Analysis of The Mechanical Properties of Conveyor Belt On The Three Main Stages of Production

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DOI: 10.1177/1528083714559567
properties of conveyor jit.sagepub.com
belts on the three main

stages of production
Marcin Barburski
Abstract
Conveyors belts are used wherever it is necessary to transport materials quickly and
promptly. They are made of fabric-rubber core (carcass) and rubber covers. The carcass
may consist of several spacers made of synthetic polyamide–polyester fabrics impreg-
nated with a solution of latex that provides an intermediate layer to prevent delamin-
ation of the vulcanized composite. The main goal of this research work is to analyse the
mechanical properties of conveyor belts during three main stages of production: raw
fabric, fabric impregnated with latex, and conveyor belt. For this purpose, nine fabrics of
different weaves with a width of 1 m were produced with polyester warp and polyamide
weft threads. The fabrics were coated with latex and then vulcanized. Subsequently, the
structural parameters and the mechanical properties of each product were measured at
each of the three stages of conveyor belt production. This article presents the effect of
fabric structure on the mechanical properties of the products of these three production
stages. Results show that differences in the mechanical properties of products at dif-
ferent stages of conveyor belt production depend on number of intersections of yarns
in woven fabrics. In addition, significant differences were observed in the mechanical
properties depending on the applied weaves.
Keywords
Woven fabric, internal structure, mechanical properties, bending rigidity, strain,
strength, conveyor belt
Institute of Architecture of Textile, Technical University of Lodz, Poland
Corresponding author:
Marcin Barburski, Technical University of Lodz, Institute of Architecture of Textile, 116 Zeromskiego Street,
90-924 Lodz, Poland.
Email: marcin.barburski@p.lodz.pl
Downloaded from jit.sagepub.com at UNIV CALIFORNIA SAN DIEGO on April 20, 2016
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2 Journal of Industrial Textiles 0(00)
Introduction
Conveyor belts are designed for the technological transport of all kinds of bulk
materials of granulation 1–100 mm and damp in order to prevent permanent adher-
ence to the belt and conveyor construction elements. These conveyors are used
wherever it is necessary to transport materials quickly andpromptly. Typical
fabric–rubber conveyor belts are designed to transport bulk materials in ambient
temperatures from 25 C to þ60 C [1]. Conveyor belts are typically used in coal-
mines, cement and lime industries, paper and sugar mills, in agriculture and in
power plants [1–3]. Because of the widespread use of conveyor belts, there are
many standards to be met before they can be put to use in the industry [4–10].
The conveyor belt is made of fabric–rubber carcass and rubber covers. The carcass
may consist of two to six spacers made of synthetic polyamide–polyester fabrics
impregnated with a solution of latex that provides an intermediate layer preventing
the delamination of fabric and rubber [11–17]. Covers and rims protect the carcass
from damage, weather and chemicals [18].
All materials used in the production of conveyor belts, i.e. rubber, polyvinyl
chloride, cotton, polyamides, polyesters and aramids, are characterized by a strong
non-linear mechanical behaviour. While running on a conveyor, the belt is sub-
jected to a time-varying load, not only in transient states but also in steady
motion [11,19].
Unlike homogeneous structures, it is difficult to express the tensile force as
force per area unit of the cross-section in the case of conveyor belts because of
the heterogeneous structure of the cross-section of conveyor belts. When analys-
ing the loads of conveyor belts, the cross-section is assumed to be one dimen-
sional and tension is expressed in force units per unit width of the
conveyor belt.
The weaving structure of woven fabric can be determined at the very
beginning of its production. The variety of weaves enables shaping the surface
of fabric to obtain optimal properties in the final product. The structure of
the fabric also influences several of the features such as appearance, smooth-
ness, permeability, arrangement, thermal protection, flexibility and drapeability
[20–26].
During draping, there are four different types of deformations that can be
observed: in-plane and bi-axial tension, in-plane shear, out-of-plane bending and
transverse compression. The way in which each fabric complies or resists these
modes is different.
In this article, the deformation in-plane tension and out-of-plane bending are
studied, which are the most important mechanical properties of conveyor belts.
Bending rigidity is the resistance of a substance of specific width under deform-
ation caused by the external bending force [5]. This parameter is very important
when designing composites for a specific purpose and structure. Few studies have
accounted for the bending behaviour while considering the formation of fibrous
materials as composite reinforcements. Most of the studies were conducted on the
bending behaviour of textiles for garments, as the effect of bending is considered to
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Barburski 3
be most important in the textile industry [27,28]. Nowadays, more research on

bending properties of composite reinforcements is stimulated by their effect on
composite forming processes, especially for the simulation of the phenomena of
wrinkling and local orientations of fibre and yarn [29].
The bending behaviour of reinforcement is a multiscale hierarchical problem. At
the microscopic scale, yarn is made up of fibres that interact with the each other
and the bending rigidity of the yarn is not the sum of the bending rigidity of the
fibres. The relationship between the mechanical behaviour of fabric, yarns and
fibres is complex [30–33].
Bending rigidity in particular determines the correct shape of wrinkles that
appear during draping at macroscale [9] or macroscopic extension of fabrics. In
comparison to continuous materials, bending and tension rigidities of fibrous
materials are not directly related. Consequently, extra experiments are usually
required to determine bending rigidity of the material [28,34–39].
One of the aims of this study is to understand the effects of different weaves on
the bending rigidity and internal structure of woven fabric and to minimize the
stresses on the internal structure during turning of the conveyor belt.
According to the literature [20,21,40–44], the mechanical properties of fabrics
depend on the material used, the type of yarns, the weaving parameters as well as
the weave types. Each of these factors is important individually but the interactions
between them make it difficult to isolate the effect of each on the mechanical
properties of the fabric.
Preliminary studies [45] showed that in a single weave fabric, bending modulus is
significantly affected by the direction of the test samples. A larger number of warps
stiffen the fabric in their direction. It was also proved that the larger the number of
the system coverings in a certain direction, the lower the bending rigidity the fabric
has in that direction. Increasing the number of intersections in the fabric and
setting the coverings evenly increase the rigidity of fabrics as well [45].
As shown in the study by Barburski et al. [46], basic parameters of the internal
structure of fabrics PA6.6/PET change significantly under heat treatment during
vulcanization and formation of conveyor belts. In addition, the fabric weave sub-
stantially influences its internal structure and vulnerability to higher temperature.
Presumably, these changes have a significant effect on the mechanical properties of
the fabric at each stage of production of the conveyor belt.
Particularly in the case of conveyor belts of high strength used in arduous con-
ditions, intensive research is being conducted to identify new types of fibres, weaves
and spacers systems that can meet the growing requirements of the end users.
In the context of the above-mentioned requirement, an experiment was con-
ducted to determine the mechanical properties of the fabrics used in conveyor
belts and the effect of individual processes of creating the belts on these properties.
The experiment uses yarns and loom setting parameters commonly used in
the production of fabrics as reinforcement of a monolayer conveyor belt of
symbol EP550 (A minimum strength of 550 N/mm for the belt along the warp
direction).
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Material
Nine samples of fabrics were prepared with various weave types, each having the
same sets of polyester warp and polyamide 6.6 weft (Figure 1). The weaves are
classified according to the bending rigidity of fabrics and length of thread overlap.
This was the criterion for the diversity of the weaves. Fabrics were made of differ-
ent weaves with PES 2200 4/60 warp, 120/dm sett and PA6.6 1400 5/90 weft of
33/dm sett. The weft sett was defined empirically as a maximum sett of weft inser-
tion for the plain weave on Dornier loom.
The fabrics were made with harness machine in ‘Metso Fabrics’ company in
Lodz on Dornier loom. The chosen and produced fabrics have the following
weaves: (A) plain weave 1/1, (B) twill weave 1/3Z, (C) twill cross-weave 1/7X,
(D) satin weave 1/7(3), (E) warp rep weave 1/1(0,1,0), (F) weft rep weave 2/2(2),
(G) weft rep weave 4/4(4), (H) warp rep weave 1/1(0,0,0,1,0,0,0) and (K) satin
weave 1/7(3) with higher density of weft.
The wefts were inserted by rapier and warps were let off from one weaver’s
beam. Width of weaving and the density of reed blade are 118 cm and 30/dm,
respectively, four warp threads exist between two reeds blades.
Figure 1. Weaves and surfaces of particular fabrics: (a) plain weave, (b) twill weave, (c) twill
cross-weave, (d) satin weave, (e) warp rep weave, (f) weft rep weave, (g) weft rep weave, (h) warp
rep weave and (k) satin weave [34].
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With the co-operation of Conveyor Belt Factory Wolbrom SA, the fabrics were
coated with latex by spray in order to increase the rubber adhesion to synthetic
fibres and then to vulcanize them. For all fabric samples, the preparation and
vulcanization conditions were the same. The tension during the impregnation
was controlled by two sets of gauge rollers, regulating the speed difference between
the drive stations. The tension was between 5400 and 7500 N and the speed of the
process was 9 m/min. The vulcanization was performed at a temperature of 160 C
under tension. The resulting belts were 7.3 0.5 mm thick [47].
Experiment
After making nine fabrics of different weaves, their geometrical structure param-
eters were determined with their mechanical properties such as strength, strain and
bending rigidity. There are several methods for testing bending rigidity. Some are
based on the deformation of the fabric under its own weight, while others are based
on testing force or energy required to bend the sample [48].
In order to study the relationship between the weave of the fabric and its bend-
ing rigidity, a method of fixed angle was applied using standard PN-73/P-04631
and Flexometer.
This study was used to classify the weaves of fabrics in terms of their effect on
the bending rigidity [49]. According to the standard, bending rigidity parameter (G)
is the resistance of a substance of specific width under deformation caused by the
external bending force. Bending rigidity is measured in micronewton metres
(mNm) and is equal to the bending moment needed to change the curvature by
of a 1 cm wide sample by 1 cm1 [5]. Bending rigidity was measured along the warp
and weft threads and on both sides of the sample. In order to determine the mean
value, 10 measurements were conducted for each option on each of the 9 unfinished
fabrics.
Tensile strength and strain of fabrics were measured according to ISO 13934-1
[50]. In conducting the experiment, strain was defined as the ratio of sample stretch
to its original length, expressed as a percentage. Breaking strength (N/mm) was
calculated by the ratio of the force recorded at the time of sample fracture under
extension to its width. Strength measurements were made for a raw fabric and a
fabric impregnated with latex. The measurements were repeated seven times for
each of the fabrics along the warp and weft directions. The initial strength and the
measurement speed were set at 10 N and 100 mm/min, respectively. Measurements
of the belt strength were performed in the longitudinal (warp) and transverse (weft)
directions using standard PN-EN ISO 283-1:2002 [4].
Most of conveyor belts take the trough shape during operation. It is an import-
ant parameter describing the belt. Shaping the belt in trough requires application of
certain forces in order to overcome its bending rigidity. This property of the belt,
according to ISO 703 or DIN 22107, is measured and described by the transverse
flexibility index h/B defined as the ratio of the free displacement of the belt sample
h (under its own weight) to the belt width B when it is flat (Figure 2) [6]. The value
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Figure 2. Device to measure the conveyor belt transverse flexibility according to ISO
703:2007 [6].
Figure 3. Values characterizing fabrics and conveyor belts: (a) thickness, (b) fabric areal density,
(c) sett of warp and (d) sett of weft.
of transverse flexibility enables verification of the correctness of the belt selection to

the installed set of rollers.
Analysis of measurements results

The results of measurements of the thickness, fabric areal density and threads sett
along the warp and weft directions of the raw fabric after latex impregnation and
vulcanization (conveyor belt) are presented in Figure 3 as bar charts. These are the
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Barburski 7
Figure 4. Total bending rigidity of raw fabrics depending on the weave.
results of structure analysis on the three main stages of conveyor belt production.
According to the results, a significant impact of the weave on the scope of struc-
tural changes was observed under high temperature.
Although setting parameters of the loom were the same for all fabrics of differ-
ent weaves, there was a variation in the structural parameters of raw fabrics such as
warp and weft sett and fabric thickness changed. These changes clearly depend on
the weave used.
Most significant increase was observed in the weft sett in fabric H (warp rep
weave). This weave easily enables grouping the weft threads. A similar result was
observed in the weft rep of fabric G in which the warp threads group. This leads to
an increase in areal density of the fabric.
In weaves of long weft interlaces, the warp threads group (weft rep, satin, twill
cross-weave). In weaves of short warp interlaces (plain A, weft rep. E and H),
thickness and areal density are low compared with the other fabrics (Figure 3).
The structure prevents the building-up of the threads, resulting in the lowest
warp sett per width unit. In weaves with short interlaces, there is a high thread
crimp.
In weaves of long weft coverings such as twill cross, satin and weft rep, the
thickness of the fabrics is the highest. Warp during weaving is highly tense, causing
an increase in the weft displacement. Moreover, the fabric structure approaches
phase 1 and the thickness becomes the maximum. On the other hand, loosely
placed warp on the surface of the fabric after removing it from the loom can
accumulate.
During impregnation of fabric with latex in higher temperatures, the fabric
shrank, resulting in an increase in the warp sett (Figure 3c) and the weft sett
(Figure 3d) as well as areal density of the fabrics (Figure 3b). However, the thick-
ness of the latex fabric decreased as a result of tension during the impregnation
process. Vulcanization caused unification of the conveyor belt thickness (Figure 3a)
and fabric areal density (Figure 3b).
The measurements of bending rigidity of nine raw fabrics showed that the
grouping of the threads was the reason for the differences in bending rigidity
(Figure 4).
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The analysis of conducted research showed that there were significant differences
between bending rigidity of fabric along the weft and the warp directions. The
bending rigidity along the warp is much greater than that along the weft due to
the larger sett of warp than that of weft.
Total bending rigidity of the fabric along warp and weft depends on the weave
(Figure 4) and on the length of coverings of the threads set. The number of thread
floats also influences bending rigidity. The more the intersections in a set, the
higher is the bending rigidity of the set. In plain and weft rep weaves of large
number of warp intersections (A, F, G), bending rigidity of fabric is the largest
in both directions. Short coverings and the consequent large number of intersec-
tions increase the rigidity of fabrics significantly. In weaves with long coverings of
warp and weft, bending rigidity of fabrics is lower (twill weave B, C, satin weave D)
(Figure 4).
The results of measurements of strength (Figure 5) and strain (Figure 6) with
respect to the weave of raw fabric show that strength is the lowest in the fabrics of
short floats where there are a large number of intersections. Long floats cause an
increase in the forces acting along the yarn of the set, and hence, an increase in the
strength of the fabric. In fabrics of short floats, breaking force is low as the forces
Figure 5. Tensile strength of fabrics: (a) along warp and (b) along weft.
Figure 6. Strain of fabrics: (a) along warp and (b) along weft.
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Barburski 9
acting on the yarn/fibre cause shearing, bending and compression. This results in
faster deformation and finally tearing of the fibres.
Strain along the weft in fabric G (weft rep) is the largest. The warp threads are
grouped and the weft on the long coverings has a large crimp (Figure 6b). In fabrics
with lots of warp floats, the strain along the warp is higher than that of the fabrics
with long floats.
Theoretically, large thread crimp with many intersections decreases the strength
of the fabric. The forces acting along the fabric cut the yarn and the fibres and do
not act along their axis. Long floats in the set make the thread straighter and
therefore more forces act along their axis, resulting in greater strength in that
direction. This is clearly demonstrated in the two reps, E and F.
In rep 8 thread weaves, grouping was observed in warp and weft threads in
fabrics G and H, respectively. As a result, the sett (thus the strength) increases
compared with other weaves.
After impregnation, the strength increases significantly in most fabrics.
However, in the subsequent process, i.e. vulcanization, the strength decreases
even below the strength of the raw fabric (Figure 5).
According to the results of strain measurement, the strain after impregnation
increases even by 100% compared with the raw fabric, which is an adverse effect
during operation of the conveyor belt. Although vulcanization reduces this nega-
tive effect, the strain is still higher compared with the raw fabric.
The tensile strengths of the raw fabric and the conveyor belt are almost the same
because the maximum strength of fabric depends on the carcass (i.e. on the woven
fabric). But the big difference in the strain, on comparing raw fabric with the
conveyor belt, can be explained by high flexibility of rubber.
The above results of research on mechanical properties at various stages of the
conveyor belts production processes show that further research should focus on
developing an optimal process of their production in order to exploit the best
qualities of the raw fabric. With an optimized impregnation and vulcanization
processes, good quality fabric can be produced.
Besides the above research, transverse flexibility (in weft direction) of all the nine
conveyor belts was measured and results are shown in Figure 7 as a bar plot.
Figure 7. Transverse flexibility of the conveyor belts.
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The analysis of measurements of the transverse flexibility of the conveyor

belts proves that the higher the rigidity of a conveyor belt, the lower is its
transverse flexibility. Although the belt contains significantly more rubber
than the fabric carcass, it does not cause a loss in the mechanical properties.
The differences for raw material (woven fabric) are more significant. On the
belt the differences are smaller but still visible.
The rigidity of a fabric influences the rigidity of the conveyor belt. The higher
the rigidity of the fabric, the higher the rigidity of the conveyor belt and, conse-
quently, the lower is its transverse flexibility.
Conclusions
This article shows the results of measurements of the internal structure of nine
fabrics on three stages of conveyor belt production, i.e. raw fabric, fabric impreg-
nated with latex and vulcanized. The mechanical properties of fabrics on each of
these stages were examined and the transverse flexibility of conveyor belts was also
analysed. The conclusions based on the survey are the following:
1. Although setting parameters of the loom were the same for all the fabrics, their
structural parameters and the warp/weft sett were changed due to the different
weaves.
2. Fabrics of short floats with lots of intersections have the lowest strength. Long
floats cause forces to act more along the yarn of the set, increasing the strength
of the fabric.
3. Rep warp and weft weaves cause grouping of the warp and weft threads, respect-
ively, causing an increase in the sett, compared with other weaves.
4. The larger the rigidity of a fabric, the larger the rigidity of a conveyor belt and,
consequently, the lower its transverse flexibility.
5. Impregnation with latex is beneficial for the fabric strength. However, the
strength drops even below the strength of the raw fabric after vulcanisation.
6. Impregnation and vulcanization increase the strain of the fabric compared with
that of the raw ones.
This study showed differences in the mechanical properties of products at

different stages of conveyor belt production and the dependence of the
properties on the intersection numbers of yarns in woven fabrics. These conclusions
set the base for further research on the optimization of the conveyor belts produc-
tion process so that the mechanical properties of the reinforcement fabric can be
improved.
Acknowledgements
Our thanks are due to Metso Fabrics Lodz for help in production of woven fabrics.
Conveyor Belts Factory Wolbrom SA is kindly acknowledged for delivering the materials.
We specially thank Marek Gardela for useful collaboration.
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Barburski 11
Funding
The work was funded by the National Science Centre (Poland), project no. 3215/B/T02/
2011/40.
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Analysis of The Mechanical Properties of Conveyor Belt On The Three Main Stages of Production

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Analysis of The Mechanical Properties of Conveyor Belt On The Three Main Stages of Production

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Analysis of the mechanical Reprints and permissions:

belts on the three main

Institute of Architecture of Textile, Technical University of Lodz, Poland

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be most important in the textile industry [27,28]. Nowadays, more research on

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of transverse ﬂexibility enables veriﬁcation of the correctness of the belt selection to

Analysis of measurements results

Figure 4. Total bending rigidity of raw fabrics depending on the weave.

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Figure 7. Transverse flexibility of the conveyor belts.

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The analysis of measurements of the transverse ﬂexibility of the conveyor

This study showed diﬀerences in the mechanical properties of products at

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[22] Szosland J. Structure of woven fabrics. Lodz, Poland: PAN, 2007.

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