w45-7Y4Y/X7 13.00 + 0.

00
Q 1987 Pergamon Journals Ltd.

STRESSES AND DEFORMATIONS OF A CONVEYOR

POWER PULLEY SHELL UNDER EXPONENTIAL
BELT TENSIONS

S. P. DASHand M. C. PALS
TExperimental Stress Analysis Section, Central Mechanical Engineering Research Institution. Durgapur,
India
IDepartment of Mathematics, Regional Engineering College, Durgapur 713 209, west Bengal, India

(Received 12 h.?nuary 1987)

Abstract-Theoretical analysis of stresses and deformations of the cylindrical shell of a conveyor power
pulley under exponential belt loading has been carried out. The present analysis is found lo be in good
agreement with the experimental results for steel conveyor pulleys. Results using different parameters are
computed and obtained in graphical form. They are also in good agreement with those obtained by
Siegfried Scholich under equal tight and slack side belt tensions.

INTRODUCIION MATHEMATICAL FORMULATION

Theoretical analysis of stresses and deformations of The shell is considered to be subjected to belt
the cylindrical shell of a conveyor power pulley under tensions T2 and Tl (T, > T,). Assuming tension at
linear distribution of belt tensions between the slack any point (a, 9) on the shell as
and tight sides was presented by Scholich (11. To the
T = T2&-@), (1)
authors’ knowledge, no other such work has so far
been done. The present analysis is carried out with the equations [3,4] of equilibrium are
the Euler’s [2] distribution of belt loading which gives
an exponential relationship between the slack and a% i-va*u I+V a% vaw-,
tight side tensions. The formulation consists of i@+ -GP+--- 2 atab ay -
differential equations of equilibrium [3,4] for bending
of a circular cylindrical shell. Equilibrium equations I+~ ab a*v i - V~*V aw (1- v*)a* y
--
2--=
at a4
together with boundary conditions [3] are solved by 2 a~ag+Zj?+ 2 Eh
assuming the displacement components in double tri-
gonometric series that satisfy the boundary conditions. au a0
-_&I_ c*A AW = (* -;)‘* Z, (2)
It is clarified that the effects of exponential load on 'Z+ag
the study of the numerical behaviour-of a conveyor
where
power pulley are very important. Load components
have been represented by double Fourier series and
the shell is considered as simply supported at both the
ends. A general computer program is developed for a = Radius of cylinder
computation of stresses, strain and displacement 4 = Angular distance of any point P
components. The results are obtained for different Y, 2 = the load components along y and z directions
wrap angles of a pulley which was a limitation in the E = Young’s Modulus of elasticity
paper by Scholich [ 1] that considered only 180” wrap v = Poisson’s ratio
angle. Although 180” wrap angle is usually consid- h = thickness of the shell,
ered as the critical case for design purposes, the and assuming [3]
analysis may lead to over design of such a pulley for
wrap angles other than 180”. ANSI standard B
105.1-1976[5] specifies pulley load ratings on the m-l.3a-0.1
recommendations of a manufacturer’s individual
stress analysis but the results have not yet been B, sin n4 sin A,,,c
published. The present method establishes a rational
design procedure of a conveyor power pulley shell.
The results of the theoretical analysis are also vali- (3)
dated by experimental findings for steel conveyor
pulleys. to satisfy the simply supported conditions.
787
788 S. P. DAS and M. C. PAL

Now, the applied loads along the 4’and z directions where

at any point P on the shell are
E/l
Y = tension at P per unit area D1=; and D=- (8)
1 -v*.
= T2p ep(a-d)/al for 0 < 4 <a
Solving eqn (8) we obtain
=0 for a<4<n (4)

and A_=;, B+ C+ (9)

Z=T,ep(“-@/al for 0<4<a
where
=0 for a <f$ <a, (5)
where p = coefficient of friction between pulley and
belt.
Expanding the loads Y and Z in Fourier series we
obtain

Y= f f D,sinn4sin1,(
m=l,3n-0.1

Z = f f D~cosn~$ sin A,,,<,

m=l.3n=O.I

(10)
where

e’@- 9)sin n& dQ,

8T,p n d” - p sin na - n cos na

=- x F(l +c*(n*+1;)2)-v
mn’al p*+fl*

=0 for p=O (6) +D~{!$n2-v(n2+~,i~)}] (11)

and

efl@- 4) cos nd d4 A2= .,[,.{(L:.!+n2)

8T, pe”“+nsinna-pcosna x (1 + c2(1; + fr*)*- v21i)

=-
mdal p*+n*

for both p, n # 0

4T,a
DA,=- for both p, n = 0. (7)
mn*al (12)

Substituting the expressions for u, u, w, Y and Z in

eqns (2), we obtain

1+v
--nl,A,

2 2 l-v
+(n2+I ,,,- ) B,,-nC,,=Dl.D,
2

x v.ImA,-nB,,,,,
Now the strains L,, c+ and yXoat any point in the
+{1 +c2(lt,+n2)}C,,= Dl .Dh, shell are expressed in terms of the middle plane
 Stresses and deformations of a conveyor power pulley shell 789

displacements u, u, w by the following relations [4]: (T), give the midplane displacements u, tr and w.
Equations (14) and (15) are then used to compute
(x=-- i au _r-- i a*w strain and stress components at any point on the
aax a2 ax* shell.
COMPUTATIONAL RESULTS
Iau zia*W w
64 = - --_ -7+-
aad aa +zaq5 a+z Numerical calculations are carried out for a con-
veyor power pulley shell with various parameters.
1 au a + z av
*x4 =--++- ax
The case of uniform belt tensions
a+za4 a2
In this case. belt tension T is considered to be
constant on the shell, which implies T = T, = T2. The
(14) results are shown in graphical form in Figs 1-6.
The following notations are used in the graphs to
and the relations between stress components a,, B+, represent stress and displacement components:
rxb and strain components cx, L+ and yx+ are
sxo = a,
SPO = Q# on the outside fibre

E TX0 = rx,,
c7
4 =j---+v2(cg+*Lx)

SXf = a,
E
(15)
T”“=2(1+Yy,@ SPI = a* on the inside fibre

Eqns (3), together with eqns (9)-(13) and eqns (6) and TXI = ‘I,~

+ Compression

- Tension

T, Tz
- SPO 2 531
- TX0
_ TX1

;;

% - _ SPI
z 0 - SXI
x
L
z

-F -2 531

7.12

-wo 5
E . -
:: 0 -::
0 X
B -V
2

- WI -b -7.12

Fig. I. Angle (4) = 30.0“; wrap angle = 60.0”; T, = 9.277 kN; T2 = 9.277 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.012 m; Poisson’s ratio = 0.3; material = steel.
 S. P. Dti and M. C. PAL

",Y

IO- -k
+ Compression w
d - .-.

- Tension z

I=%-+ @
TI Tr

- SPI

_TXI
-SXI

2 I51 I 506 -

0
D
Iuv
x

-2 I51 1 _W

Fig. 2. Angle (4) = 0.0”; wrap angle = 120.0”; T, = 9.277 kN; Tz = 9.277 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.012 m; Poisson’s ratio = 0.3; material = steel.

” *Y
+ Compression w
d _ .~.
- Tenslon z
I+- -3-
r-= I----+ @f?
T, T,

,036
- SPO

- SPI

_ sxo
_ TX0 _ TX1

-I ,036 L -I ,603 L

Fig. 3. Angle (4) = 0.0”; wrap angle = 180.0”; 7’, = 9.277 kN; Tz = 9.277 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.012 m; Poisson’s ratio = 0.3; material = steel.
 Stresses and deformations of a conveyor power pulley shell 791

Compression

Tension

Ef+-----’
I,, /
T,

_ TX1

_ SPI

_ SXI

r
0
z x
e
t;

- 3.975
Fig. 4. Angle (4) = 90.0”; wrap angle = 180.0”; T, = 9.277 kN; T2= 9.277 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.012 m; Poisson’s ratio = 0.3; material = steel.

-=
+ Compression

- Tension

0 907

_
_ TX1

P - sxo 2
/L SPI

P
0 - SXI
x 2 x
E
UJ

-0 907 - -3.663
10.654
-WI z

,r

-6.725 1 -10.654

Fig. 5. Angle (4) = 90.0”; wrap angle = 180.0”; T, = 9.277 kN; T2= 9.277 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.008 m; Poisson’s ratio = 0.3; material = steel.
792 S. P. DA.Tand M. C. PAL

+ Compression

- Tension

T, T,

-1.309 1 -h
za
z

0
E
8
0
.2
- 0.996

-0.996
0
X
_V

_U

_W

Fig. 6. Angle (4) = 30.0”; wrap angle = 240.0”; T, = 9.277 kN; T, = 9.277 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.012 m; Poisson’s ratio = 0.3; material = steel.

t Compression

- Tension

-w
0 871
r

;;
s-
0
: X -
E
iti

- 0.871

7.189

-7.189

Fig. 7. Angle (4) = 90.0”; wrap angle = 180.0”; T, = 13.223 kN; T2= 6.029 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.008 m; Poisson’s ratio = 0.3; material = steel.
 Stresses and deformations of a conveyor power pulley shell 793

+ Compression
- Tension

T, T,

_TXO z _ SPI
- TX1
k

_ SPO 2 O _ SXI
_ sxo ?!
x

Fig. 8. Angle (4) = 120.0”; wrap angle = 180.0”; T, = 13.223 kN; T2 = 6.029 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.012 m; Poisson’s ratio = 0.3; material = steel.

t Compression

- Tension

- SPO ,
_ TX0 - SPI

- TX1

-0.712 L

WI 0.715

=wo ;

P
- 1

R?J?f
E 0
X
,o _lJ
.-8
0

-1.204 L
-0.715 - -W
Fig. 9. Angle (4) = 60.0”; wrap angle = 240.0”; T, = 14.634 kN; T2 = 5.136 kN; length (I) = 0.712 m;
diameter (d) = 0.626 m; thickness = 0.012 m; Poisson’s ratio = 0.3; material = steel.
194 S. P. DN and M. C. PAL
b9- SCALE
- MICRONS
0 IO 20 30
Fig. 10. Exaggerated radial displacement diagrams of shell cross section at its mid-length for wrap angles
of 180.0 and 240.0”. (a) and (c) r, = 9.277 kN; (b) r, = 13.223kN, T2= 6.029kN; (d) T, = 14.634kN,
T2= 5.136 kN; length (I) = 0.712 m; diameter (d) = 0.626 m.
WO = working stress on outside fibre
WI = working stress on inside fibre
u, o, w are the displacement components
a = half of the wrap angle.
The case of non-uniform tensions
In this case belt tension at any point is considered
as
T = T, e’(“- 4).
The results are shown in graphical form in Figs 7-9.
T, and T2 in this case are obtained satisfying the
relation
J%JT,=2JT,,
where TO is the initial belt tension [6].
From the Figs 7-9 it can be seen that stresses and
deflections increase nonlinearly with the decrease in
the thickness of the shell. It is also observed that
uniform belt tensions give higher deflection and
stresses on the shell. In all cases deflection and
T2
Cd) -
stresses are found to be symmetric with respect to the
midsection and q5= 0” line. It is further noted that
stresses are at a maximum on the line of belt sepa-
ration. The pictorial view of the radial displacement
of the mid-section of the shell is shown in Fig. 10.
Deformations were found to be greater on the belt’s
contact zone of the shell and they are also symmetric
with respect to the 4 = 0” line.
CONCLUSION
The stresses and deformations of a conveyor power
pulley shell have been studied under exponential belt
tensions. The present analysis aids the study of the
mechanical behaviour of the power pulley shell for
various wrap angles which hitherto have not been
studied.
The present method is important in the rational
design of the conveyor power pulley shell.
Acknowledgernears-The authors gratefully acknowledge
the support given by the Director, CMERI for carrying out
this research and Dr P. B. Chauha, Scientist, CMERl for his
constant encouragement and valuable suggestions. They are
indebted to Mr S. L. Roychaudhury and Dr S. Dasgupta,
Scientists, CMERI for computation of the results on the
digital computer HP 1000/45 at CMERI.
 Stresses and deformations of a conveyor power pulley shell 79s

REFERENCES P/ares and Shells, p. 514. McGraw-Hill, New York

I. S. Scholich, Spannungen und Verformungen an Gurt-
bandtrommeln Bergbautechnik. IS. Jg. Hejt 10,
517-522 (1965).
2. V. Dobrovolsky, Machine Elements, 3rd edn, p. 213.
Mir, Moscow.
3. S. Timoshinko and S. Woinowsky-Krieger, Theory of
(1959).
4. W. Fliigge, Stresses in Shells, p. 220. Springer, New
York (1962).
5. ANSI standard B 105.1 - 1976, Specification for welded
steel conveyor pulleys.
6. M. F. Spotts, Design of Machine Elements, 3rd edn, p.
221. Prentice-Hall, New Delhi (1965).