2/11/2019

BELTING

A v-belt drive

A Flat belt drive

A typical open flat belt drive

1
 2/11/2019

DESIGN OF BELTS

V-belt cross section

•Designing a belt drive using

basic equations. V-pulley

•Designing a belt drive using

manufacturer’s data.

dN= normal force, due to

T+dT T reaction from pulley
= coefficient of friction T+dT T
T1 = Tension on tight side.
T2 = Tension on slack side
dN = friction force
 = angle of wrap
T1
T2  = groove angle
Forces
Forces
in Flat belt drive in V-belt drive

Design of flat belts

D, n2
d, n1
Problem

The following particulars refer

to an open belt drive:
Driving pulley:
diameter = 630 mm
rpm = 150
Driven pulley:
rpm = 380
Centre distance = 2.4 m
Coefficient of friction = 0.3 Given
Power transmitted = 3.7 kW n1=380 rpm =0.3
Determine the width of the belt. n2=150 rpm P=3.7 kW
Safe permissible tension per mm D=630 mm C = 2.4 m
=2400 mm
width of belt = 13.4 N/mm

2
 2/11/2019

Design of flat belts

Steps involved

Step 1
Finding Pulley Diameters (D and d):

In some problems, diameters of the driving

and driven pulleys may be given. If any one
of them is not given, use the following
equation to find it:
n1 D 380 630
velocity ratio   
n2 d 150 d
where,  d  248.68 mm
n1→ Speed of the driving pulley in rpm
n2→ Speed of the driven pulley in rpm
D → Diameter of the larger (driven) pulley in m Take d=250 mm
d → Diameter of the smaller (driving) pulley in m
Change it to the nearest standard value and
fix it as the permanent value. p7.54 under
recommended series of pulley diameters

Design of flat belts

Step 2

Finding the Speeds of Driving and

Driven Pulleys (N1 and N2): Assume there is no slip.

n D s s 
 1 
1
1 2

n d
2
100 
where,
s1 → Percentage slip between the driving pulley and
the belt
s2 → Percentage slip between the belt and
the driven pulley

If thickness of belt (t) is considered, use the following

equation:

n D  t   s  s 
1
 1  1 2

n2
d  t   100 

3
 2/11/2019

Design of flat belts

Step 3
Determination of Correction Factors
Load Correction Factor: Table on p7.53 For intermittent loads, 1.3

Dd o 630  250 o o

180  x 60  170.5
Arc of contact  180 o  X 60 o 2.4 x1000
C
Arc of contact factor based on the following: Take, 1.0
Table on p7.54

Smaller Pulley Diameter Factor:

Smaller Pulley Diameter (in mm) Smaller Pulley Diameter Factor
Upto 100 0.5
100-200 0.6 Take, 0.7
200-300 0.7
300-400 0.8
400-750 0.9
Above 750 1.0

Design of flat belts

Step 4

Finding Design Power in kW:

rated kW Power x Load correction factor 3.7 x1.3

Pdes  Pdes   6.8714 kW
Arc of contact factor x smaller puley diameter factor 1x0.7

Step 5
dn  x 250 x 380
Finding the Belt Velocity V  1
  4.9742 m / s
60 60 x 1000

4
 2/11/2019

Design of flat belts

Step 6

Selection of Belt

There are two types of belts:

•Dunlop “HI – SPEED” 878 g duck belting – Used in light

and medium duty applications with high belt velocity.
Choose this belt as
For design power < 20 kW and belt velocity > 16 m/s. power and speed match.

•Dunlop “FORT” 949 g duck belting – Used in heavy duty

applications with medium belt speeds.

For design power > 20 kW and belt velocity < 16 m/s.

Step 7 Design of flat belts

Determination of number of plies:

The number of plies can be determined using
the maximum belt velocity and the minimum No. of plies = 6
pulley diameter from Table, p7.52.

Step 8
0.023
Finding Load Rating at V m/s p7.54. Frating  x 4.9742 kW per mm. per ply
10
corresponding to the belt selected  0.01144066 kW per mm. per ply

Step 9

design power 6.8714

Finding Belt Width b 
no. of plies X Load rating 6 x0.01144066
 100.10 mm
After finding the belt width, change it to the nearest
standard and fix it as the permanent value, p7.52
b = 112 mm
Refer the table to choose a standard belt width
according to the number of plies and the type of belt
used.

5
 2/11/2019

Step 10
Design of flat belts

Determining Pulley width

Pulley width = Belt width (chosen standard)
= 112 + 13
+ Additional width
= 125 mm
Additional width has to be chosen according to the belt width,
Table on p7.54.

Step 11
D  d   D  d 
2

L  2C 
Determining the length of flat belt (L):, p7.53 2 4C
- for open belt drive
+ for cross belt drive

d D
For open belt drive
2

L  2C 

D  d   D  d 
2 4C
2

 2 x 2.4  0.630  0.250  (0.630  0.250)
2 4 x 2.4
 6.197 m
d D

Design of flat belts

D, n2
d, n1
Problem

The following particulars refer

to an open belt drive:
Driving pulley:
diameter = 630 mm
rpm = 150
Driven pulley:
rpm = 380
Centre distance = 2.4 m
Coefficient of friction = 0.3 Given
Power transmitted = 3.7 kW n1=380 rpm =0.3
Safe permissible tension per mm n2=150 rpm P=3.7 kW
width of belt = 13.4 N/mm D=630 mm C = 2.4 m
Determine the width of the belt. =2400 mm

6
 2/11/2019

Finding Pulley Diameters (D and d): 380 630


150 d
n1 D  d  248.68 mm
velocity ratio  
n2 d
where,
n1→ Speed of the driving pulley in rpm
n2→ Speed of the driven pulley in rpm
D → Diameter of the larger (driven) pulley in m
d → Diameter of the smaller (driving) pulley in m

Angle of wrap over small pulley Dd 4.5565o

sin  
2C

    2 rad 2.98254 rad

Peripheral velocity v  dn  DN 4.948 m/s

t1
Ratio of tensions in the belt  e  t1 = 204468 t2
t2
Power transmitted P  (t1  t 2 )v t1 - t2 =747.77

t2= 516.85 N
t1= 1264.63 N

Maximum tension in the belt t1= 1264.63 N

Width of the belt= maximum tension/permissible tension b= 94.31 mm

7
 2/11/2019

DESIGN OF V BELTS

Problem It has been decided to maintain the rotational speed of the driven
pulley at 375 rpm, and the driver shaft 1000 rpm. The proposed
diameter of the driver pulley is 300 mm, the power to be
transmitted to be 95 kW. Design a suitable V- belt drive for heavy
duty service.

Given: To find:
Driver pulley: A suitable V-belt drive.
Diameter, d = 300 mm Cross section of v-belt
Rotational speed = 1000 No. of v-belts
Driven pulley: Lengths of belt.
Rotational speed = 375 rpm Final diameter of pulleys
Diameter, D = ?
Power transmitted P = 95 kW
Heavy duty

DESIGN OF V BELTS

Step 1 Find speed ratio, diameter of n 784 mm (929.73)

Dd 
the unknown pulley, 7.61 N = 800 mm (1000)
For diameters, Rseries, 7.20. D n

d N
Otherwise change d, D by keeping rpm of pulleys. 800 1000
  2.6667
300 375
As D/d varies, change d. (2.817)
d= (1000 x 375/1000)= 375 mm

Step 2 Service factor (Fa) is determined

Fa = 1.4
from the table Correction factor for
industrial service.p7.69

Step 3 Design power in kW = Fa × transmitted power 1.4 x 95 = Pdes = 133 kW

Use the name plate power on the

motor or engine in case the transmitted
power or consumed power is not
mentioned.

8
 2/11/2019

DESIGN OF V BELTS

Step 4 The belt section is determined from the

Let’s select D section
value of design power. data on standard dmin = 355 mm
V belt sections, p7.58 d min. is larger than d=300 mm.
Get the new values of d, D by keeping the Recompute D (GO to Step 1)
rotational speed unaltered so that the
peripheral speed of the pulley is constant.

Step 5 Write down the final values of D, d, D= 1000 mm

D/d d= 375 mm
D/d= 2.6667

Step 6 Belt speed, S = π dn1 m/s S= 19.63 m/s

Step 7 smaller pulley diameter factor (Fb) Fb= 1.13.

Based on the value of D/d, 7.62

DESIGN OF V BELTS

Step 8 Determine de, in mm d d xF

e b = 423.75 mm.
Check for maximum value of de against the Since de<425 mm, proceed to
selected Belt Section in the formula. If it’s okay, Step 7.
proceed further, else GOTO Step 4 ; choose the
next cross section and continue therefore .

Step 9 Compute the power rating Pmax for the Pmax= 21.266 kW
selected section, p7.62

Step 10 Selection of centre distance C/D=1.0

For the D/d ratio, find the recommended C=1000 mm
C/D ratio.

9
 2/11/2019

DESIGN OF V BELTS

Calculate L,7.61 L  2C   ( D  d )  ( D  d )
2

Step 11 L=4275.5 mm
2 4C
From table, L= 4473 mm
Get the nominal value of pitch length
from table, 7.60 L=4641.25 mm
From table, L= 4651 mm

Step 12 Calculate again C using the following C= 1112.69 mm > 1000 mm

expression with L selected from Table.,
So choose another C/D =1.2
7.61
2
GOTO Step 11
C  A A  B
where L Dd C= 1205.05  1200 mm
A 
4 8
(D  d )2
B
8

Step 13 Determine Correction factor (Fd) for an Angle of arc of contact = 145.93o
arc of contact, Table on p 7.68. Fd= 0.83 for v-belt.

DESIGN OF V BELTS

Step 14 Fc - the correction factor for length -is Fc= 0.93

determined by using the selected length and
belt section from the Table, p7.59-7.60.

Step 15 Adjusted rated power = (rated power) Fd Fc =16.4152 kW

Step 16 Number of belts needed = Design =133/16.41522

power/Adjusted rated power =8.1
= 9 belts (say)

Step 17 Specify the dimensions of standard v-

grooved pulleys for the selected cross
section, 7.70.

10
 2/11/2019

DESIGN OF V BELTS

A v-belt drive connects two parallel shafts whose shafts are one metre
apart. The driving pulley that runs at 1000 rpm is supplied with 95 kW
Problem power and has diameter of 300 mm. The driven pulley runs at 375 rpm.
The angle of groove on the pulley is 40o. Permissible tension in 400 mm2
cross sectional belt is 2.1 MPa. The density of belt material is 1100
kg/m3. The driven pulley is overhung, the distance of the centre from the
nearest bearing being 200 mm. The coefficient of friction between
pulley and belt is 0.28. Determine the number of belts required and the
diameter of driven pulley shaft if permissible shear stress is 32 MPa.
Given: To find:
Driver pulley: A suitable V-belt drive.
Diameter, d = 300 mm Cross section of v-belt
Rotational speed = 1000 No. of v-belts
Driven pulley: Lengths of belt.
Rotational speed = 375 rpm Final diameter of pulleys
Diameter, D = ?
Power transmitted P = 95 kW

Diameter of driven pulley D n 0.8 m


d N

Angle of lap on the smaller pulley 151o=2.62 rad

Mass of belt/m length of belt, area

0.44 kg/m
x length x density

Belt velocity 15.71 m/s

Centrifugal tension 108.6 N

Maximum tension in the belt,  x a 840 N

Tension in the tight side of the belt 731.4 N

Tension in the slack side of the belt 83.9 N

11
 2/11/2019

Power transmitted per belt 10.172 kW

Number of belts required= total power 9.34=10 belts
transmitted/power transmitted per belt

Torque transmitted by driven pulley shaft 2420 Nm

=2420 x 103 Nmm

Since the driven pulley is overhung, the 2065 x 103 Nmm

B.M. on the shaft due to pull of the belt-
(t2+t1+tc) x radius x no. of belts

3181 x 103 Nmm

Equivalent twisting moment, Te

Diameter is given by 72.8= 75 mm

Te=(/16)x τ D3

Relationship among Tensions, Friction, and Wrap angle

dN= normal force, due to
reaction from pulley
= coefficient of friction
T1 = Total tension on tight side. T1=t1+tc
T2 = Total tension on slack side T2=t2+tc
dN = friction force tc = tension due to
 = angle of wrap centrifugal force fc
= groove angle
m= mass per unit length

Equilibrium forces in x and y direction

 d   d 
(T  dT ) cos   T cos   dN 1
 2   2 

 d   d  2  
(T  dT ) sin    T sin    mv d  dN sin  2
 2   2  2

 d  d  d 
T As d is very small, sin   ; cos   1
T+dT  2  2  2 
From Eq.1
T  dT  T  dN
2
v dT  dN
f  mrd 
c dT
r dN  3
f  mv d
c
2


12
 2/11/2019

From Eq.1

d d  d   
T1
dT  
T  dT 2
 T    mv d  dN sin     d
2 2  2  2 T2 (T  mv ) 2
0  
sin 
2T
d
 dT
d  
 mv d  dN sin  
2 2
2 2 2 T1  

  ln(T  mv ) 2
 
Td  mv d  dN sin  
2
T2
  0

2 sin  
2
 
(T  mv ) d  dN sin  
2
(T  mv ) 2

2 ln 1

dT  
(T  mv ) 2
 
2
(T  mv ) d  sin  
2
sin  
 2 2

dT  2
 d 4 (T  mv )  
sin  
2
(T  mv ) 2
 
1
e 5
sin   (T  mv ) 2

2 2

Integrating Eq.4 with limits:

Angle of contact 0 to , and

tension, T1 to T2

For flat belt, =180o

T+dT T
2
(T  mv )
1
 e  2
6
(T  mv )
2

T2
T1

dN= normal force, due to

reaction from pulley
= coefficient of friction
T1 = Tension on tight side.
T2 = Tension on slack side
dN = friction force
 = angle of wrap

13
 2/11/2019

Centrifugal tension v2
f c  mrd 
r
f c  mv 2 d 7

Equilibrium forces in x and y direction

 d   d 
t c cos   t c cos   dN 8
 2   2 
 d   d   
t c sin    t c sin    mv 2 d  dN sin   9
 2   2  2

 d  d  d 
As d is very small, sin    ; cos   1
 2  2  2 
From Eq.1 t  t  dNc c

dN  0
 dN  0 10

tc tc d d  
From Eq.2 t c
t  mv d  dN sin 
c
2

2 2 2
d
2t c
 mv d 2

2
2
t  mv
c 11

Substituting the value of tc in the ratio of total

tensions for v-belt and flat belt drive, we obtain

For v-belt drive, For flat belt drive,


2
(T  mv )  
sin  
2 t1
1
e
(T  mv ) 2  e  13
2


t2
2
(t  t  mv )  
sin  
2
1 c
e 2
(t  t  mv )
2 c


2 2
(t  mv  mv )  
sin  
2
1
2
e 2
(t  mv  mv )
2


 
t1 sin  
 e 2 12
t2

14
 2/11/2019

MAXIMIZING THE POWER TRANSMISSION

 
 1 
Considering centrifugal tension, the belt P  T  mv 2 1   v
 sin   
 

should withstand the maximum tension T  e 2 

Assumptions  C T  mv 2 v For v-belt drive
 1 
Belt does not slip over pulleys. P  T  mv 1   v
2

Belt length is constant even with initial tension  e 

 C T  mv v 2
For flat belt drive

P  (t1  t2 )v
  For maximum power,
 
1
 t1 1  v dP
 t1   C T  3mv   0
2

 t2  dv

 C  0, T  3mv  0 2

T  t tc 1

t T t T
1 c v 
 T  mv 2 3m

Effect of initial belt tension Fi on maximum power

Belt must be given initial tension at the time of installation.

When the driving pulley starts rotating, the belt on tight side
elongates by t in overcoming the friction, causing the
tension on the belt to increase from ti to T1.

Once the belt crosses the driven pulley, the belt retracts to
its original length.

This reduces the tension on the slack side from ti to T2 and

the belt contracts by s

T1  ti  ti  T2
T1  T2
ti 
2

15
 2/11/2019

From

T t
1
 e  c

T t
2 c

Get two Eqs. by adding and subtracting 1 e   1

T1  T2  T1  T2  2tc 
T t T t e   1
1
 e   1
c 2 c
1  K (ti  tc )
T t 2 c

T t T  t Power P  T1  T2 v
1 c
 e   1 2 c
2
T t 2 c
 K ti  mv 2 v
T1  T2  2tc 3
 e   1 For maximum power
T2  tc
T1  T2 dP
 e   1 4  K t  3mv   0
i
2

T2  tc dv
 K  0; t  3mv  0
i
2

dividing Eq.3 by Eq.4

T  T  2t e  1
1
 2 c
t  3mv 2

T T 1
e 1 2
i

The maximum t
optimum belt speed v i

3m

TOOTHED BELT DRIVES

Also referred as ‘timing belt drives’.

-positive drives that operate on toothed
pulleys.
The belts have flat outer surface and evenly
spaced teeth on the inner surface.

A toothed belt is made of rubberized fabric

reinforced with steel wires to take the load.
The steel wire is located at the pitch line and
the pitch length is the same regardless of the
thickness of belt.

Toothed belts do not have joints.

The toothed pulley looks like a spur gear, but

the tooth profile is not involute.

16
 2/11/2019

VARIABLE SPEED DRIVES

By shifting the driver and driven discs axially

and simultaneously, the effective diameters of
the discs over which the belt passes are varied,
thus varying the output speed.

To increase the output speed (spindle speed),

the input discs are moved closer to each other
and the output discs are moved apart and vice
versa. Depending on the preciousness of the
control mechanism, the speed of the output
can be varied infinitesimally and continuously.

This is called PIV (Positively Infinitesimally

Variable) drive.

Crowning of pulleys

Pulleys are provided a slight dwell to prevent the belt

from running off.

The crowning may be tapered or rounded.

Normally a crown height of 10 mm per metre face

width is provided.

Tapered crown Rounded crown

17
 2/11/2019

SPEED RATIO

Thickness of belt = t


 r
n

Vn,n,r ,d, sn

Vr,r,R ,D, sr

Slip: difference between the linear speed of pulley and

belt over that pulley.
 t
Linear or peripheral speed of driver at mean radius V    R   r r
1
 2
Let sr slip between driver and the belt.
The linear speed of the belt. V    R  t 1  s b r r
2
 2
Let sn be the slip between the belt and the driven pulley.

The linear speed of the driven pulley V    R  t 1  s 1  s n r r n

3
 2

But, the speed of driven pulley

 D  t 

n
1  s  s  5
 d  t 
r n
 t
V  R  
n n 4
r

 2
 D  t  6

n
1  s 
 d  t 
Equating Eq.3 and Eq.4 r

Where s is the total slip.

 t
R  1  s 1  s
r n

  2
 n

  t
r
R  
 2
 D  t 
 n
1  s 1  s 
 d  t 
r n
r

 D  t 
n
1  s  s   s s 
 d  t 
r n r n

18
 2/11/2019

LENGTH OF BELT

3 b

a 
e


1 n
o1 o2 r 2
C
g
Vn,n,r ,d, sn 3 h
Vr,r,R ,D, sr
o2 e R  r D  d
sin    
o1o2 C 2C

 n    2 and arc length ga  r   2  1

 r    2 and arc length bh  R  2  2

1
ab 2  o1e 2  C 2  R  r 
2

ab  C 2  R  r  
2 2 3

Length of belt L =arc length ga + arc length bh + 2ab

1

L   R  r   2  R  r   2 C 2  R  r 
2 2

1


2

( D  d )   ( D  d )  2 C 2  R  r  
2 2
4
1
  R  r 2  2
L   R  r   2 R  r   2C 1    
  C  
 1 Rr 2 1 1 2 2 
      R  r   
  R  r   2 R  r   2C 1       1     
 2  C  2  2   C   
2
 1  R  r  
  R  r   2 R  r   2C 1    
 2  C  
 Dd  1  D  d  2 
 D  d   ( D  d )  2C 1    
2 2C  2  2C  
2


D  d    D  d   2C 
D  d 2
2 2C 4C

 D  d   D  d 
2
 5
L  2C 
2 4C

19
 2/11/2019

Derive an expression for finding the length

of belt in the case of crossed belt drive.

Check your answer with

 D  d   D  d 
2

L  2C 
2 4C

dN- Normal force, due to reaction from pulley

- coefficient of friction
F1- tension on slack side
F2- tension on tight side.
dF- friction force
-angle of wrap

20
 2/11/2019

dN/2- Normal force, due to reaction from pulley

- coefficient of friction
F1- tension on slack side
F2- tension on tight side.
dF- friction force
- groove angle
Equilibrium forces in x and y direction

 d   d 
( F  dF ) cos   F cos   dN
 2   2 
 d   d   
( F  dF ) sin    F sin    mv 2 d  dN sin  
 2   2  2

As  is very small
    
sin    ; cos   1
2 2 2

dF
dN 


dF d

F  mv 2  
sin  
2

Integrating the above with limits:

Angle of contact 0 to , and
tension, F1 to F2


 
F2  mv 2 sin  

2
 e 2
F1  mv

For flat belt, =180o

21