cross pattern. Once the bolts are tightened check the parallelism of the two collars, considering that the maximum error allowed is 0,25-0,35% of the external diameter of the Shrink Discs to avoid distorting the connection angle thereby risking further displacement of the rings with a loss of specified pressure (P alb ) and, as a consequence, a reduction in the (Mt) and (Fax) values. By following this advice and carefully assembling the discs, it is possible to achieve coupling of excellent quality, without eccentricity or vibration and good power transmission characteristics wherever it is necessary to use hollow shafts or thin walled hubs. REMOVAL Leaving three or four bolts in place unscrew and remove the others. Unscrew the remaining bolts in a crosswise pattern ensuring that the two collars separate progressively and parallelely until it is free. Remove the shaft from the hub and free the hub and the Shrink Disc. NOTE: all MAV Shrink Discs are white Zink-plated and feature (starting from diameter 140mm) a rubber O-ring between the two cones. from mm DIMENSIONS d alb to mm ISO Tolerances Maximum clearance mm H6 - j6 0, H6 - h6 0, H6 - g6 0, , ,079 H7 - g , ,101 SCREWS 2008 SPECIFICATIONS d alb d x D H1 H2 H3 H4 Iv d 1 e n. Size Ma X Mt Fax Pm P alb x ,0 59, M x ,0 59, M x ,0 66, M x ,0 70, M x ,0 78, M x ,0 78, M x ,0 95, M x ,0 95, M x ,0 95, M x ,0 114, M x ,0 121, M x ,0 133, M x ,0 145, M x ,0 153, M x ,0 153, M x ,0 169, M x ,0 173, M x ,0 179, M

30 LIGHT DUTY SERIES HEAVY DUTY SERIES DIMENSIONS DIMENSIONS SCREWS SCREWS SPECIFICATIONS d alb d x D H1 H2 H3 H4 Iv d 1 e n. Size Ma X Mt Fax Pm P alb x M x M x M x M x M x M x M x M x M x M x M x M SPECIFICATIONS d alb d x D H1 H2 H3 H4 Iv d 1 e n. Size Ma X Mt Fax Pm P alb x M x M x M x M x M x M x M x M x M x M x M x M POSSIBLE HUB CONFIGURATIONS FOR THE AXIAL POSITIONING OF THE SHRINK DISC. Quite often axial positioning of the Shrink Disc needs to be precise, taking into consi deration that the height (H2 and H4) are calculated with a 5% approximation. In this case the hollow shaft must present shoulders to support the Shrink Disc, while ensuring that they do not cause sharp variations in the cross section of the shaft that would run the risk of fatigue failure. The example beside (right) make several suggestions that could be useful for the designer. NOTE: all MAV Shrink Discs are white Zink-plated and mount (starting from diameter 140mm) a rubber O-ring between the two rings. PRESSURE DISTRIBUTION ON DIAMETER (d alb ) The drawing below provides an indication of the effective distribution of contact pressure on the shaft. This indication is also particularly useful in cases where the shaft is hollow and deformation must be calculated. Theoretically the hollow shaft could block the counter shaft: the effective pressure on (dalb) is useful for the calculation of the resulting twisting moment.

31 SPLIT (Shrink Disc) CONFIGURATION This Shrink Disc configuration is of interest in applications where length of hub projection is insufficient to accomodate standard Shrink Discs. Since two hub projections are available for torque transmission, a "thinner" hub together with a Shrink Disc smaller than required for standard applications may be selected. By using only one outer collar and a corresponding half inner ring of a SPLIT Shrink Disc offers substantial cost reductions in low torque applications. To order SPLIT Shrink Disc simply add suffix "SPLIT" to Shrink Disc designation and specify web thickness "Z" to provide for proper screw length (screws are normally supplied by MAV, upon request) SPLIT d x D L Iv d 1 e a R 24 x 50 7, ,5 2,0 30 x 60 8, ,5 2,0 36 x 72 9, ,5 2,0 44 x 80 10, ,5 2,0 50 x 90 11, ,5 2,0 55 x , ,5 2,0 62 x , ,5 2,0 68 x , ,5 2,0 75 x , ,0 4,5 80 x , ,0 4,5 85 x , ,0 4,5 90 x , ,0 4,5 95 x , ,0 4,5 100 x , ,0 4,5 105 x , ,0 4,5 110 x , ,0 4,5 115 x , ,0 4,5 120 x , ,0 4,5 125 x , ,0 4,5 130 x , ,0 4,5 140 x , ,0 4,5 155 x , ,0 4,5 165 x , ,0 4,5 175 x , ,0 4,5 185 x , ,0 4,5 195 x , ,0 4,5 200 x , ,0 4,5 220 x , ,5 7,0 240 x , ,5 7,0 260 x , ,5 7,0 280 x , ,0 9,5 300 x , ,0 9,5 320 x , ,0 9,5 340 x , ,0 9,5 360 x , ,0 9,5 380 x , ,0 9,5 e ØIv 2108 SPLIT d x D L Iv d 1 e a R 125 x , ,0 4,5 140 x , ,0 4,5 155 x , ,0 4,5 165 x , ,0 4,5 175 x , ,0 4,5 185 x , ,0 4,5 195 x , ,0 4,5 220 x , ,0 4,5 240 x , ,5 7,0 260 x , ,5 7,0 280 x , ,5 7,0 300 x , ,5 7,0 320 x , ,5 7,0 340 x , ,5 7,0 a L Z L 2208 SPLIT d x D L Iv d 1 e a R 125 x , ,0 4,5 140 x , ,0 4,5 155 x , ,0 4,5 165 x , ,0 4,5 175 x , ,0 4,5 185 x , ,0 4,5 200 x , ,5 7,0 220 x , ,5 7,0 240 x , ,5 7,0 260 x , ,5 7,0 280 x , ,0 9,5 300 x , ,0 9,5 320 x , ,0 9,5 340 x , ,0 9,5 SPLIT VERSIONS The use of Shrink Disc SPLIT on a large welded pulley. Excellent torque transmission and high resistance to bending moments. R > e LOCATION AGAINST THE HUB FACE This configuration (except in light duty applications with 2108 where a simple relieve radius of R=e is enough) requires a hub undercut with R>e for smooth hub transition. R a e SPLIT For the transmission of medium to low torque, it is convenient to use half of a SPLIT Shrink Disc which gives excellent characteristics of concentricity. ORDER EXAMPLE For a shaft diameter dalb= 95mm the outer diameter of the hollow shaft will be 130mm, therefore, considering the dimension Z=20mm, the required clamping element will be ordered as: MAV 2008 SPLIT 130x215,

32 H4 H3 H2 H1 RIGID COUPLING MEDIUM TORQUES rear cone class 12.9 DIN912 - UNI5931 inner ring ØIv Ød ØD 1004 DIMENSIONS SCREWS SPECIFICATIONS d x D H1 H2 H3 H4 I v n. Size Ma Mt Fax Pa 15 x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M x M s e front cone Ma screw tightening torque Nm Mt transmissible torque (with Fax=0) Nm Fax axial force (with Mt=0) kn Pa specific pressure on the shaft N/mm 2 s e equivalent stress on the outer ring N/mm 2 MAV 1004 coupling is a good alternative to those which, like the shell system, have already been on the market for some time. This system exploits all the advantages of Shrink Discs. Even in this case the transmissible torque depends on the pressure exercised by the cones which are coupled to the inner ring by a low degree tapering. It is most important to check the torque setting of the screws, on which will depend the performances of the rigid coupling. In favour of this type of coupling are several interesting characteristics such as the high transmissible torque in relation to the number of screws, low weight and small size and easy installing and removal operations. It is most important that between the two joined shafts there is zero misalignment, both angular and assial. Where the transmissible torque is particularly high, or in case of shaft bending moments, or in case of coupling of large shafts, it is recommended that use be made of sleeves that are locked onto the shaft by two Shrink Discs. By modifying the inner ring in the appropriate way (special rigid coupling, availability and prices on request), or adding a reduction sleeve, it is possible to connect two shafts of different diameters (see below sketch). In this case it must be taken into account that the transmissible torque is directly proportional to the smaller diameter of the two shafts. Due to the high stress to which the external rings are subject, MAV manufactures them by heat treated compound steel. Any other solution should be treated with caution. INSTALLATION 1- Before assembly ensure that the tolerances of the two shafts, which must fall within the range h7 - h9, are not too dissimilar. 2- Carefully clean the parts which should then be light-ly oiled. It is recommended that MOLYBDENUM BISULPHIDE based products are not used to lubricate the shafts. 3- Assemble the parts paying attention to the alignment of the shafts and the necessity of any angular timing. 4- Tighten the screws cross-wise using a normal spanner and at the same time check the parallelism of the rings. 5- The last two passes should be done clockwise or anti-clockwise using a torque wrench calibrated at 3-4% more than the torque shown in the catalogue. The torque should later be set to the correct value and the tightness of each bolt checked. The screws should not tighten further. If this is not the case repeat the operation from point 4. connecting two shafts of different diameters: see above description REMOVAL Loosen the screws by three or four turns. The rings should now separate if they are assisted by light taps with an hammer.

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