Materials &

Hardware

26/3/2020
 TABLE OF CONTENTS
1. Gear Types And Their Applications
2. Definitions And Terminology
3. Classification Of Gears
4. Gear Operation
5. Belts And Pulleys, Chains And Sprokets

ACMN 222 Spring 2018

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 GEAR TYPES AND THEIR APPLICATIONS

üA transmission or gearbox provides speed and torque conversions from a

rotating power source to another device using gear ratios

üThe term transmission refers to the whole drive train, including gearbox,
clutch, prop shaft (for rear-wheel drive), differential and final drive shafts

üOften, a transmission will have multiple gear ratios (or simply "gears"), with
the ability to switch between them as speed varies

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 GEAR TYPES AND THEIR APPLICATIONS

üThis switching may be done manually (by the operator), or automatically.

Directional (forward and reverse) control may also be provided

üSingle-ratio transmissions also exist, which simply change the speed and
torque (and sometimes direction) of motor output

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 GEAR TYPES AND THEIR APPLICATIONS

üA typical two-stage planetary gearbox is a device incorporating two planetary

systems in series

üThis will achieve multiple reduction ratio but at a multiple reduction in efficiency
à Operates at an efficiency level of 80 to 85

üGears in transmission also require some backlash to allow the tooth faces to
slide in and out of contact without binding.

üGears are components widely used in machines in mechanical engineering and

thus in aeronautic field as well

üRole of gears à to transmit a movement or a power between two shafts, with

a constant speed ratio

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 GEAR TYPES AND THEIR APPLICATIONS

üMaterial used for gears:

1. Steel
2. Cast iron

Plastic materials are more and more used to transmit small forces

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 DEFINITIONS AND TERMINOLOGY

ü ADDENDUM is the height by which a tooth projects beyond the pitch circle
or pitch line

ü BASE DIAMETER is the diameter of the base cylinder from which the
involute portion of a tooth profile is generated

ü BACKLASH (B) is the amount by which the width of a tooth space

exceeds the thickness of the engaging tooth on the pitch circles

ü BORE LENGTH is the total length through a gear, sprocket, or coupling

bore

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 DEFINITIONS AND TERMINOLOGY

ü CIRCULAR PITCH is the distance along the pitch circle or pitch line
between corresponding profiles of adjacent teeth

ü CIRCULAR THICKNESS is the length of arc between the two sides of a

gear tooth on the pitch circle, unless otherwise specified

ü CLEARANCE-OPERATING is the amount by which the dedendum in a

given gear exceeds the addendum of its mating gear

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 DEFINITIONS AND TERMINOLOGY

ü CONTACT RATIO in general, the number of angular pitches through which

a tooth surface rotates from the beginning to the end of contact

ü DEDENDUM is the depth of a tooth space below the pitch line. It is

normally greater than the addendum of the mating gear to provide clearance

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 DEFINITIONS AND TERMINOLOGY

ü DIAMETRAL PITCH is the ratio of the number of teeth to the pitch

diameter

ü FACE WIDTH is the length of the teeth in an axial plane

ü FILLET RADIUS is the radius of the fillet curve at the base of the gear
tooth

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 DEFINITIONS AND TERMINOLOGY

ü FULL DEPTH TEETH are those in which the working depth equals 2.000
divided by the normal diametral pitch

ü GEAR is a machine part with gear teeth. When two gears run together, the
one with the larger number of teeth is called the gear

ü HUB DIAMETER is outside diameter of a gear, sprocket or coupling hub

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 DEFINITIONS AND TERMINOLOGY

ü HUB PROJECTION is the distance the hub extends beyond the gear face

ü INVOLUTE TEETH of spur gears, helical gears and worms are those in
which the active portion of the profile in the transverse plane is the involute of
a circle

ü LONG- AND SHORT-ADDENDUM TEETH are those of engaging gears

(on a standard designed center distance) one of which has a long addendum
and the other has a short addendum

ü KEYWAY is the machined groove running the length of the bore. A similar
groove is machined in the shaft and a key fits into this opening

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 DEFINITIONS AND TERMINOLOGY

ü NORMAL DIAMETRAL PITCH (Pn) is the value of the diametral pitch as

calculated in the normal plane of a helical gear or worm

ü NORMAL PLANE is the plane normal to the tooth surface at a pitch point
and perpendicular to the pitch plane

ü NORMAL PRESSURE ANGLE in a normal plane of helical tooth

ü OUTSIDE DIAMETER (Do) is the diameter of the addendum (outside)

circle

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DEFINITIONS AND TERMINOLOGY

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 CLASSIFICATION OF GEARS
Gears are classified according to the shape of the tooth pair and disposition
into:
ü Spur gear
ü Helical gear
ü Straight bevel gear
ü Spiral bevel gear
ü Hypoid bevel gear
ü Worm gear
ü Internal gear
ü Rack and pinion

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 CLASSIFICATION OF GEARS
1. Spur gears
üMost common type of gear
üThey have straight teeth and are mounted on parallel shafts

üPopular due to their simplicity in design, easy of manufacture and

maintenance
üCreate large stress on the gear teeth due to their design spur gears

üKnown as slow speed gears

üSeen as noisy due to their design à because every time a gear tooth
engages a tooth on the other gear, the teeth collide, and this impact makes a
noise

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 CLASSIFICATION OF GEARS

Spur gears can be

found in
applications like
aircraft
transmissions,
electric
screwdrivers, etc

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 CLASSIFICATION OF GEARS
2. Helical gears
üThe teeth on helical gears are cut at an angle to the face of the gear

üWhen two teeth on a helical gear system engage, the contact starts at one
end of the tooth and gradually spreads as the gears rotate, until the two teeth
are in full engagement

üThis gradual engagement à Operate much more smoothly and quietly than
spur gears à used in almost all transmissions

üBecause of the angle of the teeth on helical gears, they create a thrust load
on the gear when they mesh à Devices that use helical gears have bearings
that can support this thrust load

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 CLASSIFICATION OF GEARS
One interesting thing about helical gears is that if the angles of the gear
teeth are correct, they can be mounted on perpendicular shafts, adjusting
the rotation angle by 90 degrees

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CLASSIFICATION OF GEARS

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 CLASSIFICATION OF GEARS
3. Bevel gears

üBevel gears are useful when the direction of a shaft's rotation needs to be
changed

üUsually mounted on shafts that are 90 degrees apart, but can be designed
to work at other angles as well

üThe teeth on bevel gears can be straight spiral or hypoid

üStraight bevel gear teeth actually have the same problem as straight spur
gear teeth, as each tooth engages, it impacts the corresponding tooth all at
once

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 CLASSIFICATION OF GEARS
ü Straight bevel gears

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 CLASSIFICATION OF GEARS
ü Spiral bevel gears

•The solution to this problem is to curve the gear teeth

•These spiral teeth engage just like helical teeth: the contact starts at one
end of the gear and progressively spreads across the whole tooth

Remark:
§On straight and spiral bevel gears, the shafts must be perpendicular to each
other, but they must also be in the same plane
§If you were to extend the two shafts past the gears, they would intersect

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CLASSIFICATION OF GEARS

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 CLASSIFICATION OF GEARS
ü Hypoid bevel gears
•Can engage with the axes in different planes

•Depending on which side the shaft is offset to, relative to the angling of the
teeth, contact between hypoid gear teeth may be even smoother and more
gradual than with spiral bevel gear teeth, the pinion can be designed with
fewer teeth than a spiral bevel pinion, with the result that gear ratios of 60:1
and higher are entirely feasible using a single set of hypoid gears

•This feature is used in many car differentials. The ring gear of the differential
and the input pinion gear are pinion both hypoid
à Allows the input to be mounted lower than the axis of the ring gear

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CLASSIFICATION OF GEARS

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 CLASSIFICATION OF GEARS
Figure below shows the input pinion engaging the ring gear of the differential.
Since the driveshaft of the car is connected to the input pinion, this also
lowers the driveshaft.

This means that the driveshaft doesn't

intrude into the passenger
compartment of the car as much,
making more room for people
and cargo.

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 CLASSIFICATION OF GEARS
4. Worm gears
üUsed when large gear reductions are needed. It is common for worm gears
to have reductions of 20:1, and even up to 300:1 or greater

üMany worm gears have an interesting property that no other gear set has:
the worm can easily turn the gear, but the gear cannot turn the worm à the
angle on the worm is so shallow that when the gear tries to spin it, the friction
between the gear and the worm holds the worm in place

üThis feature is useful for machines such as conveyor systems, the torsion
differential, which is used on some high-performance mechanisms

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CLASSIFICATION OF GEARS

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 CLASSIFICATION OF GEARS
5. Internal gear
üAn internal gear may be described as the opposite of an external gear in
that the teeth point towards rather than away from the center, and addendum
and dedendum take reverse positions

üInternal gears provide a compact parallel shaft transmission drive with large
speed reduction

üUsed with a stock spur pinion the ratio is the same as that of two external
gears, but the center distance is much smaller

üIn cases where it is necessary to have two parallel shafts rotate in the same
direction, the internal gear eliminates the use of an idler gear

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 CLASSIFICATION OF GEARS

qSeveral advantages à reduced sliding action

qThe corresponding working surfaces of the teeth of an internal gear and

pinion are more nearly of the same length than is the case with an external
gear and pinion having the same tooth ratio and tooth length

qTherefore the relative slippage of the teeth is less in the case of the
internal. This point presents one of the advantages of using Internal gears

qThe sliding action of one tooth over another causes friction; and as friction
results in tooth wear, a reduction in the amount of sliding action is desirable

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 CLASSIFICATION OF GEARS
Internal gear drives may be
operated with the gear in a
fixed position and the pinion
rotating along the pitch line,
or the gear may be free to rotate
with the pinion rotating in a fixed
position.

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 CLASSIFICATION OF GEARS
6. Rack and pinion

üRack is a segment of a gear of infinite diameter

üThe tooth can be spur or helical

üThis type of gearing is used for converting rotary motion into translatory
motion or visa versa

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CLASSIFICATION OF GEARS

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 GEAR OPERATION
1. GEAR RATIOS
The fundamental law of gearing states that the angular velocity ratio between
the gears of a gear set must remain constant throughout the mesh.
Where:

•Pinion speed (rpm): n

•Gear speed (rpm): N
•Pinion pitch diameter: d
•Gear pitch diameter D
•Pinion teeth number: z
•Gear teeth number: Z

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 GEAR OPERATION

In order to maintain constant

angular velocity ratio between
two meshing gears, the
common normal of the tooth
profiles, at all contact points
with in mesh, must always
pass through a fixed point on
the line of centers,
called pitch point

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 GEAR OPERATION
2. PROFILES SATISFYING THE GEAR RATIOS

Profiles which can satisfy the law of gearing are:

ü Involute gear tooth profile

ü Cycloidal gear tooth profile
ü Circular geartooth profile

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 GEAR OPERATION
2. PROFILES SATISFYING THE GEAR RATIOS

• Cycloidal was the first to be evolved

• Followed by the invention of involute profile which replaced many of
the other profiles due to several technological advantages
circular profile has some advantages over the other profiles
• Due to manufacturing difficulties it did not become so popular
• With powder metallurgy process it is slowly getting into industry now
for specific application

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 GEAR OPERATION
ü Involute gear tooth profile

•Involute profiles have special properties

•Imagine two involute teeth in contact. If a normal is drawn at the contact
point to the involute profile, it will be tangent to the generating circles

•This can be visualized better from Figure below where the taut thread is
normal to the profile as well as tangent to the reel which forms the generating
or the base circle

•The profile will be involute above the base circle only

•The common normal to the profile at the contact point will be tangent to the
base circles

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 GEAR OPERATION

•It passes through a fixed point lying at the intersection of the tangent to the
rolling/pitch circles and the line connecting the centers of the gear wheels

• This point is known as the pitch point

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GEAR OPERATION

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GEAR OPERATION

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GEAR OPERATION

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 GEAR OPERATION
üAs the gears rotate the contact point travels along the common tangent to
the base circle. Hence this line is also known as the line of action
üThe movement of the contact point along the line of action can be seen in
the gear meshing

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GEAR OPERATION

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 GEAR OPERATION

The following figures show how the cutter shaves a portion of the tooth during
each reciprocation, only a few of which are illustrated

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 GEAR OPERATION

üThe base, standard pitch, addendum and dedendum circles are dashed,
and the rack reference origin is highlighted

üThe diameter of the cylindrical gear blank before cutting would exceed the
addendum diameter

üThe useful involute flank of a tooth exists only outside the base circle
however the flank of the illustrated tooth is interrupted just outside the base
circle by the large trochoidal fillet - the tooth is severely undercut and would
not be practical in a power transmission application

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 GEAR OPERATION
Remark: Mesh patterns - Pressure angle:
§The pressure angle is defined as the angle between the line-of-action
(common tangent to the base circles) and a perpendicular to the line-of-
centers. the geometry of these figures, it is obvious that the pressure angle
varies (slightly) as the center distance of a gear pair is altered

§The geometry shows that the larger the pressure angle the smaller the base
circle
§Thus, for standard gears, 15° pressure angle gears have base circles much
nearer to the roots of teeth than 20° gears
§It is for this reason that 15° gears encounter greater undercutting problems
than 20° gears

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GEAR OPERATION

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 GEAR OPERATION
ü Calculations applied to involute gears

The diametric pitch physically represents the size of the tooth. It is

defined by:
Where:
N is the number of teeth
D the diameter.
The larger the diametric pitch, the smaller the tooth.

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 GEAR OPERATION
The transverse pitch p is the distance between two consecutive teeth; it
is measured on the pitch circle:

as

Therefore

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 GEAR OPERATION
The module of the teeth is given by the relation:

The distance between centers of gears (C) is described as the distance

between the axes of the gears. It is measured at their perpendicular. It is
expressed by the formula:

Where N is the number of teeth and P is the diametric pitch

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 GEAR OPERATION
Advantages of involute tooth gears :

üVariation in centre distance does not affect the velocity ratio

üPressure angle remains constant throughout the engagements which

results in smooth running

üStraight teeth of basic rack for involute admit simple tools à Hence,
manufacturing becomes simple and cheap

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 GEAR OPERATION
ü Cycloidal gear tooth profile

§Cycloid is the locus of a point on the circumference of a circle when it rolls

on a straight line without slipping

§If the circle rolls on the outside of another circle or inside of another circle
gives rise to epicycloid and hypocycloid respectively. The profile of a cycloidal
tooth consists of two separate curves or double curvature

§This tooth form also satisfies the law of gearing or conjugate action similar to
an involute gear

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GEAR OPERATION

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 GEAR OPERATION
Advantages of cycloidal gears:

Ø Cycloidal gears do not have interference

Ø Cycloidal tooth is generally stronger than an involute tooth owing to
spreading flanks in contrast to the radial flanks of an involute tooth
Ø Because of the spreading flanks, they have high strength and compact
drives are achievable
Ø Cycloidal teeth have longer life since the contact is mostly rolling which
results in low wear

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 GEAR OPERATION
Disadvantages of cycloidal gears:
– For a pair of cycloidal gears, there is only one theoretically correct center
distance for which a constant angular-velocity ratio is possible
– The hob of cycloidal gear has curved teeth unlike involute rack teeth.
Hence hob manufacture is difficult and costly
– Cycloidal gear will cost more

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 GEAR OPERATION
ü Circular arc tooth profile

§Circular gears are having circular tooth surfaces in the transverse section
§Normally pinion has a convex tooth profile and the gear tooth has a concave
tooth profile. They can also have concave profile for pinion and convex profile
for the gear or convex profiles for both
§The teeth of circular gears have point contact in mesh. Hence to increase
the contact ratio the teeth are made helical
§The height of a circular gear tooth is about half that of the corresponding an
involute tooth of the same module
§Hence these teeth can with stand high load with weight of the gears
approximately half the size of involute gears

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 GEAR OPERATION
Circular gear also satisfies the law of gearing since the common normal to
the gears at the point of contact will always be passing through a fixed
point

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 GEAR OPERATION
Advantages of circular gears:

Ø A convex surface is always in contact with another concave surface

Ø The beam strength is much higher for the pinion than for the gear when
the gear is much larger than the pinion

Ø The contacting teeth have rolling action and hence wear is less

Ø If the convex profile is on the pinion teeth, and within the practical limits,
the radii are close to the same value to provide the maximum possible wear
strength

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 GEAR OPERATION
Disadvantages of circular gears

Ø The circular-arc profiles are not conjugate and consequently, in a plane

each tooth can make contact at only one point in each revolution

Ø The circular-arc gears are very sensitive to variations in center distances

and are hence best suited for slow-speed operation

Ø For the circular-arc gears in a plane, the contact ratio is zero

Ø Hence, the circular-arc teeth cannot be used on spur gears but must be
used on helical gears, where the contact ratio for the gear can be made
greater than 1.0 by providing overlap ratio

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 GEAR OPERATION
3. REDUCTION AND MULTIPLICATION GEAR SYSTEMS
Gears are generally used for one of four different reasons:
§To reverse the direction of rotation
§To increase or decrease the speed of rotation
§To move rotational motion to a different axis
§To keep the rotation of two axes synchronized

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 GEAR OPERATION
ØThe two gears are rotating in opposite directions, that the smaller gear is
spinning twice as fast as the larger gear, and that the axis of rotation of the
smaller gear is to the right of the axis of rotation of the larger gear

ØThe fact that one gear is spinning twice as fast as the other is because of
the ratio between the gears - the gear ratio

ØThe diameter of the gear on the left is twice that of the gear on the right

ØThe gear ratio is therefore "two to one“ à Every time the larger gear goes
around once, the smaller gear goes around twice

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 GEAR OPERATION
4. GEAR TRAINS

üA gear train made up of multiple gears can have several drivers and several
driven gears

üIf the train contains an odd number of gears, the output gear will rotate in
the same direction as the input gear

üIf the train contains an even number of gears, the output gear will rotate
opposite that of the input gear

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 GEAR OPERATION
4. GEAR TRAINS

üThe number of teeth on the intermediate gears does not affect the overall
velocity ratio, which is governed purely by the number of teeth on the first and
last gear

üIn simple gear trains, high or low gear ratios can only be obtained by
combining large and small gears

üIn the simplest basic gearing involving two gears, the driven shaft and gear
revolves in a direction opposite that of the driving shaft and gear

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GEAR OPERATION

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 GEAR OPERATION
ü Idler gear
If it is desired that the two gears and shafts rotate in the same direction, a
third idler gear must be inserted between the driving gear and the driven
gear. The idler revolves in a direction opposite that of the driving gear.

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 GEAR OPERATION
ü Gear train relationships
The study of gear trains is based on some kinematics laws referring to:
the tangential speed of two gears in contact:

and knowing that

we obtain:

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 GEAR OPERATION
which expresses the speed ratio of the two gears in contact

§ the relative speed of a point

§ absolute velocity of a point, which is equal to the vectorial sum of this

point compared to a mobile system and rate of travel of this mobile
frame of reference compared to a fixed frame of reference

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 GEAR OPERATION
5. COMPOUND GEAR TRAINS:
üMore complex compound gear trains can achieve high and low gear ratios
in a restricted space by coupling large and small gears on the same axle

üIn this way gear ratios of adjacent gears can be multiplied through the gear
train

üFigure shows a set of compound gears with the two gears B and D
mounted on the middle shaft

üBoth rotate at the same speed because they are fastened together

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 GEAR OPERATION
5. COMPOUND GEAR TRAINS:

üIf gear A (80 teeth) rotates at 100 rpm clockwise, gear B (40 teeth) turns at
200 rpm counter clockwise because of its velocity ratio of 1 to 2

üGear D turns also at 200 rpm counter clockwise

üFinally gear C rotates at 400 rpm clockwise because of its velocity ratio of 1
to 2

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GEAR OPERATION

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 GEAR OPERATION
6. PLANETARY GEARS

•A planetary gear is a gear train whose axes move in space

•Usually, they consist of straight cylindrical, helical and conical spur gears
•They combine a high speed ratio to a small overall dimension

•From the same planetary gear, it is possible to obtain different speed ratios
according to the desired operating mode
•It is necessary to show a high degree of accuracy during the assembly to
ensure an effective operation and to reduce noise to a minimum

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 GEAR OPERATION
These three main elements are: the planet, the satellite and satellite support,
also known as the "lever or "frame“

Ø The planet: any gears rotating around a fixed axis

Ø The satellite: any gears rotating around a moving axis
Ø The frame: the element that supports the satellites, maintaining them
in a constant relative position, compared to the others

The interest of such an assembly is that the frame or any planet can be the
driving, the driven or fixed. It is therefore possible to obtain different speed
ratios depending on what it is needed for

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

1. BELTS AND PULLEYS

Belts and pulleys have two uses:

q to increase or reduce speed or torque, or
q to transfer power from one shaft to another. If the transfer of power is
all you need, then two pulleys of the same diameter will do the trick

But most of the time you'll also want to take the opportunity to trade speed
for torque, or vice versa
This is done by using pulleys of different pitch diameters

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BELTS AND PULLEYS, CHAINS AND SPROKETS

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

ü Pitch diameter of the pulley

The pitch diameter of a pulley is not the outside diameter but the inside
diameter.

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

ü Pitch diameter of the pulley

– The pitch diameter is very difficult to measure directly,
– If you cut a belt and look at the end you will see a row of fibers near
the outside surface.
– This is the tension carrying part of the belt; the rest of the belt
– The rest of the belt exists only to carry the forces from the pulley to and
from these fibers
– The pitch diameter of any pulley is measured at these fibers
– Pitch diameter also depends on width of the belt

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

ü Power and drive ratio

•The ratio of the pitch diameters is called the drive ratio, the ratio by which
torque is increased and speed is decreased, or vice versa
•Power is the product of speed and force, or in the case of things that spin,
speed and torque. Pulleys do not affect power; when they increase torque, it
is at the expense of speed, and vice versa

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

If the drive ratio is < 1, this means that the driver pulley wheel revolves
more rpm compared to the driven pulley wheel and the diameter of the
driver pulley is lower than the diameter of the driven pulley.

Example:
The diameter of the driver pulley wheel is 200 mm and the driven pulley
wheel is 400 mm. This means for every single revolution of the larger
driver pulley wheel, the smaller driven pulley wheel rotates half time. The
drive ratio is 0.5.

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

If the drive ratio is > 1, this means that the driver pulley wheel revolves
less rpm compared to the driven pulley wheel and the diameter of the
driver pulley is greater than the diameter of the driven pulley.

Example:
The diameter of the driver pulley wheel is 600 mm and the driven pulley
wheel is 200 mm. This means for every single revolution of the larger
driver pulley wheel, the smaller driven pulley wheel rotates three times.
The drive ratio is 3.

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

ü Type of belts:
Some of the many forms of belt are introduced below:

Ø V-belts:
Classical banded V-belts comprise cord tensile members located at the pitch
line, embedded in a relatively soft matrix which is encased in a wear resistant
cover

The wedging action of a V-belt in a pulley groove results in a drive which is

more compact than a flat belt drive, but short centre V-belt drives are not
conducive to shock absorption

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BELTS AND PULLEYS, CHAINS AND SPROKETS

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

Ø Wedge belts:
Wedge belts are narrower and thus lighter than V-belts.
Centrifugal effects which reduce belt-pulley contact pressure and hence
frictional torque are therefore not so deleterious in wedge belt drives as
they are in V-belt drives.

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

2. CHAINS AND SPROCKETS

qA chain transmits power by means of tensile forces, and is used

primarily for power transmission systems

qThe function and uses of a chain are similar to a belt

qA sprocket is a toothed wheel upon which a chain rides. Contrary to

popular opinion, a sprocket is not a gear

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

2. CHAINS AND SPROCKETS

qSprockets and chains offer another method for transferring rotating

motion from one shaft to another where the friction of a drive belt would be
insufficient to transfer power

qThe speed relationships between sprockets of different diameters

coupled by chains are the same as those between pulleys of different
diameters coupled by belts
qà Therefore, if the chains are crossed, the sprockets will rotate in
different directions

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BELTS AND PULLEYS, CHAINS AND SPROKETS

Bicycles have sprocket and chain drives. The teeth on the sprockets
mesh with the links on the chains.

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

ü Functions of chain parts

Plate:

ØThe plate is the component that bears the tension placed on the chain
ØUsually this is a repeated loading, sometimes accompanied by shock
ØTherefore, the plate must have not only great static tensile strength, but
also must hold up to the dynamic forces of load and shock
ØFurthermore, the plate must meet environmental resistance
requirements (for example, corrosion, abrasion, etc.)

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

Pin:

qThe pin is subject to shearing and bending forces transmitted by the

plate
qAt the same time, it forms a load-bearing part, together with the bushing,
when the chain flexes during sprocket engagement

qTherefore, the pin needs high tensile and shear strength, resistance to
bending, and also must have sufficient endurance against shock and wear

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

Bushing:

ØThe bushing is subject to shearing and bending stresses transmitted by

the plate and roller, and also gets shock loads when the chain engages
the sprocket
ØIn addition, when the chain articulates, the inner surface forms a load-
bearing part together with the pin
ØThe outer surface also forms a load- bearing part with the roller's inner
surface when the roller rotates on the rail or engages the sprocket
ØTherefore, it must have great tensile strength against shearing and be
resistant to dynamic shock and wear

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

Roller:

ØThe roller is subject to impact load as it strikes the sprocket teeth during
the chain engagement with the sprocket
ØAfter engagement, the roller changes its point of contact and balance
ØIt is held between the sprocket teeth and bushing, and moves on the
tooth face while receiving a compression load
ØFurthermore, the roller's inner surface constitutes a bearing part together
with the bushing's outer surface when the roller rotates on the rail
ØTherefore, it must be resistant to wear and still have strength against
shock, fatigue, and compression

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

Cotter Pin, Spring Clip, T-Pin:

ØThese are the parts that prevent the outer plate from falling off the pin at
the point of connection
ØThey may wear out during high-speed operation, therefore, for this
application, these parts require heat treatment

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BELTS AND PULLEYS, CHAINS AND SPROKETS

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

ü Sprockets
The sprocket looks like a gear but differs in three important ways:
Ø Sprockets have many
engaging teeth;
gears usually have only
one or two.
Ø The teeth of a gear touch
and slip against each other;
there is basically no
slippage in a sprocket.
Ø The shape of the teeth
are different in gears and
sprockets.

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ü Chain drive systems

Ø Consists of two or more sprockets connected with chain

Ø The sprockets are mounted on shafts that are supported by bearings
Ø Purpose: to transmit power and motion between shafts
Ø Advantages over belt drive systems:
Ø Do not slip or creep (no power loss from slippage)
Ø More compact for a given capacity
Ø Lower loads on shafts (because high tension is not required as with
belt drives)
Ø Easy to install

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 BELTS AND PULLEYS, CHAINS AND SPROKETS

Ø Not affected by sun, heat, or fluids (such as oil and grease)

Ø Do not deteriorate with age More effective at lower speeds Require
little adjustment

Advantages over gear drive systems:

Ø Flexible center distances
Ø Less expensive
Ø Simpler installation and assembly
Ø Better shock absorption

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Disadvantages over gear drive systems:

Ø Require lubrication (in most cases)

Ø Noisier than belt drives
Ø More expensive than belt drives
Ø Impractical for extremely long center-to-center distances where flat
belts could be used
Ø Less efficient than flat belts at extremely high-speed ranges
Ø Must be used on parallel shafts; cannot twist chain like belts

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Standard roller chain numbers:

Ø Last number indicates whether the chain has rollers (0), is lightweight
(1), or is rollerless (5)
Ø First number(s) indicates the pitch in eighths of an inch
Ø A hyphenated number after the chain number indicates the multiple-
strand chain
Multiple strand chain: basically an assembly of two or more single-strain
chains placed side by side with pins that extend through the entire width to
maintain alignment of the different strands; this increases the hp at which
the system will operate
Example: No. 40-2 chain is a .5 (4/8) inch pitch 2-strand chain with rollers

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