UNIT - I

DESIGN OF TRANSMISSION SYSTEMS FOR FLEXIBLE ELEMENTS

Selection of V Belts and Pulleys Selection of Flat belts and Pulleys Wire ropes and pulleys
Selection of Transmission chains and Sprockets. Design of pulleys and sprockets.
Introduction
To transmit poer! fle"ible elements such as belts chains and ropes are fre#uently used. Pullerys are
mounted on a shaft and a continuous belt or rope is passed o$er them. %n belt and ropes! poer is
transmitted due to friction beteen them and pulleys. %n case of chain dri$es! sprocket heels are used.
Classiication o Dri!"s
T#$"s o B"lts
&. Flat Belts
'. V Belts
(. )ibbed Belts
*. Toothed or timing belts
&
+hain
Dri$es
Fel"ible
Dri$es
Direct Dri$es
Belt )ope ,ear Dri$e +am Dri$e
F-.T B/-TS
V0B/-TS
'
)%BB/D B/-TS
T11T2/D 1) T%3%4, B/-TS
S"l"ction o Flat B"lt Dri!"
%t depends on
Poer to be Transmitted
Speed of Dri$er and Dri$en Shafts
Shaft relationship
Ser$ice conditions
Speed reduction ratio
+entre distance
Positi$e dri$e re#uirement
Space a$ailable
(
T#$"s o Flat B"lt Dri!"s
%& O$"n B"lt Dri!"
5sed ith shafts arranged parallel and rotating in same directions
'& O$"n B"lt Dri!" (it) On" Idl"r *ull"#
5sed ith shafts arranged parallel and hen an open belt dri$e cannot be used due to small angle of
contact on the smaller pulley.
%dler pulleys also knon as 6ockey pulleys are pro$ided to obtainhigh $elocity ratio and hen the
re#uired belt tension can not be obtained by other means.
+& O$"n ,"lt dri!" (it) -an# idl"r $ull"#
*
5sed hen it is desired to transmit motion from one shaft to se$eral parallel shafts
.& Cross"d or t(ist"d ,"lt dri!"
5sed ith shafts arranged parallel and rotating in the opposite directions.
7
/& 0uart"d t(ist or 0uart"r turn dri!"
5sed ith shafts arranged at right angles and rotating in one definite directions
1& St"$$"d or Con" $ull"# dri!"
5sed for changing the speed of the dri$en shaft hile the main or dri$ing shaft runs at constant speed.
8
2& Fast and loos" $ull"#
5sed hen the dri$en shaft is to be started or stopped hene$er desired ithout interfering ith the
dri$ing shaft.
3& Co-$ound dri!"
5sed hen se$eral units are to be dri$en from one central shaft.
B"lt Mat"rials
The desirable properties of belt materials are
2igh +.1.F
Fle"ibility
Durability
Strength
9
&. -eather Belts
made of animal hides
-eathers for belting may be tanned ith oak! or chrome salts.
1ak tanned belt is fairly stiff
+hrome tanned leather is soft and pliable
Belts specified according to number of layers as single ply! double ply or triple ply belts. Double
belts or triple belts are made by cementing to or three strips together ith hair sides outside.
'. Fabric : +otton Belts
1btained by stitching to or more plies of can$as or cotton duck. Treated ith linseed oil to make
it ater proof. These belts are cheap and most suitable for farmork! #uarry and sa mills.
(. )ubber Belts
These belts are made up of plies of fabric impregnated ith $ulcani;ed rubber or synthetic
rubber.
/asily made endless.
Sa mills! creameries! chemical plants and paper mills largely use rubber belts
*. Balata Belts
Balata is gum similar to rubber. Balata belts are made in the same manner as the rubber belts made.
They are acid proof and ater proof. These belts cannot be used at temperatures abo$e *<=+!
because at this temperature it softens and became sticky.
7. 4ylon +ore Belts
8. +amel>s 2air belts
4"locit# ratio o ,"lt dri!"
The ratio beteen the speeds of the dri$er and dri$en respecti$ely.
4"locit# ratio 5 4'?4& @ A'?A& @ D?d
Where D : d @ diameter of dri$er and dri$en respecti$ely
4' : 4& @ Speed of dri$en : dri$er respecti$ely
A' : A& @ .ngular $elocities of dri$en : dri$er respecti$ely
E"ct o ,"lt t)ic6n"ss on !"locit# ratio
+onsidering the thickness of belt BtC
4'?4& @ BD D tC?Bd D tC
E"ct o sli$ on !"locit# ratio
Slip is defined as the relati$e motion beteen the belt and pulley.
The difference beteen the linear speed of the pulley rim and belt is the measure of slip.
The reason is! there is a tendency for the belt to carry ith it on the underside beteen
the pulley and the belt. The frictional grip beteen the pulley and the grip is insufficient.
The slip reduces the $elocity ratio of the dri$e.
Slip can be reduced BE
F
)oughening the belt by dressing
By croning the pulley
-et S& @ Percentage slip beteen the dri$er and the belt.
S' @ Percentage slip beteen the dri$en and the belt.
S @ Total percentage slip @ S& D S'
Velocity ratio @ 4'?4& @ D?d G& BBS& D S'C?&<<CH @ D?d G& BS?&<<CH
%f thickness of the belt BtC is considered! then
Velocity ratio @ 4'?4& @ BDDtC?BdDtC G& BBS& D S'C?&<<CH
@ BDDtC?BdDtC G& BS?&<<CH
E"ct o cr""$ on ,"lt
-et I& @ stresses in the belt on tight side
I' @ stresses in the slack side
/ @ Eoung>s modulus of belt material
Velocity ratio @ 4'?4& @ BDC?BdC GG/ D J I& H?G/ D J I' HH
La( o B"ltin7
-aof belting states that! the centre line of the belt! as it approaches the pulley! must lie in a plane
perpendicular to the a"is of that pulley or must lie in the plane of the pulley. 1therise the belt ill run
off the pulley
*o("r Trans-itt"d ,# t)" ,"lt
P @ BT& T' C $ atts
Where T& @ tension in the tight side.
T' @ tension in the slack side.
V @ linear $elocity of the belt in m?s
C"ntriu7al T"nsion 8Tc9
.s the belt mo$es round the pulley it ould e"perience a centrifugal force hich has the tendency to
separate the belt from the pulley surface.
To maintain the contact beteen pulley and belt! the centrifugal force produce additional tension in the
belt! this is knon as the centrifugal tension.
Tc @ aste load! increases the tension ithout increasing poer capacity.
Tc 5 mV
'
m @ mass ? unit length BKg?mC
L
V @ linear $elocity Bm?sC
%nitial tension
To 5 :T% ; T'<=' :n"7l"ctin7 c"ntriu7al t"nsion<
To 5 :T% ; T' ; 'Tc<=':consid"rin7 c"ntriu7al t"nsion<
3a"imum tension hen the belt sub6ected to centrifugal tension
T @ T% ; Tc
T 5 -a>i-u- str"ss X cross s"ctional ar"a o t)" ,"lt
5 ? , t
? 5 -a>i-u- str"ss in N=-
'
, 5 (idt) in -
t 5 t)ic6n"ss in -
When +entrifugal tension taken for consideration
Tension in tight side is Tt& @ T& D Tc
Tension in tight side is Tt' @ T' D Tc
Then Poer Transmitted by the belt
P @ BTt& Tt' C V att
.fter simplification P @ BT& T' C V att
%t shos centrifugal tension doesn>t ha$e any effect on poer transmission.
Ratio o dri!in7 t"nsions o lat ,"lt dri!"&
T
&
?T
'
@ e
MN
+onsidering centrifugal tension
Tension ratio @
T
t&
?T
t'
@ BT
&
0mV
'
C?BT
'
0 mV
'
C @ e
MN
@)"r"
M @ coefficient of friction beteen belt and pulley
N @ angle of contact or angle of rap
+ondition for 3a"imum poer transmission
The poer transmitted is ma"imum hen the centrifugal tension Tc is one third of the ma"imum
tension BTC.
Bi.eC T @ ( Tc
3a"imum $elocity V @ JBT?(mC
&<
Str"ss"s in ,"lt
%9 Du" to -a>i-u- (or6in7 t"nsion
?t 5 Ti7)t sid" t"nsion=cross s"ction ar"a& 5 T% = 8,>t9
'9 Du" to ,"ndin7
?, 5 8E > t9=d&
+9 Du" to c"ntriu7al orc"
?c 5 Tc = 8,>t9 5 -!
'
=8,>t9 5 A!
'
sinc" A 5 -=8,>t9
.9 Ma>i-u- str"ss in ti7)t sid" o s-all"r $ull"#
?-a> 5 ?t ; ?, ; ?c
D"si7n *roc"dur" or lat ,"lt dri!" usin7 Manuactur"s Catalo7u"
St"$ % From the gi$en data determine the design poer using the folloing procedure
a. From the center distance and dia of pulley find speed ration B%C O% D i @ dia of larger
pulley ? dia of smaller pulley.
i @ Speed of smaller pulley
Speed of larger pulley
b. +alculate the $elocity using the formula
V @ dn ? 8< or D4 ? 8<
c. Determine the arc of contact from page 9.7. of data book and select the rating of the
belt at &< m?s and &F<
o

d. Determine the poer rating for the belt for the actual $elocity and the actual arc of
contact.
e. Fi" the number of plies and calculate the rating of the belt.
f. +alculate the design poer using the formula
Design poer@ )ated Poer " Ks ? Kc
St"$ ' Determine the idth of the belt using the formula idth
Width @ Design poer and standardi;e it
-oad )ating
&&
St"$ + +alculate the pulley idth and length of the belt
St"$ . Write the specification
St"$ / Do the pulley design! +alculate the dia of pulley! idth of the pulley and
thickness of the pulley in from page 4o. 9.79
St"$ 1 Dra the neat diagram of pulley ith dimensions.
*ro,l"-s
*ro,l"- %
D"si7n a lat ,"lt to trans-it %' 6( at ./B r$- or an "n7in" to a s)at runnin7 at %'BB
r$- t)" dia o "n7in" $ull"# is 1BB -- and c"ntr" distanc" ' -
Given data
P @ &' k
4 @ *7< rpm
n @ &'<< rpm
D @ 8<< m
+D @ ' m
Step 1: i
a. Speed ratio i @
n
@
&'<<
@ '.889
4 *7<
i 5 '&112
i @
D
@ '.889@
8<<
d d
d 5 ''/ -
,& 4"locit#
V @
dn
@
" .''7 " &'<<
@ &*.&(9 m?s
8< 8<
V @ &*.&(9 m?s
&'
C. .rc of +ontact 9.7*BPS, Data BookC
@ &F< 0
<.8<< <.''7
"8<
'
.rc of +ontact P @ &8F.97
o
Selecting high speed belt load rating of belt at &F<
o
and &< m?s
-oad rating at &F<
o
: &< m?ac @ <.<'( k ? mm ? ply
d. -oad rating at &8F.97 arc of contact : V @ &*.(9 3?sec.
@ <.<'( "
&*.&(9
"
&8F.9F
&< &F<
-oad )ating @ <.<(<*F k?mm?ply
Step 1: i
a. Speed ratio i @
n
@
&'<<
@ '.889
4 *7<
i 5 '&112
*ro,l"- '
%n electric motor dri$es the e"haust fan using flat belt design the belt dri$e as per the folloing
specification a center distance beteen the pulley is '.7 m. The permissible stress on the belt is
'.7 n?mm
'
the thickness of the belt is 7 mm and its able to transmit ''.7 k check the idth of
the belt using standard formula .
Dia-"t"r 8--9
Dri!"r
8Motor *ull"#9
Dri!"n
8Fan $ull"#9
BrodC *<< &8<<
<.( <.'7
Speed BrpmC 9<< Q
Given
P @ ''7 k
d @ *<< rpm
&(
.rc of +ontact P @ &F< 0
D0d
" 8<
+
D @ &8<< mm
+D @ '.7 m
Step 1:
a. Speed ratio i @
D
@
&8<<
@ *
d *<<
i 5 .
i @
n
@
9<<
@ &97 rpm
4 *
'& Calculation o ,"lt s$""d
V @
dn
@
" <.* " 9<<
@ &*.88 m?s
8< 8<
V @ &*.88 m?s
C. .rc of +ontact
.rc of +ontact P @ &F< 0
D0d
" 8<
+
@ &F< 0
&.8<< <.*<<
"8<
'
.rc of +ontact P @ &7&.'
o
Selecting high speed belt load rating of belt at &F<
o
and &< m?s
<.<'( k ? mm ? ply
-oad rating at '<F.F
o
arc of contact : Velocity @ &*.88 3?sec.
@ <.<'( "
&*.88
"
&7&.'
&< &F<
4o. of plies @ F
-oad )ating @ <.<'F " F @ <.''* k?mm
Design Poer @ Fatal Poer " ks ? kc
ks @ &
kc @ &.<F
@ ''.7 " & ? &.<F @ '<.F( $
Width @ '<.F( ? <.''* @ L(mm
&*
(
(
Width @ '<< mm
Pulley idth @ belt idth D '7
@ '<< D '7 @ ''7 mm
-ength belt
- @ 'c D

BDDdCD
BD0dC
'
' *c
- @ 7 D

B'CD
B&.7C
'
' &<
@ F'Lm
The obtain initial tension <.7 R of belt length should be shorten
.ctual -ength @ BLL.7 ? &<<C " c @ <.LL7 " F.'L @ F.'* m
Specification
Belt idth @ '<< mm
4o.of plies @ F
Width of pulley @ ''7 mm
-ength of pulley @ F.'* mm
BaC 4o.of arm @ * for dri$en pulley
@ 8 for dri$er pulley
BbC 5?s of arm elliptical
Thickness of arm near boss @ '.L* aD ? *n
Dri$er pulley @ '.L*
(
B''.7 " &8<<C?B*"8C
@ &'.7 mm
Dri$en pulley @ '.L* ''7 " *<< ? '* @ *7.8F m
Thickness of arm near boss @ '?( " breath of boss
Dri$er pulley @ '?( " 9'.7
@ *F.(( mm
Dri$en pulley @ '?( " *7.8F @ (<.*7 mm
)adius of +?s of arm @ S D
Dri$er pulley @ B( ? *C " *7.8F
@ (*.'8 mm
3in -ength of the bore l @ B'?(C " a
@ '?( " ''7 @ &7<mm
Thickness of boss @ <.*&
'
aD D 8
Dri$er pulley @ <.*&
'
''7 " &8<< D 8
@ (7.(& mm
Dri$en pulley @ <.*&
'
''7 " *<< D 8
@ '*.*8 mm
Poer BT&0T'CV
&7
T&0T' @ B''.7 " &<C
(
? &*.8<
@ &7(*.9F
T&?T' @ e

@ e
<.(' " '.7

T& @ '.&&T'
T'&.&&9 @ &7(*.9F
T' @ &(*.<*
T& @ 'L<F.9L
3a" Tension T @ Fn t
T@ T& D T+
T @ T&
'L<F.9L @ F8 " '.( " 7
b @ '7'.L mm
b @ '7(mm
Selecting high speed belt load rating of belt at &F<
o
and &<m?s
-oad rating at &F<
o
d &< ?m?sc @ <.<'(k?mm?pl
d. -oad rating at &79.7
o
arc of contact V @ &F.F*L m?s
@ <.<'( "
&F.8*L
"
&79.7
&< &F<
-oad )ating @ <.<(9L k?mm?ply
e. 4o. of plies 9.7'
The minimum pulley dia is '7< mm and $elocity is &F.F*L m?s
4o. of plies @ 7
-oad rating @ <.<(9L " 7
@ <.&FL7 k?mm
g. Design Poer
Design Poer @ Fatal Poer " ks ? kc
ks @ &
kc @ &.<F
Design Poer @ &< " & ? &.<F @ L.'8 k
*ro,l"- +
Design a flat belt dri$e for a tan running at (8< rpm hich is dri$en by &<k! &**< rpm belt
dri$e is open type hen the space a$ailable for centre distance 'm appro"imately diameter of
dri$en pulley is &<<< mm.
Given
n @ &**< rpm
4 @ (8< rpm
&8
P @ &< k
c @ ' m
+D @ &<<< mm
Solution
%& Calculation o *ull"# dia
D
@
n
d 4
d @
&<<<
@'7<mm
*
'& Calculation o ,"lt s$""d
V @
dn
@
" &<<< " (8<
@ &F.F*L m?s
8< 8<
3. .rc of +ontact
.rc of +ontact P @ &F<
o
0
D0d
"8<
o
+
.rc of +ontact P @ &79.7
o
*. Selecting high speed belt load rating of belt at &F<
o
and &< m?s
@ <.<'( k ? mm ? ply
7. -oad rating at &79.7
o
a: &F.F*L 3?s
@ <.<'( "
&F.F*L
"
&79.7
&< &F<
@ <.<(9L k?mm?ply
4o. of plies @ 7 Bfor d @ '7< mm! V @ &F.F*LC
-oad )ating @ <.<(9L " 7 @ <.&FL8 k?mm
Design Poer @ Fatal Poer " ks ? kc
@ &< " &.' ? &.<F @ &&.&&
Width of belt @ Design Poer ? -oad rating
@ &&.&& ? <.&FL8
Width of belt @ 7F.8< mm
Pulley idth @ belt idth D &(
&9
(
(
@ 98 D &( @ FL mm
Calculat" o$"n ,"lt l"n7t)
- @ 'c D

BDDdCD
BD0dC
'
' *c
-@ '"'D

B&D<.'7CD
B&0<.'7C
'
' * "'
- @ 8.<((m
%nitial tension
.ctual -ength reduced @ B8.<(( " &<
(
C & ? &<<C
@ 8<.(( mm
.ctual -ength @ 8.<(( " &<
(
0 8<.(&
@ 7L9'.L8 mm
Specification
Belt Speed @ &F.F*L 3?s
.ctual -ength Belt @ 7L9'.L8 mm
Pulley idth @ FL mm
*ull"# D"si7n
Selecting +% Pulley
Dri$er Pulley @ * arms
Dri$en Pulley @ L arms
+?s of arm is elliptical
Thickness of arm b @ '.L* aD ? *n
Dri$er pulley @ '.L* BFL " &<<<C?B*"8C
@ *7.7<8 mm
Thickness of arm b! near arm
@ '?( " *7.7<8
@ (<.((
)adius of +?s of arm r@ S b
r @ B( ? *C " *7
@ ((.97 mm
*ro,l"- .
Design a flat belt to transmit &' k *7< rpm for an engine to a shaft running at &'<< rpm the dia of
engine pulley is 8<< mm centre distance is ' m gi$en
P @ &'k
/ngine Speed @ *7< rpm @ 4
Shaft Speed @ &'<< rpm @ n
/ngine pulley dia @ 8<< mm @ D
+D @ ' m
+alculate the speed ratio
&F
i @
n
@
&'<<
'.8<9
4 *7<
i @
D
@ d @
8<<
d '.889
d 5 ''/ --
'. +alculation of belt speed
V @
dn
@
"8<<"*7<"&<
0(
@ &*.&(9 m?s
8< 8<
3. .rc of +ontact
.rc of +ontact P @ &F<
o
0
D0d
"8<
o
+
.rc of +ontact P @ &F<
o
0
8<<0''7
"8<
o
+
.rc of +ontact P @ &<F.97
o
*. Selecting high speed belt load rating of belt at &F<
o
and &< m?s
@ <.<'( k ? mm ? ply 9.7*BPS, Data BookC
7. -oad rating at &<F.97
o
a: &*.&(9 3?s
@ <.<'( "
&*.&(9
"
&8F.97
&< &F<
@ <.<(<* k?mm?ply
4o. of plies @ 7 Bfor d @ ''.7 mm! V @ &*.&(9 m?sC
-oad )ating @ <.<(<* " 7 @ <.&7'< k?mm
Design Poer @ Fatal Poer " ks ? kc
ks @ Ser$ice -oad +orrection factor
ks @ & B.ssume 4ormal loadC
kc @ &.<*
&L
(
(
(
Design Poer @ &' " & ? &.<* @ &&.7(F k
Width of belt @ Design Poer ? -oad rating
@ &&.7(F ? <.&7'7
Width of belt @ 97.88 mm 9.7' BPS, Data BookC
Pulley idth @ belt idth D &(mm 9.7*BPS, Data BookC
@ 98 D &( @ FL mm
L"n7t) o t)" B"lt 8Assu-" O$"n B"lt9 2&/+BPS, Data BookC
- @ 'c D

BDDdCD
BD0dC
'
' *c
-@ ' " '<<< D

B8<<D''7CD
B&8<<0''7C
'
' * "'<<<
- @ 7.(&( " &<
(
mm
To gi$e %nitial tension to the belt the length is reduced by one percentage
-ength reduced @ B7(&( C " B& ? &<<C
@ 7(.&( mm
.ctual -ength of the belt @ 7(&(
@ 7.'7LF m
Specification
Width of the belt @ 98 mm
4o of plies @ 7
-ength of the Belt @ 7.'7LF m
Pulley idth @ FL mm
*ull"# D"si7n
Selecting +% Pulley 9.78BPS, Data BookC
Dri$er Pulley @ 8 arms
Dri$en Pulley @ * arms
b. +ross section s of arm is elliptical
c. Thickness of arm b @ '.L* aD ? *n
Dri$er pulley @ '.L* BFL " 8<<C?B*"8C
@ (F.(F mm
b @'.L* aD ? *n
Dri$er pulley @ '.L* BFL " ''7C?B*"8C
@ (&.8F mm
Thickness of arm b! near arm
b& @ '?( " (F.(F Bfor dri$erC
'<
(
(
(
@ '7.7F mm
b' @ '?( " (&.8F Bfor dri$enC
@ '&.&' mm
)adius of +?s of arm r@ S b
r @ B( ? *C " (F.(F
@ 'F.9F7 mm Bfor dri$erC
r @ B( ? *C " (&.8F
@ '(.98 mm Bfor dri$enC
3inimum -ength of bore
l @ '?( " a
@ B' ? (C " FL
@ 7L.((( mm
BfC Bd&0 d'C ? ' @ <.*&'

aD D 8
@ &7.7&7 Bdri$erC
Dri$er pulley @ <.*&' Ba " dC D 8
@ <.*&' FL " ''7 D 8
@&9.&FF mm Bfor dri$enC
*ro,l"- /
. Stone crushing machine recei$es poer from motor rated at 7< k at &F<< rpm by means of a
flat belt pulley dia are '<< mm and 9<< mm distance beteen pulley is * m design the belt
dri$e the direction or rotation of ' pulley opposite to each other.
Given
P @ 7< k
+.D. @ * m
D @ 9<< mm
d @ '<< mm
n @ &F<< rpm
%& Calculat" t)" s$""d ratio
i @
D
@
9<<
(.7
d '<<
'& Calculation o ,"lt s$""d
V @
dn
@
"'<<"&F<<"&<
0(
@ &F.F*L m?s
8< 8<
3. .rc of +ontact
.rc of +ontact P @ &F<
o
0
D0d
"8<
o
+
'&
i @
n
@ (.7
4
9.7*
4 @
&F<<
@ 7&*.'F7 rpm
(.7
P @ &F<
o
0
9<<'<<
"8<
o
*<<<
.rc of +ontact P @ &9'.7
o
*. Selecting high speed belt load rating of belt at &F<
o
and &< m?s
@ <.<'( k ? mm ? ply
7. -oad rating at &9'.7
o
a: &F.F*L 3?s 9.7(
@ <.<'( "
&F.F*L
"
&9'.7
&< &F<
@ <.<*&7 k?mm?ply
''