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Design of Belts, Ropes and Chains -- U8

INTRODUCTION
Power is transmitted from the prime mover to a machine by means of intermediate
mechanism called drives. This intermediate mechanism known as drives may be belt or chain
or gears. Belt is used to transmit motion from one shaft to another shaft with the help of
pulleys, preferably if the centre distance is long. It is not positive drive since there is slip in
belt drive.

Three types of belt drives are commonly used. They are:

Flat belt drive
V-belt drive
Rope or circular belt drive

FLAT BELT DRIVE
When the distance between two pulleys is around 10 meters and moderate power is required
then flat belt drive is preferred. This may be arranged in two ways
Open belt drive
Cross belt drive
When the direction of rotation of both the pulleys are required in the same direction , then we
can use open belt drive; if direction of rotation of pulleys are required in opposite direction
then cross belt is used. The pulleys which drives the belt is known as driver and the pulley
which follows driver is known as driven or follower.

MERITS AND DEMERITS OF FEAT BELT DRIVE

Merits:
Simplicity, low cost, smoothness of operation, ability to absorb shocks, flexibility and
efficiency at high speeds.
Protect the driven mechanism against breakage in case of sudden overloads owing to
belt slipping.
Simplicity of care, low maintenance and service.
Possibility to transmit power over a moderately long distance.

Open belt drive

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Cross belt drive

Demerits:
It is not a positive drive.
Comparatively large size.
Stretching of belt calling for resewing when the centre distance is constant.
Not suitable for short centre distance.
Belt joints reduce the life of the belt.
High bearing loads and belt stresses.
Less efficiency due to slip and creep.

Creep in Belts
Consider an open belt drive rotating in clockwise direction as shown in figure. The portion of
the belt leaving the driven and entering the driver is known as tight side and portion of belt
leaving the driver and entering the driven is known as slack side.

During rotation there is an expansion of belt on tight side and contraction of belt on the slack
side. Due to this uneven expansion and contraction of the belt over the pulleys, there will be a
relative movement of the belt over the pulleys, this phenomenon is known as creep in belts.
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Flat belt drive system

Serpentine belt system

Flat belt drive system

3D arrangement of belt drive

Velocity Ratio
The ratio of angular velocity of the driver pulley to the angular velocity of the driven pulley
is known as velocity ratio or speed ratio or transmission ratio.

Let d1 = Speed of driver pulley

d2 = Speed of driver pulley
n1 = Speed of driver pulley
n2 = Speed of driver pulley
Neglecting slip and thickness of belt,
Linear speed of belt on driver = Linear speed of belt on driven
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Velocity Ratio

The ratio of angular velocity of the driver pulley to the angular velocity of the driven
pulley is known as velocity ratio or speed ratio or transmission ratio.

Let d1 = Speed of driver pulley

d2 = Speed of driver pulley
n1 = Speed of driver pulley
n2 = Speed of driver pulley
Neglecting slip and thickness of belt,
Linear speed of belt on driver = Linear speed of belt on driven

i.e., d1 n1 = d2 n2

Considering the thickness of belt

Slip in Belts
Consider an open belt drive rotating in clockwise direction, this rotation of belt over the
pulleys is assumed to be due to firm frictional grip between the belt and pulleys.

When this frictional grip becomes in sufficient, there is a possibility of forward motion of
driver without carrying belt with it and there is also possibility of belt rotating without
carrying the driver pulley with it, this is known as slip in belt.

Therefore slip may be defined as the relative motion between the pulley and the belt in it. This
reduces velocity ratio and usually expressed as a percentage.

Effect of Slip on Velocity Ratio

Let s1 = Percentage of slip between driver pulley rim and the belt.
s2 = Percentage of slip between the belt and the driven pulley rim.
Linear speed of driver = d1 n1
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Material Used for Belt

Belts used for power transmission must be strong, flexible, and durable and must have a
coefficient of friction. The most common belt materials are leather, fabric, rubber, balata,
Camels hair and woven cotton.

Length of Open Belt

Consider an open belt drive as shown in Figure.
Let, D = diameter of larger pulley
d = diameter of smaller pulley
C = distance between centers of pulley
L = length of belt
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Where L and s are in radians.

For equal diameter pulleys L = s = radians.
For unequal diameters pulleys, since slip will occur first on the smaller diameter pulley, it is
necessary to consider s while designing the belt.

Length of Cross Belt

Consider a cross-belt drive as shown in Figure
Let, D = diameter of larger pulley
d = diameter of smaller pulley
L = Length of belt
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Ratio of Belt Tensions

Consider a driven pulley rotating in clockwise direction as shown in Figure.
Let, T1 = Tension on tight side
T2 = Tension on slack side
= Angle of lap
RN = Normal Reaction
F = Frictional force = RN

Now consider a small elemental portion of the belt PQ subtending an angle at the centre.
The portion of the belt PQ is in equilibrium under the action of the following forces, (i)
Tension T at P (ii) Tension T + T at Q (iii) Normal reaction RN (iv) Frictional force F =
RN
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Centrifugal Tension

Consider a driver pulley rotating in clockwise direction, because of rotation of pulley there
will be centrifugal force which acts away from the pulley. The tensions created because of
this centrifugal force both on tight and slack side are known as centrifugal tension.
Let, m = Mass of belt per meter length
v = Velocity in m/sec
TC = Centrifugal tension in N
r = Radius of pulley
FC = Centrifugal force

Consider a small elemental portion of the belt PQ subtending an angle shown in Figure.
Now the mass of belt PQ = M = Mass per unit length x Arc length PQ = mrd
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Effect of Centrifugal Tension on Ratio ofTensions

Ratio of belt tension considering the effect of centrifugal tension is

T1 TC
T2 TC
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Initial Tension
The motion of the belt with the pulleys is assumed to be due to firm frictional grip between
the belt and pulleys surface. To increase this grip the belt is mounted on the pulleys with
some tension when the pulleys are stationary.
The tension provided in the belt while mounting on the pulley is Initial tension and is
represented by T0. Since in actual practice the belt is not perfectly elastic, C.G.Barth has
given the relation as

Design Procedure for Flat Belt Drive

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3. Centrifugal stress

4. Capacity

Calculate eLL and ess and take the smaller value as the capacity. If the coefficient of
friction is same for both pulleys then find only es since it is smaller than eL
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Example

A belt is required to transmit 18.5 kW from a pulley of 1.2 m diameter running at 250
rpm to another pulley which runs at 500 rpm.The distance between the centers of pulleys is
2.7 m. The following data refer to an open belt drive, = 0.25. Safe working stress for
leather is 1.75 N/mm2. Thickness of belt = 10mm. Determine the width and length of belt
taking centrifugal tension into account. Also find the initial tension in the belt and absolute
power that can be transmitted by this belt and the speed at which this can be transmitted.
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Area of cross section of belt

Total given power 18.5

= 2
= = 1503.18 mm 2
Power transmitted per mm area 0.01231
Also A = b x t
1503.18
= b x 10
Therefore, b = 150.318 mm

Standard width b = 152 mm

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V- BELT DRIVE
Introduction

When the distance between the shafts is less, then V-belts are preferred. These are endless and
of trapezoidal cross section as shown in Figure. It consists of central layer of fabric and
moulded in rubber or rubber like compound. This assembly is enclosed in an elastic wearing
cover. The belt will have contact at the two sides of the groove in the pulley. The wedging
action between the belt and groove will increase the coefficient of friction making the drive a
positive one.
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Types of V - belts

a) Endless V-belt
b) Assembling of V-belt
c) Narrow V-belt
d) Wide V-belt with cogs
e) Narrow V-belt with cogs
f) Double angle V-belt
g) Great angle V-belt
h) Vee-band
i) Pol-rib belt

Advantages of V-belt over Flat belt

Advantages:
Compact and give high velocity ratio.
Provides shock absorption between driver and driven shafts.
Positive and reliable drive.
Because of wedging action in the grooves, loss of power due to slip is less.
There is no joints problem as the drive is of endless type.

Disadvantages:
Initial cost is more as the fabrication of pulleys with V-grooves are complicated.
Cannot be used when the center distance is large.
Improper belt tensioning and mismatching of belt results in reduction in service life.
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Ratio of belt tensions for V-belt or rope drive

V-Belt drive or rope drive runs in a V-grooved pulley as discussed earlier. The cross-section
of V-belt is shown in Figure.

Let, 2 = angle of groove

RN = normal reaction between each side of groove
and the corresponding side of the belt strip PQ

From Figure Resolving Forces Vertically,

R = RN sin + RN sin = 2 RN sin

Total frictional force = RN + RN = 2 RN

In case of V-belt or rope, there are two normal reactions as

shown in Figure, so that the radial reaction R is 2 RN sin
and the total frictional force = 2( RN) = 2 RN
Consider a short length PQ of belt subtending angle at
the center of the pulley as shown in Figure.
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Let, R = radial reaction between the belt length

PQ and the pulley rim = 2RN sin
RN = Normal reaction between the belt length PQ and
the pulley rim.
T = Tension on slack side of the shot strip PQ
T+T = Tension on tight side of short strip PQ
T = Difference in tension due to friction between the
length PQ and the surface pulley rim
= Coefficient of friction between the belt and pulley
surface
= effective coefficient of friction = /sin
The strip PQ will be in equilibrium (figure) under the action of four forces T, T+ T, 2
RN and R where 2 RN is the frictional force which is opposing the motion
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DESIGN PROCEDURE FOR V-BELT

1. Selection of belt c/s

Equivalent pitch diameter of smaller pulley
de = dp.Fb
Where , dp = d1
Fb = smaller diameter factor

Based on de select the c/s of belt

If d is not given them based on power select the c/s of beltand diameter d1

2. Velocity

3. Power capacity
Based on the cross-section selected, calculated the power capacity N* from the formulas.

4. Number of V belts

N= Total power transmitted in kW

N*= power capacity
Fa= Service factor
If the condition is not given then assume medium duty and 10-16 hours duty per day.

Dd

= 2 cos 1  
 2C

or

Dd

= 180 - 2 sin 1  
 2C
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Correction factor for angle of contact = Fd

(If the type is not given select V - V - Belts)

Therefore, Number of belts = i

Select a V-belt drive to transmit 10 kW of power froma pulley of 200 mm diameter mounted
on an electric motor running at 720 rpm to another pulley mounted on compressor running at
200 rpm. The service is heavy duty varying from 10 hours to 14 hours per day and centre
distance between centre of pulleys is 600 mm.
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v. Number of Belts

The nearest standard value of nominal pitch length for the selected C-cross section belt L =
2723 mm
Nominal inside length = 2667 mm

For nominal inside length = 2667 mm, and C-cross section belt, correction factor for length
Fe = 0.94
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ROPE DRIVES
Introduction

When power is to be transmitted over long distances then belts cannot be used due to the
heavy losses in power. In such cases ropes can be used. Ropes are used in elevators, mine
hoists, cranes, oil well drilling, aerial conveyors, tramways, haulage devices, lifts and
suspension bridges etc. two types of ropes are commonly used. They are fiber ropes and
metallic ropes. Fiber ropes are made of Manila, hemp, cotton, jute, nylon, coir etc., and are
normally used for transmitting power. Metallic ropes are made of steel, aluminium. alloys,
copper, bronze or stainless steel and are mainly used in elevator, mine hoists, cranes, oil well
drilling, aerial conveyors, haulage devices and suspension bridges.

Hoisting tackle (Block and Tackle Mechanism)

It consists of two pulley blocks one above the other. Each block has a series of sheaves
mounted side by side on the same axle. The ropes used in hoisting tackle are
Cotton ropes
Hemp ropes and
Manila ropes
The pulleys are manufactured in two designs i.e. fixed pulley and movable pulley.

Pulley system
A pulley system is a combination of several movable and fixed pulleys or sheaves.
The system can be used for a gain in force or for a gain in speed. Hoisting devices employ
pulleys for a gain in force predominantly. Pulley systems for a gain in forces are designed
with the rope running off a fixed pulley and with the rope running off a movable pulley.
Consider a hoisting tackle (block and tackle mechanism) as shown in fig.
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STEEL WIRE ROPES

A wire rope is made up of stands and a strand is made up of one or more layers of wires as
shown in fig. the number of strands in a rope denotes the number of groups of wires that are
laid over the central core. For example a 6 19 construction means that the rope has 6 strands
and each strand is composed of 19(12/6/1) wires. The central part of the wire rope is called
the core and may be of fiber, wire, plastic, paper or asbestos. The fiber core is very flexible
and very suitable for all conditions.

The points to be considered while selecting a wire rope are

Strength
Abrasion resistance
Flexibility
Resistance of crushing
Fatigue strength
Corrosion resistance.
Ropes having wire core are stronger than those having fiber core. Flexibility in rope is
more desirable when the number of bends in the rope is too many.

DESIGN PROCEDURE FOR WIRE ROPE

Let d=Diameter of rope
D=Diameter of sheave
H= Depth of mine or height of building
W= total load
WR= Weight of rope
dw= Diameter of wire
A= Area of c/s of rope
Pb= Bending load in the rope
Fa= allowable pull in the rope
Fu= Ultimate of breaking load of rope
n= Factor of safety
Ws= Starting load
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problem
Select a wire rope to lift a load of 10kN through a height of 600m from a mine. The weight of
bucket is 2.5kN. the load should attain a maximum speed of 50m/min in 2 seconds.

Solution:
From table select the most commonly used type of rope i.e. 619
From table for 619 rope Fu= 500.8 d2 N where d in mm
Weight per meter length = 36.310-3 d2 N/m where d in mm
Wire diameter dw = 0.063 d, mm
Area of c/s A = 0.38 d2, mm2
Sheave diameter D= 45 d, mm

From table for 600 m depth

F.O.S = n = 7
1. Total load
W= Load to be lifted + weight of skip = 10000+ 2500= 12500N
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CHAIN DRIVE
Introduction
Chain is used to transmit motion from one shaft to another shaft with the help of
sprockets. Chain drives maintain a positive speed ratio between driving and driven
components, so tension on the slack side is considered is as zero. They are generally used for
the transmission of power in cycles, motor vehicles, agricultural machinery, road rollers etc.

Merits and demerits of chain drives Merits

1. Chain drives are positive drives and can have high efficiency when operating under ideal
conditions.
2. It can de used for both relatively long centre distances.
3. Less load on shafts and compact in size as compared to belt drive.

Demerits
1. Relatively high production cost and noisy operation.
2. Chain drives require more amounts of servicing and maintenance as compared to belt
drives.
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Velocity ratio in chain drive

Let n1= speed of driver sprocket in rpm
n2 = speed of driven sprocket in rpm
z1= number of teeth on drivers sprocket
z2 = number of teeth on driven sprocket
Therefore Velocity ratio n1/n2= z1/z2

Chains for power transmission

The different types of chain used for power transmission are:
i. Block chain ii. Roller chain iii. Inverted-tooth chain or silent chain.

ROLLER CHAIN
It consists of two rows of outer and inner plates. The outer row of plates in known as pin link
or coupling link whereas the inner row of plates is called roller link. A Pin passes through the
bush which is secured in the holes of the inner pair of links and is riveted to the outer pair of
links as shown in Fig. Each bush is surrounded by a roller. The rollers run freely on the
bushes and the bushes turn freely on the pins.

A roller chain is extremely strong and simple in construction. It gives good service under
severe conditions. To avoid longer sprocket diameter, multi-row-roller chains or chains with
multiple strand width are used. Theoretically, the power capacity multistrand chain is equal to
the capacity of the single chain multiplied by the number of strand, but actually it is reduced
by 10 percent.

Inverted tooth chain or silent chain

It is as shown Fig. these chains are not exactly silent but these are much smoother and quieter
in action than a roller chain. These chains are made up of flat steel stamping, which make it
easy to built up any width desired. The links are so shaped that they engage directly with
sprocket teeth. In design, the silent chains are more complex than brush roller types, more
expensive and require more careful maintenance.
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Chordal action
When a chain passes over a sprocket, it moves as a series of chords instead of a continuous
arc as in the case of a belt drive. Thus the center line of a chain is not a uniform radius. When
the driving sprocket moves at a constant speed, the driven sprocket rotates at a varying speed
due to the continually varying radius of chain line. This variation in sped ranges from

Where
n1= Speed of the driving sprocket in rpm
d1 Pitch circle diameter of the driving sprocket in mm
z1 = number of teeth on driving sprockets.
It is clear from above that for the same pitch, the variation in speed and articulation
angle decreases, if the number of teeth in sprocket is increased. The average speed of the
sprocket as
given by

Where p = pitch of the chain in mm and z = number of teeth in sprocket. This chordal action
of the chain is shown in Fig.
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DESIGN PROCEDURE FOR ROLLER CHAIN

Let p = Pitch
d1 = diameter of smaller sprocket
d2 = diameter of larger sprocket
n1 = speed of smaller sprocket
n2 = speed of larger sprocket
z1 = number of teeth on smaller sprocket
z2 = Number of teeth on larger sprocket
L = Length of chain in pitches
C = Center diameter
Cp = Center distance in pitches

1. Pitch of chain

Where p in mm, and n1= speed of smaller sprocket

Select standard nearest value of pitch from Table
Chain number
Breaking load Fu
Measuring load w

2. Number of teeth on the sprockets

From Table for the given ratio select the number of teeth on the smaller sprocket (z1)
Since

Number of teeth on larger sprocket = z2

3. Pitch diameters
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= pitch diameter of smaller sprocket

= pitch of larger sprocket

4. Velocity

5. Required pull

6. Allowable pull

7. Number of strands in a chain

8. Check for actual factor of safety

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6. Allowable pull

10. length of chain

11. Correct centre distance

Select a roller chain drive to transmit power of 10 kw from a shaft rotating at 750 rpm to
another shaft to run at 450 rpm. The distance between the shaft centers could be taken as 35
pitches.
Data:
N= 10 kw; n1 = 750 rpm; n2 = 450 rpm; C = 35 pitches
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