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CEMA Technical Report 2019 - 01

Conveyor Chain Sprocket Types & Definitions
March 2019

CEMA Technical Report 2019 - 01

Conveyor Chain Sprocket Types & Definitions

Created by: CEMA Conveyor Chain & Sprocket Section

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DISCLAIMER

The information provided herein is advisory only.

These recommendations provided by CEMA are general in nature and are not intended as a
substitute for professional advice. Users should seek the advice, supervision and/or consultation of
qualified engineers, safety consultants, and other qualified professionals.

Any use of this publication, or any information contained herein, or any other CEMA publication
is made with the agreement and understanding that the user and the user’s company assume
full responsibility for the designs, safety, specifications, suitability and adequacy of any conveyor
system, system component, mechanical or electrical device designed or manufactured using this
information.

The user and the user’s company understand and agree that CEMA, its member companies, its
officers, agents and employees are not and shall not be liable in any manner under any theory
of liability to anyone for reliance on or use of these recommendations. The user and the user’s
companies agree to release, hold harmless and indemnify and defend CEMA, its member
companies, successors, assigns, officers, agents and employees from any and all claims of
liability, costs, fees (including attorney’s fees), or damages arising in any way out of the use of this
information.

CEMA and its member companies, successors, assigns, officers, agents and employees make
no representations or warranties whatsoever, either expressed or implied, about the information
contained herein, including, but not limited to, representations or warranties that the information
and recommendations contained herein conform to any federal, state or local laws, regulations,
guidelines or ordinances.

Conveyor Equipment Manufacturers Association

5672 Strand Ct., Suite 2
Naples, Florida 34110-3314
www.cemanet.org
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Conveyor Chain Sprocket Types & Definitions
March 2019

Conveyor Chain
The CEMA Conveyor Chain & Sprocket Section has prepared this document for the purpose of providing a com-
mon level of understanding and terminology of the various types of sprockets used for conveying chains and
belts found throughout the industry today. The scope of this document includes descriptions and definitions of
several sprocket types used for the following types of chains: roller chains, forged chains, cast chains, welded
steel chains, agricultural chains, steel bushed chains, chain drive belts, and plastic chains. Overall, this compi-
lation is not intended to be exhaustive, but it does cover most of the types of sprockets one would find when
working with conveyor chains and belts used in the most typical industry applications.

Standard Roller Chain Sprockets

Standard roller chain sprockets are a series of toothed wheels that are designed to engage with its conjoining
roller chain counterpart in effort to transmit power from the driver sprocket to the driven sprocket. They can be
made with many different types of hub styles and sizes. A few of the most common hub styles are:

A-Hub (sprocket plate only) B-Hub (hub projected on one C-Hub (hub projected on
side of sprocket plate) both sides of sprocket
plate)

Standard roller chain sprockets can also consist of plain bore styles and finished bore styles. Plain bore styles can
be found with a minimum bore diameter in A-Hub, B-Hub, and C-Hub sprockets with the capability to machine the
bore size to the maximum bore diameter allowed. Finished bore styles can be found in B- Hub and C-Hub sprockets
with various fixed bore sizes with keyways and 2 set screws that are per ANSI regulated standards. The set screws
are commonly placed with one right on the keyway and the second set screw at 90 degrees from the keyway.
These sprockets are generally made of steel to ensure strength requirements for transmitting power. Most
finished bore sprocket sizes, typically used as the drive sprocket are made of induction hardened teeth that
provide wear resistance, while having anywhere between 2– 3 times the service life as compared to non-hardened
sprockets made of a mild carbon steel. Standard roller chain sprockets are also available for extended chain
pitch sizes. For corrosive environments, carbon steel sprockets can be black oxidized, plated, or stainless steel.
Common sizes of sprockets are readily available which can be used with their chain counterpart such as: 25,
35, 40, 41, 50, 60, 80, 100, 120, 140, 160, 180 standard roller chains in A-, B-, or C-Hub styles, or double pitch
(extended pitch chains) in A- or C-Hub styles typically 2040/2042, 2050/2052, 2060/2062, and 2080/2082.
Agricultural Chain Sprockets
Sprockets used with agricultural, pintle, or detachable chains are typically made from cast or wrought ferrous
materials. Wear resistance is frequently designed into the material of the tooth faces. Sprocket bodies are
of many configurations. When hubs containing the sprocket mounting bore are employed, they may project
from either side or from both sides of the sprocket body (B- and C-Hub styles). Since these sprockets are often
used in areas where debris is likely to engage it, root diameters should be decreased and pitch line clearances
increased accordingly. Mud reliefs may be incorporated to prevent root diameter build up. ASME B29.300
contains specifications relating to these sprockets.

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Conveyor Chain Sprocket Types & Definitions
March 2019
Forged Chain Sprockets
Forged chain sprockets are typically of segmental construction consisting of four segments bolted onto a solid
or split B- or C-Hub types. The segmental construction facilitates the replacement of worn tooth segments by
allowing the hub to remain mounted to the shaft.
Sprocket segments are generally made from carbon steel, case hardened to 450-550 BHN, or AR400-500 steel.
They are also available in grade 420 stainless steel for corrosive applications. Sprocket hubs are typically made
from mild steel or 304 stainless steel.
The engagement method with drop forged chain is quite different from traditional chains. The spine of the chain
links engage between sprocket segments as shown in figure below. As such, it is critical that the channel between
segments remain clear for the chain to engage. For this reason, sprocket cleaners are normally incorporated
onto the return rail to strip away any product build up within this area.

Sprockets are fabricated and hardened at a slightly lower hardness

compared to the chain to minimize wear. Sprocket replacement is
recommended when the teeth are worn 1/4” below original surface
engagement with the chain, as illustrated in the figure below.
Operating the chain on worn sprockets creates an improper pitch
diameter, which can result in damage to the chain, circlips, and lead to
chain separation. This condition will also shock load the chain and cause
“hooking”, resulting in higher stress loads on the chain due to improper
sprocket engagement.

Although sprockets are critical to proper conveyor operation, they often get overlooked during routine
maintenance. Typically, sprocket tooth segments should be replaced 1 or 2 times throughout the lifecycle of the
chain.
Always install new chain with new sprocket segments.
Additional variations of forged chain sprockets are depicted in the figure below.

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Conveyor Chain Sprocket Types & Definitions
March 2019

Engineered Class Chain Sprockets

Cast Chain Sprockets
Cast sprockets are generally used with cast chains. They are used in applications that handle abrasive materials
such as sand, gravel, ash or cement.
Cast iron chilled rim (C.I.C.R.) sprockets differentiate themselves because of their hardened teeth. The hardened
teeth are achieved by adding a steel ring or rim in the sprocket pocket of the mold. The steel then quenches the
iron creating a hard surface. The resulting hardness is approximately 350 BHN at 3/16” depth.
The three types of construction that are available for cast sprockets are solid, split and segmental. The solid
and split construction are furnished with either a solid center plate or a spoked arm center. Lightening holes
are occasionally used in solid center plates to reduce weight and ease the handling process. The spoked arm
sprockets are used on larger sprockets to reduce weight as well.
Split and segmental sprockets are used when ease of installation
is required without disturbing the shaft, bearings or other
sprockets.
An additional feature of cast sprockets is the characteristic of
chain saver rims. They are often used in sewage treatment
applications. The rims are located under the sidebars, and as the
chain wraps the sprocket, they allow for the sidebars to rest on
them. The chain saver rims help the chain to run at the pitch
diameter of the sprocket.
Lastly, hunting tooth designs are available on cast sprockets.
Hunting tooth sprockets have an odd number of teeth, with the
pitch of the teeth one half that of the chain. This makes the
chain barrel advance one half pitch for each sprocket rotation.
This action allows the teeth to alternate which teeth come in Cast Iron Sprocket with Spoked Arm Center and
contact with the chain, thereby doubling the sprocket life. Chain Saver Rim

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Conveyor Chain Sprocket Types & Definitions
March 2019
Welded Steel Chain Sprockets
Welded Steel Chain is generally categorized as mill or drag chain. These two chains contain diverse design
characteristics and features. Mill chains are typically narrower than drag chains. Therefore, the sprocket
requirements for the two are different.
Mill Chain Sprockets
Flame cut flame hardened (F.C.F.H.) sprockets are normally operated in conjunction with mill chains. These
sprockets are generally manufactured from medium carbon steel. The teeth on carbon steel sprockets are
flame hardened. The flame hardening of medium carbon steel results in a hardness of 40 Rc minimum, with an
approximate depth of 1/8”. Flame cut flame hardened sprockets can also be manufactured from alloy steels, as
well as stainless.
The two types of construction that are available for mill chain sprockets are solid and split. The split sprockets are
used when ease of installation is required without disturbing the shaft, bearings or other sprockets. Four basic
hub types are available in both solid and split construction.
• Type “A” is a flat plate with no hub extensions on either side.
• Type “B” is a flat plate with a hub extension on one side of the plate.
• Type “C” is a flat plate with hub extensions that project the same amount on both sides of the plate.
• Type “C Offset” is a flat plate with hub extensions that have different length projections on both sides of
the plate.

Type “A” Type “B” Type “C” Type “C Offset”

An additional feature available on mill chain sprockets are mud

reliefs. Mud reliefs are used to help keep material from building
up in the pocket of the sprocket. The relief is normally machined,
burnt or ground in the sprocket plate.

Flame Cut Sprocket with Mud Reliefs

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Conveyor Chain Sprocket Types & Definitions
March 2019
Drag Chain Sprockets
Drag chain sprockets are found in applications where wide drag chains are used. These sprockets are manufactured
with full width teeth or a double plate design. The benefit of a full width tooth sprocket design is that they allow
for a greater contact area. Larger contact area is a benefit because it allows for reduced wear on a sprocket. In
the case where material build up is an issue, double plate sprockets are preferred. The double plate allows the
extra clearance for material to pass over the drum in the conveyor. Lastly, many drag chains are manufactured
with a non-round barrel. The barrel could be a formed, have a two piece welded design or an elliptical shape
found in cast chains. These deviations from a round barrel along with chain direction need to be accounted for
in the sprocket design.
The two types of construction that are available for drag chain sprockets are solid or split. The teeth are normally
flame hardened and in some instances the drum is also. The teeth are welded to a drum, which is typically either
a pipe or a piece of rolled steel. The center part of the drum would consist of one center plate or for wider
sprockets they could have end plates with hubs.

Drag Sprocket with Full Tooth

Drag Sprocket with Double Plate

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Conveyor Chain Sprocket Types & Definitions
March 2019
An additional feature of drag chain sprockets is the option of flanges. Flanges are side extensions added to the
drum that keep material from falling onto the shaft. This sprocket feature is usually used in conjunction with
drag chains that contain wing attachments. It is imperative that the location of the flange does not interfere with
the chain articulation.

Drag Sprocket with Full Tooth and Flanged Rim

Elevator Chain Sprockets

Elevator chain can operate on sprockets or traction wheels. Sprockets and Traction wheels can be found at the
head shaft or the tail shaft.
Traction wheels do not have teeth to engage the chain, consequently they rely on friction to drive the chain.
Traction wheels are normally made from medium carbon steel, but can also be made from alloy steels as well
as stainless. As a general rule of thumb, the weight of the buckets, material and chain on the carrying side vs.
the return side must not exceed a ratio of 1.5:1. Due to the nature of traction wheels, they should not be used
when materials are oily or have high lubricity. Additionally, they should not be used in conjunction with chains
that contain rollers. Traction wheels are designed so that the outside diameter plus the bushing diameter of the
chain do not equal the pitch diameter of a toothed sprocket. This allows the chain to engage in a different spot
of the traction wheel increasing the wear life of the traction wheel and the chain bushings. Another advantage
of a traction wheel is that the chain will slip in the event of an obstruction or an overload.

Traction Wheel

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Conveyor Chain Sprocket Types & Definitions
March 2019
Flame cut flame hardened (F.C.F.H.) sprockets are generally used in conjunction with elevator chains. These
sprockets are normally made from medium carbon steel. The teeth on carbon steel sprockets or the outside
diameter on traction wheels are flame hardened. The flame hardening of medium carbon steel results in a
hardness of 40 Rc minimum, with an approximate depth of 1/8”. To achieve higher hardness and deeper case
depths, sprocket and traction wheel could be carburized and induction hardened. Flame cut flame hardened
sprockets can also be made from alloy steels, as well as stainless.
The three types of construction that are available for elevator sprockets are solid, split and segmental. The solid
and split construction is furnished with either a solid center plate or a spoked arm center. Spoked arm sprockets
are used on larger sprockets to reduce weight. Split and segmental sprockets are used when ease of installation
is required without disturbing the shaft, bearings or other sprockets. Lightening holes are sometimes used in
solid center plates for reduced weight as well as for handling.

Solid Construction Split Construction

Segmental Rim Construction

In double strand elevator chain, sprocket configurations

are important for the head and tail shafts. The head
sprockets must have teeth that are in line with each
other. This is achieved by having the sprockets matched.

Matched Sprockets

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Conveyor Chain Sprocket Types & Definitions
March 2019
Plastic Chain and Belt Sprockets
Sprockets that are used to positively drive plastic chains and belts come in many different shapes, sizes, and
materials – the variations of which are too numerous to list. The teeth on these sprockets are designed and
molded to match the size and shape of the mating surfaces on the chain and belts. These sprockets can be
solid or split, and can be molded to have round bores with keyways, square bores, or even hexagonal bores.
The width of the teeth vary according to the width of the drive cavity within a particular style of chain or belt.
The sprockets can have single or multiple rows of teeth; multiple rows of teeth can be aligned or offset – again
depending on the matching design of the particular chain or belt. Split sprockets, though molded in plastic,
can include assembly hardware made from stainless steel to hold the sprockets securely assembled. Stainless
steel hardware is also sometimes inserted into keyways on round bore sprockets to increase the torque transfer
capacity of the sprocket while preventing wallowing of the keyway during service.
Though some sprockets intended for use with plastic chain and belts may be produced in steel of stainless
steel, by far most are produced from plastic resin, mostly acetal and nylon, though other resins are also used
depending on the application. The plastic materials typically selected for sprockets promote excellent wear
resistance while providing a high level of bearing capacity and a high PV rating. The materials for the sprockets
can be selected to be substantially different than the materials used for the mating chains or belts in order to
minimize component wear due to contact between like materials.

General Technical Note: Chordal Action

During operation, both belt and chain drives typically experience a vibration known as chordal action or polygonal
effect which occurs as the effective radius of action in the chain and sprocket system changes during each
revolution. Chordal action can cause increased wear on the chain and sprocket. The effect can be minimized by
using a sprocket with more teeth and virtually eliminated with a sufficiently large sprocket.
As the sprocket rotates, the engagement position of the chain is restricted by the pitch points of the links. These
pitch points create a polygon, with the number of vertices equal to the number of sprocket teeth. The resulting
polygon defines the maximum and minimum effective radii illustrated in Figure 1. The radii can be calculated
using Equations 1 and 2. During rotation, the instantaneous speed of the chain changes, however, the percent
variation will always be constant for a sprocket with a number of teeth N. Figure 2 illustrates the percentage
speed variation versus the number of teeth.

Figure 1: Defining Effective Radii

Figure 2: Percentage speed gap for common sprockets

Equations 1 & 2: Minimum and maximum effective
radii

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Conveyor Chain Sprocket Types & Definitions
March 2019
Chordal action can be minimized by reducing the speed of the chain or by using a sprocket with more teeth. As
the percentage chordal speed variation is solely dependent on the number of sprocket teeth, the percentage
can be found using Equation 3.

Equation 3: Speed Differential

In addition to the number of teeth, if the shaft center distance is a common multiple of the chain pitch, chordal
action is small. But if the shaft center distance is multiple of the chain pitch +0.5 pitch, chordal action increases.
In chain conveyors, compensating sprockets are sometimes used to cancel speed variations resulting from chordal
action. The compensating sprocket would be used as the driven sprocket and mounted on the head shaft with
the conveyor sprocket. The cancellation is a result of specific timing of the teeth between the sprockets. When
the conveyor sprocket is located at its fastest position due to chordal action, the compensating sprocket would
be located at its slowest position. When the conveyor sprocket is located at its slowest position due to chordal
action, the compensating sprocket would be located at its fastest position.

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