Machine Tool Design – Mechanical

Design Of Belts and Pulleys

By:
HV RajaShekara
SENIOR DIRECTOR - Design Institute,
IMTMA
 DRIVES

FLEXIBLE RIGID

BELT CHAIN ROPE GEAR DRIVE

 Advantages of Flexible Drive

• Flexible Drive transmit power over a long distance.

• Absorbs shock loads.
• Dampens vibration.
• Tolerance on center distance not critical as in gear Drive.
• Flexible in the location of Driving & driven shaft.
• Cheap compared to geared Drive.
• Maintenance cost is low
 BELT DRIVES

DRIVING PULLEY DRIVEN PULLEY BELT

 Advantages of Belt Drive

• Belt drive can transmit Power over considerable distance

between axis of Driving & Driven shaft.
• Operation is smooth.
• Operation is Silent.
• Can transmit a definite load.
• Overload protection.
• Absorbs shocks & dampens the vibration.
• Simple in Design.
• Low initial cost.
 Disadvantages of belt Drives

• Large dimensions & occupies more space.

• Velocity ratio is not constant due to Belt slip.
• Impose heavy loads on shaft & bearings.
• Considerable loss of power resulting in low efficiency.
• Short service life.
Types of Belts

TYPE OF BELTS

FLAT V- BELT TOOTHED

 Advantages of Flat Belt

• Relatively Cheap.
• Easy to maintain
• Periodic adjustment between 2 shaft to take care of stretching.
• No precise alignment between shaft & pulley is required.
• Easy to replace.
• Can be used as a clutch by having some provision of shifting.
• Different velocity ratio can be obtained using step pulley.
• Can be used in dusty & abrasive atmosphere
• Design is simple.
• Can be used upto a distance of 15meters.
• Efficient transmission speed is 22.5m/s.
• Can be used for parallel or squed shaft.
 Disadvantages of Flat Belt

• The power transmitting capacity is low.

• Occupies more space.
• Generates more noise.
• Suitable for horizontal drives not vertical.
 Applications of Flat Belts

• Belt conveyors
• Baking machines
• Crushing machines
• Bucket elevators
Application
 Advantages of V-Belts

• Increase in Power transmission.

• Compact construction in view of short center distance.
• High speed reduction ratio.
• Smooth operation.
• Drive is positive due to wedge action.
• Can operate in any position- vertical or horizontal.
 Disadvantages of V-Belts

• Bending stresses are more due to increase in pulley diameter.

Also affects durability.
• Efficiency is lower.
• Creep is higher.
• V-Groove pulleys are complicated & costly.
 Application of V-Belts

• Machine tools.
• Prime movers.
• Pumps
• Fans
• Automobile
 Advantages of Toothed Belts

• Positive drive
• No slip
• No variation output speed
• High strength to weight ratio
• High pitch line velocity 80m/s
• Small cross section allows smaller pulleys
• Belt length does not increase appreciably during working.
• No lubrication
 Disadvantages of Toothed Belts

• High initial cost.

• Pulley manufacturing is costly & accuracies required are
higher.
• Sensitive to misalignment.
• Noise level is slightly higher.
Applications Toothed Belts
 Material of Belts

• Leather
• Cotton or Fabric belt.
• Rubber belts.
 Working Stresses/Speed

• Allowable Working stress for a belt is 17.5kg/cm2.

• Efficient transmission of power is at a belt speed 20 to 22m/s.
 Formulas for Belt Length calculations

• L- length of belt
• D- diameter of large Pulley
• d – Diameter of small Pulley
• C- center distance
 Length of Belt L

• Open Drive
L= 2C+3.14(D+d)/2+(D-d)(D-d)/ 4C
• Cross Drive
L= 2C+3.14(D+d)/2+(D+d)(D+d)/ 4C
 Step by Step procedure for Belt Length
calculation

• Step 1: Determine Service factor Fa from table

(refer belt catalogue)
• Step 2: Calculate design Power
Fa X Power to be transmitted
Step 3 : Selection of Belt cross section from graph (Refer belt
catalogue)
Step 4 : Select minimum pulley diameter for the selected cross
section of the belt.
• Step 5: Calculate Bigger pulley diameter depending upon
speed ratio.
• Step 6 : Calculate belt length by using formula.
• Step 7: Check the availability of standard belt length.
• Step 8: Find the correct center distance.
• Step 9 : Find out the correction factor Fc for Belt pitch length
(Refer belt catalogue)
• Step 10: Find out arc of contact Fd from table
Arc of contact formula (on smaller pulley):
180°- 57.3( D-d)/C
• Step 11:
Number of belts = Fa X Power / Pr X Fc X Fd
where:
Pr- Power per belt of the cross section selected & the
pulley diameter of the smaller pulley
 Pulley

Material:
• Pulleys are normally made of
a. Cast Iron
b. Mild Steel
c. Aluminum
Crowning to be provided on flat pulleys.
 Pulley

• Surface finish for the pulley grooves < 3.2uRa

• Idler width should be equal to pulley width
• Radial run-out should be < 0.05
• Axial run-out should be < 0.05
 Balancing of Pulleys & Idlers

• Poor Balancing creates pre-mature failure of bearing .

• Creates Vibration
• Imbalance can cause shaft breakage
 Method of Attachment to the Shaft

• Pulleys can be fixed on the shaft in different ways depending

upon the application. The major are:
• Keys
• Taper bush
• Ring-fedder
Flat Belt Pulley
V-Belt Pulley
Toothed Belt Pulley
 Do’s & Don’ts
• Check the complete specifications of the belt selected marked on the
belt.
Eg: Belt cross section, belt length
• Groove angle should be correct.
• Over Belt rather than under belt i.e. the correct number of belts to get
increased life
Eg: 6.3 to 7 rather than to 6
• Match set of belt to be used.
• Pulley grooves to be checked for any damages.
• Keep the grooves clean & in good condition.
• Never fit the belt with levers.
• Locate the belt on the slag side on one side of the pulley before taking
up
• Avoid excessive & unwanted tension.
• Check the drive for the alignment.
 Chain Drive (Rigid Drive)

• Chain Drive consist of an endless chain rapped around tooth

sprocket.
• Chain can be defined as a series of links connected by pin
joints.
• Chain drive is in between belt & gear drive, as it has some
features belt & chain drive.
 Advantages of Chain Drive

• Can be used for long & short distance.

• Normally used for medium center distance.
• Number of shafts can be driven in same or opposite
direction.
• Smaller overall dimensions than belt drive, hence compact.
• Efficiency is 96 to 98%.
• Does not slip & is a positive drive
 Disadvantages

• Chain drive requires lubrication.

• Not suitable for non-parallel shaft.
• Not suitable where precise motion is required.
• Chain drives requires alignment.
• Generates noise.
• Requires tensioning device.
 Application of Chain drive

• Transportation industry like bicycle, motorcycle,& automobile

vehicle.
• Agricultural , wood working machinery.
• Oil well drilling rigs.
• Building construction & material handling equipments.
• Velocity ratio less than 10:1 & chain velocity 25m/s.
 Installation

• Belt tension
• Pulley Alignment
• Drive idler
• Belt handling
• Belt storage
• Ambient during operation: -34 to +85 deg C
• Environment
• Thanks !!