BAHIR DAR UNIVERSITY

BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING
Mechanical Engineering Program
Group two (2)
Group Assignment: For the course Material handling
TITEL
LITERATURE REVIEW ON WELDED AND ROLLER CHAIN FLEXIBLE
EQUIPEMENT

Group name Id number

1 Humnesa legese …………………………………………………..... 1102857

2 Ananiya kesatebirhan……………………………………………… 1103429
3 Salehadin nuredin…………………………………………………… 1103458
4 Biruk tamirat …………………………………………………………. 1102923
5 Tamru bantie ………………………………………………………… 1103400

Submitted To: Mr. Meket M

Submission Date: 27/09/2014

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 CONTENTS PAGE
Abstract………………………………………………………….………….........................................3
1INTRODUCTION……………………………………………………………………………..………….4
1.1 BACKGROUND HISTORY…………………………………………………………….5
1.2 CLASSIFICATION OF CHAINS…………………….……………..…………..………6
1.2.1HOISTING CHAINS………………………….……………………..………6
1.2.2 CONVEYOR CHAINS……………………………….………………..……7
1.2.3 POWER TRANSMISSION CHAIN………………….………………..……8
1.3Advantages and disadvantage Chain drive……………………….……….………….…. 11
1.4 Application of chain drive:………………………………………………………………12
1.5 general objective ……………….…………………………………..……………………12
2 LITERATURE REVIEW…………………………………..…………………………………….…….. 12
3 DISCUSSION…………………………..……….…………………………………………...…………..… 16
4 CONCLUSION…………………………….……………………………………………………………….. 17
5 REFIRENCE…………………………………………………………………………………………..…… 17

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Abstract
This project deals with survey of design welding and rolling chain flexible hoisting equipment.
Welded and roller chains equipment are widely used in various high-speed, high-load and
power transmission application. They are used to transport goods in production line or
assembly lines, such as pallets, automobiles or drill rig applications. They are occasionally used
in dusty environments, soiled with waters, foreign particle, chemicals or other contaminates.
The typical use will result in stress and wearing down of the components of the chain which can
lead to unexpected failure and expensive production downtime. By considering this we try to
look for best solution

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 1 INTRODUCTION

A chain is a series of connected links which are typically made of metal. A chain may consist
of two or more links. Chains can be classified in many different ways. From a theoretical
viewpoint, a chain is a continuous flexible rack engaging the teeth on a pair of gears. A
sprocket, being a toothed wheel whose teeth are shaped to mesh with a chain, is a form of
gear. From a viewpoint based on its history and development, chain is a mechanical belt
running over sprockets that can be used to transmit power or convey materials. Chains have
the following four basic functions.

Roller chain or bush roller chain is the type of chain drive most commonly used for
transmission of mechanical power on many kinds of domestic, industrial and agricultural-
machinery,including conveyors, wire-and tube-drawing machines, printing
presses, cars, motorcycles, and bicycles. It consists of a series of short cylindrical rollers
held together by side links. It is driven by a toothed wheel called a sprocket. It is a simple,
reliable, and efficient[1] means of power transmission.

There are two types of links alternating in the bush roller chain. The first type is inner links,
having two inner plates held together by two sleeves or bushings upon which rotate two
rollers. Inner links alternate with the second type, the outer links, consisting of two outer
plates held together by pins passing through the bushings of the inner links. The
"bushingless" roller chain is similar in operation though not in construction; instead of
separate bushings or sleeves holding the inner plates together, the plate has a tube stamped
into it protruding from the hole which serves the same purpose. This has the advantage of
removing one step in assembly of the chain.

The roller chain design reduces friction compared to simpler designs, resulting in higher
efficiency and less wear. The original power transmission chain varieties lacked rollers and
bushings, with both the inner and outer plates held by pins which directly contacted
the sprocket teeth; however this configuration exhibited extremely rapid wear of both the
sprocket teeth, and the plates where they pivoted on the pins. This problem was partially
solved by the development of bushed chains, with the pins holding the outer plates passing
through bushings or sleeves connecting the inner plates. This distributed the wear over a
greater area; however the teeth of the sprockets still wore more rapidly than is desirable,
from the sliding friction against the bushings. The addition of rollers surrounding the bushing
sleeves of the chain and provided rolling contact with the teeth of the sprockets resulting in
excellent resistance to wear of both sprockets and chain as well. There is even very low
friction, as long as the chain is sufficiently lubricated. Continuous, clean, lubrication of
roller chains is of primary importance for efficient operation as well as correct tensioning.

Welded chains tend to be a lot stronger than weld less chains type and are commonly used
for security, hoisting or lifting, and other heavy duty applications.
In the USA, mild steel varieties of welded link chain are available as:
Short Link Chains, Medium Link Chains, Long Link Chains

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The longer the chain link, the lighter the chain will be per unit length, which is advantageous.
However, long link chain does not pass through devices such as pulleys or windlasses as
readily as short link chain will.
Welded chains are used only in some hand operated mechanism and in few powers driven
mechanism

1.1 BACKGROUND HISTORY

The word meaning "chain" can be traced back to an ancient word in the Indo-European
language family. As early as 225 BC, chain was used to draw a bucket of water up from a
well. This very early bucket chain was composed of connected metal rings.

In the 16th century, Leonardo da Vinci made sketches of what appears to be the first steel
chain. These chains were probably designed to transmit pulling, not wrapping, power
because they consist only of plates and pins and have metal fittings. However, da Vinci's
sketch does show a roller bearing.

It took some time for the technology to catch up with the concept. Problems in the
manufacturing and processing of steel prevented chain growth until the 19th century,
when new technologies made steel chain and bearings realities. In the 1800s, a
Frenchman named Gull obtained a patent for a similar chain for use on a bicycle. This
chain, called "Gull Chain," is still used today in hanging applications.

When molded chain was invented in the 19th century, things began to move rather
quickly. First came the cast detachable chain, which is composed of identical cast links.
Next, the pintle chain, which has a separate pin, appeared. The cast detachable chain and
the pintle chain have been improved over the years, and they are still in use today in some
special applications. They are being replaced—gradually—by large pitch steel conveyor
chain.

In the late 1800s, a new development—the bushing—revolutionized steel chain. Chains

with bushings had greater wear resistance than Gull Chain because the bushing acted as
a bearing, protecting the pin. At this point, the chain story moves into superspeed. Steel
bushing chain was used on bicycles, in the rear-wheel drive of early automobiles, and, in
1903, as the propeller drive in the Wright brothers' airplane.

It wasn't until 1800 that James Fussell patented the first roller chain, as part of a balance
lock that would transport canal boats up and down a hill. Unfortunately, his efforts ultimately
failed as the project was abandoned for financial reasons. However, the design of the roller
chain was developed from this point and would later become a pivotal component within the
power transmission industry.

1.2 CLASSIFICATION OF CHAINS

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chains drive can be classified into three broad categories and those are:

 Hoisting Chains
 Conveyor Chains
 Power transmission Chains.

1.2.1HOISTING CHAINS

Let me tell you what is hoist? A hoist is a mechanical device which is used to lift a load or
lowering a load, it can be used for shifting of some heavy product from one place to another
place in a workstation.

The chains used in this type of devices is named hoist chain, these chains are quite strong to
handle heavyweight.

Figure; hoist

Hoist chains can be classified into two categories:

A) Oval-Link Chains.

B ) Stud-Link Chains.

A) OVAL-LINK CHAINS (WELDED CHAIN)

It is one of the common types of chain used in hoist; it consists of many oval links attached to
each other. These types of chains are also called Coil Chains. Links of this type of chain is

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oval. However, there are square link types of chains that are also available, but the kinking is
occurred easily due to high loading.

Generally, we used these types of chains at low speeds only.

B) STUD-LINK CHAINS

The stud-link chains used to minimize the deformation and link or tangle easily.

In this type of chain, a round bar or stud is used to fit inside the oval-link chains to provide
more strength to the chain. It is used in Ship to up and down the anchor of the ships, and
some crane hoist where we need to lift a very high amount of load.

1.2.2 CONVEYOR CHAINS

As the name suggests conveyor chains, which means these types of chains are mostly used in
the conveyor. If you don't know the conveyor, it is a mechanical device system that is used to
move the materials from one place to another.

This type of chain is well shaped that it can easily run over the sprocket. 

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Generally, this type of chain is made of malleable cast iron and used in Low-Speed
Machinery approx. 2 m/s.

The one major disadvantage of this type of chain is the motion of the chain is not smooth,
there are chances of wear and tear out.

Figure A general layout of conveyor chain

A) DETACHABLE OR HOOK JOINT TYPES CONVEYOR CHAIN

Detachable or Hook Joint types Conveyor chains are used in a conveyor where the length
between power transmission is short.

B) CLOSED-END PINTLE TYPE CONVEYOR CHAIN

This type of chain is consists of a barrel and link and made in a single casting, then the chain
is heat-treated to provide higher strength.

1.2.3 POWER TRANSMISSION CHAIN

You can easily find out by name of the chain that it is used to transmit the power.

This type of chain is made of steel and sometimes it heats treated to minimize wear and tear.

This type of chain has greater accuracy and can easily run over the sprocket.

Power Transmission Chains are categorized into three types:

1. Block Chain
2. Roller Chain
3. Silent Chain or Inverted tooth Chain

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Block Chain:

This type of chain is used in low-speed areas and will produce noise due to the sudden
contact between sprocket and chain, however, this is used in some low-speed conveyor
machines.

2 ROLLER CHAIN

Roller chain or bush roller chain is the type of chain drive most commonly used for
transmission of mechanical power on many kinds of domestic, industrial and agricultural-
machinery,including conveyors, wire-and tube-drawing machines, printing
presses, cars, motorcycles, and bicycles. It consists of a series of short cylindrical rollers
held together by side links. It is driven by a toothed wheel called a sprocket. It is a simple,
reliable, and efficient [1] means of power transmission.

Figure of roller chain

Uses

 Roller chains are used in low- to mid-speed drives at around 600 to 800 feet per minute;
however, at higher speeds, around 2,000 to 3,000 feet per minute, V-belts are normally
used due to wear and noise issues.
 A bicycle chain is a form of roller chain. Bicycle chains may have a master link, or may
require a chain tool for removal and installation. A similar but larger and thus stronger

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 chain is used on most motorcycles although it is sometimes replaced by either a toothed
belt or a shaft drive, which offer lower noise level and fewer maintenance requirements.
 The great majority of automobile engines use roller chains to drive the camshaft(s). Very
high performance engines often use gear drive, and starting in the early 1960s toothed
belts were used by some manufacturers.
 Chains are also used in forklifts using hydraulic rams as a pulley to raise and lower the
carriage; however, these chains are not considered roller chains, but are classified as lift
or leaf chains.
 Chainsaw cutting chains superficially resemble roller chains but are more closely related
to leaf chains. They are driven by projecting drive links which also serve to locate the
chain onto the bar.

 A perhaps unusual use of a pair of motorcycle chains is in the Harrier Jump Jet, where a
chain drive from an air motor is used to rotate the movable engine nozzles, allowing them
to be pointed downwards for hovering flight, or to the rear for normal forward flight, a
system known as Thrust vectoring.

This type of chain is constructed by:

1. A bush
2. Inner Link
3. A pin
4. Outer Plate
5. Inner plate
6. Rollers

In this type of chain, a bush along with the roller is fitted inside both the plates then a pin is
passed through both the end of the roller to fasten it.

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The rollers are free to rotate inside the bush so that when it contacts between the sprocket the
wear tear would be minimized.

Generally, it is made of steel.

It is soundless and wears less as compared to the blockchains and used in any circumstances
and this type chains gave much service area if proper lubrication is maintained.

It is used in high-speed power transmission devices, like a motorcycle. 

3 SILENT CHAIN OR INVERTED TOOTH CHAIN

The operation of this type of chain is quite silent and can be used in high-speed power
transmissions areas.

This type of chain does not have any roller, it is accurately shaped that it can easily sit over
the sprocket. 

However, lubrication is an important factor for this type of chain otherwise it will wear and
tear out.

1.3Advantages and disadvantage Chain drive

A chain drive has several advantages like:

 Low maintenance.
 Greater efficiency up to 97 percent.
 Slipping is negligible
 Chain drive can operate in wet conditions too.
 It can withstand abrasive conditions.
 The chain drive is easy to install.
 Initial tension is not required in chain drive.
 Even in fire hazards it does not faces any bad problem.
 Multiple hafts can be driven from a single chain drive.
 Chain drive requires less space and it is more compact than belt drive.
 It produces less stress on the shaft because the sprockets are lighter than pulleys.
 Transmit higher power compared to belt drive.
 Chain drive, the speed ratio is good as compared to belt drive.
 It can be used in reversing drives.
 It can be operated at a high temperature Like a belt which cants not operate at high
temperatures.
 Chain drive can be used up to 3 m in distances between small and large centers.

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Disadvantages of Chain drive:

These are some disadvantages of using Chain:

 The major disadvantages are here it requires more and frequent lubrication otherwise
rust problem comes.
 It cannot be used where there is a requirement of slips.
 We can’t keep chain drive-in open. It needs housing or covering.
 It cannot be used for précised motion requirements.
 It is noisy and therefore there is a problem of vibration too.
 The installation or initial cost is more.
 The velocity fluctuation is more.

1.4 Application of chain drive:

There are plenty of applications of a chain drive some of them are:

 Chain drive used for transmission of power.

 It is used for lifting loads and also used to carry material.
 This is also used in woodworking machinery.

Chain drive used in several industries for several purposes like:

 Transportation Industry.
 Agriculture Machinery.
 Material Handling Equipment.
 Building construction.

1.5 General objectives

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The general objective of this project to survey the design of welded and rolling chain flexible
hoisting equipment that is used for various high-speed, high-load and power transmission
application.

2 LITERATURE REVEIW

V. Sousaa , F. J. G. Silvaa *, J. S. Fecheiraa, pp, (2020) Welding still plays a major role in the
construction industry, being applied in the fabrication of minor to structural components. This process
is widely used in the construction industry, in the fabrication of many components, such as, beams,
profiles and pipes. There are many welding processes, and they are usually a very good choice
depending on the applications. Certain processes bring advantages, such as, lower welding times, or a
better-quality joint. There is much research on this subject, especially on the study of the performance
of welded joints of certain materials, such as the recent study by Silva [1].

R. D. S. G. Campilhoa and V. Vandermeulena,(2018) Flexibility is of utmost importance for the

industry, robots and automation bring this flexibility to certain processes ,ensuring as well high levels
of quality and reproducibility. However, these equipment’s must be designed with this flexibility in
mind. For example, the use of separate cells, to produce different products. Regarding part production,
gigs that accommodate different parts, as shown in these studies [, thus promoting production
flexibility [2]

R. Mulik, S. S. Ramdasi (2015) mainly because its mechanical properties multiple production
cars are equipped with roller chains. Besides being strong, durable, less noisy as spur gears and
relatively efficient they also do have some measure of vibration dampening. When comparing
belts with roller chains it can be said that chains do come with less frictional losses. On the other
hand the drive train inertia is increased. To ensure a correct timing the chain has to be
preloaded on the unloaded side by some sort of tensioner, like with belts. Additionally longer or
multiple-curved chains require guides that may be pretension as well. When the chain is not
properly lubricated it will wear out rapidly. Another problem with roller chains is the variation
in speed. This is known as ‘surging’, caused by a constant acceleration and deceleration of the

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links around the sprocket(s). The chain is pulled towards the pitch circle of the sprocket at the
tooth contact. The opposite holds at the last tooth contact. Since the pitch line of the links is
fixed it cuts the virtual radius of the sprocket, between the two pitch points. The rising and
falling of the links pitch line is what leads to the chordal effect of speed variation. Speed
variations may lead to vibrations inside the drivetrain as the effective radius of the chain
continuously changes during revolution (Mulik, 2015)

XU Lixin et. al. 2, 2010, [1] had made the study on dynamic modeling of a roller chain drive
system. Roller chain drives are widely used in various high-speed, high-load and power
transmission applications, but their complex dynamic behavior is not well researched. Most
studies were only focused on the analysis of the vibration of chain tight span, and in these
models, many factors are neglected.

A mathematical model is developed to calculate the dynamic response of a roller chain drive
working at constant or variable speed condition. The complete chain transmission with two
sprockets and the necessary tight and slack spans had used. The effect of the flexibility of
input shaft on dynamic response of the chain system is taken into account, as well as the
elastic deformation in the chain, the inertial forces, the gravity and the torque on driven
shaft. For getting an accurate simulation results, the equivalent contact stiffness must be
given reasonably.

Since a link is an assembly of several components, the contact effect can be described as a
pin-bush-roller assembly contact with the tooth surface. The equivalent contact stiffness can
be seen as a series connection of the three contact stiffness. They are contact between pin and
bush (kpb), contact between bush and roller (Krb) and contact between roller and tooth
surface (krt). Then the equivalent contact stiffness kc can be given by

Tae-Gu KIM et.al. (2010), EISSN: 2093-7997, [2], made a case study on engineering failure
analysis of link chain, the effect of chain installation condition on stress distribution that
could eventually cause disastrous failure from sudden deformation and geometric rupture.

The Fractographic method had used for the failed chain indicates that overstress was
considered as the root cause of failure. 3D modeling and finite element analysis for the
chain, used in a crane hook, were performed with a three-dimensional interactive application
program, CATIA ANSYS. The results showed that the state of stress was changed depending

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on the initial position of the chain that was installed in the hook. Especially, the magnitude of
the stress was strongly affected by the bending forces.

The structural safety of a crane chain was investigated through the prediction of the chain’s
material behavior and the calculation of maximum allowable load with respect to tension and
bending loads. The results are summarized as follows.

The results of finite element analysis show that the state of stress is strongly affected by the
condition of the chain installed in the hook. FEA results are in accordance with the
Fractographic analysis, in that the change of load condition from tension to bending severely
affects the failure of parts.

Using the ANSYS FEA software the stress distribution was analyzed when the bending load
was applied to the chain.

Fig.- 3 shows the results of the ANSYS analysis when tension is applied under bending load.

Krishna Kumar K. et. al. (2015), ISSN: 0974-4290 [3] had conducted a review on the most
of the chain that is under tension which causes failure of chain assembly which is a major
trouble for the industrial sector. This study described the universal failure modes of chain in
various engineering applications.

The existing studies in the field are examined to ascertain the trends of research in the field
and to identify unsolved problems. The distinction of roller chain from the leaf and conveyor
chains were highlighted and the novel perspectives that are necessary for the analysis of the
chain plate and bearing pin of the roller chains in particular are recommended. Chains are
operating under tensile cyclic load condition.

The failure of a chain assembly is the most important problem in industry applications which
causes failures that are of unacceptable material selection, heat treatment causing other
uncertainties in the manufacturing process.

They are used to transport goods in production lines or assembly lines, such as pallets,
automobiles or drill rig applications. It is occasionally used in dusty environments, soiled
with water, foreign particles, chemicals or other contaminants. The typical use will result in
wearing down of the components of the chain which can lead to unexpected failure and
expensive production downtime.

Mr. Nitin G. Barge (2017) ISSN: 2278-0181, et. al. [4] had studied the improvement of
breaking load, reducing the percentage elongation and failure mode, increases the strength
of drag chain conveyor system. They found that the maximum stress is 500 N/mm2 for drag
chain and for modified drag chain it is 486.49 N/mm2 by FEA. From these two values, it is
cleared that stresses are reduced by 13.51 N/mm2 in modified drag chain by FEA. Also, load

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carrying capacity is less in old drag chain, then by improving in manufacturing processes,
mechanical properties and heat treatment processes, can increase the strength and
loadcarrying capacity of new drag chain by keeping the area and material same. Apply finite
element analysis method for both old and new drag chain link assemblies. Von misses stress
and displacement has been obtained for different force magnitudes. From the calculations it
is shown that percentage error is reduced in new drag chain link assembly as compare to the
old chain link assembly. The finite element analysis gives maximum load carrying capacity of
old chain is 87 KN and for new chain the maximum load carrying capacity increased up to
the 100 KN.

3. DISCUSION
Roller chain drives are widely employed in a variety of high-speed, high-load, and power
transmission applications, as stated above, but failure of chain happened in many ways such
as;

 The effect of chain installation condition on stress distribution that could eventually
cause disastrous failure from sudden deformation and geometric rupture.
 The chain that is under tension which causes failure of chain assembly which is a
major trouble for the industrial sector.
 Chains are occasionally used in dusty environments, soiled with water, foreign
particles, chemicals or other contaminants. The typical use will result in wearing
down of the components of the chain which can lead to unexpected failure and
expensive production downtime.

The strength of drag roller chain drives is increased by improvement of breaking load,
lowering the percentage elongation, and minimizing the failure mode. It is also feasible to
enhance the strength and load carrying capacity of new drag chain by upgrading
manufacturing techniques, mechanical qualities, and heat treatment procedures while
keeping the area and material the same. They also look into dynamic modeling of roller
chains; however there are several drawbacks, such as the fact that the intricate dynamic
behavior of a roller chain isn't well understood. Many aspects were neglected. Welding plays

16
a significant part in the construction sector, being used in the production of minor to
structural components. There are many welding processes; certain processes bring
advantages, such as, lower welding times, or a better-quality join t. Robots and
automation add flexibility to some operations, maintaining high levels of quality and
repeatability as well.

4. CONCLUSION
the state of stress is strongly affected by the condition of the chain
installed.to solve the problem of chain elongation and breaking, numerical
calculations are performed based on numerous criteria to determine the
total load on the chain and total elongation of the roller chain The total draw
obtained is less than the maximum breaking load, and the chain elongation is
within the acceptable range. The FEA approach may be used to deepen the
analysis and validation. Finally, we may compare the two outcomes in terms
of attaining the goal. The fault of elongation and breaking of chain might be
addressed by making specific adjustments to the chain design. Further FEA
methods for analysis and validation might be used to determine whether a
new roller chain would be suitable to solve the chain problem.

5. REFERENCE

[1] “A Novel Modular Design of an Equipment to Produce ‘T’-Profiles by

laser welding,” V. Sousaa , F. J. G. Silvaa *, J. S. Fecheiraa, pp. 456–465, 2020.

[2] R. D. S. G. Campilhoa and V. Vandermeulena, “Design of welding chain

in hoisting equipment,” vol. 4, pp. p91-97, 2018.

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[3] R. Mulik, S. S. Ramdasi (2015) Development of indigenous methodology
for design and dynamic analysis of engine valve train system with timing
chain drive for high speed applications, SAE International, India

[4] Li-xin Xu et al, “Dynamic Modelling of a Roller Chain Drive System

Considering the Flexibility of input Shaft ”, DOI: 10.3901/CJME.2010.02,
Chinese Journal of Mechanical Engineering, June 2010.

[5] Tae-Gu Kim et. al, (2010)”A Case Study on Engineering Failure Analysis
of Link Chain”, EISSN: 2093-7997

[6] Krishna Kumar. K et.al, (2015)”A Review of Failure analysis found in

Industrial Roller Chains, International Journal of ChemTech Research”, Vol.8,
No.12 pp. 598- 603, 2015,ISSN: 0974-4290.

[7] Barge N. G. et. al, “Design and Analysis of Drag Chain to Reduce Failure
Modes for handling of Fertilizer Materials”, ISSN: 2278-0181, International
Journal of Engineering Research & Technology(IJERT), Vol. 6 Issue 06, June –
2017.

[8] N. I. B. Haris,’ Failure Analysis of Conveyor Chain Links: A Case Study

at Top Glove SDN. BHD. PhD thesis, Universiti Tun Hussein Onn Malaysia,
2013

[9]. Jagtap M. D., G. B. D., and P. P. M., “Study of Roller Conveyor Chain Strip
under Tensile Loading,” International Journal Of Modern Engineering
Research (IJMER), vol. 4, no. 5, pp. 61–66, 2014.

[10] Conwell J. C. and Johnson G. E. (1996), “Experimental Investigation of

Link Tension and Roller-Sprocket Impact in Roller Chain Drives,” Mechanism
and Machine theory, Vol. 31, No. 4, pp. 533–544.

[11]. J. C. Conwell and G. E. Johnson, “Experimental Investigation of Link

Tension and Roller-Sprocket Impact in Roller Chain Drives,” Mechanism and
Machine theory, vol. 31, no. 4, pp. 533–544, 1996.

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[12]. N. I. B. Haris, Failure Analysis of Conveyor Chain Links: A Case Study
at Top Glove SDN. BHD. PhD thesis,University Tun Hussein Onn Malaysia,
2013.

[13]. Jagtap M. D., G. B. D., and P. P. M., “Study of Roller Conveyor Chain
Strip under Tensile Loading,” International Journal Of Modern Engineering
Research (IJMER), vol. 4, no. 5, pp. 61–66, 2014.

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