BELTS CONNECTING PARALLEL SHAFTS (FLAT BELT)

1. Open Belt Connection

Characteristics:
o Pulleys are of the same sense or direction of rotation
o No slipping between the belt and pulley surfaces
o Angle of contact for bigger pulley is greater than the angle of contact for smaller pulley
o Surface speeds of smaller pulley is the same as the bigger pulley
o Belt speed is the as the pulleys surface speeds.
o Used for connecting parallel shafts.

Figure 9.2. Open Belt Connection

1 2
1

C
 D1 N 1  D 2 N 2
Belt Speed, Vb = = Eq. 9.1
60 60

D 2 N1 R 2 1
Speed Ratio, SR = = = = Eq. 9.2
D1 N 2 R 1  2

 R − R1 
Arc of Contact,  =   2sin −1  2  Eq. 9.3a
 C 

D2 − D1
   Eq. 9.3b
C

Where,  = arc of contact, radians

(+) – is used for larger pulley
(-) – is used for smaller pulley

( D2 − D1 )
2

Belt Length, L = ( D1 + D 2 ) + 2C + Eq. 9.4
2 4C
Where Vb = belt speed, m/s, fpm
D1 = diameter of smaller pulley 1, cm, m, inch., ft.
D2 = diameter of the bigger pulley 2, cm, m, inch., ft.
N1 = rpm of pulley 1
N2 = rpm of pulley 2
R1 = radius of pulley 1
R2 = radius of pulley 2
1 = angular speed or velocity of pulley 1, rad/s
 2 = angular speed or velocity of pulley 2, rad/s
C = center distance, cm, m, inch., ft.

2. Crossed Belt Connection

Figure 10.3. Crossed Belt Connection

1 2

C
Characteristics:
o Pulleys are in opposite directions of rotation
o Belt is moving without slipping on the pulley surface
o Angles of contact for both pulleys are the same
o Surface speeds of smaller pulley is the same as the bigger pulley
o Belt speed is the same as the pulleys surface speeds.
o Used for connecting parallel shafts

N  N 
Belt Speed, Vb = D1  1  = D2  2  Eq. 9.5
 60   60 

D 2 N1 R 2 1
Speed Ratio, SR = = = = Eq. 9.6
D1 N 2 R 1  2

 R − R1   D2 − D1 
Arc of Contact,  =  + 2sin −1  2   +  Eq. 9.7
 C   C 
( D2 + D1 )
2

Belt Length, L = ( D1 + D 2 ) + 2C + Eq. 9.8
2 4C

ACTUAL SPEED

❑ Actual Speed of the driven shaft will always be somewhat less, the difference being due to “slip”, which in practice
amounts to 2 to 4 % of the ideal speed.

Actual rpm = ideal rpm (1 - % slip / 100) Eq. 9.9

Ex. # 9.1] A shaft turning 120 rpm is to drive another shaft at 200 rpm. Find the diameter of the two pulleys to give
as nearly as possible a belt speed of 13 m/s.

Solution:
60Vb 60 ( 30 )
Solving for the diameter of pulley 1, D1 = = = 1.379 meters
N1  ( 200 )
 D1 N1 200
Solving for diameter, D2 = = (1.379 ) = 2.069 meters
N2 120

Ex. # 9.2] Two parallel shafts, 92 cm apart, are connected by a belt drive. The driving pulley rotates at 300 rpm and
the driven pulley at 800 rpm. The smaller pulley diameter is 25 cm. For both an open belt and crossed belt, determine:
a) the diameter of the larger pulley; b) the linear velocity of the belt, in m/s; and c) the length of the belt.

Solution:
• Consider an open belt,
2

92 cm
N1  800 
a) For the diameter of pulley 2, D2 = D1 = ( 25 )   = 66.667 cm
N2  300 

N   800 
b) For the linear velocity of the belt, Vb = D1  1  =  ( 25)   = 1047 cm / s = 1.047 m / s
 60   60 

c) For the belt length

(D − D )  ( 66.667 − 25)
2 2

L= ( D1 + D2 ) + 2C + 2 1 = ( 25 + 66.667 ) + 2 ( 92 ) + = 332.71 cm
2 4C 2 4 ( 92 )

Consider the Crossed Belt Connection

1 2

92 cm
a) For the diameter of the larger pulley

o Diameter of the larger pulley is the same as the diameter of larger pulley in an open belt.

b) For the belt speed

o Belt speed is the same as the belt speed of the belt in an open belt connection.

c) For the belt length

(D − D )  ( 66.667 + 25)
2 2

L= ( D1 + D2 ) + 2C + 2 1 = ( 25 + 66.667 ) + 2 ( 92 ) + = 350.82 cm
2 4C 2 4 ( 92 )
DESIGN CALCULATIONS

❑ Angle of Contact or Wrap Angle and Design Considerations for open belt connection

f
• In the power capacity formula, the factor e governs the design.
• If pulleys are of the same material, f is the same and the smaller pulley is the basis of design calculations.

 D−d 
s =  −   Eq. 9.9
 C 

Where, s = wrap angle of smaller pulley, radians d = diameter of smaller pulley, inches, mm.
D = diameter of larger pulley, inches, mm. C = center distance, inches, mm.

f
• If pulleys are of different materials, compute for the value of e for both pulley and use the smaller value.

 D−d 
s =  −   Eq. 9.10
 C 

 D−d 
l =  +   Eq. 9.11
 C 

Where, l = angle of contact for larger pulley, radians.

❑ Angle of Contact or Wrap Angle and design considerations for Crossed Belt connection

• For the crossed belt connection the angles of contact for both pulleys are the same.
 D−d 
1 = 2 =  +   Eq. 9.12
 C 

• If the pulleys are of the same material, smaller pulley is the basis of design calculations.
f
• If the pulleys are of different materials, thee pulley with smaller value of the factor e will be the basis of
design calculations.
• Belt wider than 8 inches (203.2 mm) should be avoided for crossed belt installation.
• Use reversing drive with idler pulley if wider belts are used.
• The capacity of a crossed belt should only be 75 % as that of an open belt.
• If pulley or speed ratio is greater than 3, the capacity of a crossed belt should only be 50 % as that of an open
belt.

❑ Belt Tensions

• In a belt drive, the belt tensions are not equal. As illustrated in Figure 9.8 below, consider a driving pulley
with a direction of rotation shown.

Figure 9.8. Belt Tensions F1

F2
• Belt tensions ratio, if the effect of centrifugal force is neglected

F1
= ef Eq. 9.13
F2

• Belt tensions ratio, if the effect of centrifugal force is considered

F1 − Fc
= ef Eq. 9.14
F2 − Fc

• Centrifugal force on the belt

12btVs2
Fc = Eq. 9.15
g

• Belt net tension or tangential load

 ef − 1 
F = ( F1 − F2 ) = ( F1 − Fc )  f  Eq. 9.16
 e 
Let F1 = sA = sbt and substituting the value of Fc,

 12Vs2  ef − 1 
( F1 − F2 ) = bt  s −   Eq. 9.17
 g   ef 

• Transmitted Torque

d  d  63000 Hp 30 P
T = F   = ( F1 − F2 )   = =
2 2 n n Eq. 9.18
English S.I.
• Transmitted Hp or Power

Tn F Vm
Hp = = Eq. 9.19a
63000 33000

nT
P= Eq. 9.19b
30
Where, F1 = tight side belt tension, lb F2 = slack side belt tension, lb
F = net belt tension, lb Hp = transmitted Hp
P = transmitted power, Kw T = transmitted torque, in-lb, kN-m
 = angle of contact, radians f = coefficient of friction
f = 0.3 for leather belt on iron or steel pulleys f = 0.5 for leather belt on paper pulleys
s = maximum allowable stress of the belt, psi b = belt width, inches
t = belt thickness, inch Vs = belt speed, fps
 Vm = belt speed, fpm Vm = 4000 to 4500 fpm, most economical belt speed.
 = belt density  = 0.035 lb/in3., for leather belt
 = 0.045 lb/in3., for flat rubber belting

❑ Belt Joint Design Considerations

▪ Most likely failure occurs at the belt joint.

Joint
Figure 9.9. Belt Joint.

• Design at belt joint: Tensile failure

o For equal strength (belt and joint)

F1
F1 = s t ( bt ) = s ( bt ) bt = Eq. 9.20
st

o For good design, the maximum induced fiber stress should be equal to the design or allowable stress.

s t = s design = s = max . allowable stress Eq. 9.21

• Computation of design stress if not directly given

su
s= JF Eq. 9.22
N
Where, s = design or maximum allowable stress, psi, kPa su = ultimate stress, psi, kPa
N = factor of safety JF = joint factor

• Joint Factors and belt strength data are indicated in Table 9.1 and Table 9.2 below.

Table 9.1. Typical Strength and Factor of Safety

Ultimate Stress
Type (tension), su Factor of Safety Mass density, 
psi MPa lb / in3 kg / mm3
Leather 4000 27.0 10 0.035 3.7 x 10-7
Rubber 4200 29.0 12 0.045 1.137 x 10-6

Table 9.2. Joint Factor

Type of Joint JF
Cemented by belt maker 1.0
Cemented 0.98
Wire laced by machine 0.90
Wire laced by hand 0.82
Rawhide laced 0.60
Metal belt hook 0.38

❑ Determination of Belt Size (Cross section)

 • Belt size if power capacity is given or known (English system)
550 Hp  ef 
bt =   Eq. 9.23
  12  Vs2    ef − 1 
Vs s −  
  g 

Where, b = belt width, inch. t = belt thickness, inch.

 = angle of contact, radians f = coefficient of friction
s = design or maximum allowable stress, psi. Vs = belt speed, fps.
 = belt density, lb/in3. g =32.2 fps2.

• Belt size if belt power is given (Metric system)

746 Hp  ef  1000 P  ef 

bt =   =  f 
V ( s − 1000  V 2 )  e − 1  ( s − 1000V 2 )  e − 1 
f
Eq. 9.24

Where, b = belt width, mm. t = belt thickness, mm.

s = design or maximum allowable stress, N/mm2(MPa). V = belt speed, m/s.
 = belt density, kg/mm3.

• Belt Speed (If % slip is considered)

 Ddriver n driver (1 − % slip ) Ddriven n driven (1 − %slip )

V= = Eq. 9.25
60 60
• Belt speed (If % slip is not considered)

 Ddriver n driver  Ddriven n driven

V= = Eq. 9.26
60 60

• Leather Belt Thickness Data

Table 9.3. Leather Belt Data

Belt Thickness, inch (mm)
Grade of
Belting Single-Ply 2-Ply 3-Ply 4-Ply Increment of
Width, in.
Light 1 / 8 inch 1 / 4 inch ½ to 1 by 1/8
3.2 mm 6.2 mm 1 to 4 by ¼
Medium 5 / 32 inch 5 / 16 inch 1 / 2 inch 11 / 16 inch 4 to 7 by ½
4.0 mm 8.0 mm 12.7 mm 17.5 mm 8 to 30 by 1
Heavy 3 / 16 inch 3 / 8 inch 9 / 16 inch 3 / 4 inch 32 to 59 by 2
4.8 mm 9.5 mm 14.3 mm 19.0 mm 60 to 84 by 4

❑ Transmitted Power

• Power transmitted in terms of belt velocity

 P=
( F1 − F2 ) Vs = ( F1 − F2 ) Vm = ( F1 − F2 ) V
550 33000 Eq. 9.27
Hp Hp kW

• Power transmitted in terms of rpm

Tn 2 T n
P= =
63000 60 Eq. 9.28
Hp kW

❑ Rated Capacity of Leather Belt

• The rated capacity of a leather belt is obtained from a manufacturers’ catalogue

Hp = ( Hp / in ) b Cm Cp Cf Eq. 9.29

Where, Hp = transmitted Hp
Hp/in = belt capacity per inch of belt width, obtained from Table 17.1(Faires)
b = belt width, inches
Cm = correction factor for the type of drive = 1.0 for electric motor (Table 17.2)
Cp = correction factor for smaller pulley (Table 17.2)
Cf = correction factor for the environmental conditions (Table 17.2, Faires)

V-BELTS

USEFUL INFORMATION
❑ V-belts are used with electric motors to drive a great number of components such blowers, compressors, machine
tools, etc.
❑ Used to drive accessories on automotive and other internal combustion engines.
❑ V-belts are made to standard lengths and with standard cross-sectional sizes.
❑ V-belts run on grooved pulleys, called sheaves.
❑ V-belts are used on short center distances
❑ Sheaves are usually made up of cast iron, pressed steel, or die-cast iron.
❑ V-belts have a fiber glass-reinforced neoprene core and fabric-impregnated neoprene jacket that protects the
interior and provide a wear resistant surface for the belt.
❑ V-belt cross-sections are trapezoidal and are classified into A, B, C, D, and E.

Advantages of V-belt
• Wedging action permits a smaller arc of contact
• Shorter center distances that economize space
• Lower belt tension due to its gripping action
• Absorbs higher shock than flat belts
• Do not require frequent adjustment of initial tension

Figure 9.10. V-belt connection

1
2
 
(D1 + D 2 ) + 2 C + (D 2 − D1 )
2

• Belt Length, C = Eq. 9.30

2 4C

• Arc of Contact,  = −
( D2 − D1 ) Eq. 9.31
C

B + B2 − 32 ( D2 − D1 )
2

• Center Distance, C= Eq. 9.32

16

Where, B = 4L − 6.28 ( D 2 + D1 )

• Minimum Center Distance (if D1 and SR are known)

D1 + D 2
C= + D1 or C = D2 Eq. 9.32
2
o Take whichever is larger

DESIGN CONSIDERATIONS
❑ Steps on V-belt Design

1. Choose the type of belt cross-section

o Use Table 14-3, p281 (Machine Design: Black & Adams). Selection using normal (or template) Hp and
motor rpm.
o Selection using Fig. 17.14, p457 (Faires) based on design Hp and rpm of smaller sheave.

2. Solve for the number of belts to be used

❑ Rated Hp per belt

  103 0.09 c  Vm2   Vm

Rated Hp = a   − − e  6  3 Eq. 9.33
  Vm  K d D1  10   10

Where, a, c, and e = constants for a particular belt section, Table 17.3 (Faires).
Kd = small-diameter factor, Table 17.4 (Faires) Vm = belt speed, fpm
D1 = diameter of smaller sheave, inches
❑ Rated Hp per belt of a B-section V-belt

  103 
0.09
13.962  Vm2   Vm
Rated Hp =  4.737   − − 0.0234  6  3 Eq. 9.34
  Vm  K d D1  10   10
❑ Design Hp

Design Hp = Nsf(Hp) Eq. 9.35

Where, Nsf =service factor, Table 17.7 (Faires) Hp = transmitted Hp

❑ Adjusted Rated Hp

Adjusted Rated Hp = K KL (Rated Hp) Eq. 9.36

Where, K = correction factor for arc of contact other than 180 degrees, Table 17.5
(Faires)
KL = belt length correction factor, Table 17.6 (Faires)

❑ Number of belt required

Design Hp
Number of Belt = Eq. 9.37
Adjusted Hp

POWER-TRANSMISSION CHAINS

USEFUL INFORMATION

❑ Chains are made of a series of jointed metal links in a variety of forms in accordance with their uses as a) hoisting
and hauling, b) elevator and conveyor chains, and c) power-transmission chains.
❑ The roller chain is used mainly as a power-transmission chain. The construction at the joints is as shown in the
figure below.

Types of Chains
1. Detachable Chains
• The links of this type of chain, which are identical, are easily detachable.
• Each link has a hook-shaped end in which the bar of the adjacent link articulates.
• These chains are available in malleable iron or pressed steel.
• The chief advantage is the ease with which any link can be removed.
2. Cast Roller Chains
• Cast roller chains are constructed, wholly or partly, of cast metal parts and are available in various styles.
• In general the rollers and sidebars are accurately made castings without machine finish.
• The links are usually connected by means of forged pins secured by nuts or cotters.
• These chains are used for slow speeds and moderate loads, or where the precision of standard roller chains
is not required.
3. Pintle Chains
• Pintle chain is composed of hollow-cored cylinders cast or forged integrally with two offset sidebars and
each link identical.
 • The links are joined by pins inserted in holes in the ends of the sidebars and through the cored holes in
the adjacent links. Lugs prevent turning of the pins in the sidebars ensuring articulation of the chain
between the pin and the cored cylinder.

Roller Chains
• A roller chain is made up of two kinds of links: roller links and pin links alternately spaced throughout the
length of the chain as shown in Figure 9.11 below.
• Roller chains are manufactured in several types, each designed for the particular service required.
• All roller chains are so constructed that the rollers are evenly spaced throughout the chain.
• The outstanding advantage of this type of chain is the ability of the rollers to rotate when contacting the teeth
of the sprocket.
• Two arrangements of roller chains are in common use: the single-strand type and the multiple-strand type.
• In the multiple-strand type roller chains, two or more chains are joined side by side by means of common pins
that maintain the alignment of the rollers in the different strands.

Figure 9.11. Roller Chain

Types of Roller Chains

1. Standard roller chains

• These roller chains are manufactured to the specifications in the American National Standard for
precision power transmission roller chains, attachments, and sprockets.
• These roller chains and sprockets are commonly used for the transmission of power in industrial
machinery, machine tools, motor trucks, motorcycles, tractors, and similar applications.
2. Nonstandard roller chains
• These roller chains are similar in form and construction to standard roller chains but do not conform
dimensionally to standard chains.
• Some sizes of these chains are still available from the originating manufacturers for replacement on
existing equipment.
• These are not recommended for new installations.
3. Standard double-pitch roller chains
• These roller chains are like standard roller chains, except that their link plates have twice the pitch of the
corresponding standard-pitch chain.
• These are especially useful for low speeds, moderate loads, or long center distances.

DESIGNATION OF CHAIN SIZES

❑ Roller chain sizes are in terms of pitches measured in inches with the corresponding chain number as indicated
Table 9.2 below.

Table 9.2. Roller Chain Sizes

Chain # 25 35 40 50 60 80 100 120 140 160 200

Pitch, inch ¼ 3/8 ½ 5/8 ¾ 1 1¼ 1½ 1¾ 2 2½

Standard Roller Chain Numbers

❑ The right-hand figure in the chain number is zero for roller chains of the usual proportions, 1 for a lightweight
chain, and 5 for a rollerless bushing chain.
❑ The numbers to the left of the right-hand figure denote the number of 1/8 inch in the pitch.
• Heavy Series: These chains, made in 3.4-inch and larger pitches, have thicker link plates than those of the
regular standard. Their value is only in the acceptance of higher loads at lower speeds.
• Lightweight Machinery Chain: This chain is designated as No. 41. It is ½ inch pitch; ¼ inch wide; has 0.306-
inch diameter rollers and a 0.141-inch pin diameter. The minimum ultimate tensile strength is 1500 pounds.
• Multiple-strand Chain: This is essentially an assembly of two or more single-strand chains placed side by
side with pins that extend through the entire width to maintain alignment of the different strands.

Roller Chain Sprockets

• The Figure 9.11 below illustrates the roller chain sprocket.

Figure 9.11. Roller Chain Sprocket

GENERAL CONSIDERATIONS IN ROLLER CHAIN DESIGN

• The recommended minimum number of teeth of smaller sprocket

12 teeth → for very slow speeds 17 teeth → for slow speeds
21 teeth → for moderate speeds 25 teeth → for high speeds
23 teeth → for speed increasing drives
• Maximum speed ratio is 7:1 but higher ratios are feasible. Higher ratios could be attained by two or more
stages of reduction.
• The general rule for center distance between sprockets: C  1.5D 2 or 30P  C  50P .
• Arc of contact of the chain on the smaller sprocket should not be smaller than 120o.
• The number of teeth of the bigger sprocket should not be more than 120 teeth.
• Preferred arrangement for chain drive: with the center line of the sprocket horizontal, the tight side on top.
• The chain length must be an integral multiple of the pitch and an even number of pitches is recommended.

Types of Sprockets for Chain Drive

• Type A → is a plain plate
• Type B → is the one that has hub on one side only
• Type C → is a sprocket with hub on both sides
• Type D → is a sprocket with detachable hub

Types of Chain Lubrications

• Type I – is a manual lubrication applied at least once every 8 hours of operation.
• Type II – is the so called dip lubrication
• Type III – is the bath or disc lubrication
• Type IV – is the oil stream lubrication

DESIGN EQUATIONS

❑ Sprocket Pitch Diameter

 o Pitch diameter of the sprocket is the diameter of the circle passing through the roller chain

P
D = Eq. 9.38
 180 o 
sin  
 T 

Where, D = sprocket pitch diameter P = roller chain pitch

T = number of teeth of the sprocket

❑ Outside Diameter of the Sprocket

  180 o 
D o = P 0.6 + cot   Eq. 9.39
  T 

❑ Sprocket Circumference

Circumference = P x T Eq. 9.40

❑ Roller Chain Speed

D PT N
Vm =    N = Eq. 9.41
 12  12

Where, Vm = linear speed, fpm D = sprocket diameter, inches

N = sprocket rpm P = chain pitch, inch
T = number of teeth of sprocket

❑ Sprockets Center-to-center Distance (Average Good Center Distance)

D1
C = D2 + Eq. 9.42
2
Where, C = sprockets center-to-center distance, inches D1 = pitch diameter of sprocket 1, inches
D1 = pitch diameter of sprocket 2, inches

❑ Center Distance Between Sprockets (PSME Code Equation)

P
C= 2P − T2 − T1 + ( 2L − T2 − T1 ) − 0.810 ( T2 − T1 ) 
2 2
Eq. 9.43
8  

Where, C = center distance, mm P = pitch, mm

L = length of chain, pitches T1 = number of teeth of smaller sprocket
T1 = number of teeth of bigger sprocket

o General rule for center distance: C  1.5D 2 or 30P  C  50P

❑ Length of Chain
 T + T2 (T2 − T1 )
2

L = 2C + 1 + Eq. 9.44
2 40 C

Where, L = length of roller chain, in pitches

C = center-to-center distance, pitches (may contain a fraction or decimal)

❑ Design Hp

Design Hp = Nsf (Nominal transmitted Hp) Eq. 9.45

❑ Rated Hp

• The two equations below are used to determine the rated Hp of the chain and use whichever is smaller.

1.5
3− 0.07P  100T1 
Hp = 0.004T 1.08 0.9
1 n P
1 and Hp = K r   P
0.8

 n1  Eq. 9.46

(Link Plate Fatigue) (Roller-Bushing Impact)

Where, T1 = number of teeth of the smaller sprocket n1 = rpm of the smaller sprocket
P = chain pitch, inches
Kr = 17 for chain # 40 to 240, except for # 41 Kr = 3.4, # 25 & 35, Kr = 29,

DESIGN PROCEDURE IN DETERMINING THE NUMBER OF STANDS

❑ This procedure applies if the size of chain, speed, number of teeth of smaller sprocket, and power transmitted are
given or obtained.

1. Find the service factor from Table 17.7 (Faires), then solve for the design Hp.
2. Find the Hp rating per strand from Table 17.9 (Faires).
3. Divide the design Hp by the Hp rating per strand to get the number of strands.