CHAPTER FOUR

PART B
FLATE BELT,V-BELT,ROPE AND
CHAIN DRIVES
 BELT DRIVE
1. A belt is a looped strip of flexible material, used to
mechanically link two or more rotating shafts.
2. They may be used as:
1. a source of motion,
2. to efficiently transmit power,
3. or to track relative movement.

Belts are looped over pulleys, in a two pulley system,

1. the belt can either drive the pulleys in the same
direction,
2. or the belt may be crossed, so that the direction
of the shafts is opposite.
 SELECTION OF A BELT DRIVE
➢ selection of a belt drive depends:
▪ Speed of the driving and driven shafts
▪ Speed reduction ratio
▪ Power to be transmitted
▪ Centre distance between the shafts
▪ Positive drive requirements
▪ Shafts layout
▪ Space available and
▪ Service conditions
 MATERIALS USED FOR BELT
1. Leather belt: mostly used for flat belts. Both side these
type of belt not similar characters.
✓ hair side: contact to pulley since fiber
perpendicular to surface
✓ Flesh side: used to resist stress since harder side
which fiber parallel to surface
2. Cotton or fabric belts :
▪ are made by folding cotton duck to three or more layers
(depending upon the thickness desired) and stitching
together
▪ are cheaper and suitable in warm climates, in damp
atmospheres and in exposed positions. Therefore
these belts are mostly used in farm machinery, belt
conveyor etc.
 CONT…
3. Rubber belt
▪ are made of layers of fabric impregnated with rubber
composition and have a thin layer of rubber on the
faces
▪ These belts are very flexible but are quickly destroyed if
allowed to come into contact with heat, oil or grease.
▪ These belts are found suitable for saw mills, paper
mills where they are exposed to moisture.
4. Balata belts
 balata gum is used
 These belts are acid proof and water proof and it is not
effected by animal oils or alkalies.
 The strength of balata belts is 25 per cent higher than
rubber belts.
V- BELT
TIMING BELT
ROUND BELT
 FLAT BELT
 are used to transmit power from one shaft to another by
means of pulleys which rotate at the same speed or at
different speeds.

 The amount of power transmitted depends upon the

following factors
➢ The velocity of the belt

➢ The tension under which the belt is placed on the pulleys.

➢ The arc of contact between the belt and the smaller pulley.

➢ The conditions under which the belt is used

 TYPES OF FLAT BELT DRIVES
1. Open belt drive
•Shafts arranged as
parallel and rotate in
same direction

2. Crossed or twist belt drive.

•Shafts arranged as parallel and
rotate in opposite direction
3. Quarter turn belt drive CONT…

• shafts arranged at right angles

• the width of the face of the
pulley should be greater or
equal to 1.4 b, where b is width
of belt
• provided to obtain high
velocity ratio
4 . Belt drive with idler pulleys. • To increase angle of
contact on small pulley
• when the required belt
tension cannot be
obtained by other means.
• When it is desired to
transmit motion from one
shaft to several shafts
 CONT…
5. Compound belt drives:
▪used when power is transmitted
from one shaft to another through
a number of pulleys.

6. Stepped or cone pulley drive

Advantages of belt drive
1. They are simple. They are economical.
2. Parallel shafts are not required.
3. Overload and jam protection are provided.
4. Noise and vibration are damped out. Machinery life is
prolonged because load fluctuations are cushioned
(shock-absorbed).
5. They are lubrication-free. They require only low
maintenance.
6. They are highly efficient (90–98%, usually 95%). Some
misalignment is tolerable.
7. They are very economical when shafts are separated by
large distances.
Disadvantages of belt drive
1. The angular-velocity ratio is not necessarily constant or equal
to the ratio of pulley diameters, because of belt slip and stretch.

2. Heat buildup occurs. Speed is limited to usually 7000 feet per

minute (35 meters per second). Power transmission is limited to
370 kilowatts (500 horsepower).

3. Operating temperatures are usually restricted to –31 to

185°F (–35 to 85°C).

4. Some adjustment of center distance or use of an idler pulley

is necessary for wear and stretch compensation.

5. A means of disassembly must be provided to install endless

belts.
 VELOCITY RATIO
➢ is the ratio between the velocities of the driver and the follower
or driven
Let d1 = Diameter of the driver, d2 = Diameter of the follower,
N1 = Speed of the driver in r.p.m., N2 = Speed of the
follower in r.p.m.,
Length of belt pass over driver pulley = π d1 N1
Length of belt pass over driven pulley = π d2 N2
So velocity ratio

When thickness of the belt (t) is considered, then velocity ratio

 SLIP OF THE BELT
 Is the forward motion of driver without carrying the belt.
 Expressed as percentage

 Let s1 % = Slip between the driver and the belt, and

s2 % = Slip between the belt and follower,

 Velocity of the belt passing over the
driver per second

 velocity of the belt passing over the

follower per second

 If thickness of the belt (t) is considered, then

when S = S1 +S2
 CREEP OF BELT
 is the relative motion between the belt and pulley due to the

tension difference in slack and tight side.

 The total effect of creep is to reduce slightly the speed of the

driven pulley or follower.

 Considering creep, the velocity ratio is given by:

 σ1 and σ2 = Stress in the belt on the tight and slack side

respectively, and E = Young’s modulus for the material of the belt.

 Since the effect of creep is very small, therefore it is generally

neglected.
POWER TRANSMITTED BY BELT
 RATIO OF DRIVING TENSIONS FOR FLAT BELT DRIVE
 consider the following fig

 or
 Length of the Belt
For any type of the belt drive it is always desirable to know the length of belt
required. It will be required in the selection of the belt.
Open Belt Drive
The open belt drive is shown in Figure 5.4. Let O1 and O2 be the pulley
centers and AB and CD be the common tangents on the circles representing
the two pulleys. The total length of the belt ‘L’ is given by

L = AB + Arc BHD + DC + Arc CGA

Let r be the radius of the smaller pulley,
R be the radius of the larger pulley,
C be the center distance between the pulleys, and
𝛽 be the angle subtended by the tangents AB and CD with O1 O2.
𝜋 𝐷−𝑑 2
Lopen= 𝐷 + 𝑑 + 2𝐶 +
2 4𝐶 See the drive from Gupta text
book Pg 688-690
Crossed-Belt Drive

𝜋 𝐷+𝑑 2
Lcross= 𝐷 + 𝑑 + 2𝐶 +
2 4𝐶
 CENTRIFUGAL TENSION.
 Since belts runs over the pulleys some centrifugal force is caused
whose effect is to increase the tension on both the tight and the
slack sides.
 Not consider for below 10 m/s speed.

Power transmitted Ratio of driving tensions

P = (Tt1 − Tt 2 )v
 INITIAL TENSION IN BELT
 Let α Coefficient of increase of the belt length per unit force
 Increase of tension in the tight side = T1 – T0

 Increase in the length of the belt on the tight side =α(T1-T0).

 Decrease in tension in the slack side = T0-T2

 Decrease in length of the belt on the slack side = α(T0-T2)

 Assuming that the belt material is perfectly elastic such as the length
remains constant:
 α(T1-T0) = α(T0-T2) then the initial tension in belts will be:
T + T2
 Neglecting centrifugal tension T0 = 1
2

T1 + T2 + TC
 Considering centrifugal tension T0 =
2
T0
0 =
 Initial stress A
BENDING STRESS
 This stress appears when the belt goes round the pulley at its
value is
Belt thickness
b = E
Pulley diameter

 Maximum stresses in belts

Maximum stresses in belt appears at the point where the belt
runs onto the smaller pulley and are equal to the sum of:
➢ The initial tensile stress in belt,

➢ the stress due to the peripheral force that transmit,

➢ the stress due to centrifugal forces and

➢ the bending stress in the belt.

 ROPES DRIVES
➢ Used where a large amount of power is to be transmitted
at long distance a part.
➢ The ropes drives use the following two types of ropes :

a. Fiber robes (up to 60m a part)

b. Wire ropes (up to 150 m a part)
Fiber robes :
➢ usually made from fibrous materials such as hemp, manila
and cotton.
➢ The diameter of manila and cotton ropes usually ranges
from 38 mm to 50 mm
➢ For manila ropes, the average value of the ultimate tensile
breaking load may be taken as 500 d 2 kN and for cotton
ropes, it may be taken as 350 d 2 kN, where d is the
diameter of rope in mm.
 SHEAVE FOR FIBER ROPES
➢ Theproper size of sheave wheels is 40 d and the minimum
size is 36 d, where d is the diameter of rope in cm.

➢ Ratio of Driving Tensions for Fiber Rope:

similar to v- belt
 WIRE ROPES
 Are widely used in elevators, mine hoists, cranes, conveyors,
hauling devices and suspension bridges.
Example 1: Two pulleys, one 450 mm diameter and the other 200
mm diameter, on parallel shafts 1.95 m apart are connected by a
crossed belt. Find the length of the belt required and the angle of
contact between the belt and each pulley.
What power can be transmitted by the belt when the larger
pulley rotates at 200 rev/min, if the maximum permissible
tension in the belt is 1 kN, and the coefficient of friction between
the belt and pulley is 0.25?

Solution: (On blackboard)

Example 2: Design a belt drive to transmit 110 kW for a system
consisting of two pulleys of diameters 0.9 m and 1.2 m, centre
distance of 3.6 m, a belt speed 20 m/s, coefficient of friction 0.3,
a slip of 1.2% at each pulley and 5% friction loss at each shaft,
20% over load.
Assume
σ= Safe stress for the belt = 2.5 MPa = 2.5 × 106N/m2
t = Thickness of the belt = 15 mm = 0.015 m
Fig shown below a system of flat belt drive consisting of two
pulleys.
Let N1= Speed of the smaller or driving pulley in r.p.m., and
and N2 = Speed of the larger or driven pulley in r.p.m.

We know that speed of the belt (v),

Since the belt speed is more than 10 m/s, therefore centrifugal
tension must be taken into consideration. Assuming a leather belt for
which the density may be taken as 1000 kg / m3
∴ Mass of the belt per metre length,

and centrifugal tension,

We know that maximum tension in the belt,

The standard width of the belt (b) is 400 mm.

 UNIT 5
Bearing
 Design and Selection of Bearings
Bearing is a machine element is used to support shafts to carry
radial and thrust loads.
• The main function of a rotating shaft is to transmit power from
one end of the line to the other.
– It needs a good support to ensure stability and frictionless
rotation. The support for the shaft is known as “bearing”.
• The shaft has a “running fit” in a bearing. All bearing are
provided some lubrication arrangement to reduced friction
between shaft and bearing.
 Bearings are classified under two
main categories:
– Plain or slider bearing : -
• In which the rotating shaft
has a sliding contact with the
bearing which is held
stationary . Due to large
contact area friction between
mating parts is high requiring
greater lubrication.

– Rolling or anti-friction bearing

:-
• Due to less contact area
rolling friction is much lesser
than the sliding friction ,
hence these bearings are also
known as antifriction
bearing.
Bearings are manufactured to take:
Pure radial loads.
Pure thrust loads.
Combination of the two kinds of loads.
 Classification of rolling bearings
1. Ball bearings
▪ Deep groove (Conrad) bearing
▪ Filling notch ball bearing or maximum
capacity bearing
▪ Angular contact bearings (AC)

2. Roller bearings
▪ Cylindrical bearings
▪ Needle bearings
▪ Tapered bearings
▪ Spherical bearings
 Ball and roller bearings
due to low rolling friction these bearings are aptly called “antifriction”
• Frictional resistancebearing .
considerably less than in plain
bearings

• Rotating – non-rotating pairs separated by balls or rollers

• Ball or rollers has rolling contact and sliding friction is

eliminated and replaced by much lower rolling friction.

• In plain bearing the starting resistance is much larger than

the running resistance due to absence of oil film.

• In ball and rolling bearings the initial resistance to motion

is only slightly more than their resistance to continuous
running.

• Hence ball and rolling bearing are more suitable to drives

subject to frequent starting and stopping as they save
power.

• Owing to the low starting torque, a low power motor can be

used for a line shaft running in ball bearing.
Design Considerations
 UNIT 6
LUBRICATION
 Lubrication
• The lubricating system delivers oil to the moving
parts to reduce friction (e.g. IC engine)
✓It holds an adequate supply of oil to cool, clean and seal
the engine.
• To accomplish the above, they should have the
following properties:
✓good lubricity
✓ ideal viscosity
✓chemical stability
✓fire resistance
✓good heat transfer capability and the like
 Selection Stage of Lubricant
• Based on the usage, a particular type of lubricant can be
chosen. The choice is governed by the properties of these
lubricants.
• Lubricant should replace dry friction between two
surface in contact and reduce the wear and surface
breaking.
• They should also eliminate the probability of thermal
deformation or stresses induced due to rubbing.
• Choice of the suitable lubricant also depends on:
(a) continuous working (b) periodic working and
(c) intermittent working.
 Selection Stage of Lubricant
• As described above selection of lubricant is merely
choosing a lubricant which matches best with the design,
operation and environmental requirements.
• Unfortunately there is no set procedure by which a user
can select a lubricant rationally.
• However, sufficient considerations should be given at
the following three stages of the development of a
machine.
(a) Design stage
(b) Manufacturers level
(c) Selection at user level
 Design Stage
• Based on the design parameters, that is, the product of
pressure and speed, a designer can find a suitable type of
lubricant needed for the machine.
• If the choice is oil, then it is necessary to look into the
operational requirements and suitably select an additive
package.
• If the machine is conventional then for a given viscosity
grade there may be a different grades of oil available and
the designer can suggest any one based on the
information's given in manufacturers product guidebook.
 Manufacturers Level
• Based on the designers recommendation or on the report
from the user, a manufacturer can review the additives
package or develop a new package, conducting an expensive
physicochemical or performance and field tests.
• By optimizing the additives type and quantity, a new
lubricant package can be selected.
• It is pertinent to mention here that the selection of additive
package is also a sort of lubricant selection.
• Some organization like ISO, SAE, AGMA and ASTM set
new test limits for new lubricants. If these limits have already
been standardized, user and manufacturers follows these
standards for testing the oils before selection.
 Selection at User level
• For conventional machine elements various types of
lubricants are available and the user has to refer to a
catalogue to choose anyone of them.
• In case a lubricant does not work effectively, the failures
may increase.
• It is essential to check the physico-chemical properties of
the oils while selecting.
• The viscosity is the basic property of the lubricant for given
grade and class, such as industrial, automotive, metal
working or special lubricant.
• User must ask for performance evaluation test in all cases.
• For effective monitoring, it may be necessary to do
spectroscopic oil analysis to know the increase in parts per
million of constituent elements as TBN analysis to know or
predict the possible state of replenishment.
 Additives improve the quality of lubricants

a) Viscosity index improver: A single viscosity oil could be

too thick at low temperatures and very thin at high
temperatures. Viscosity-index improvers are added to
lubricants so that viscosity stays nearly the same.
b) Resistance to carbon formation: When oil is refined,
chemicals are added to fight carbon formation and
oxidation. These can occur at the high temperatures.
c) Corrosion and rust inhibitors: Additives are put in the oil
to help fight corrosion and rust in the engine. These
additives displace water from metal surfaces so oil coats
them. The additives also neutralize acids.
 Cont’d
d) Detergent-dispersant: These additives are similar in action
to soap. They loosen and detach particles of carbon and grit
from moving parts.
e) Extreme pressure resistance: Additives put into the oil to
improve the resistance of the oil film to penetration (engine
oil subjected to very high pressure in the bearings and valve
train).
The extreme-pressure (EP) additives react chemically
with the metal surfaces. The result is a strong, slippery film
that resists penetration and being squeezed out.
 Lubrication Regimes
• Lubrication is commonly classified according to the degree
with which the lubricant separates the sliding surfaces.

❖ Hydrodynamic lubrication
❖ Boundary lubrication (boundary and
extreme pressure) lubrication
❖ Elastohydrodynamic lubrication
Fig. 1 Types of lubrication (Schematic representation)
 1. Hydrodynamic lubrication
Hydrodynamic lubrication means:-
• The load-carrying surfaces of the bearing are
separated by a relatively thick film of lubricant, so as
to prevent metal-to-metal contact.
• The film pressure is created by the moving surface
itself pulling the lubricant into a wedge-shaped zone
at a velocity sufficiently high to create the pressure
necessary to separate the surfaces against the load
on the bearing.
• Hydrodynamic lubrication is also called full-film, or
fluid, lubrication.
 1. Hydrodynamic lubrication

• When the contact geometry and the operating conditions are

such that the load is fully supported by a fluid film, the
surfaces are completely separated. This is generally referred to
as the hydrodynamic lubrication.
• There are two conditions for the occurrence of hydrodynamic
lubrication:
✓Two surfaces must move relatively to each other with
sufficient velocity for a load-carrying lubricating film to be
generated and,
✓Surfaces must be inclined at some angle to each other (if
the surfaces are parallel a pressure field will not form in the
lubricating film to support the required load.)
Fig.2 The principle of hydrodynamic pressure generation
 2. Boundary lubrication
• In boundary lubrication;
➢ Surface contact is continuous and extensive
➢ The lubricant is continuously “smeared” over the
surfaces and provides a continuously renewed adsorbed
surface film that reduces friction and wear.

• Boundary lubrication usually occurs under high load

and low speed conditions (bearings, gears, cam and
tappet interfaces, piston rings and liner interfaces etc.)