DESIGN A CHAIN DRIVE Design a chain drive to transmit 6 KW at 300 vpm of a sprocket pinion. Speed reduction is 2.5:1.

Driving motor mounted on an adjustable base. Assume that load is steady, drive is horizontal and service is 16 hours/day. 1. Tooth numbers for sprockets z1 = 27 for I = 2.5 (preferable to have an odd number) z2 = iz1 = 2.5 x 27 = 67.5 = 67 z2 < z2 max = 100 to 120 Actual speed radio i= 67/27 = 2.48 (small deviation) 2. Selection of pitch Take p = 15.875 mm for z1 = 27 and maximum sprocket speed = 1300 rpm, from Design Data Book. 3. Centre distance = (30 50)p =30x15.875 to 50x15.875, Take a = 476.25 mm

476.25 to 93.75mm

4. Assume simplex chain, 10A1/R50 with m=1.01kg/m. 5. Total load on the driving side of chain, PT=Pt+Pc+Ps Tangential force Pt = 1020 N/v N = 6 kW
v= z1 p n1 27 15.875 900 = = 6.43m / s 60 1000 60 1000

Pt = 1020 x 6 / 6.43 = 951.78 N Pc = mv2 = 1.01 x 6.432 = 41.75 N Ps = k. w. a K = 6 for horizontal drive W = mg = 10.1 N/m (weight per metre) = 6 x 10.1 x 476.25x10-3 = 28.86 N PT = P = 951.78 + 41.75 + 28.86 = 1022.4 N 7. Design load = PT x k3 ks = k1, k2, k3, k4, k5, k6

k1 = 1 (for constant load) k2 = 1 (for adjustable supports) k3 = 1 (for = 30p to 50 p) k4 = 1 (for horizontal drive, inclination upto 60o) k5 = 1.5 (assumed for periodic lubrication) k6 = 1.25 (for 16 hours) = 1 x 1 x 1 x 1 x 1.5 x 1.25 = 1.875 Design load = 1022.4 x 1.875 = 1917 N 8. Factor of safety = Breaking load / Design load Breaking load for 10A1 =22,200N n = 22,200 / 1917 = 11.5 This value is greater than the recommended value given in Table ( n = 11, for 1000 rpm). 9. Check for wear of rollers Induced bearing stress = Pt x ks/A
= 951.78 1.875 = 25.5 N/mm2 70

A=70mm2

>[] Not satisfactory. []=22.4N/mm2 10. Trial 2 Assume drop lubrication. K5 = 1 ks = 1 x 1 x 1 x1 x 1x 1.25 = 1.25 Design load = 1022.4 x 1.25 = 1278 N n = 22,200/1278 = 17.3
= Pt k s 951.8 1.25 = A 70

=16.9 N/mm2 < [] = 22.4 N/mm2 Satisfactory. 11. Length of chain

z + z 2 z 2 z1 lp = 2ap + 1 + / ap 2 2
2

ap = a0/p = 476.25/15.875 = 30

27 + 67 67 27 = 2 x 30 + + / 30 = 108.35 = 110links 2 2

(No. of links is rounded off to an even number) 12. Exact centre distance
a= e + e 2 8M p 4 e=lp z1 + z 2 27 + 67 = 110 = 63 2 2
2 2

z z1 67 27 M= 2 = = 40.53 2 2 = 63 + 63 2 8 10.53 15.875 = 489.63 mm 4

Design a chain drive to run a compressor from a 11 kW electric motor arg at 970 rpm, the compressor sped being 330 rpm. The compressor operates 16 hours / day. The centre distance should be approximately 500 mm. The chain tension can b adjusted by shifting the motor on slides. 1. Determination of the Transmission Ratio I = 970/330 = 2.94 (Table need not be consulted, because in this particular case, the ratio required is 2.94 as calculated from the data given.) 2. Selection of Teeth on the Driver Sprocket From Design Data Book Z1 = 25 (for I = 2 to 3) is chosen. 3. Number of Teeth on the Driven Sprocket z2 = iz1 = 2.94 x 25 74 z2 max = 100 to 120 z2 = 74, is satisfactory. 4. Optimum Centre Distance a = (30-50)p a = 500 mm (given) Pmax = a/30 = 500/30 = 16.6 mm Pmin = a/50 = 500/50 = 10 mm

Assume a standard pitch closer to Pmax. (Larger pitch is chosen so as to arrive at a quicker solution, but this may not be the best solution. Any standard pitch between 10 mm and 16.6 mm can be chosen and the chain should be checked for strength and bearing pressure.) P = 15.875 mm (standard) is chosen. 5. Assume the chain to be duplex. Chosen chain number is 10A-2/DR50 6. Total load on the driving side of the chain PT = Pt + Pc + Ps Tangential force = Pt = 1020 N/v
No. of teeth on the sprocket x pitch x rpm 60 1000 25 15.875 970 = = 6.42 m/s 60 1000 1020 11 Pt = 1748 N 6.42 v=

Centrifugal tension, Pc = wv2/g = mv2 m = 1.78 kg/m Pc = 1.78 x 6.422 75 N Tension due to sagging = Ps = k.w.a. k = 6 (for horizontal drive) w = mg 17.8 N/m a = 0.5 m Ps = 6 x 17.8 x 0.5 = 53.4 N PT = 1748 +75 +53.4 = 1876.4 N 7. Design Load = ks x PT ks = k 1 k2 k3 k4 k5 k6 k1=1.25 (for variable loads with mild shocks) k2 = 1 (for adjustable supports) k3=1 (because we have taken ap=(30to50)p] k4=1 (drive is horizontal) k5 = 1 (for drop lubrication) k6 = 1.25 (for 16 hours/day working) ks = 1.25 x 1 x 1x 1x1x1.25 = 1.5625 1.6 Design load = 1.6 x 1876.4 3002 N

8. Factor of Safety = Breaking load/Design load Breaking load = 44400 N = 44400/3002 = 14.79 Consulting Table, we find for smaller sprocket speed of 1000 rpm and pitch 15.875 mm, the required minimum factor of safety is 11. We find that the actual factor of safety is greater and hence the design is satisfactory. 9. Bearing Stress on Rollers Induced stress = =
Pt k s A

A = 140 mm2 =
1748 1.6 = 19.97 N/mm2 140

Allowable stress, [] = 22.4 N/mm2 for small sprocket speed of 1000 rpm and pitch 15.875 mm from Table. We find that the induced stress is less than the permissible value. 10. Length of Chain
z + z 2 z 2 z1 Ip = 2ap 1 + / ap 2 2
2

ap = ao/p = centre distance / pitch = 500 / 15.875 = 31.49

25 + 74 74 25 Ip = 2 ( 31.49 ) + + / 31.49 2 2
2

= 114.4 116 links (rounded off to an ever number) Actual length of chain = 116 x p = 116 x 15.875 = 1.842 m 11. Exact Centre Distance

a=

e + e 2 8M p 4

e= Ip -

z1 + z 2 25 + 74 = 116 = 66.5 2 2

z z1 74 25 M= 2 = 60.8 = 2 2
66.5 + 66.52 8 60.8 15.875 4

a=

= 512.91 mm 12. Sprocket Diameters Pcd of smaller sprocket, d1 =

p sin (180 / z1 )

15.875 = 126.66 mm sin (180 / 25 )

Sprocket outside diameter, do1 = d1 + 0.8 dr dr = 10.16 mm = 126.66 + (0.8 X 10.16) = 134.788 MM Pcd of larger sprocket, d2 =
P sin (180 / z2 )

15.875 = 374.034 mm sin (180 / 74 )

do2 =d2 +0.8dr =374.034+ (0.8 x 10.16) = 382.162 mm Note: It is preferable to have an odd number of teeth for the sprocket (especially for the smaller sprocket) which in combination with the even number of chain links facilitates more uniform wear. In the solution given above, z2 is not odd. Now try with z2 = 73. Using steps 10, 11 & 12 obtain the results as given below. Ip 114 links; e = 65; M = 58.36 a = 501.26 mm; d2 = 368.99 mm; do2 = 377.118 mm At z2 = 74,
i= 74 = 2.96 25

z2 = 73, i =

73 = 2.92 25

Deviation of I from the required value of 2.94 is same for both the cases. Therefore having z2 = 73 is the better design. A 7.5 kW electric motor running at 1400 rpm is used to drive the input shaft of the gear box of a special purpose machine. Design a suitable roller chain to connect the motor shaft to the gear box shaft to give an exact speed ratio of 10 to 1. Assume the minimum centre distance between driver and driven shafts as 600 mm. 1. Assume z1 = 11. Recommended values of z1 is greater than 17, according to Table. Since I = 10 (given), if z1 = 17, z2 will be greater than 120 which is not acceptable. Hence, considering this as an exceptional case, z1 can be taken as 11 so that Z2 = iz1, z2 = 10 x 11 = 110 We can not have z2 as an odd number, because deviation in I is not acceptable. Since z1 is odd, wear is minimized to some extent. 2. Pitch Calculation. Centre distance a = (30-50)p 600 = (30 to 50)p P = 600/50 to 600/30, 12 to 20 mm 3. Take p = 12.7 mm (standard) The chain is 08B-1 i.e., a simplex chain is assumed. 4.
Pt = 1020 N v v= z1pn1 60 1000

1020 7.5 3.26

11 12.7 1400 60 1000

= 2346.6 N
Pc = wv 2 = mv 2 g

= 3.26 m/s. m 0.7 kg/m

= 0.7 x 3.262 = 7.58 N = kwa = 6 x 7 x 0.6 = 25.2 N

k=6 (horizontal position) w = mg 7 N/m

Total load PT = Pt + Pc + Ps = 2346.6 + 7.58 + 25.2

= 2379.38 N

5. Factors of Safety Ks = k1 k2 k3 k4 k5 k6 K1 to k6 = 1 (assumed) =1x1x1x1x1x1=1 Design load = ks x PT = 1 x 2379.38 = 2379.38 N Breaking load = 18200 N Factor of safety = Breaking load / Design load = 18200/2379.4 = 7.65 For pitch 12.7 mm, for smaller sprocket speed 1400 rpm, the required factor of safety will lie between 11.7 and 13.2 (Table). The actual factor of safety is very much less than the required. Now we choose 08B-2 duplex chain with breaking load 31800 N. Design load will have to be recalculated to account for increased centrifugal tension due to sagging.
Pc = wv 2 2 = mv 2 =1.32x3.26 =14.3 N m = 1.32 kg/m g

Ps=kwa = 6 x 13.2 x 0.6=47.52 N w = mg 13.2 N/m PT = Pt + Pc + Ps = 2346.6 + 14.3+47.52 = 2408.4 N Design load = ks x PT = 1 x 2408.4 = 2408.4 N Factor of safety = 31800 / 2408.4 = 13.2 By interpolation we obtain the required factor of safety for 1400 rpm
= 11.7 + 13.2 11.7 200 1600 1200

= 12.45 Hence, we find the actual factor of safety is greater than the required one. 6. Bearing Stress Bearing area for 08B-2 = 100 mm2
=
Pt k s 2346.6 1 = = 23.47N / mm2 A 100

Allowable bearing stress, [], for smaller sprocket speed of 1400 rpm and for pitch 12.7 mm may lie between 18.5 and 21 N/mm2. We find that the induced stress is greater than the allowable stress. The chain links may not tail by tensile loading but the rollers and pins will fail by wear. 7. Now we try duplex chain 10A-2. The pitch is 15.875 mm. Breaking load is 44400 N so that the actual factor of safety will be much greater than the required value. Bearing area is 140 mm2

2346.6 1 = 16.76 N/mm2 140

By interpolation we calculate the permissible stress.

[ ] = 21

( 21 18.5 ) 200
1600 1200

= 19.75 N/mm2

< [] This is satisfactory. 8. Exact Centre Distance

z + z 2 z2 z1 Ip = 2ap + 1 + / ap 2 2 a 600 = 37.79 ap = 0 = p 15.875 11 + 110 110 11 = 2 37.79 + + / 37.79 2 2
2 2

= 142.6 144 links

a= e + e2 8M p 4 z + z2 11 + 110 e = Ip 1 = 144 = 83.5 2 2
2 2

z z1 110 11 M= 2 = = 248.26 2 2 a= 83.5 + 83.52 8 248.26 15.875 = 611.64mm 4