44

Roller Chain Drives

44.1 Introduction
Roller chain drives is a type of segmented link drive most commonly used for transmission
of mechanical power of many types of domestic, industrial and agricultural machinery.
It consists of short cylindrical rollers held together by side links and driven by a toothed
wheel called a sprocket.
Though Hans Renold is credited with inventing the roller chain in 1880, Leonardo da
Vinci showed sketches of a chain with roller bearings in a sixteenth century Codex.

44.2 Advantages and Disadvantages of Using a Roller Chain

Roller chain drives have characteristics that in certain applications are more favorable
than belt or gear drives for providing power transmission between two or more shafts.
Figure  44.1 gives the salient features of an individual roller chain link, and Figure 44.2
shows a typical chain sprocket.
The advantages of a roller chain drive over a belt drive system are as follows:

• There is no slip or creep (no power loss resulting from slippage).

• Chain drives are more compact for a given capacity.
• There are lower loads on the drive/driven shafts (high tension is not required as
with a belt drive).
• Chain drives are easier to install.
• They are unaffected by environmental issues, such as ultraviolet rays or high
ambient temperatures.
• They will not deteriorate with age.
• Chain drives are more effective at lower speeds.
• They require little adjustment.

The advantages of a roller chain drive over gear drive systems are as follows:

• Chain drives are more flexible with center distances.

• They are more economical.

1061
1062 Design Engineer’s Sourcebook

Bush Inner plate Outer plate

dr pin

W
Roller
Outer link

p
Inner link

FIGURE 44.1
Detail of individual roller chain link.

Pitch circle diameter

Outside diameter

Hub diameter
Keyway

Bottom

Bore

FIGURE 44.2
Typical roller chain sprocket.

• They are simpler to install.

• Chain drives absorb shock better than gear drives.

The disadvantages of a roller chain drive over a belt drive system are as follows:

• Chain drives generally require lubrication.

• Chain drives are noisier than belt drives.
• They are more expensive than belt drives.
• Impracticable for extremely long center-to-center distances where flat belts could
be used more effectively.
• They are less efficient than flat belts at extremely high-speed ranges.
Roller Chain Drives 1063

• They must be used on parallel shafts; they are unable to twist like belts.
• Chordal action—slight pulsation in the output drive; this becomes less pro-
nounced as the number of sprocket teeth is increased

44.3 Geometry Design Proportions of Roller Chains

Figure 44.1 and Table 44.1 list the main geometric properties of a roller chain link and
nomenclature.
Main roller chain properties are based on national standard recommendations. Specific
sizes of chains also define the corresponding dimensions for the sprockets to engage cor-
rectly with the chain.

TABLE 44.1
Nomenclature of Roller Chain Properties
α Roller seating angle
B Maximum width over bearing pins
b1 Minimum width between the inner plates
Ba Tooth side relief
baxf Tooth side relief factor
br Tooth width
bs Minimum shroud diameter
d1 Maximum roller diameter
d2 Maximum bearing pin body diameter
Da Tip diameter
Dg Measuring pin diameter
Dp Pitch diameter
Dr Root diameter
dr Maximum bush or roller diameter
Ds Maximum shroud diameter
h1 Maximum inner plate depth
h2 Maximum outer or intermediate plate depth
ha Height of the tooth above pitch line
hmax Maximum plate depth
K Number of strands
Mr Measurement over pins or direct measurement
P Pitch
p1 Transverse pitch
Pc Chordal pitch equals to chain pitch
ra Shroud fillet radius
re Tooth flank radius
ri Roller seating radius
rx Tooth side radius
SC Seating clearance
t1 Thickness of inner plates
t2 Thickness of outer plates
Z Number of teeth
1064 Design Engineer’s Sourcebook

Toothed Sprocket Properties

Sprocket dimensional properties are based on a specific chain size, together with the
national standard recommendations. For more details on exact sprocket dimensions,
please refer to the corresponding chain standards.
Figure 44.2 illustrates a typical roller chain sprocket.
In this chapter, two types of tooth form are considered:

• Theoretical tooth form

• Simplify ISO tooth form

The theoretical tooth form is designed so that the chain rollers ride out toward the tips of
the sprocket teeth as the chain wears and elongates. The final tooth form may not exactly
match the theoretical tooth form.
Simplified ISO tooth form is determined by the minimum and maximum tooth gap forms
and shall have tooth flanks of a form that lies between maximum and minimum flank radii
and blending smoothly with the roller seating profile subtending the respective angles.
For maximum service life, smooth operation and optimum performance, the following
points should be considered when determining the optimum number of teeth in the pinion:

1. As most drives have an even number of pitches in the chain, the use of a pinion with
an odd number of teeth ensures even distribution of chain and wheel tooth wear.
2. Pinions for normal, steady drives should generally not have fewer than 17 teeth,
the reason being that a chain forms a polygon around the pinion. When the
pinion speed is constant, the chain speed is subject to regular cyclic variation.
The percentage of cyclic variation becomes less marked as the number of teeth
increases—and, in fact, becomes insignificant for the majority of applications
when the number of teeth in the pinion exceeds 17.
3. A minimum of 23 teeth is recommended on moderate shock drives where the
speed of the pinion exceeds 50% of the maximum rated speed, and for heavy shock
drives where the speed of the pinion exceeds 25% of the maximum rated speed.
4. The pinion should be heat treated to HV 10–550 for smooth drives where the pin-
ion speeds exceed 70% of the maximum speed and operates under full horse-
power rating.

The following equations describe the profiles of the sprocket tooth form (Figure 44.3):
π
Dp = (44.1)
p
sin
z
π
Da = D p ⋅ cos + 2 ⋅ h a (44.2)
z
D f = D p − 2ri (44.3)

bs = pt ( k − 1) + bf (44.4)

ba = bax p (44.5)

dr
ri = + SC (44.6)
2
Roller Chain Drives 1065

Pt

Dr bf ba
Re
rx
ha
ra
r1
α

Ø Ds
Df
Da Dp
bs

FIGURE 44.3
Roller chain sprocket proportions.

π
D z = D p ⋅ cos − h max − 2 ⋅ ra (44.7)
z
Measuring Toothed Sprocket
The roller seating radius is a critical dimension when measuring the roller chain sprocket.
It controls the position of the chain bushing relative to the tooth profile. If wear has taken
place and the chain bushing is sitting lower than the root diameter, then there will be a
possibility for the chain to catch the tip of the sprocket, causing eventual damage and
shock to the chain, resulting in a reduced life.
One method for checking roller chain sprockets is to take a measurement over pins that
have an identical diameter as the chain roller. Figure 44.4a and b shows the sprocket pro-
file for a duplex chain considering even and uneven teeth.
Figure 44.4a and b depicts the method for measuring the sprocket over pins for even and
uneven toothed sprockets, respectively, and Table 44.2 shows the terminology used in this
method.
Measuring a toothed sprocket:
When measuring an even-toothed sprocket over pins (see Figure 44.4a),

(a) (b)
Dg Dg

Mr Mr

FIGURE 44.4
(a) Measurement of sprocket teeth over pins for even teeth. (b) Measurement of sprocket teeth over pins for
uneven teeth.
1066 Design Engineer’s Sourcebook

TABLE 44.2
Nomenclature for Measuring Sprocket Properties
Symbol Description
Dp Pitch diameter
Da Tip diameter
Df Root diameter
dr Maximum bush or roller diameter
Z Number of sprocket teeth
P Chordal pitch equals to chain pitch
pt Strand transverse pitch
k Number of strands
SC Seating clearance
r1 Roller seating radius
re Tooth flank radius
α Roller-seating angle
ha Height of tooth above pitch polygon
bf Tooth width
ba Tooth side relief
bax f Tooth side relief factor
rx Tooth side radius
ra Shroud fillet radius
bs Minimum shroud width
Ds Maximum shroud diameter
hmax Maximum plate depth hmax = max(h2, h3)

M f = D P + 2 ⋅ D g − d r (44.8)

When measuring an odd number of teeth over pins (see Figure 44.4b),

π
M f = D P ⋅ cos + 2 ⋅ D g − d r (44.9)
z
where:
DP = Pitch diameter
Dg = Measuring pin diameter
Mf = Measurement over pins or direct measurement
Z = Number of sprocket teeth
dr = Maximum chain roller diameter
Note:
For measuring over pins, Dg = dr. When measuring directly the root diameter without the
use of pins, Dg = 0.

44.4 Design Procedure
The following method is used to determine the type and size of a roller chain.
Roller Chain Drives 1067

44.4.1 Calculate the Design Power to Be Transmitted (kW)

The design power is the specified input power to the chain drive multiplied by the service
factor obtained from Table 44.2.

Design power = specified input power x service factor (44.10)

44.4.2 Determine the Chain Service Factor

From Table 44.3, select the most appropriate service factor covering the chain drive
application.
The service factor takes into consideration the conditions the chain drive will be operat-
ing under. Shock loads created by the driving machine and driven load require a more
robust design. From Table 44.3 determine the type of the driven machinery, and from the
correct column for the driving machinery determine the selection factor for the number of
teeth on the smallest sprocket.

44.4.3 Determine the Drive Ratio

Use Table 44.4 to select a ratio based on the standard sprocket sizes available. It is preferred
to select one pulley with an odd number of teeth, combined with an even number of chain
pitches.
Ideally, chain sprockets with a minimum of 19 teeth should be selected. If the chain is
operating at high speed or is subjected to impulsive loading, then the smaller sprocket ide-
ally should have a minimum of 25 teeth and should also be hardened.
It is recommended that larger chain sprockets should have a maximum of 114 teeth.

TABLE 44.3
Service Factor
Source of Power
Internal Combustion
Engine
Electric With Without
Motor or Hydraulic Hydraulic
Type of Impact Machines Turbine Drive Drive
Smooth Belt conveyors with small load 1.0 1.0 1.2
fluctuation, chain conveyors,
centrifugal blowers, general textile
machines with small load fluctuations
Some impact Centrifugal compressors, marine 1.3 1.2 1.4
engines, conveyors with some load
fluctuations, automatic furnaces,
dryers, pulverizers, general machine
tools, compressors, general paper
mills
Large impact Press, construction or mining 1.5 1.4 1.7
machines, vibration machines, oil
well rigs, rubber mixers, general
machines with reverse or large impact
loads
1068 Design Engineer’s Sourcebook

TABLE 44.4
Chain Reduction Ratios to One Using Preferred Sprockets
Number of Teeth Number of Teeth
Driven Sprocket (Z2) Drive Sprocket (Z1)
15 17 19 21 23 25
25 — — — — — 1.00
38 2.53 2.23 2.00 1.80 1.65 1.52
57 3.80 3.35 3.00 2.71 2.48 2.28
76 5.07 4.47 4.00 3.62 3.30 3.04
95 6.33 5.59 5.00 4.52 4.13 3.80
114 7.60 6.70 6.00 5.43 4.96 4.56

Calculate the drive ratio R (velocity ratio) given the speed of the input drive and the
output drive from the following formula:

Speed of input (rev / min) Number of teeth on input sprocket

Drive ratio R = =
Speed of output (rev / min) Number of teeth on driven sprocket
 (44.11)

For larger ratio drives, the angle of lap on the smallest sprocket (Z1) should not be less than
120° (see Figure 44.5).

44.4.4 Select Chain Size

From the power rating chart (Figures 44.6 and 44.7), select the most appropriate chain size.
The design power rating for simplex, duplex, and triplex chains are shown in the three
columns on the left-hand side of the chart. Wherever possible, due to cost factors, use a
simplex chain. The design power on the vertical axis is referenced with the speed of the
smaller sprocket on the horizontal axis to obtain a chain size and lubrication requirements.

120°
Min

Driver sprocket

FIGURE 44.5
Angle of lap.
Roller Chain Drives 1069

Simplex
Duplex
Triplex

2,000

3,000

4,000
5,000
6,000
7,000
8,000
9,000
200

300
400
500
600
700
800
900
15
20

30

40
50
60
70
80
90
1000
900
800
700
600
500
400
750 510 300

500 340 200

O
250 170 100 il/
225 153 90 m
h ist
itc
200 136 80
lu
)p
175 119 70
150 102 60 br
m ic
125 85 50 m at
6.2 tc
h io
n
100 68 40
” (7 pi
3.0 )
75 51 30 m
m
3.5
6
”(
50 34 20 O
il
2.5 h
Power (kW)

itc ba
th
)p h
m tc lu
25.0 17.0 10.0
. 3m ) pi br
22.5 15.3 9.00 ic
20.0 13.6 8.0 50 m at
17.5 11.9 7.0 ”( 5m io
15.0 10.2 6.0 2.0 4 .4
h
n
5.0 (4 tc
5”
12.5 8.5
6.8 4.0 .7 ) pi
10.0 1 m
m h
7.5 5.1 3.0 .1 itc
D

3 8 )p
rp

( m
0”
fe

1.5 5m
e

5.0 3.4 2.0

d

. 7
lu

1
(3
br

h
5” itc
ica

.2
)p
tio

2.50 1.70 1.0 1

m
n

2.25 1.53 0.9 m

2.00 1.36 0.8
.4 h
5 tc
pi
1.75 1.19 0.7
1.50 1.02 0.6 ” (2 )
0 m h
1.25 0.85 0.5
1.0 5 m ) pi
tc
1.00 0.68 0.4
9.0
(1 m h
5m tc
M

0.75 0.51 0.3 5” 7 pi

an

0 .7 .8 )
m
ua

15 tc
h
5( .7m
ll

0.50 0.34 0.2 Pi

ub

2 1 2
0.6 ( m
ric

0” m
tio

0.5 8.
0
n

0.250 0.17 0.1

2,000

3,000

4,000
5,000
6,000
7,000
8,000
9,000
200

300
400
500
600
700
800
900
15
20

30

40
50
60
70
80
90

Pinion speeds (rev/min)

FIGURE 44.6
Power rating chart (BS/ISO). Note: Rating chart based on using 19T driving sprocket.

44.4.5 Determine the Sprocket Size

The sprocket pitch diameters can be calculated as follows:

Pitch of chain (p)

Pitch circle diameter = (44.12)
 180 
sin 
 No. of teeth in sprocket 
1070 Design Engineer’s Sourcebook

Simplex
Duplex
Triplex

10,000
1,000

2,000

3,000
4,000
5,000
6,000
7,000
8,000
9,000
100

200

300
400
500
600
700
800
900
10

20

30
40
50
60
70
80
90
1320.0 680.0 400.0
990.0 510.0 300.0
660.0 340.0 200.0

330.0 170.0 100.0

292.0 153.0 90.0
264.0 136.0 80.0
231.0 119.0 70.0 h Oi
198.0 102.0 60.0 itc ls
165.0 85.0 50.0 )p tre
132.0 68.0 40.0 m am
5 m
99.0 51.0 30.0 3 . lu
(6 h br
0” itc ica
2.5 )p tio
66.0 34.0 20.0 m itch Oi n
m p lb
.80 m) ath
( 50 5 m itch lu
33.0 17.0 10.0 0” .4 )p br
6
2. ” (4 mm 4 ica
29.7 15.3 9.00 tio For selection of drives to the
26.4 13.6 8.00 7 5 4 0 n
Power (kW)

23.1 11.9 7.00 1. 38. c h right of this line, consult the

19.5 10.2 6.00 0 ”( pit
) Dr chain manufactures for
16.5 8.50 5.00 1.5 m ip
13.2 6.80 4.00 5m fe e information on optimum
1.7 itc
h dl drive performance
9.90 5.10 3.00 (3 )p ub
. 25” m h ric
6.60 3.40 2.00 1 4 m
p itc ati
2 5. m
) tch on
0 ”( m ) p i
1.70 1.0 .0 5 m
3.30 1.00 ch
2.97 1.53 0.90 ( 19 5 m it
1.36 5” .87 )p h
2.64 0.80 0.7 15 m itc
2.31 1.19 0.70 ”( m )p
1.98 1.02 0.60 . 6 25 1 2.7 m
m
0 (
1.61 0.85 0.50 0” 25
1.32 0.68 0.40 M 0.5 9.5 itc
h
0.99 0.51 0.3 an ”(
ua
l lu 3 75 )p
0 . m
0.66 0.34 0.20 br 5 m
ica .3
tio (6
n 5”
0.2
0.33 0.17 0.10

10,000
2,000

3,000
4,000
5,000
6,000
7,000
8,000
9,000
1,000
100

200

300
400
500
600
700
800
900
10

20

30
40
50
60
70
80
90

Pinion speeds (rev/min)

FIGURE 44.7
Power rating chart (US). Note: Rating chart based on using 19T driving sprocket.

44.4.6 Calculate the Chain Length (in Pitches)

The chain length can be calculated as follows:
2
 Z 2 − Z1 
p
Z1 + Z 2 2C  2 π 
Length (L) = + + (44.13)
2 p C

The calculated number of pitches should be rounded up to a whole number of even pitches.
Odd numbers of pitches should be avoided, as this will involve the use of a cranked link
that is not recommended. If a jockey sprocket is used for adjustment purposes, two addi-
tional pitches should be added to the chain length (L).
C is the proposed center distance in mm and should generally be between 30 and 50
pitches.
For example,
For a 38.1 mm pitch chain, C = 38.1 x 40 = 1524 mm.

44.4.7 Calculate the Actual Center-to-Center Distance (mm)

The actual center distance for the chain length (L) that has been calculated by the method
in Section 44.4.8 will generally be greater than that originally considered. The revised cen-
ter distance can be calculated from Equation 44.12:

p  π 
C=  2L − Z 2 − Z 1 + ( 2L − Z 2 − Z1 )2 −  ( Z 2 − Z1 )2   (44.14)
8  3.88 
Roller Chain Drives 1071

44.4.8 Lubrication
Chain life will vary extensively depending on the method used to lubricate the drive. A
correctly lubricated chain can last as long as 100 times more than the same chain incor-
rectly lubricated. It is recommended to use a good grade of clean petroleum oil without
additives and free flowing at the prevailing temperature. Some additives leave a varnish or
gum deposits that prevent the oil entering the chain joints. Heavy oils or greases are gen-
erally too stiff to enter the chain joints and should not be used unless the oil is indirectly
heated and the chain is immersed in the molten oil.
With correct lubrication, a separate wedge of lubricant is formed between the bushings and
pins in the chain joints, similar to that formed between the mating surfaces of a journal bear-
ing. The viscosity of the oil will greatly affect its separating force and the ability to become
a wedge between the moving surfaces. The highest viscosity oil that will flow between the
chain link plates and fill the pin bushing will provide the best wear protection. This being
essential to minimize metal-to-metal contact, and if sufficient volume of lubricant is supplied
this will also provide effective cooling and also improve damping at higher chain speeds.
Figure 44.8 is a lubrication chart recommending types of lubrication methods against
chain pitch and chain speeds.
15.0
12.5

10.0
Oil stream lubrication
8.0

6.0
5.0
4.0
Chain speed (m/s)

3.0
2.5

2.0
1.75
Oil bath or disc lubrication
1.5
1.25
1.0
0.8

0.6
Drip feed lubrication
0.5
0.4
Manual lubrication
0.3
0.25
8.0
9.525
12.7
15.875
19.05

25.4

31.75

44.45

50.8

62.5

76.2

Chain pitch (mm)

FIGURE 44.8
Lubrication chart.
1072 Design Engineer’s Sourcebook

(a) Manual lubrication

oil
Brush

(b) Drip feed lubrication

Oil tank

(c) Oil bath lubrication

Oil level

(d) Oil bath lubrication

Disc

Oil level

(e) Forced lubrication

Oil bath

FIGURE 44.9
(a) Manual method of lubrication. (b) Drip method of lubrication. (c) Bath or disc method of lubrication. (d) Oil
stream method of lubrication. (e) Forced lubrication.

Figure 44.9a depicts the manual method of lubrication for a chain drive that is low power
and low speed. The oil is applied periodically with a brush or oil can, preferably every 8 h
of operation. Volume and frequency should be sufficient to just keep the chain wet with oil
and allow penetration with clean fluid into the chain joints.
Figure 44.9b describes the drip lubrication method in which oil drips are directed
between the link plate edges from the drip lubricator. The volume and frequency should
be sufficient to allow the penetration of the oil into the chain pins.
The bath or disc lubrication method is shown in Figure 44.9c in which the strand of the
chain runs through a sump of oil in the chain housing where the oil level covers the chain
strand at its lowest point.
Roller Chain Drives 1073

In some designs, a disc is attached to the lower chain sprocket drive and this runs
through the oil and flings the oil onto the chain strand. The oil is deposited onto the chain
via deflector plates within the housing. The peripheral speed of the disc should be a mini-
mum of 180 and 2440 m/min.
The fourth method, “oil stream lubrication” (Figure 44.9d), uses a continuously circulat-
ing stream of oil directed onto the chain from a circulating pump. It is essential that the
spray holes are in line with the chain plate edges. The spray holes should be positioned
such that the oil is delivered onto the chain just before it engages with the drive sprocket.
This ensures that the oil is centrifuged through the chain and assists in cushioning the
roller impact on the sprocket wheel (Table 44.5).

Example 44.1
The task is to provide a suitable roller chain drive for a small rotary kiln (Figure 44.10) to
transmit 3.0 kW from a geared electric motor running at 200 rev/min to a rotary kiln at 100
rev/min. Assume moderate shock loads. Use a center distance that is twice the pitch diam-
eter of the wheel sprocket. Figure 44.11 shows the proposed drive schematic of the kiln.
Calculate:

1. The length of the chain in pitches.

2. The exact center distance.

TABLE 44.5
Combinations for Input and Output Sprockets for a Drive Ratio of 2.00
Z1 30 38 47 57
Z2 57 76 95 114
R 1.90 2.00 2.02 2.00
Z2 (PCD) mm 288.18 384.15 480.14 576.13

UNIQUE PERENY RTC Series rotary kiln

FIGURE 44.10
A small rotating kiln.
1074 Design Engineer’s Sourcebook

Rotary kiln Driven sprocket

Burner
Wet slurry
In Fuel gas

Dry product out

Support roller Support roller

Drive motor
Chain drive

FIGURE 44.11
A schematic of a rotary kiln.

Rotary kilns (or rotary dryers) are used extensively in industry for drying solids or
slurries.
The kiln is a cylindrical vessel, inclined slightly to the horizontal, that is rotated
slowly about its axis. The material to be processed is fed into the upper end of the cyl-
inder. As the kiln rotates, material gradually moves down toward the lower end, and
may undergo a certain amount of stirring and mixing. Hot gases pass along the kiln,
sometimes in the same direction as the process material (co-current), but usually in
the opposite direction (countercurrent). The hot gases may be generated in an external
furnace, or may be generated by a flame inside the kiln. Such a flame is projected from
a burner pipe (or “firing pipe”) which acts like a large Bunsen burner. The fuel for this
can be gas, oil, pulverized petroleum coke, or pulverized coal.
Kilns come in a wide range of sizes from small to very large, several meters in diameter.

Solution
Known data:

Power transmitted ( P ) = 3.0 kW

Drive motor — geared electric motor — speed 200 rev/min

Driven machine — rotary kiln — speed 80 rev / min — medium impulse load
Estimated center distance ( C ) — 2 x pitch circle diameter wheel sprocket

1. Calculate the drive ratio:

Speed of driver (rev / min)

Drive ratio (R) =
Speed of driven (rev / min)

200
=
100
( R ) = 2.0/1

2. Select the sprocket size:

Z 1 = number of teeth in pinion ( driver )

Z 2 = number of teeth in wheel ( driven )

Z 2 = R × Z1 (44.15)
Roller Chain Drives 1075

Consider chain pitch = 15.875 mm

Note:
The size of the driven sprocket will be dictated by the throat of the rotary
kiln. Assuming the design allowed for a throat of 500.0 mm, the appropriate
combination would be Z1 = 57 teeth and Z2 = 114 teeth, having a pitch circle
diameter (PCD) of 576.13 mm and giving a drive ratio of 2.0 (see Table 44.5).
The most suitable combination is
Z 1 = 57, Z 2 = 114

Exact drive ratio (R) = 114/57

= 2.0 (required drive ratio)
Determine the service factor:
From Table 44.3,
Medium impact load − service load = 1.3.

3. Calculate the design power:

P = Theoretical power x service factor

P = 3.0 kW x 1.3
P = 3.9 kW
4. Select the chain size: from Figure 44.8 together with an approximate chain
speed.
Chain selection:
15.875 mm pitch, manual lubrication
19.05 mm pitch, drip lubrication

5. Determine the center distance:

Given : C = 2 x PCD wheel (44.16)

= 2 x 114 mm
C = 228 mm

6. Length of chain in pitches:

2
 Z 2 − Z1 
p
Z1 + Z 2 2C  2 π 
L= + + (44.17)
2 p C
2
  
57 + 114 2 × 228   114 − 57  
L= + +   × 15.875 
2 15.875  2π  
 228  
 
L = 158 pitches

TABLE 44.6
Nomenclature for Figure 44.14
Curve Description
A Chain drive power capacity limited by link plate fatigue
B Chain drive power capacity limited by roller and bush impact fatigue
C Chain drive power capacity limited by pin-bush galling
1076 Design Engineer’s Sourcebook

7. Actual center distance:

p   π 
CD =
2
 2 ⋅ L − Z 2 − Z 1 + ( 2 ⋅ L − Z 2 − Z 1 ) −  ( Z 2 − Z1 )2    (44.18)
8   3.88   


15.875    π 
CD =
2
 2 x 113 − 57 − 23 + ( 2 x 158 − 114 − 57 ) −  (114 − 57 )2   
8    3.88   


CD = 163 mm

44.5 Roller Chain Calculation Basics

The following notes cover the basic issues to be considered when designing a roller chain
drive system.

44.5.1 Wear
Wear in the roller chain drive is an important consideration. Roller chains are normally
most affected by chain joint wear and sprocket wear.
Chain joint wear will result in the roller chain increasing in length. Sprockets are
designed to accept an increase in length up to 3% from wear. When the chain has elon-
gated beyond this value, it no longer fits the sprockets and the chain drive will not oper-
ate correctly. If the worn chain is to be replaced, it is recommended that the sprockets are
either replaced as well or the sprocket (if possible) is reversed on the shaft; this sometimes
extends the life of the worn sprocket.
Sprocket wear will result in the modification of the tooth shape. The teeth will begin to take
on a hooked shape, as shown in Figure 44.12. For idler sprockets, these usually wear at the
bottom of the tooth shape (see Figure 44.13). When the tooth shape is worn deeply enough,
the roller chain may bind against the tooth tips as the link enters and leaves the idler sprocket.
This type of wear can be the source of shock loads in the chain, resulting in reduced chain life.
See Section 44.4.9 on considerations for lubrication.
Normally at the beginning of the chain drive service, the wear progresses rapidly as
the chain beds in. Initial wear can be minimized by preloading the chain, a practice some
chain manufacturers undertake to increase the service life of the chain.
The chain joint wear continues at a reduced rate and becomes what is known as normal
wear. If the chain is adequately lubricated, then the chain joint wear continues to exhibit
normal wear to a point when the chain reaches the end of its useful life. When this point
is reached, the chain joint wear begins to rapidly increase again.

44.5.2 Ultimate Tensile Strength of the Chain Fu

The ultimate tensile strength of the roller chain is the highest value of load that the chain
can withstand in a single application of load before breaking. A minimum value of the
ultimate tensile strength is used as a quality-control criterion to ensure that the chain has
been manufactured and assembled correctly.
Roller Chain Drives 1077

Wear profile

FIGURE 44.12
Wear profile on a driver sprocket.

FIGURE 44.13
Wear profile on an idler sprocket.

The default value of the ultimate strength is arrived from standard recommendations
for a given chain size. This tensile strength may differ for the same size of chain between
different chain manufacturers as well as different materials.

44.5.3 Specific Chain Mass m

The specific mass of the chain (m) is used for computing the centrifugal force acting on
the chain, and is also used in vibration analysis in the chain drive. The default value is
taken from standard recommendations or the closest value of a steel chain produced by
the chain manufacturers.

44.5.4 Chain Construction Factor

The chain construction factor defines the actual quality of the chain. It has a direct impact
on the chain power rating as well as the chain’s permissible bearing area pressure. The
1078 Design Engineer’s Sourcebook

default factor is equal to unity. If the chain is manufactured from material that has
improved strength to the default chain, then the factor will be greater than unit, or if the
quality of the chain is better than that mentioned in national standards.

44.5.5 Chain Power Rating PR

The chain power rating (PR) represents the chain capacity rating for specific operat-
ing conditions. Normally, the chain capacity is limited by link plate fatigue, roller and
bushing impact fatigue and galling between the pin and bushing. See Figure 44.14 and
Table 44.6.

44.5.6 Power Correction Factors

Chain power rating equations provide valid power capacity for chain drives that work
under normal operating conditions.
The criteria for a roller chain drive operating under normal conditions are covered in
Table 44.7.

44.5.7 Shock Factor Fs
The service factor (FS) takes into account the dynamic dependency to overloads on the
chain drive operating conditions, driver, and driven characteristics. The shock factor
determines the degree of the service factor together with the dynamic factor of safety
(FoS). The peak loads can be caused by unexpected shock, and these peak overloads can
significantly increase when there are large moments of inertia within the drive system
(see Table 44.8).

44.5.8 Service Factor Sf
The service factor (Sf) considers any dynamic overloads occurring in the chain drive due to
the driving conditions. The values of the FoS are listed in Table 44.9.
Chain power rating PR (W)

Speed of sprocket, NS (rev/min)

FIGURE 44.14
Chain power rating.
Roller Chain Drives 1079

TABLE 44.7
Criteria for Normal Operating Conditions
1 Chain drive with two sprockets on parallel horizontal shafts
2 Small sprocket with 19 teeth
3 Simplex chain without a cranked link
4 Chain length:
  120 pitches of ISO chain
  100 pitches of ANSI and CSN chains
5 Speed ratio of 1:3 or 3:1
6 Expected service life:
  15,000 h for ISO, ANSI, and Din chains
7 Operating temperature between 5°C and +70°C
8 Sprocket correctly aligned and chain maintained with correct adjustment
9 Uniform operation without overload, shocks, or frequent starts
10 Clean and adequate lubrication throughout the working life of the chain

TABLE 44.8
Shock Factors in Chain Drives
Shock Factor Fs Application
1.0 Smooth running
1.5 Smooth running with occasional shocks
2.0 Slight shocks with moderate temporary overloads
3.0 Moderate shocks with heavy temporary peak overloads
4.0 Heavy shocks with moderate constant peak overloads
5.0 Heavy shocks with heavy constant peak overloads

TABLE 44.9
Values of FOS
Driver Machine Characteristics
Driven Machine
Characteristics Smooth Running Slight Shocks Moderate Shocks
Smooth running 1.0 1.1 1.3
Moderate shocks 1.4 1.5 1.7
Heavy shocks 1.8 1.9 2.1

44.5.9 Definitions of Characteristics of Driver Machines

Table 44.10 defines the characteristics of driver machines used in roller chain drive systems.
Table 44.11 gives examples of driven machine types used in roller chain drive systems.

44.5.10 Sprocket Size Factor (f 2)

The sprocket size factor (f2) takes into account the number of teeth on the smallest sprocket.
The factor is equal to one if the power rating equations consider the number of teeth on the
smallest sprocket in the drive. The size of the smallest sprocket may have a specific impact
on each portion of the chain power rating.
1080 Design Engineer’s Sourcebook

TABLE 44.10
Characteristics of Driver Machines
Driver Machine
Characteristics Examples of Drive Machine Types
Smooth running Electric motors, steam and gas turbines, internal combustion engines
fitted with a hydraulic coupling
Slight shocks Six-cylinder or more internal combustion engines fitted with
mechanical coupling. Electric motors subject to frequent stop and
starts greater than twice a day
Moderate shocks Internal engines having fewer than six cylinders fitted with
mechanical coupling

TABLE 44.11
Characteristics of Driven Machines
Driven Machine
Characteristics Examples of Driven Machine Types
Smooth running Centrifugal pumps and compressors, printing machines, uniformly
loaded belt conveyors, escalators, liquid mixers and agitators, rotary
driers
Moderate shocks Reciprocating pumps and compressors having three or more cylinders,
concrete mixers, non-uniformly loaded conveyors, solid agitators and
mixers
Heavy shocks Excavators, roll and ball mills, rubber-processing machines, planers,
presses, compressors having more than one or two cylinders, oil
drilling rigs

The relationship between the sprocket size factor (f2) and the number of teeth on the
smallest sprocket is
1.08
 19 
f2 =   (44.20)
 Zs 

where Zs is the number of teeth on the smallest sprocket.

44.5.11 Lubrication Factor (f4)

The lubrication factor (f4) determines the amount of lubrication the chain is receiving, and
has a direct bearing on the chain power capacity as well as service life. If the lubrication
is adequate, then the factor will be equal to 1. If the lubrication is inadequate, then the
factor will decrease the chain power rating, which will be limited by pin-bush galling.
Table 44.12 shows the effect on the degree of lubrication received.

44.5.12 Center Distance Factor (f 5)

The minimum center distance factor (f5) is one half the sum of the outside sprocket diam-
eters, to avoid tooth interference. To ensure adequate wrap on the small sprocket (approxi-
mately 120°), it is suggested to have minimum center distance of the sum of the outside
diameter of the large sprocket plus one-half the outside diameter of the small sprocket.
Roller Chain Drives 1081

TABLE 44.12
Effect of Lubrication with Respect to Chain Speed
Lubrication Factor
Lubrication No Lubrication

Insufficient

Chain Speed (m/s) Recommended Clean Environment Soiled Environment

Up to 4 1.0 0.6 0.3 0.15
Up to 7 0.3   0.15 Inadmissible
Up to 12 Inadmissible
More than 12

It is good practice to set the center distance at 30–50 times the chain pitch. The longest
practical center distance is about 80 times the chain pitch, because chain sag and catenary
tension become very large.
The center distance factor corrects the design power and takes into account the differ-
ence of the actual center distance from the normal. The reason for the center distance fac-
tor comes from modification of load tension distribution and its affect to chain fatigue. The
center distance factor is determined as follows:

0.4
X 
f5 =  B  (44.21)
 X

where
f5 = Center distance factor
XB = Number of chain links for normal operating conditions
X = Actual number of chain links in the drive

44.5.13 Ratio Factor (f 6)
The design power is corrected by the ratio factor (f6) and it takes into account the difference
between the transmission ratio from the normal. The reason for this factor comes from the
modification of load tension distribution and its effect on the chain fatigue. Figure 44.15 is
a chart showing the ratio factor with respect to the actual transmission ratio.
Transmission ratio is given from the number of teeth on the driver and driven sprockets:

For z 1 < z 2 , i = Z 2 / Z 1 (44.21)

For z 1 > z 2 , i = Z 1 / Z 2 (44.22)

where
f6 = Ratio factor
i = Transmission ratio
Z1 = Number of teeth on the driver sprocket
Z2 = Number of teeth on the driven sprocket
1082 Design Engineer’s Sourcebook

1.3
1.2
1.1
Ratio factor (Fr) 1.0
0.9
0.8
0.7
0.6
1 2 3 4 5 6 7
Transmission ratio (Ft)

FIGURE 44.15
Relationship between the ratio factor and the transmission ratio.

44.5.14 Service Life Factor (f 7 )

The service life factor (f7) corrects the design power and takes into account the difference of
the required service life from the normal. By default, the ratio factor is determined as follows:
0.4
 L 
f7 =  h  (44.23)
 L hB 

where
f7 = Service life factor
Lh = Required service life (h)
LhB = Normal expected service life (h)

44.5.15 Pressure in Chain Bearing Area Analysis

The fluctuating tensile load acting in the roller chain during service acts on the contact sur-
faces between the pin and bushing, and it is this that causes the level of pressure between
the chain bearing area. If this pressure exceeds the permissible pressure, then the chain
service life will be significantly reduced. The level of the actual bearing pressure in the
chain bearing area is computed from Equation 44.22 and is based on the maximum tension
in the chain span:
F 
PB =  T max  (44.24)
 A 

where
PB = Actual pressure in chain bearing area (Pa)
FTmax = Maximum tension in taught section of chain span (N)
A = Chain bearing area (m2)

44.5.16 Chain Bearing Area (A)

The chain bearing area (A) is defined by the width of the internal chain link and the pin
diameter, as shown in Table 44.13.
Roller Chain Drives 1083

TABLE 44.13
Area of Pin and Bush
b2 A = b2 d2
where
A = Chain bearing area (m2)
ød2 b2 = Width of internal chain link (m)
d2 = Chain pin diameter (m)
b2

A d2

44.5.17 Permissible Pressure in Chain Bearing Area (Po)

The permissible pressure obtained from Figure 44.16 is also corrected by the chain con-
struction factor, so the amount of permissible pressure in the chain-bearing area (Po) is
defined as follows:

Po = PBo ϕ (44.25)

where
Po Permissible pressure in chain-bearing area for normal conditions (Pa)
PBo Specific permissible pressure in chain-bearing area for normal operating conditions (Pa)
ϕ Chain construction factor

44.5.18 Specific Friction Factor (λ)

The specific friction factor corrects the permissible pressure in the chain bearing area. The
size of the factor is dependent on the difference between the actual operating conditions
and the normal, and is defined as follows:

35

30

25

20
PBo (MPa)

23 25
15

10
11 13 15 17 19 21
5

0
0 2 4 6 8 10 12 14 16 18 20 22 24
v (m/s)

FIGURE 44.16
Permissible pressure in chain bearing.
1084 Design Engineer’s Sourcebook

f4
λ= (44.26)
f1 , f5 , f6 , f7
where
λ = Specific friction factor
f1 = Service factor
f4 = Lubrication factor
f5 = Center distance factor
f6 = Ratio factor
f7 = Service life factor

44.6 Static Safety Factor

The static FoS from the chain breaking under a constant load is determined as follows:
Fu
Ss = ≥ S s min (44.27)
Ft max
where
Ssmin = Minimum allowed static safety factor
Fu = Ultimate tensile strength of the selected chain (N)
Ftmax = Maximum tension in the taut section of the chain span (N)

44.7 Dynamic Safety Factor

The dynamic FOS from selected chain breaking from peak load is determined as follows:
Fu
SD = ≥ SD min (44.28)
Ft max .Y
where
SDmin = Minimum allowed dynamic safety factor
Fu = Ultimate tensile strength of the selected chain (N)
Ftmax = Maximum tension in the taut section of the chain span (N)
Y = Shock factor

44.8 Design Power and Chain Power Rating

The chain power rating PR is compared to the design power PD. The chain power rating
must be greater than the design power for a satisfactory life:

PD > PR
Roller Chain Drives 1085

where:

1
PD = P ⋅ f1 ⋅ f2 ⋅ f5 ⋅ f6 ⋅ f7 ⋅ (44.29)
f4
PR = PRN·f3·Cf
P = Power to transmit (W)
PRN = Single-strand chain power rating for normal operating conditions (W)
f1 = Service factor
f2 = Sprocket size factor
f3 = Chain strand factor
f4 = Lubrication factor
f5 = Center distance factor
f6 = Ratio factor
f7 = Service life factor
Cf = Chain construction factor