Sprocket and Chain Drives

 Sprocket - a profiled wheel with teeth that meshes with a chain, track or other perforated
or indented material.
 Chain - a connected flexible series of metal links used for fastening or securing objects
and pulling or supporting loads.

Functions of sprocket and chain drive

 Transmitting power
 Conveying materials
 Timing purposes

Advantage
1. As no slip takes place during chain drive, hence perfect velocity ratio is obtained.
2. Since the chains are made of metal, therefore they occupy less space in width than a belt or
rope drive.
3. It may be used for both long as well as short distances.
4. It gives a high transmission efficiency (upto 98 percent).
5. It gives less load on the shafts.
6. It has the ability to transmit motion to several shafts by one chain only.
7. It transmits more power than belts.
8. It permits high speed ratio of 8 to 10 in one step.
9. It can be operated under adverse temperature and atmospheric conditions.

Disadvantage
1. The production cost of chains is relatively high.
2. The chain drive needs accurate mounting and careful maintenance, particularly lubrication and
slack adjustment.
3. The chain drive has velocity fluctuations especially when unduly stretched.

Types of sprocket
 Type A: Plain Plate Sprockets – are sprockets without hubs and held onto shafts by a
flange
 Type B: Hub on one side - Type B sprockets have one hub protruding from one side of
the sprocket.
 Type C: Hub on both sides – are sprockets that have hubs extended on both sides of the
sprockets plate surface.
 Type D: Detachable hub - has a split hub which could be of Type B or Type C design.
This type permits installation or replacement of the sprocket without disturbing shafts or
bearings.

Types of sprocket according to body style

 Arms: This type of sprocket is used where large sprocket sizes are needed. The use of arms
lowers weight-- and therefore inertia--and cost.
 Split body: By segmenting the sprocket body the sprocket is easier to assemble and
disassemble from around a shaft.
 Plate body: A plated body provides stronger sprocket structure, and is typical on smaller
circumference sprockets.
 Fabricated cuts: Fabricated, cut sprockets are flame cut and have flame or induction
hardened components.
 Flanged: With a short extension on the sprocket rim, the chain's plates rest on the sprocket
as well, allocating some load from the chain's pins. These are sometimes called "chain-
saver sprockets" because of the enhanced chain lifespan.
Sprocket Tooth Style
 Double-duty sprockets incorporate an extra row of teeth between the chain's pins, so once
one set of sprocket teeth are worn, the drive can be adjusted to run on the second, unused
set of teeth.
 Hunting sprockets have a similar concept as double-duty sprockets, with the half-pitched
sprocket teeth earning wear alternatively..
 Multiple-duty sprockets operate without sprocket tooth alteration, but also have flanges
to distribute some load to the chain plates
 Skip-tooth sprockets are of double-pitch and only engage the chain on every other pin.
This lightweight option places more wear on the sprocket, but less on the chain.
 Gap-tooth sprockets are of specialty design and are used in conjunction with roller chains
containing attachments such as hooks or saw blades. These are usually custom fabricated.

Sprocket mounting
 Set screws
 Keyway:
 Simple bore:
 Taper bushing:
 Shear pin:

Types of Chain
• Roller Chain
• Standard Roller Chain
• Heavy Series Roller Chain
• Multiple-Strand Roller Chain
• Double-Pitch Roller Chain
• Self-Lubricated Roller Chain
• Pre-Lubed Roller Chain
• Detachable Chain
• Pintle Chain
• Silent Chain
• Leaf Chain
• Laminated Metal Chain
 Gear Drives
Advantage
1. It transmits exact velocity ratio.
2. It may be used to transmit large power.
3. It may be used for small centre distances of shafts.
4. It has high efficiency.
5. It has reliable service.
6. It has compact layout.

Disadvantage
1. Since the manufacture of gears require special tools and equipment, therefore it is costlier
than other drives.
2. The error in cutting teeth may cause vibrations and noise during operation.
3. It requires suitable lubricant and reliable method of applying it, for the proper operation of
gear drives.

Classification of Gears
• According to the peripheral velocity of the gears
(a) Low velocity, (b) Medium velocity, (c) High velocity
• According to the position of teeth on the gear surface.
(a) Straight, (b) Inclined, and (c) Curved
• According to the type of gearing
(a) External gearing, (b) Internal gearing, and (c) Rack and pinion.
• According to the position of axes of the shafts.
(a) Parallel, (b) intersecting and (c)non-intersecting and nonparallel

Types of Gears
1. Spur gears have teeth parallel to the axis of rotation and are used to transmit motion from
one shaft to another, parallel, shaft.
2. Helical gears have teeth inclined to the axis of rotation. The inclined tooth also develops
thrust loads and bending couples, which are not present with spur gearing.
3. Bevel gears have teeth formed on conical surfaces and are used mostly for transmitting
motion between intersecting shafts.
4. Hypoid gears are quite similar to spiral bevel gears except that the shafts are offset and
nonintersecting.
5. Worms and worm gears. The direction of rotation of the worm gear, also called the worm
wheel, depends upon the direction of rotation of the worm and upon whether the worm
teeth are cut right-hand or left-hand.

Forms of Teeth
1. Involute Teeth
2. Cycloidal Teeth

Causes of gear failures

1. Bending failure. Every gear tooth acts as a cantilever
2. Pitting. It is the surface fatigue failure which occurs due to many repetition of Hertz contact
stresses
3. Scoring. The excessive heat is generated when there is an excessive surface pressure, high speed
or supply of lubricant fails.
4. Abrasive wear. The foreign particles in the lubricants such as dirt, dust or burr enter between
the tooth and damage the form of tooth.
5. Corrosive wear. The corrosion of the tooth surfaces is mainly caused due to the presence of
corrosive elements such as additives present in the lubricating oils.
 Clutches
A Clutch is a machine member used to connect the driving shaft to a driven shaft, so that the driven
shaft may be started or stopped at will, without stopping the driving shaft. A clutch thus provides
an interruptible connection between two rotating shafts

Primary Component
1. Flywheel
2. Clutch Disc
3. Pressure Plate
4. Release bearing

Types of clutches
➢ Positive clutches
Advantage of Positive Clutches
(i) Simple
(ii) No slip
(iii) No heat generated compact and low cost

➢ Square jaw type

➢ Spiral Jaw Type

➢ Friction clutches
Advantage of Friction Clutches
(i) They friction surfaces can slip during engagement which enables the driver to
pickup and accelerate the load with minimum shock.
(ii) They can be used at high engagement speeds since they do not have jaw or teeth
(iii) Smooth engagement due to the gradual increase in normal force

Characteristics of Materials for Friction Clutches

1. It should have a high and uniform coefficient of friction.
2. It should not be affected by moisture and oil.
3. It should have the ability to withstand high temperatures caused by slippage.
4. It should have high heat conductivity.
5. It should have high resistance to wear and scoring.

Design Considerations for Friction Clutches

1. The suitable material forming the contact surfaces should be selected.
2. The moving parts of the clutch should have low weight in order to minimize the inertia
load, especially in high speed service.
3. The clutch should not require any external force to maintain contact of the friction
surfaces.
4. The provision for taking up wear of the contact surfaces must be provided.
5. The clutch should have provision for facilitating repairs.
6. The clutch should have provision for carrying away the heat generated at the contact
surfaces.
7. The projecting parts of the clutch should be covered by guard.

Types of Friction Clutches

1. Disc or plate clutches
➢ single disc clutch
➢ multiple disc clutch
2. Cone clutches, and
3. Centrifugal clutches

Advantage of Centrifugal clutch

 This type of mechanical clutch is automatic, so no kind of control mechanism is
necessary.
Centrifugal clutch is fairly cheap compare to normal type on clutch.
It prevents engine from stalling in other words minimizes engine braking force.
It is very helpful in various speed ranges compare to direct drive system.

Disadvantage of Centrifugal Clutch

This clutch is not appropriate for transferring significant torque or power because
they can slip if loaded heavily.
Sometimes the centrifugal clutch do not engage or disengage reliably and therefore
can cause a safety hazard.
Some loss in hose power to rear wheel due to friction pads or shoes movement.

Brakes
➢ A brake is a mechanical device which inhibits motion.
➢ As a machine element used to control the motion by absorbing kinetic energy of a moving
body or by absorbing potential energy of the objects being lowered by hoists, elevators,
etc.
➢ Braking system is necessary in an automobile for stopping the vehicle. Brakes are applied
on the wheels to stop or to slow down the vehicle.

Classification of brakes
• On the Basis of Method of Actuation
(1) Foot Brake (2) Hand Brake
• On the Basis of Mode of Operation
(1) Mechanical (Disk and Drum)
(2).Hydraulic
(3) Air
(4) Vacuum
(5) Electric
• On the Basis of Action on Front or Rear Wheels
(1) Front Wheel
(2) Rear Wheel
• On the Basis of Method of Application of Braking Contact
(1) Internally Expanding
(2) Externally Contracting
 Flywheel

 Is a rotating mechanical device that is used to store rotational energy

 It is an inertial energy-storage device.

Functions of Flywheel
 It can control the orientation of a mechanical system.
 It used to provide continuous energy in systems where the energy source is not continuous.
 It can smoothen out variations in the speed of a shaft caused by torque fluctuations.

Advantages of Flywheel
 Power and energy are nearly independent
 Fast power response
 Potentially high specific energy
 High cycle and calendar life
 Relatively high round-trip efficiency
 Short recharge time

Disadvantages of Flywheel
 Complexity of durable and low loss bearings
 Mechanical stress and fatigue limits
 Material limits at around 700M/sec tip speed
 Potentially hazardous failure modes
 Relatively high parasitic and intrinsic losses
 Short discharge times

Applications of Flywheel
 Providing continuous energy when the energy source is discontinuous.
 Delivering energy at rates beyond the ability of a continuous energy source.
 Energy storage in small scale electricity generator sets
 Recently, flywheels have become the subject of extensive research as power storage
devices for uses in vehicles.

Types of Flywheel
 Single mass flywheel
 Dual mass flywheel
 Spring
 A spring is an elastic machine element which deflects under the action of load and returns
to its original shape when the load is removed. It can take any shape and form depending
on its application.

Functions
 Springs are used to absorb shocks and vibrations.
 Springs are used to store energy.
 Springs are used to measure forces.
 Springs are used to apply force and control motion.

Applications
• To apply forces and control motion, as in brakes and clutches.
• To measure forces, as in the case of a spring balance.
• To store energy, as in the case of springs used in watches and toys.
• To reduce the effect of shocks and vibrations in vehicles and machine foundations.

Materials for Spring

1. Hard drawn high carbon steel.
2. Oil tempered high carbon steel
3. Stainless steel
4. Copper or nickel based alloys.
5. Phosphor bronze.
6. Chrome Silicon
7. Chrome Vanadium

Types of Spring
• Helical Spring
• Leaf Spring
• Conical & Volute Spring
• Torsion Spring
• Laminated Spring
• Belleville or Disc Spring
• Special Purpose Spring

Mode of Failure
1. Fracture (Tension)
2. Buckling
3. Corrosion
4. Deformation
5.