DESIGN OF FLAT BELTS

Condition For Maximum Power: v =

Pi , Where P = (P +P )/2
i 1 2
3m
SELECTION OF FLAT BELT FROM THE MANUFACTURES CATALOGUE:
(1) (KW)max=Fa (KW)
Where (KW)max = power transmitted by the belt for design purpose
(KW) = actual power transmitted by belt in a given application
Table 13.1 Load correction factor (Fa)
Type of load Fa
Normal load 1.0
Steady load e.g. centrifugal pumps -fans-light machine tools-conveyors 1.2
Intermittent load e.g. heavy duty fans-Blowers compressors-reciprocating pumps-line shafts-heavy
1.3
duty machines
Shock load e.g. vacuum pumps-rolling mills-hammers-grinders 1.5
(2) (KW)corrected =(KW)max X Fd
Table 13.2 Arc of contact factor (Fd)
αd (degrees) 120 130 140 150 160 170 180 190 200
Fd 1.33 1.26 1.19 1.13 1.08 1.04 1.00 0.97 0.94

(3) Corrected KW/belt rating:

HI SPEED belt: = 0.0118 v/5.08 HI-SPEED 0.0118 kW per mm width per ply
FORT belt =0.0147v /5.08 FORT 0.0147 kW per mm width per ply
Where v= velocity of belt (m/s)
(4) Width X No. of piles = corrected power/corrected belt rating
Table: Recommended Width and Plies
3-ply 25 40 50 63 76
4-ply 40 44 50 63 76 90 100 112 125 152
5-ply 76 100 112 125 152
6-ply 112 125 152 180 200

SELECTION OF V BELT FROM THE MANUFACTURER’S CATALOGUE

Fa x Power Transmitted
No. of belts =
KW ratingof belt x Fd x Fl
Where
Fa=correction factor for industrial services (Table 13.6)
Fd= correction factor for arc of contact (Table 13.13)
Fl= correction factor for belt length (Table 13.7)
KW rating of belt (Table 13.5)

1
 Table 13.3 Dimensions of standard cross
sections Table: Preferred pitch diameter of pulley (mm)
Belt Width Thickness Minimum 125 132 140 150 160 170 180 190 200
section W(mm) T(mm) pitch 212 224 236 250 265 280 300 315 355
diameter 375 400 425 450 475 500 530 560 600
of pulley
630 670 710 750 800 900 1000
(mm)
A 13 8 125 Table 13.4 Conversion of inside length to pitch length
B 17 11 200 of the belt
C 22 14 300 Belt section A B C D E
D 32 19 500 Difference between pitch
36 43 56 79 92
E 38 23 630 length and inside length (mm)

Table 13.5: Power rating of V-belts

0
(αs =180 ; speed of the faster pulley=1440 rpm) (D=pulley diameter (mm); PR=power rating in kw)
D 75 80 85 90 100 106 112 118 125
Section A
PR 0.73 0.86 0.99 1.12 1.38 1.50 1.63 1.81 2.00
D 125 132 140 150 160 170 180 190 200
Section B
PR 2.24 2.46 2.77 3.30 3.60 4.00 4.39 4.77 5.23
D 200 212 224 236 250 265 280 300 315
Section C
PR 6.14 6.81 7.68 8.28 9.40 10.10 11.10 12.10 12.50
D 350 375 400 425
Section D
PR 15.7 17.5 19.3 20.60

Table 13.6 Correction factor (Fa) for industrial service

Type of service Operational hours per day
0-10 10-16 16-24
Light duty: agitators-blowers-centrifugal pumps-fans (up to 7.5 kw) and 1.1 1.2 1.3
compressors
Medium duty: conveyors-fans (above 7.5 kw)-line shafts-machine tools- 1.2 1.3 1.4
presses and positive displacement pumps
Heavy duty: conveyors-bucket elevators and hammers 1.3 1.4 1.5

Table 13.7 Correction factor FL for belt length

(Li=nominal inside length of belt in mm)
Belt section
Li A B C D E
1905 1.02 0.97 0.87 - -
1981 1.03 0.98 - - -
2032 1.04 - - - -
2057 1.04 0.98 0.89 - -
2159 1.05 0.99 0.90 - -
2286 1.06 1.00 0.91 - -
2438 1.08 - 0.92 - -
2464 - 1.02 - - -
2540 - 1.03 - - -
2667 1.10 1.04 0.94 - -
2845 1.11 1.05 0.95 - -
3048 1.13 1.07 0.97 0.86 -
3150 - - 0.97 - -
3251 1.14 1.08 0.98 0.87 -
3404 - - 0.99 - -
3658 - 1.11 1.00 0.90 -
4013 - 1.13 1.02 0.92 -
4115 - 1.14 1.03 0.92 -
4394 - 1.15 1.04 0.93 -
4572 - 1.16 1.05 0.94 -
4953 - 1.18 1.07 0.96 - Fig.: Selection of cross section of V-belt
5334 - 1.19 1.08 0.96 0.94
6045 - - 1.11 1.00 0.96
6807 - - 1.14 1.03 0.99

2
 Extension Spring
8CDFi 8CDFi
τi = , τ max = τ i + Where Fi = initial tension
πd 3 πd 3
8n t (F − Fi ) K 16FD 4F 2
4 C1 − C1 − 1 , C 2R /d
δ= , σA = b 3 + 2 , K b = 1= 1
Gd 4 πd πd 4C1 (C1 − 1)
K 8FD 4C 2 − 1 , C =2R /d, Where R = side bend radius
τB = T 3 , KT = 2 2 2
πd 4C 2 − 4

Table1: Values of allowable shear stress, modulus of elasticity and of

rigidity for various spring materials

Table 2: Standard wire gauge (SWG) number and corresponding diameter of spring wire
SWG Diameter (mm) SWG Diameter (mm) SWG Diameter (mm) SWG Diameter (mm)
7/0 12.70 7 4.470 20 0.914 33 0.2540
6/0 11.785 8 4.064 21 0.813 34 0.2337
5/0 10.973 9 3.658 22 0.711 35 0.2134
4/0 10.160 10 3.251 23 0.610 36 0.1930
3/0 9.49 11 2.946 24 0.559 37 0.1727
2/0 8.839 12 2.642 25 0.508 38 0.1524
0 8.229 13 2.337 26 0.457 39 0.1321
1 7.620 14 2.032 27 0.4166 40 0.1219
2 7.010 15 1.829 28 0.3759 41 0.1118
3 6.401 16 1.626 29 0.3454 42 0.1016
4 5.893 17 1.422 30 0.3150 43 0.0914
5 5.385 18 1.219 31 0.2946 44 0.0813
6 4.877 19 1.016 32 0.2743 45 0.711

3
 Table 3: Dimensions for centre bolts

Width of leaves in mm Dia. of centre bolt in mm Dia. of head in mm Length of bolt head in mm
Upto and including 65 8 or 10 12 or 15 10 or 11
Above 65 12 or 16 17 or 20 11

Table 4: Values of buckling factor Kb

Table 5: Dimensions of clip, rivet and bolts
Hinged end Built in end
Lf/D
spring spring Spring width (B) Clip section Dia. of rivet Dia. of bolt
2
1 0.72 0.72 in mm (b x t) in mm (d1) in mm (d2) in mm
2 0.63 0.71 Under 50 20X4 6 6
50,55 and 60 25X5 8 8
3 0.38 0.68
4 0.20 0.63 65,70,75 and 80 25X6 1 8
5 0.11 0.53 90,100 and 125 32X6 10 10
6 0.07 0.38
7 0.05 0.26
8 0.04 0.19

Table 6: Physical properties of materials commonly used for leaf springs

Ultimate tensile strength Tensile yield Brinell hardness
Material Condition
(MPa) strength(MPa) number
50 Cr 1 1680-2200 1540-1750 461-601
Hardened
50 Cr 1 V23 and 1900-2200 1680-1890 534-601
Tempered
55 Si 2 Mn 90 1820-2060 1680-1920 534-601

WIRE ROPE
Stresses in wire ropes
W+w 4) Impact load on starting
1) Direct stress, σd = No Slack: Wst = 2(Ws + Wr )
A
W=load lifted, w=weight of rope Ws = load lifted, Wr = Wt. of wire rope
A=cross sectional area of rope  2ahE r 
If Slack is ‘h’ : W = (W + W )1 + 1 + 
Er x dw st s r
 σ d lg 
2) Bending stress, σb =
D a = acceleration of rope, h = slackness in the rope
Equivalent bending load: Wb= σ b A , l = length of rope

Er = Effective modulus of elasticity Ws + Wr

σd = is static stress in the rope neglecting
dw =diameter of wire, A=cross sectional area, A
D= sheave dia. the effect of core, A = Area of metallic portion of rope
3) Stresses due to starting and stopping
W+w a W+w 5) Effective stress in rope during:
σa = x , Wa = xa,
g A g (i) During Normal working = σd + σb
Wa= additional load, g= acceleration due to gravity, (ii) During starting = σ st + σ b
a=acceleration of rope and load = V/t or (V2 – V1)/t
(V2 – V1) = change in speed, t = time (iii) During acceleration = σd + σb + σa

Table: Wire Rope data

Type of Modulus of elasticity Diameter of Metallic area of Sheave diameter ,
2 2 Recommended
construction of rope, Er (N/mm ) wire , dw (mm) rope , A (mm ) D (mm)
6x7 97000 0.106dr 0.38 dr2 42 dr 72 dr
2
6x19 83000 0.045 dr 0.40 dr 18 dr 27 dr
2
6x37 76000 0.045 dr 0.40 dr 18 dr 27 dr

4
 Table: Factors of safety for wire ropes Table: Breaking load and mass for 6x19 (12/6/1) construction wire
ropes with fibre core
Application Class 1 Class 2 and 3 Class 4
Nominal Approx. Minimum breaking load to tensile
Hoisting where jibs are designation of wires (kN)
diameter mass
supported by roes and
(mm) kg/100m) 1230 1420 1570
where shock 4.0 4.5 5.5
absorbing devices are 6 12.5 13.6 15.7 17.4
provided in jib support
7 17.0 18.5 21 24
Cranes and hoists in
4.5 5.0 6.0
general hoist blocks 8 22.1 24 28 31

9 28.0 31 35 39

10 34.6 38 44 48

11 41.9 46 53 58

12 49.8 54 63 69

Table: Breaking load and mass for 6x7 (6/1) construction wire ropes

Nominal Minimum breaking load to tensile designation of

Approximate mass
diameter wires (kN)
(kg/100m)
(mm) 1570 1770 1960
Fibre Steel Fibre Steel Fibre Steel Fibre Steel
core core core core core core core core
8 22.9 25.2 33 36 38 41 42 45
9 28.9 31.8 42 46 48 51 53 57
10 35.7 39.1 52 56 59 64 65 70
11 43.2 47.6 63 68 71 77 79 85
12 51.5 56.6 75 81 85 91 94 101

Bearings
1. Clearance C=R-r 3. FLAT PIVOT BEARING
R=radius of bearing π 2 2
r= radius of journal Total axial force: F= (d o − d i ) p
4
2. arc length= (π d x B)/360 T = µFrmean
µ = coefficient of friction, p=bearing pressure, V=rubbing velocity

Thick Cylinders – Principal Stresses

CYLINDERS WITH INTERNAL PRESSURE:
pi Di
2
 Do2  pi Di
2
 Do 2 
σr = −  − 1 t σ = + + 1
( )
D 2 o − D 2 i  4r 2 
;
( 
D 2 o − D 2 i  4r 2  )
At inner surface: r=Di/2: σ r = − p i ; σ r = +
pi D o + D i
2
( 2
)
(
D2o − D2i )
2
2p i D i
σ r = 0; σ r = +
At outer surface: r=Do/2:
(D 2 o − D 2 i )
Fig. : Variation of principal stresses
(cylinders with internal pressure)

5
CYLINDERS WITH EXTERNAL PRESSURE :
poDo
2
 Di 2  po Do
2
 Di 2 
σr = − 2 1 −  σ = − 1 +
( )
D o − D 2 i  4r 2 
; t
( ) 
D 2 o − D 2 i  4r 2 
2
2p o D o
At inner surface: r=Di/2: σ r = 0 σ t = −
(D 2 o − D 2 i )
p 0 (D 2 o + D 2 i
At outer surface: r=Do/2: σr = − po ; σt = −
(D o − D i )
2 2

Fig. : Variation of principal stresses

(cylinders with external pressure)
COMPOUND CYLINDER:

,
δ = δJ + δC

Chain Drives
Notations: n: Factor of safety
P: Pitch of chain (m) W: Total load on the driving side of chain
D: Pitch circle diameter (m) Wb : Breaking strength of chain
D1: Pitch circle of smallest sprocket θ: angle subtended by one pitch length at the centre of
D2: Pitch circle of larger sprocket sprocket
D0: Sprocket outside diameter v : Average velocity of chain (m/s)
Di: Diameter of chain roller x : Centre distance between sprockets(m)
K: Number of chain links σb: Allowable bearing stress in MPa of N/mm²
Ks: Service factor A : Projected bearing area (mm²)
Ft: Tangential driving force re : Tooth flank radius
Fc: Centrifugal tension in the chain ri : Roller seating radius
Fs: Tension in the chain due to sagging α : Roller seating angle
L: Length of chain ha: Tooth height above the pitch polygon
m: Mass of chain in kg per metre Da: Top diameter
N1: Speed of rotation of smaller sprocket (rpm ) Df: Root Diameter
N2: Speed of rotation of larger sprocket bf1: tooth width
P: Power transmitted by chain rx: Tooth side radius
T: Number of teeth on the sprocket ba: Tooth side relief
T1:Number of teeth on smaller sprocket bf1 and bf2: width over teeth
T2:Number of teeth on larger sprocket

Formulae for chain drives

360 o
1. θ=
T
2. θ  180 
p = D sin   = D sin  
2  T 
3. Do=D+0.8d1
4. Angle of articulation= θ / 2
5. Velocity ratio, V.R.= N2/N1=T2/T1
πDN TpN
6. v= =
60 60

6
 2
T1 + T2 2 x  T2 − T1  p
7. L = Kp, where K = + +
2 p  2π  x
 2
2

8. p T1 + T2  (T1 + T2 )   (T1 − T2 )  
x = K− + K −  − 8 
4 2  2   2π  
 
D1 + D 2
For velocity transmission ratio of 3, x min = + 30 to 50 mm (For best results, min. distance centre
2
distance should be 30 to 50 times the pitch.
Factor of safety
9. n = Wb/W
2
10. Wb =106 p (Newtions) for roller chains; p – pitch in mm
= 106 p (Newton) per mm width of chain for silent chains
11. FT = Power transmitted / Speed of chain = P/ v (Newtons)
12. Fc = m v2 (Newtons)
13. Fs = k m g x (Newtons)
K – constant which takes into account the arrangement of chain
drive.
K = 2 to 6, when center line of chain is inclined to the horizontal at
0
an angle less than 40 .
K = 1 to 1.5, when center line of chain is inclined to the horizontal
0
at an angle greater than 40 .
Power transmitted by chains
Wb v
14. P=
nK s
15. P =
σ b Av , Where Ks = Service factor = K1.K2.K3 Fig. : Tooth profile of sprocket
Ks
K1 = Load factor K2 = Lubrication factor K3 = rating factor
=1, for constant load = 0.8, for continuous lubrication = 1, for 8 hrs/day
= 1.25, for variable load with mild shock = 1, for drop lubrication = 1.25, for 16 hrs/day
= 1.5, for heavy shock loads
= 1.5, for periodic lubrication = 1.5, for continuous service
Number of teeth on smaller or driving sprocket
16. Vmax =
πD1 N
( m / s) ,
60
D1: pitch circle diameter of smaller sprocket
17. Vmin =
πD1 N cos(θ / 2)
( m / s)
60
Principle Dimensions of tooth profile
2
18. re = 0.008d1(T +180) [max]
= 0.12 d1(T+2) [min]
19. ri = 0.505 d1+0.069(d1)1/3 [max]
= 0.505 d1 [min]
o
20. α = 140 o − 90 [max]
T
90 o [min]
= 120 o −
T
21. ha = 0.625p – 0.5 d1 + 0.8p/T [max]
= 0.5 (p-d1) [min]
p
22. D= = p cos ec (180 / T )
sin (180 / T ) 26. rx = p
23. Da = D+1.25p-d1 [max] 27. ba= 0.1p to 0.15p
= D+p(1-1.6/T)-d1 [min] 28. bf2 and bf3 = (Number of strands – 1)pt + bf1
24. Df = D-2ri 29. Design Power = Rated Power X Service factor
25. bf1 = 0.93 b1 when p<= 12.7 mm 30. Load (W) = Rated power / Pitch line velocity
= 0.95 b1 when p> 12.7 mm

7
 Table: Number of teeth on the smaller sprocket Table: Maximum allowable speed for chains in r.p.m.

Type of chain Number of teeth at velocity ratio Chain pitch (p) in mm

1 2 3 4 5 6 Number
Roller 31 27 25 23 21 17 Type of teeth
Silent 40 35 31 27 23 19 of on the
12 15 20 25 30
chain smaller
Table: Power Rating (in kW) of simple roller chain sprocket
(T1)
Speed of Power ( kW) 15 2300 1900 1350 1150 1100
smaller 06B 08B 10 B 12B 16B 19 2300 2000 1450 1200 1050
Roller
sprocket or 23 2400 2100 1500 1250 1100
Chain
pinion 27 2550 2150 1550 1300 1100
(rpm) 30 2600 2200 1550 1300 1100
100 0.25 0.64 1.18 2.01 4.83 Silent
17-35 3300 2650 2200 1650 1300
200 0.47 1.18 2.19 3.75 8.94 Chain
300 0.61 1.70 3.15 5.43 13.06
500 1.09 2.72 5.01 8.53 20.57 Table: Permissible speed (rpm) of smaller sprocket or
700 1.48 3.66 6.71 11.63 27.73 pinion
1000 2.03 5.09 8.97 15.65 34.89 Number Pitch of chain (p) in mm
1400 2.73 6.81 11.67 18.15 38.47 Type of teeth
1800 3.44 8.10 13.03 19.85 -- of on
12 15 20 25 30
2000 3.80 8.67 13.49 20.57 -- chain sprocket
pinion
15 2300 1900 1350 1150 1000
• Factor of safety (n) for bush roller and silent Bush 19 2400 2000 1450 1200 1050
chain: Table 14.38 P. 287. Roller 23 2500 2100 1500 1250 1100
• Characteristics of roller chains according IS chain 27 2550 2150 1550 1300 1100
:2403 – 1991 : P. 287 B , Table:14.40a. 30 2600 2200 1550 1300 1100
Silent
17-35 3300 2650 2200 1650 1300
Chain

Spur Gear
P = Ft x v; P: Power ( kW), v: pitch line velocity (m/s), Ft: tangential force (kN)
Ft = Fn cos α ; α: pressure angle, Fn: normal force.
Static Load: Beam Strength: Fbeam = bmσ d Y ; where 9.5 ≤ b ≤ 12.5m
C s Ft
Ft max = ; Check: Fbeam ≥ Ft max
Cv
Cs: Service factor Table: 12.20, p. 187; Cv: Velocity factor, p. 164.
Form factor: Y = π  0.154 − 0.912  for 20o involute full-depth tooth;
 z 
 0.95  for 20 stub tooth;
o  0.684  for 14.5o tooth
Y = π 0.175 −  Y = π 0.124 − 
 z   z 
Dynamic Load: refer data book p. 166 and 167
Fen = Fdyn x FOS = bmσ en Y ; σ en : endurance limit (=1.75BHN)
Gear Construction:
1. For pitch diameter d ≤ 14.8m+60 (mm): pinion/gear is solid disc type
2. For pitch diameter d ≥23.5m+85 (mm): gear is arm type
3. In other cases gear is web type with web thickness=(1.6-2)m (m: module)
4. Rim thickness, h= (2-4) m, Rim to be tapered 1 : 5 towards the centre.
5. Hub diameter , dh= (1.6-2)ds; ds is shaft dia. Number of arms (j):
6. Thickness of the stiffening rib, q =(1-1.25) h j=4 (If d≤500mm);
7. Hub length, lh = 2ds or at least equal to face width b. j=6 If 500 mm ≤ d ≤1500 mm
0.15 0.45
j=8 If d ≥ 1500mm
Static stress concentration factor K = 0.18 t  t 0
  for 20 pressure angle
t
r h Section modulus of the arm
bmσ d Y ; K = fatigue stress concentration factor Fo (d − d h )l
Fbeam = f section: Z =
Kf 2 jσ d