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  1. How to Connect Shafts

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     Shaft couplings play a key role in transferring power or torque for motors, pumps, compressors, conveyors, turbines, and other mechanical equipment. Rigid shaft couplings can achieve this goal and allow for different types of shaft connections. Stepped couplings can be used for connecting different size shafts.  Shaft adapters can solve compatibility issues, such as changes in shaft size or length. Inch-to-metric couplings can solve incompatibilities occurring when mating an English shaft to a metric one.  Custom shaft couplings and adapters can accommodate unusual variations or configurations not satisfied by standard products.

    Stafford Manufacturing produces shaft collars, rigid shaft couplings, and specialty mechanical products for motion control, power transmission, automation, and other MRO and OEM applications. Here we’ll discuss how to connect shafts, including those with different sizes, measurement systems, and other specifications.

     

    Two-Piece Split Clamp-Style Coupling

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    What If I Have Two Different Sized Shafts?

    Connecting shafts of different sizes is a common issue that can be solved with compatible rigid shaft couplings. Designed for perfectly aligned shafts, rigid shaft couplings mate shafts with identical or different diameters while maintaining high torque transfer and preventing backlash. Many configurations of our shaft couplings have stepped bores to connect shafts that differ in size. We offer standard and custom versions of these types of rigid shaft couplings:

     

    Two-Piece Split Precision Sleeve Coupling with Keyways

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     What If Need a Close Tolerance Fit?

    A close tolerance fit is a necessity whenever you are putting the coupling on a precision machined shaft. Precision sleeve couplings are uniquely suited for applications requiring extremely precise machined shaft alignment and a close tolerance shaft-to-coupling fit.

     

    Stafford’s exclusive Precision Sleeve Coupling features a solid center section that provides a close tolerance fit on ground shafting, includes a keyway, and the Accu-Clamp™ design which incorporates integral self-centering clamping collars at both ends. This product assures shaft alignment with zero backlash. To assure precise shaft alignment, it maintains <.001″ TIR concentricity while in use. It is precision machined, non-marring, easy to adjust, with high clamping power.

    Stafford offers the following types of Precision Sleeve Couplings:

     

    Inch-Metric Conversion Coupling

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    What If I’m Connecting an Inch Shaft to a Metric Shaft?

    Inch-metric conversion couplings have a bore on one side measured in inches and the other side in a metric size. Stafford Manufacturing carries a full range of common sizes in our selection of inch-metric conversion couplings. External dimensions and screws are in inches. These couplings can be further modified to include keyways if needed.

    Our inch-metric conversion couplings can mate inch and metric shafts with zero backlash and smooth bores, which protect the shafts from damage. They have superior torque capacity compared to set screw type couplings.

    Stafford offers the following types of inch-metric conversion couplings:

     

    Step-Up Shaft Adapter

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    What If I Need a Shaft Adapter?

    While shaft couplings can connect shafts of different diameters, shaft adapters enable connections when:

    • One or both shafts are not long enough to be effectively connected with a coupling
    • Shafts differ in diameter and a coupling does not accommodate the difference
    • Shaft damage would result in a poor transfer of power or motion
    • Shaft replacement is not recommended due to cost or other considerations

    Available in step-up or step-down configurations, shaft adapters act as both an extension to an existing shaft and as a way to increase or decrease shaft diameter using a straight-bore or standard stepped-bore coupling. Our rigid shaft adapters use a clamp-style attachment to avoid shaft damage and come in keyed and keyless styles. 

     

    Rigid Shaft Coupling Configurator

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    None of These Work for Me — What Do I Do?

    Uncommon sizes or combinations of shaft diameters, shapes, keyways, or other configurations can be solved with custom shaft couplings or adapters, avoiding the need for complete shaft replacement or system reconfiguration. Customers can custom-design couplings through our rigid shaft coupling configurator tool, which can provide product recommendations based on your specifications.

    Because manufacturing custom parts is our specialty, our expert team welcomes requests for customized rigid couplings to meet your precise requirements. Custom modifications we commonly make include:

    • Bores: adjustments for special diameters, keyways, and threadings
    • Outside Diameters: surface modifications (e.g. knurling, flats, pulley grooves, notches)
    • Holding Power: adjustments for extra heavy-duty operation
    • Circumferential Keyways: to control axial shift
    • Shaft Shapes: to connect different shaped shafts
    • Balancing: to minimize misalignment, vibration, and wear
    • Materials & Finishes: meeting customer material or surface finishing requirements
    • Shaft Extenders: to accommodate length, duty, configuration, or other needs

    Customers may also modify our fully machinable Shaft Adapter Max to meet their specific needs. It is available with keyways or without, offering multiple configurations to easily extend and adapt for hex, square, or threaded shafts.

    Custom Fabrication by Stafford Manufacturing

    At Stafford Manufacturing, we pride ourselves on our wide range of standard shaft couplings, collars, adapters, and related products. Our innovative designs, extensive catalog of stock components, and customization capabilities illustrate our commitment to industry-leading components and customer service. Contact us to learn more about our standard and custom components for power transmission, motion control, automation, and related applications, or request a quote for your next project.

     

     

    Stafford Manufacturing Corp.

    256 Andover St.

    Wilmington, MA 01887

    Phone: 978.657.8000

    Email: sales@staffordmfg.com

    Website: https://www.staffordmfg.com

     

  2. General Precision Products

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    General Precision Products at Stafford

    Stafford offers several types of general precision products including both machined components and sheet metal components and enclosures. A wide variety of options are available and can be custom designed to meet your unique applications.

    • Machined components. Machined components are created using various precision machining processes, such as CNC milling, waterjet cutting, laser engraving, welding, CNC turning, and more. Machined components are used throughout demanding industries that require extremely tight tolerances and high part-to-part repeatability. 
    • Sheet metal components. Sheet metal components are produced using techniques like bending, cutting, punching, welding, and more. Whether your application requires simple parts, mated assemblies, or full enclosures, Stafford’s sheet metal fabrication meets your exact requirements .
    • Enclosures. Off-the-shelf enclosures can be modified with processes like laser cutting, MIG/TIG welding, robotic welding, and more. Many industries like biomedicine and aerospace rely on fabricated enclosures to protect sensitive components.

    Applications

    Our machined and sheet metal components are used in countless industries, especially those requiring highly accurate and repeatable parts. Depending on the particular industry, general precision products can be either simple or complex and can be made in a variety of sizes and shapes to fit different needs. 

    Examples of industries that rely on general precision products from Stafford Manufacturing include:  

    • Aerospace
    • Biomedicine
    • Construction
    • Mining
    • Pulp & Paper
    • Medical
    • Optical
    • Automation

    Capabilities: Stafford Manufacturing

    At Stafford Manufacturing, our general precision capabilities include a range of machining and sheet metal fabrication processes. We can produce components in various sizes, shapes, and complexities to meet the needs of diverse industries. 

    Our precision machining capabilities include:

    • CNC Milling
    • CNC Turn Mill
    • CNC Turning
    • CNC Bar-Fed Lathes
    • Waterjet Cutting
    • Laser Engraving
    • Welding
    • 3D Prototyping
    • Prototyping Machining

    Our sheet metal fabrication capabilities include:

    • Bending
    • Cutting
    • Laser Etching
    • Punching
    • Welding
    • Hardware Insertion

    Additionally, we deliver a range of secondary processes, including painting, plating, assembly, silk-screening, and more.

    Finished Products for Complete Applications

    Many advanced industries rely on precision products for various applications. At Stafford Manufacturing, we have the capabilities to deliver high-quality, accurate products using various machining and sheet metal fabrication techniques. Through our expertise and extensive capabilities, we can deliver the components you need with the utmost precision and repeatability. 

    For more information about our general precision products and other capabilities, contact us or request a quote today.

  3. Prototyping Parts and the SPARC Program Solution

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    Prototyping new parts isn’t always an easy endeavor even for experienced manufacturers. The process of producing, testing, and evaluating new components takes quite a bit of time and effort for all involved. As necessary as prototyping is, the traditional path for it is anything but efficient. Thankfully, Stafford Manufacturing is helping to change that with the new SPARC program. Read on to learn more about the various challenges of mechanical prototyping and how the SPARC program is tackling them.

    What are the Challenges of Prototyping?

    There are many challenges that manufacturers face when custom prototyping. These include:

    • Development time. Prototypes often require significant amounts of development time, both initial and for continued testing. New products go through several stages of development, but each new stage inevitably costs quite a bit of time, money, and effort.
    • Prototyping expenses. The more development time and hardware the prototyping process requires, the more expensive it will be.
    • Production problems. During the prototyping process, certain production issues may arise such as process issues, shortages of materials, material incompatibility with the design, and accuracy issues in the prototyped design versus the original blueprint.
    • Software issues. When converting original design files into a CAD model, there is often a risk of defects such as data loss. This greatly affects the surface quality and overall precision of the prototype. 
    • User confusion. A design may work on paper but be harder to put into action when in the hands of a user. Changes from the original design to the current one can also be a source of confusion if certain features are missing. 

    The Stafford Prototype and Repair Collar System (SPARC)

    Stafford Manufacturing Corp. Introduces Prototype and Repair Collar SystemPrototype manufacturing can be greatly simplified by using Stafford Manufacturing’s new SPARC program. SPARC is a 3-D printing solution to mechanical prototyping, allowing manufacturers to quickly produce models of shaft collars at a fraction of the cost and effort. 3-D printed models such as these can be created in only a few hours, greatly reducing both the amount of production time as well as the downtime in between production. This also means faster testing and faster feedback on designs, which further cuts design time.

    The SPARC system provides a precision-machined Master Collar, available in one-and two-piece split clamp styles, in three OD sizes, in Steel, Stainless Steel and Aluminum, and is designed to accept a customized 3D printed insert. This provides a great amount of variety for testing new designs while keeping prototypes to a precise standard. The 3-D printed prototypes do not compromise on quality, allowing testers to get a sense of how the final version of the collar will operate. Additionally, Stafford Manufacturing assists manufacturers by providing a free library of shaft collar designs to use for prototyping, saving time that would otherwise be used in designing a custom collar.

    Stafford Manufacturing for Prototyping Parts

    Prototyping can be a costly, tedious, and imprecise venture, but Stafford Manufacturing’s SPARC system of 3-D prototype generation is set to change that. Providing many of the things that traditional prototyping lacks (accuracy in design, ease of manufacturing, lower costs, quicker manufacturing, etc.), SPARC enables more effective testing and a better end product.

    To learn more about SPARC, contact Stafford Manufacturing today. As industry leaders in prototyping and manufacturing shaft collars, rigid shaft couplings, and other specialty mechanical parts, we have the experience and skill needed to provide excellent results at fair prices.