CROSS HEAD ASSEMBLY
A Report on Mini Project
Submitted by
Swaraj M. Ramdhave Sanskar M. Shrawane
Abhinav R. Fating Prajwal D. Kahate
Project Guide
Mr. Pritish G. Chitte
Department of Mechanical Engineering
Walchand Institute of Technology, Solapur
Affiliated to Punyashlok Ahilyadevi Holkar Solapur
University, Solapur, Maharashtra, India
Year 2021-22
CERTIFICATE
This is to certify that the Mini Project entitled “DESIGN AND ANALYSIS OF PULLEY
SUPPORT ASSEMBLY”, has been carried out and is submitted by the following students in
the partial fulfillment for the award of the degree of Bachelor in Mechanical Engineering as
prescribed by the Solapur University, Solapur.
Name Roll No.
Swaraj M. Ramdhave A-69
Sanskar M. Shrawane A-71
Abhinav R. Fating A-60
Prajwal D. Kahate A-62
Mr. P. G. Chitte
(Guide)
Dr. P. R. Kulkarni Dr. S.A.Halkude (PhD.,IIT
Mumbai) (Head of Mech. Engg. Dept.) Principal
ACKNOWLEDGEMENT
It is our privilege to express our sincerest regards to our project coordinator, Dr/Prof./Mr.
Pritish G. Chitte, for providing their invaluable guidance, comments and suggestions
throughout the duration of our project. We deeply express our sincere thanks to our Head of
Department Dr. P. R. Kulkarni for encouraging and allowing us to present the project on the
topic “DESIGN AND ANALYSIS OF PULLEY SUPPORT ASSEMBLY “. We take this
opportunity to thank all our lecturers who have directly or indirectly helped our project. Last
but not the least we express our thanks to our friends for their cooperation and support..
We would like to express our gratitude to the Principal Sir Dr.S.A.Halkude and our H.O.D
Dr.P.R.Kulkarni for providing all the required facility.We would like to express our gratitude
towards our parents and team members for their kind cooperation and encouragement which
help me in completion of this the projects. A special thanks and appreciations also go to my
colleagues in developing the project and people who have willingly helped us out with their
abilities.
ABSTRACT
The present work is concerned with design and analysis of pulley support assembly
used for transmitting power from one rotating shaft to another. The objective of the work
was to reduce the time, manpower & fatigue during the process.
A pulley support assembly system is a common piece of mechanical handling equipment
that moves materials from one location to another. Many kinds of pulley support assembly
systems are available and are used according to the various needs of different industries.
The current design of the pulley support assembly used timing belt that connected at the
motor to move the shaft. The problem of the current design is the timing belt disheveled,
and shaft was slipping. For the improvement we use sprocket and chain as drive
mechanism. Beyond the above improvement the pulley support assembly system is
expected to work. This project also helps student to utilize their engineering information
and improve the skill of student in solving the mechanical problems In this project 3D
model is created using Autodesk Inventor. The model is also changed by changing the
thickness of the Pulley. Structural analysis and modal analysis are done on the Ansys
Software by varying material of Pulley, The analysis is done by considering loads strength
and modal analysis is done to determine the displacements for different frequencies for
number of modes.
KEYWORDS:- Pulley support assembly, Man Power, Fatigue failure, Rotating shaft,
Timing belt, Shaft, Sprocket and Chain, Drive mechanism
iv
CONTENTS
ACKNOWLEDGEMENT.............................................................................................iii
ABSTRACT...................................................................................................................iv
CONTENTS....................................................................................................................v
LIST OF FIGURES.......................................................................................................vi
LIST OF TABLES.......................................................................................................vii
Chapter Title Page No.
1 INTRODUCTION 1-3
1.1 History 2
1.2 Importance of Area 2
1.3 Objective of the Work 3
1.4 Outline of the work 3
2 LITERATURE REVIEW 4-5
3 3D MODEL OF PULLEY ASSEMBLY 6-16
3.1 Pully Material 7
3.2 Crowning of Pully 9
3.3 Design of Pully 10
3.3.1 Dimension of Pully 10
3.3.2 Dimension of Arms 10
3.3.3 Dimension of Hub 13
3.4 Software Selection 13
3.5 Design of Model 14
4 RESULT AND DISCUSSION 17-21
4.1 Number of Persons Required for Process 17
4.2 Time Required For The Process 17
4.3 Analysis On Model 18
5 CONCLUSION AND FUTURE SCOPE 22-23
REFERENCES 23
LIST OF FIGURES
Figure No. Name of the figure Page No.
1.1 Pulley Support Assembly 01
3.1 Pulley Washer 06
3.2 Solid Pulleys 07
3.3 Split Pulley 09
3.4 Crowning of Pulleys 09
3.5 Assembly View 14
3.6 Assembly Draft 15
3.7 Assembly Parts Draft 16
4.1 Mesh 18
4.2 Strain Energy 19
4.3 Equivalent Stress 20
4.4 Total Deformation 21
vi
LIST OF TABLES
Table No. Title Page No.
3.6 Part List 15
3.7 Part List Table 17
vii
Design and analysis of Pulley Support Assembly
Chapter 1 INTRODUCTION
A pulley is a wheel on an axle or shaft that is designed to support movement and change of
direction of a taut cable or belt along its circumference. Pulleys are used in a variety of ways to
lift loads, apply forces, and to transmit power.
Pulleys can be found in many different applications around us. Not only they are used for the
obvious lifting of objects, such as by cranes, but they are also used in modern automobiles and
airplanes. Pulleys are also essential for most machines in some form or other.
Figure 1.1 Pulley Support Assembly
There are a few different types of pulleys that explains, which apply to multiple types of pulley
systems. These the naming conventions for the basic types of pulleys. In future steps you'll see
how some of them can be applied to improve mechanisms.
Driving Pulley: The "input" pulley of a two-pulley system. This is the pulley whose shaft is
being driven by something, like a motor, crank, or possibly by another pulley if in a larger
system. This pulley is what is controlling the motion of the belt.
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Driven Pulley: The "output" pulley of a two-pulley system. This is the pulley that is being turned
because of the belt's motion.
Idler Pulley: A type of driven pulley not meant to transmit power through its shaft. It spins
freely, while most driven pulleys are linked to other devices, like wheels or actuators, via their
drive shafts.
Fixed Pulley: A pulley whose axis is fixed in place. It can rotate, but it cannot translate in any
direction freely.
Movable Pulley: A pulley that can both rotate and translate based on the motions of the pulley or
belt. This is commonly used in block and tackle systems, which I'll explain later.
Guide Pulley: A smaller type of idler pulley usually used to guide cable and keep it along a
specific path.
1.1 Importance of the Project:
Material handling is one of the basic functions of the industries. We should require
minimum time for material handling. As well as material handling should require cost for the
equipment’s or machines handling the same. Also it should reduce the fatigue of the workers.
Thus material handling plays important role in the industries. If the cost of material
handling is more, it will lead to increase in the overall cost of the product which will
increase the price of the product. To be competitive, every company tries to keep the material
handling cost to the minimum. Thus it is one of the major areas in the industries where
improvements can be made.
1.2 Objectives of the work:
The following are the objectives of the work:
a. To reduce the number of persons required for this process.
b. To reduce the time required for the process.
c. To reduce the fatigue due to the process.
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1.3 Outline of report:
Introduction to the pulley , history we have seen in this chapter .
Chapter 2 explains the pulley similar applications. The advantages, disadvantages and other
things like construction, mechanisms, working etc. are covered briefly.
Chapter 3 contains actual design part. It explains how each part is designed. It also explains
how the manufacturing of the pulley is done.
Chapter 4 focuses on observations/findings of the project work. Thus, it is giving us the
results. The discussion about the results is also carried out in the same chapter.
Chapter 5 presents conclusion and future scope.
1.4 Outcome of project:-
If you have a single wheel and a rope, a pulley helps you reverse the direction of your
lifting force. So, you pull the rope down to lift the weight up. If you want to lift something that
weighs 100kg, you have to pull down with a force equivalent to 100kg, which is 1000N
(newtons). If you want to raise the weight 1m into the air, you have to pull the loose end of the
rope a total distance of 1m at the other end.
Pulleys can be much more complicated. Engineers combine many pulleys into a pulley
system that significantly reduces the amount of force required to lift an object. They often use
pulley systems to move extremely heavy objects. A block and tackle is an example of a pulley
system that can be attached to anything. It may take a lot of cable or rope, but a human using
enough pulleys could lift several tons. Engineers use the block and tackle along with motors and
electronics to create modern devices that operate with very low power requirements, such as
cranes and elevators.
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Design and analysis of Pulley Support Assembly
Chapter 2 LITERATURE REVIEW
A pulley Support assembly is a simple machine used to change the direction of
the application of a force on a load. It is a combination of a grooved wheel on
an axle, through which a rope passes. A load or weight is attached to one end
and a force applied to the other end, moving the load. Individual pulleys can be
linked together to create a mechanical advantage, reducing the force required to
move the load.
The combination of pulleys is known as a ‘block and tackle’. Making decisions
about risks is considered analogous to this combination of pulleys. The term
‘decision-making’ as applied to this model, requires an initial clarification. Hale
and Glendon (1987) have previously suggested three classes of OHS decisions –
decisions about work practices, decisions during risk assessments and planning
or design decisions.
The pulley model is most appropriately applied to work practice and risk
assessment decisions. These are decisions where a potential or actual
‘deviation’ (an event or condition in the production process that conflicts with
the norm for the faultless or planned process) (Kjellen 1987) has been noticed,
and individuals within an organization interact to establish a response to that
risk. For this model, decision-making includes the initial assessment on the
magnitude of the problem and the process that leads to some type of action (or
inaction) based on that assessment.
Modelling does not extend to an analysis of the affective (emotional) factors
and does not account for physiological factors affecting risk responses. The
model mentions, but does not address in any detail the goals and intentions of
individuals making decisions about risks. The model assumes that a hazard is
able to be perceived or observed and that the associated Issue 1 2007
VVOOLL11112risk can, to some degree, be assessed for the likelihood of an
injury outcome, local exposure, the credibility of the accident pathway and the
severity of that injury .
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The Pulley model is laden with concepts. A summary of each is provided in
Table One. An individual with certain demographic characteristics comes to
interact with a risky decision. That decision might be to actually perform a work
practice or a 3rd party assessment of the risk associated with a work practice.
The rope can be basically represented as a flow of information, and connects the
individual to the immediate social interactions in their small work team, to
wider cultural factors, to the boundaries of the model and ultimately to the risk
itself. The rope has a degree of elasticity, with actions not necessary leading to
immediate results.
The risk is considered to have a ‘load’ and that load can be moved from its
present position to one that is either more vulnerable to the risk being realised
as an accident or more resistant. The pulleys provide an advantage by assisting
to reduce the cognitive load and allowing people to make easier decisions.
The trade-off for this mechanical advantage is that it can only work within the
boundaries of the organization. There will always be some friction either
stopping decisions from being initiated or slowing decisions in progress. The
result is a descriptive, yet dynamic analogy of the process of making decisions
about risks.
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Design and analysis of Pulley Support Assembly
Chapter 3 3D Model Of Pulley Support Assembly
Pulleys are the wheels used to transmit power from one shaft to another, with the help of
belts. Proper selection of diameters of pulleys is important as the velocity ratio is the
inverse ratio of the diameters of driving and driven pulleys.
For the belt to travel in a line normal to the pulley faces, the pulleys must be perfectly
aligned with each other. Pulleys should have following important properties:
Figure 3.1 Pulley Washer
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Design and analysis of Pulley Support Assembly
1. Ability to absorb shocks
2. High heat conductivity
3. High corrosion resistance
4. High coefficient of friction to reduce belt slippage
5. High strength to weight ratio
Pulley has three main components: i. Hub
ii. Arms/spokes or web
iii. Rim
3.1 Pulley Material:
Pulleys are generally made of cast iron, forged steel, wood, or compressed paper pulp.
Because of their low cost, cast iron pulleys are most widely used. Arms or spokes of cast
iron pulleys have elliptical cross-section and can have straight, or curved shape as shown in
figure 3.1.
In some pulleys, instead of arms, web is provided to join hub with rim, as shown in figure
1.2 b. Split cast iron pulleys, shown in figure, are made in two halves that are bolted
together. These are easier to mount on shafts with a range of diameters, by tightening those
on the shaft.
A) Pulleys
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Design and analysis of Pulley Support Assembly
B) Pulley with Web
Figure 3.2 Solid
Pulleys
Steel pulleys have higher strength, are lighter in weight and can run at higher speeds. But
they have lower coefficient of friction in comparison to cast iron pulleys.
Steel pulleys are generally made in two parts, which are bolted together on the shaft.
Bushings
are provided to take care of shafts of different diameters and for normal service; power is
transmitted without key, only through frictional force obtained by clamping.
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Design and analysis of Pulley Support Assembly
Figure 3.3 Split Pulley
3.2 Crowning of Pulleys:
a. Flat Pulley b. Crowned Pulley
Figure 3.4 Crowning of Pulleys
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Design and analysis of Pulley Support Assembly
In case of flat belts, thickness of the rim is increased from the centre so that it gets
convex shape as shown in figure 1.5. This is known as crowning of the pulley. It helps
in preventing the belt from running off the pulley by bringing it to the mid-plane of
pulley whenever it moves to sides. Thus it helps in keeping the belt running in
equilibrium position near the centre of the rim.
3.3 Design of Pulleys:
The following procedure may be adopted for the design of cast iron pulleys.
3.3.1 Dimensions of Pulley
Diameter of the pulley (D) is selected depending upon the required velocity ratio, as discussed
in the selection of belts.
Width of the pulley or face of the pulley (B) is taken 1.25 times the width of belt (b).
B = 1.25 b
Thickness of the pulley rim (t) is taken between (D/300 +2)mm and (D/300 +3)mm for single
belt and for double belt.
3.3.2 Dimensions of Arms
Number of arms can be taken as follows:
Pulley Diameter
< 200 mm
> 200mm and < 450mm
> 500 mm
No. of Arms
Web (with thickness = rim thickness)
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Design and analysis of Pulley Support Assembly
Cross-section of arms is generally elliptical with major axis (b 1) equal to twice the minor axis
(a1). The cross-section of the arm is obtained by considering the arm as cantilever, fixed at the
hub end and carrying a concentrated load at the rim end and having a length equal to the
radius of the pulley.
Also, it is assumed that at any given time, the power is transmitted from the hub to the rim or
vice versa, through only half of the total number of arms.
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Design and analysis of Pulley Support Assembly
Tangential load per arm is given by,
where, T = Torque transmitted R = Radius of pulley
n= Number of arms
Maximum bending moment on the arm at the hub end,
Maximum bending stress is given by,
where, I= Moment of inertia of cross-sectional area of the arm about the axis of
rotation
= as b1 = 2a1
y = Distance from neutral axis to the outer most fiber = b1 / 2 = a1
So, required dimensions of the arm, near the hub, can be determined from above relation for a known value
the arms, from hub to rim.
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Design and analysis of Pulley Support Assembly
3.3.3 Dimensions of Hub
For known shaft diameter (d), diameter of the hub (d1) can be taken as:
But the diameter of the hub should not be greater than 2d.
Length of the hub can be taken as,
The minimum length of the hub is 2/3rd of the width of the pulley and it should not be more
than the width of the pulley.
3.4 Software Selection:
There are numerous designing software’s in Mechanical Engineering, we have learned
many different CAD software’s in our Engineering Program. We have used Autodesk
Inventor 2021 for our model designing and for analysis we have used Ansys software.
Parameters refer to constraints whose values determine the shape or geometry of the
model or assembly. Parameters can be either numeric parameters, such as line lengths or
circle diameters, or geometric parameters, such as tangent, parallel, concentric, horizontal
or vertical, etc. Numeric parameters can be associated with each other through the use of
relations, which allows them to capture design intent.
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Design and analysis of Pulley Support Assembly
3.5 Design of Model:
Designed our model on Autodesk inventor 2021 and also did rendering and calculated
different analysis.
Figure 3.5 Assembly View
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Design and analysis of Pulley Support Assembly
Figure 3.6 Assembly Draft
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Design and analysis of Pulley Support Assembly
Figure 3.7 Assembly Parts Draft
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Design and analysis of Pulley Support Assembly
Chapter 4 RESULTS and DISCUSSIONS
After manufacturing of the model, the outcome of the project is discussed below.
4.1 Number of persons required for the process:
Only 1 to 2 persons are required for the process using the developed machine.
Earlier for the same process 3 to 4 persons were required. Thus it can be seen that
number of persons require is reduced by at least 2.
4.2 Time required for the process:
The time required for the process of modelling, analysis, results including reports was 2-
3 days.
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Design and analysis of Pulley Support Assembly
4.3 Analysis on model:
At first we applied 500KN load on our model and calculated the results as
follows
Figure 4.1 Mesh
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Design and analysis of Pulley Support Assembly
Figure 4.2 Strain Energy
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Design and analysis of Pulley Support Assembly
Figure 4.3 Equivalent Stress
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Design and analysis of Pulley Support Assembly
Figure 4.4 Total Deformation
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Design and analysis of Pulley Support Assembly
Chapter 5 CONCLUSIONS
Pulley support assembly deserve great importance in mechanical
Engineering. Pulley is one of the simple machines use the to lift the weight. Pulleys are
assembled to form large block and tackle in order to provide the mechanical advantage to
apply large forces. Pulley are also assembled as apart of belt and chain drives in order to
transmit power to one rotating shaft to another . Pulley support assembly machines are
always a part of our practical life.
FUTURE SCOPE
The paper incorporates the use of all the above techniques using which, the reduction in
process set up time of pulley support assembly can be made possible. The study to be done
can provide a unified approach of production optimization problems. These techniques
are useful for increasing productivity. Each technique has its advantages and limitations
depending upon the kind of manufacturing case.
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Design and analysis of Pulley Support Assembly
REFERENCES:
1. https://www.researchgate.net/
2.https://www.slideshare.net/shariful0490/simple-pulley-pulley-block
3. https://www.academia.edu/Documents/in/Pulley
4.https://www.coursehero.com/file/p7t0oq/Conclusion-From-the results of-this-
experiment-it-is-concluded-that-moveable/
5. https://www.ropelab.com.au/pulley-system- analysis/#:~:text=Pulleys%20are
%20rope%20rigging%20devices,each%20side%20of%20t he%20device.&text=In%20this
%20case%2C%20because%20the,equal%20F%20%2B%20 P*F.
6. https://www.teachengineering.org/lessons/view/cub_simple_lesson05
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