MEC 410

Design of Machine Elements

Spring 2017
Course Overview
Jay Mendelson
Lecturer
Mechanical Engineering Department
Jay.Mendelson@stonybrook.edu
Normal office hours 1PM 3PM
Monday and Wednesday
171 Light Engineering
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 MEC 410: Chapter 7: Belt Drives and Chain Drives

Reading: Chapter 7 in Machine Elements in

Mechanical Design 5th Edition
Homework Problems:
V-Belt Drive problem 21 from textbook
Use SKF Inc. Web Based tool to design a timing belt drive
that meets close to the same requirements as problem
20 in the textbook
To do this, download belt drive software tool from this
url: www.skf.com/us/knowledge-centre/engineering-
tools/belt-drive-design-calcalutions-tool.html
Roller Chain problem 41 from textbook

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 Power Transmissions
Power screws converts rotations into translations
Many applications require transmission of rotational
motion, often changing the speeds of rotations
Belt drives, chain drives, and gears are designed for
this purpose.

www.bikesindia.org

3 www.en.wikipedia.org
1/25/2017 www.en.wikipedia.org
 Belt and Chain Drives are Flexible Transmissions
A belt drive connects two or more wheels (called pulleys)
with a belt, which is not rigid (flexible).
A chain drive connects two or more toothed wheels
(called sprockets) with a chain, which is also a flexible
transmission element but consists of rigid pieces.
Flexible elements are often used in replacement of gear
drives to deliver power over a relatively long distance
Belt Chain
Sprocket

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Pulley
Image source: www.dreamstime.com
Image source: www.machinedesign.com
4
 Applications for V-Belt Drives
Transmit power at high speed, low torque and over long distances
V-Belt powers the radiator fan and alternator on gasoline engine autos, V-
Belt linear speed between 2,500 and 6,500 ft/min, ideal at 4,000 ft/min.
At lower speeds, the tension in the V-belt becomes too large for typical
belt cross sections
At higher speeds, dynamic effects such as centrifugal forces, belt whip, and
vibration reduce effectiveness of drive and its life.

V-Belt

Image source: www.reliableplant.com

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 Applications for Chain Drives
Transmit power under low-speed and high torque conditions
Popular in bicycles, motorcycles, tanks, and conveyor belts
Where easy ability to install and uninstall the components is
important. (in a chain drive, you dont need to move the sprockets to
replace the chain.)
At higher speeds, noise caused by the impact between the chain
links and the sprocket teeth becomes very irritating.

Bicycle
Image source: Chain
www.vintagecrank.com

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 How to Get the Best of Both Worlds
Typical motors operate at very high speed and low torque, while
most practical applications for rotary actuators require lower speed,
but higher torque
Split the speed reduction into two steps. A belt drive forms the first
reduction, and a chain drive forms the second.

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 How a Belt Drive Works
A belt is installed tightly on a set of pulleys
When used for speed reduction, the smaller pulley is mounted
on the high-speed shaft (e.g. electric motor), while the larger
pulley is mounted on the driven axis.
The belt is installed by placing it around the two pulleys while
the center distance between them is reduced. Then the
pulleys are moved apart, placing the belt in high tension.
Initial tension can be controlled through an idle pulley.
Idle
Pulley

8 Image source:
1/25/2017
www.en.wikipedia.org
 How a Belt Drive Works (contd)

Power through a belt drive is

transmitted through the friction.
The driving pulley (called a sheave
in the text) rotates and grips the
belt, increasing the tension on
the tight side of the belt.
The opposite side of belt is also under tension, but at a
smaller value, called slack side of drive.
The difference between the tensile forces of two sides in
belt exerts a tangential force on the driven pulley
A torque is applied to the driven shaft via friction force.

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 Advantages of a Belt Drive

Belts can absorb vibrations and noise, and thereby allow

for smooth transmission.
Flat belts can be used for extremely long center distances
(where chain weight would be excessive)
Friction can be used for mechanical overload protection,
so that other components will not be damaged.
No lubrication required in a belt system.
Shaft center distance variation and shaft alignment is
much less critical than for gear drives or chain drives.

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 Basic Open-Belt Geometry
L = total length of the belt
d = angle of belt in contact with the
driving pulley
D = angle of belt in contact with the
machine pulley
D < C < 3 (d + D) Attach
driven
pulley to
next stage
in machine

1d = 2D 1 2

Attach driving
pulley to motor
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 Open-Belt Tension and Forces
F1
Tight side of belt
When an input torque T
is applied to the small
pulley, we have:
F1 = Fi + Fc + T/D (a)
F2 = Fi + Fc T/D (b)
Slack side of belt
Fi= initial belt tension. Fcis the centrifugal force of the belt. F2
F1= tension on the tight side after the load is applied.
F2= tension on the slack side after the load is applied.
Subtracting (b) from (a) gives

A net torque T is transmitted to the pulley by the difference in tension

between the tight and loose sides of the belt.
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 Mechanical Power Transmission
Power (P) transmitted by flat belt is the product of net
tension (F1 -F2) and belt speed, V.
P = (F1 -F2 ) x V
where F1= tight-side tension, F2 = slack side tension,
P in watts, F in Newton, V in meters/sec.
Expressing power in horsepower and using units of
pounds, feet/minute gives
P = (F1 -F2 ) x V / 33,000 (hp)
Belt speed V is given by:
V = x d x n1 / 12 ft/min
where d = diameter of the driving (i.e. small) pulley in
inches and n1 = rotational speed in RPM of the driven
pulley

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 Belt/Pulley Cross-Sections
Flat
Round Belt
Belt

Pulley Pulley

Round Belt
V - Belt Synchronous
(Timing) Belt

Pulley
Air Gap Sprocket

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 Heavy-Duty V-Belt Sizes

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 Step by Step Procedure to Design a V-Belt Drive
Given: Rated power and speed of the driving motor, speeds of
the driving (small) pulley and the driven (output) pulley
1. Determine Service Factor based on harshness of the
application. Multiply by motor power to get a design (i.e.
rated) power for the belt system.
2. Select from one of three V-belt sizes, based on the speed of
the motor and the design power of the belt
3. Compute the nominal speed ratio, which also gives you the
pulley diameter ratio
4. Assume the optimal belt speed of 4,000 ft/min, and use that
to calculate the diameter of the driving pulley
5. Look up standard, commercially available sizes of driving
pulleys that give you close to the correct output speed, when
using the computed speed ratio. You will also get the driven
pulley diameter, as a result.
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 Step by Step Procedure to Design a V-Belt Drive
6. Use tables to get a rated power per belt, based on the
driving pulley diameter, speed of the motor
7. Specify the smallest center to center distance allowable,
based on the formula D < C < 3 (d + D)
8. Compute an estimated belt length L, from these formulae

Note: the textbook subs in the

formulae for d and D to give:
L = 2C + /2 (d + D) + (D d)2/4C
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 Step by Step Procedure to Design a V-Belt Drive
9. Select a standard, commercially available belt length
that is closest to the one computed in step 8. Then
calculate the actual center to center distance of the
pulleys.
10. Compute the angle of wrap of the belt on the small
pulley d from the formula:

11. Determine correction factors for the rated power per

belt from standard graphs from the manufacturer.
Graphs are based on the belt length and angle of wrap.
12. Divide the design power of the system by the corrected
rated power per belt to get the number of belts you
need. Round up to the nearest integer

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 Solution to Problem Number 18 on Table 7-12
Design a V-belt drive that has the driving pulley on the shaft of an AC
motor, high torque (HT). The motor is rated at 25 Hp at 870 RPM,
full-speed load. The drive is to a hammer mill that is to be used 8
hours (h) daily at approximately 310 RPM.
Note: A hammer mill is a crusher that can grind, pulverize, and crush
a wide range of materials. This rock crusher machine employs a rain
of hammer blows to shatter and disintegrate the material.

V-belt
drive

AC
motor

Image source: www.Stedman-machine.com Image source:

19
www.hammer
1/25/2017 -mills.org
 Step 1: Determine Service Factor from Table 7-1

Design Power = 1.5 x 25 = 37.5 Hp

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Step 2: Select from V-belt Sizes 3V, 5V, or 8V
Using Figure 7-9

Select the 5V Belt

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Step 3: Compute the Nominal Speed Ratio

Speed Ratio = n1/n2 = 870/310 = 2.806

Pulley Diameter Ratio = D/d = 2.806

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Step 4: Calculate the diameter of the Driving
Pulley at a Belt Velocity of 4000 Ft/min

Belt speed, vb = 4000 ft/min = ( x d x n1)/12

Motor speed, n1 = 870 RPM
Small pulley d = (12 x 4000)/( x 870)
d = 17.56 in.

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Step 5: Look up Standard Sizes of Driving
Pulleys Using Table 7-3

d 2.81d D
13.4 37.6 38.4 310

Exactly n2

Actual belt speed,

vb = ( x d x n1)/12
= 3052 ft/min

Image source: www.baldor.com

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Step 6a: Use Tables to Get Rated Power Per Belt

Rated
Power
= 23 Hp
per Belt

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Step 6b: Use Tables to Get Power Power Per Belt
Added for the Speed Ratio
23 + 0.94 = 23.9 Hp per Belt (rounded off)

Use
0.94 Hp

2.8

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Step 7: Specify the Smallest Center to Center
Distance Allowable

38.4 < C < 3 (13.4 + 38.4)

38.4 < C < 155.4
Lets try C = 48

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Step 8: Compute the Required Belt Length

L = 2C + /2 (d + D) + (D d)2/4C
L = 2(48) + /2 (13.4 + 38.4) +
(38.4 13.4)2/4(48)
L = 180.6

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 Step 9: Select a Standard Belt Length and
Re-compute the Actual Center Distance, C

Note: d = D1 From the

and D = D2 textbook

Doing the math, C = 47.7

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Step 10: Compute the Angle of Wrap of the Belt
on the Small Pulley

From the
textbook

1 = 180 - 2 (15.2) = 149.6

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Step 11a: Determine the Correction Factor for
the Angle of Wrap

C = .92

1 = 149.6
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Step 11b: Determine the Correction Factor for
the Belt Length

CL = 1.06

L = 180
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Step 12: Compute the Corrected Power per Belt
and the Number of Belts

Corrected Power = C x CL x P
= .92 x 1.06 x 23.9
= 23.3 Hp per belt
No. of Belts = 37.5/23.3 = 1.61

Round up the number, use 2 Belts

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 Synchronous (Timing) Belt Drives
Ribs or teeth across underside of belt
Teeth mate with grooves in driving and driven
sprockets providing positive drive without slippage
Most commonly used to connect the crankshaft and
camshaft of an internal combustion engine, so that
all valves open and close at precise times
Timing
Belt

Sprocket
Image source: www.hitbelt.com
Image source: Krishna Transmission
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Replacing a Timing Belt on an Automobile

$1000 - $1200 job

at a dealership
Typically done at
80,000 mile
intervals
Breaking a timing
belt in motion leads
to major engine
damage!
Timing
Belt

Sprocket

35 Image source: www.Wikipedia.com

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 Cross-Sections of Timing Belts

Pitch

Pitch

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 Step by Step Procedure to Design a Timing Belt Drive
Using Web Based Tool From Manufacturer
Given: Rated power and speed of the driving motor, speeds of
the driving (small) sprocket and the driven (output) sprocket

1. Determine a service factor using spec sheets, calculate

the belt design power
2. Determine the pitch
3. Calculate the speed ratio of driving/driven sprocket
4. Select candidates for number of teeth in sprocket,
usually need integer speed ratio. Let tool determine belt
length that gets you closest to the center distance
5. Let tool verify that your belt really meets your service
factor needs
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 Timing Belt Problem, Same Specs as Problem 18

Design a Timing belt drive that has the driving

sprocket on the shaft of an AC motor, high torque (HT).
The motor is rated at 25 Hp at 870 RPM, full-speed
load.
The drive is for textile machinery that is to be used 8
hours (h) daily at approximately 310 RPM.
Note: With sprockets, you fix the driving sprocket
speed at the motor speed (870 RPM), and you select a
standard driven sprocket that gets you as close to the
machine speed (310 RPM as possible)

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 Step 1: Determine Service Factor

Design Power = 1.5 x 25 = 37.5 Hp

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 Steps 2: Determine the Pitch of Teeth
for the Timing Belt and Sprocket

Intersection of
Hp and RPM of
small sprocket
is in the
operating zone
for the 14 mm
pitch sprocket

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Step 3: Compute the Nominal Speed Ratio

Speed Ratio = n1/n2 = 870/310 = 2.806

Pulley Diameter Ratio = D/d = 2.806

Note: For a sprocket, the speed ratio is

exactly equal to the ratio of the number of
teeth of the large to small sprocket
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 Step 4: Download Design Tool From
www.skf.com/us/knowledge-centre/engineering-tools/belt-drive-design-
calcalutions-tool.html

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 Step 4: Use Tool an Specify 14M Belt

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 Exact
Step 4: Use Tool an Specify 14M Belt Conversion
of 25 Hp

Was 310 RPM

for V-Belt, but
we needed
Was 47.7 (1211
exactly 3:1
mm) for V-Belt
speed ratio You pick
standard belt
length and let
C be calculated

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 Step 5: Let The Tool Verify The Solution
The tool calculates the The tool gives the
belt speed of 9.74 m/s exact SKF part
(1811 ft/min) number to order

We specified
1.5 service
We specified a
factor and our
standard width and
belt has a 1.58
the tool suggested
service factor.
40 mm
45 This is good.
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 How a Chain Drive Works
A metal chain consisting of pin-connected links engages
mating toothed wheels called sprockets
A chain transmits much larger tensile forces than a belt
A roller chain has a roller on each pin that provides very
low friction between the chain and sprockets
Tension
The pitch is higher on
the distance side of chain
between about to
the pins of engage with
the chain or the driving
teeth of the sprocket
sprocket

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 How a Chain Drive Works (contd)
The metal chain requires constant lubrication from an oil
bath for heavy machinery, and periodic oiling for light
applications, such as the transmission in a bicycle

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 How a Chain Drive Works (contd)
Chains come in different geometries and metal gauges
Double and triple chain strands provide higher strength

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 How a Chain Drive Works (contd)
Usually the driving sprocket is of smaller diameter than the
driven sprocket, so that speed reduces and torque increases
in the machine application
Except in a bicycle your legs supply plenty of torque, so you
trade some torque for speed to get somewhere fast

Gear ratio peaks at

roughly 1:1 in first
gear (for steep hills)
and goes down as
you shift up to gear
10, 12, or 15

Image source:
www.mstworkbooks.co.za/t
49 echnology/gr8
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 Roller Chain Sizes

Sizes are classified by

pitch, digits other than
the last 0 correspond
to the pitch in eighths
of an inch
For applications where
you are lifting heavy
weight with a chain
drive, make sure the
max weight lifted is
only 10% of the
average tensile
strength

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 Advantages of a Chain Drive

Chains require no tension on the slack side, so that

bearing loads are reduced.
Chains do not slip or creep as flat and v-belt drives do (You
must use a toothed belt to counteract slip)
Chain drives are more compact than belt drives for the
same power transfer.
Chains do not deteriorate with age, heat or oil and grease.
Chains can operate at higher temperatures than belts.

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 Basic Chain Drive Geometry
L = total length of the chain
N1 = number of teeth in
small sprocket, in pitches p
N2 = number of teeth in
large sprocket in pitches p

2
Attach
1 2 driven
1D1 = 2D2 sprocket to
next stage
in machine
Attach driving
sprocket to Image source: www.Autodesk.com
52
motor
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 Design Guidelines for a Chain Drive

Small sprocket should have no less than 17 teeth

Large sprocket should have no more than 120 teeth
Max speed ratio in one stage is 7.0
Center distance (C) = 30-50 times the pitch of the chain
Chain length (L) must be an integer even multiple of
the pitch
The arc of contact 1 of the small sprocket > 120
Put the tight side of the chain vertically up
Avoid excessive chain sag on the slack side, or the
chain could jump off the sprocket (not fun on a bicycle)
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 Step by Step Procedure to Design a Chain Drive
Given: Rated power and speed of the driving motor, speeds of
the driving (small) sprocket and the driven (output) sprocket
1. Determine Service Factor based on harshness of the
application. Multiply by motor power to get a design (i.e.
rated) power for the chain drive system.
2. Compute the nominal speed ratio, which also gives you
the ratio of the number of sprocket teeth
3. Select a chain pitch based on the rated power
4. Compute the number of teeth in the sprockets
5. Use the number of teeth for the actual output speed
6. Compute the pitch diameters of the sprockets
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 Step by Step Procedure to Design a Chain Drive
7. Calculate the nominal center distance C in terms of the
number of pitches, use 40 as a first guess
8. Calculate the required chain length L in numbers of pitches
and round off the nearest even integer multiple of pitches
9. Re-calculate the center distance
10. Compute the angle of wrap for both sprockets

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 Solution to Problem Number 38 on Table 7-13
Design a chain drive that has the driving sprocket on the shaft of an
AC motor. The motor is rated at 25 Hp at 310 RPM, full-speed load.
The drive is to a hammer mill at approximately 160 RPM.

chain
drive

AC
motor

Image source: www.hammer-mills.org

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Step 1: Determine Service Factor and Design Power
from Table 7-10

Design Power = 1.5 x 25 = 37.5 Hp

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Step 2: Compute the Nominal Speed Ratio

Speed Ratio = n1/n2 = 310/160 = 1.938

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Step 3: Select a Chain Pitch from Table 7-9

Use No. 80 chain, 1 pitch, N1 = 24 teeth on

59
the small sprocket, Type B lubrication
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Step 4: Compute the No. Teeth on Large Sprocket

N2 = N1 x Speed Ratio = 24 x 1.938 = 46.5

Lets try 47 teeth

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Step 5: Compute Actual Output Speed

n2 = n1 (N1 /N2) = 310 (24/47) = 158.3 RPM

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 Step 6: Compute Pitch Diameters of Sprockets

Small sprocket, D1 = 1/sin(180/24) = 7.661

Large sprocket, D2 = 1/sin(180/47) = 14.971

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Step 7: Specify the Nominal Center Distance

Lets try C = 40 pitches = 40 because

the pitch = 1

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Step 8: Calculate the Required Chain Length

L = 116.55 pitches, but we must round

off to the nearest even number.
So, we use L =116 pitches = 116

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Step 9: Recalculate the Center Distance

N1 = 24
N2 = 47
L =116
C = 40.08 pitches = 40.08
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Step 10: Compute Angle of Wrap
D1 = 7.661
D2 = 14.971
C = 40.08

1= 169.53

66
2= 190.46
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 Chain Drive Design Summary

Pitch: No. 80 chain, 1 pitch

Length: 116 pitches = 116
Center Distance = 40.08
Sprockets: Single-Strand, no. 80 1 pitch
Small sprocket: 24 teeth, D1 = 7.661
1= 169.53
Large sprocket: 47 teeth, D2 = 14.971
2= 190.46
Type B lubrication, the large sprocket
67
dips into an oil bath
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