INSTRUCTIONAL MATERIAL (MANUAL)

FOR

MEEN 30223: MACHINE ELEMENTS 2

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Gear systems

…WORRY NOT…PROF. ED
WIIL DEMYSTIFY YOU…
Compiled by: Ready? Let’s go…
Prof. Eduael G. Usal, ME, MBM, DEM (units)
Faculty, Mechanical Engineering
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Department, College of Engineering

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Polytechnic University of the Philippines

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
MANUAL OVERVIEW
This Instructional Material aims to prepare you to the rigors of Mechanical Engineering Practice,
in the of field Machine Design in general, and Machine Elements 2 in particular

Additional linkages that are essential components of machines—gears and gear trains, belts
and pulleys, and chains and sprockets—are the concerns of your subject, Machine Elements 2,

Proficiency, having ample knowledge and skills, in the edification of the following linkage
characteristics as; geometrical configurations, principles of operation and choice of their
respective proper applications, will be expected of you after the course.

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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 TABLE OF CONTENTS

Module No. Topics Page No.

0 Manual Overview 2-3
1 Machine Elements 2 Structure 4-5

2 Cams and Followers 6-18

3 Gears and Gear Trains 13-22

4 Belts and Pulleys 23-27

5 Chains and Sprockets 28-32

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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
MODULE 1: MACHINE ELEMENTS 2 STRUCTURE
GENERAL OBJECTIVES OF THE MANUAL
After extensive perusal of the manual, you will be equipped with following:

o capacity to explain the constitution, of the different types of Gears and Gear Trains;
o explain the geometric construction of the different types of cam systems;
o explain the geometric construction of the different types of belts and pulley systems;
o explain the geometric construction of the different types of chain and sprocket systems;
o proficient in using computer simulation programs in developing gear and gear train
systems;
o proficient in oral and written communication, a must in the preparation of quality
technical reports of generated ideas to effectively educate would be users;
o team spirit to collaborate with other students to create ideas that lead to devices of great
importance to mankind; and
o abreast of the emerging new technologies in mechanical design and industrial
processes.

Laboratory Student Deportment

o strictly observe 5S inside the laboratory room;

o use proper laboratory attire and/or personal protective equipment (PPE) whenever
necessary;
o do not touch anything with which you are not completely familiar;
o carelessness may break valuable equipment and may also cause serious injury to you
and others;
o follow instructions precisely as instructed by your professor;
o do not crowd around the equipment or do horseplay inside the laboratory;

INTRODUCTION

As stated in Machine Elements 1, the main object of designing a mechanism is to develop a

system that transforms motion in a specific way, thus providing mechanical advantage or
special effect output/s that can benefits humankind.

In dealing with the input and output motion of a mechanism, additional system of linkages are
introduced, such as Cams, Gear and Gear Trains, Belts and Pulleys and Chains and
Sprockets, to complete the necessary systems that constitute machines or devices which
provides technical solutions to technical problems of mankind.
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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Gears systems or cogs are commonly used in machines that
transmits heavy loads due to its unique feature of heaving
engaging teeth for or energy transmission, it can also be used in
speed variations. Gears and their mechanical characteristics are
widely employed throughout industry to transmit motion and
power in a variety of mechanical devices, such as clocks,
instrumentation, and equipment, and to reduce or increase
Gear Types
speed and torque in a variety of motorized devices, including
automobiles, motorcycles, and machines. Other design characteristics, including construction
material, gear shape, tooth construction and design, and gear pair configuration, help to classify
and categorize the various types of gears available

Cam systems are used in many automated

machines due to its unique feature of producing
multitude of motion outputs,

Chain and sprocket systems have similar features of

carrying relatively heavy loads compared to gears; the
advantage over gears is the transmission of load at a
longer, center-to-center distance of shafts, where the
sprockets are mounted.

Belts and pulley systems on the other hand work by

transmitting motion via friction between the belt and
pulley; it can transmit lighter loads as compared to gears
and chain and sprocket systems. Like sprocket systems,
the advantage over gear systems is it can loads on a
longer distance between shafts that carry the pulleys of
the system. Belt and Pulleys
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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
MODULE 2: CAM AND FOLLOWER SYSTEMS
Overview

This Module introduces the fundamentals

of cam design.

A cam is a mechanism element that drives

a mating component known as a follower.
It accepts an input motion similar to a
crank and imparts a resultant motion to a
follower. The figure illustrates one of the
most common cam applications—the valve
train of an automotive engine.

A cam mechanism is composed of a cam

and follower, a cam is irregularly shaped
element that imparts almost any type of
motion to a second element called the
follower.

The unique feature of a cam is that it can

impart a very distinct motion to its
follower. Cams can be used to obtain Valve train of an automotive engine
unusual or irregular motion that would
be difficult or impossible, to obtain from other linkages. Because the motion of cams can
be prescribed, they are well suited for applications where distinct displacements and timing are
paramount.

Cams are often used in factory automation equipment because they can sequence
displacements in a cost-efficient manner. Cams are precision machine components that
generally cost more than conventional linkages.

Module 2 Objectives

After successful completion of the module you should poses the following attributes:

o capacity to explain the constitution, of the different cam and follower systems;
o proficient in using computer simulation programs in developing the various cam and
follower systems;
o able draw the displacement diagram of cam systems from prescribed follower motion;
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criteria to use of use inversion of linkages to modify motion of the parts especially the
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output motion of a system.

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 o graphically and analytically construct disk cam profiles with several types of followers;
o graphically and analytically construct cylindrical cam profiles;

Types of cams

Three general types of cams

1. Plate or disk cams are the simplest and most common type
of cam. This type of cam is formed on a disk or plate. The
radial distance from the center of the disk is varied
throughout the circumference of the cam. Allowing a follower
to ride on this outer edge gives the follower a radial motion.
The follower moves on a plane perpendicular to the axis of
rotation.
Plate or Disk Cam

2. A cylindrical or drum cam is illustrated in the figure. This

type of cam is formed on a cylinder. A groove is cut into
the cylinder, with a varying location along the axis of
rotation. The follower moves on a plane parallel to the axis
of rotation.

Cylindrical Cam

3. A linear or Translating cam is illustrated in figure. It is

formed on a translating block. A groove is cut into the
block with a distance that varies from the plane of
translation. The follower that rides in the groove gives
the follower motion perpendicular to the plane of
translation.
Linear or Translating Cam

Special Types of cams

1. Geneva Cam
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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 The Geneva drive or Maltese cross is a mechanism
that translates a continuous rotation movement into
intermittent rotary motion.
The rotating drive wheel is usually equipped with
a pin that reaches into a slot located in the Geneva
wheel (driven wheel) that advances it by one-step at a
time. The drive wheel also has an elevated circular
blocking disc that "locks" the rotating driven wheel in
position between steps.
Geneva Cam System
2. A positive drive cam is one that need no
spring or loader to keep the follower
constantly in contact with the cam, as
shown in the figure.
The rotary motion of the cam actuates the
follower, on a plane perpendicular to the
axis of rotation of the cam.

Positive Drive Cam

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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
DISK CAM WITH IN-LINE FOLLOWER NOMENCLATURE

Nomenclature of Disk Cam with

Radial Roller Follower

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Nomenclature of Disk Cam with

Offset Roller Follower

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Cam Nomenclature Terms

o Cam profile: Cam profile is outer surface of the disc cam.

o Base circle: Base circle is the smallest circle, drawn tangential to the cam profile.
o Trace point: Trace point is a point on the follower, trace point motion describes the
movement of the follower.
o Pitch curve: Pitch curve is the path generated by the trace point as the follower is rotated
about a stationery cam.
o Prime circle: Prime circle is the smallest circle that can be drawn so as to be tangential
to the pitch curve, with its center at the cam center.
o Pressure angle: The pressure angle is the angle between the direction of the follower
movement and the normal to the pitch curve.
o Pitch point: Pitch point corresponds to the point of maximum pressure angle.
o Pitch circle: A circle drawn from the cam center and passes through the pitch point is
called Pitch circle.
o Stroke: The greatest distance or angle through which the follower moves or rotates.

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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Topic exercises

o What is displacement diagram?

o What are the common follower motions?
o What is side thrust?
o What is the other term for pitch profile?
o Why is it that the in disk cam with point follower, the pitch profile is the same as the cam
profile.
o What is cusp?
o What is the force that tend to bind the follower and the guide?

Topic Questions

o Explain the constitution, the different types of cam and follower systems.
o What is disk cam with in-line follower?
o Discuss the effect of the pressure angle in cam design.
o Give the reasons why disk cam followers are offset.
o Discuss the effect of offsetting a follower on a disk cam and follower system.
o Explain the advantages and disadvantages of having different follower types.
o What is a positive cam drive.
o Write a technical report about emerging new technologies in cam manufacturing.

References

o https://static.learnmechanical.com/wp-content/uploads/2020/03/Cam-Follower.gif
o https://static.learnmechanical.com/wp-content/uploads/2020/03/plate-cam.png
o Kinematics of Machines Prof. A.K. Mallik Department of Mechanical Engineering
Indian Institute of Technology, Kanpur , Read the document
o Theory of mechanisms and machines - google books
o Design of Machine Elements by VB Bhandari
o Mechanical Engineering Design by J.E. Shigley
o Analysis and Design of Machine Elements by V.K.
o J. J. Uicker, G. R. Pennock, and J. E. Shigley, Theory of Machines and Mechanisms,
Fifth Ed., Oxford University Press, 2016
o L. W. Tsai, Mechanism Design: Enumeration of Kinematic Structures According to
Function, CRC Press, 2000
o Bernard J. Hamrock, Steven R. Schmid, Bo O. Jacobson McGraw-Hill Higher Education,
2007 - Technology & Eng Fundamentals of Machine Elements
engineering.uco.edu › Courses › ENGR3153 › Lectures › Chapter1
11

Videos
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o https://youtu.be/HsXWewecMLE

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
o https://youtu.be/ZCFKUqCFd_A
o https://youtu.be/MJ9xyIU9QIU
o https://youtu.be/-ld6DWnSpiQ

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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Module 3 – Gears and Gear Trains

OVERVIEW

Gears are common component used in many machines. In general, the function of a gear is to
transmit motion from one rotating shaft to another. In addition to transmitting the motion, gears
are often used to increase or reduce speed, or change the direction of motion from one
shaft to the other.

The output of mechanical power sources, such as electric motors and engines, rotates at much
greater speeds than the application requires.

A typical electric motor rotates at greater speeds than are needed for most driven elements
hence there is need for speed reduction.

A common gear speed reducing system is the use of worm and worm gear systems, the system
is also act as locking system, the worm is driver of the system and not vice versa.

The power could be transmitted between parallel shafts, intersecting shafts and neither parallel
nor intersecting shafts.

Module 3 Objectives

After successful completion of the module you should poses the following attributes:

o explain the constitution, of the different types of gear systems;

o proficient in using computer simulation programs in developing the geometrical
representations of the various gears and gear trains;
o apply knowledge in choosing the appropriate use gear standard gear geometric feature;
o calculate center distance, contact ratio, interference limitations, and backlash and other
gear and gear train’s variables;
o calculate and use the velocity ratio to determine the kinematic properties of mating
gears;
o determine the kinematic properties of gear and planetary gear trains.

GEAR TERMINOLOGIES

o addendum: The height of the tooth above the pitch circle.

o Backlash: The clearance between two mating teeth of separate gears.

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o Base circle: A theoretical circle used to generate the involute curve when creating tooth
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profiles.

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
o Center distance: The distance between the center shafts of two gears.

o Chordal addendum: The distance between a chord, passing through the points where
the pitch circle crosses the tooth profile and the tooth top.

o Chordal thickness: Tooth thickness measured along a chord passing through the
points where the pitch circle crosses the tooth profile.

o Circular pitch: Measurement of the pitch circle arc length from one point on a tooth to
the same point on the adjacent tooth.

o Circular thickness: The thickness of the tooth at the pitch circle.

o Clearance: The space between one gears minor diameter and the mating gears major
diameter.

o Dedendum: Depth of the tooth between the pitch circle and the minor diameter.

o Diametral pitch: The number of teeth per inch of pitch diameter.

o Fillet: The small radius that connects the tooth profile to the root circle.

o Module: Teeth per millimeter of pitch diameter.

o Outside diameter: The major diameter of the gear.

o Pinion: The smaller-sized gear in any meshed pair.

o Pitch circle: The circle, the radius of which is equal to the distance from the center of
the gear to the pitch point. This is where the gear’s speed is measured.

o Pitch diameter: Diameter of the pitch circle.

o Pitch point: The point of tangency of the pitch circles of a pair of mating gears.

o Pressure angle: The angle between the line of action and a line perpendicular to the
line of centers.

o Root (or dedendum) circle: The minor diameter of the tooth.

o Velocity ratio: Ratio of input gear revolutions to output gear revolutions within a
specified amount of time.

o Whole depth: The height of the tooth from major diameter to minor diameter of a gear.
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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 o Working Depth: The depth to which a tooth extends into the space between teeth on
the mating gear.

GEAR CLASSIFICATION

Gears are be classified according to the relative position of the axes of revolution. The axes
may be;

1. parallel,
2. intersecting,
3. neither parallel nor intersecting

1. Gears for connecting parallel shafts

a. Spur gears are simplest and, hence,

the most common type of gear. The
teeth of a spur gear are parallel to the
axis of rotation. They are used to
transmit motion between parallel
shafts, which encompasses the majority
of applications.
Externa Spur Gear Internal Spur Gear
b. Parallel helical gears are similar to,
spur gears and can be used in the same applications. The
difference is that the teeth of a helical gear are inclined to the
axis of rotation. The angle of inclination is termed the helix angle.
This angle provides a more gradual engagement of the teeth
during meshing and produces less impact and noise. Because of
this smoother action, helical gears are preferred in high-speed
applications. However, the helix angle produces thrust forces and Parallel Helical
bending couples, which are not generated in spur gears. Gears

Herringbone gears (or double-helical gears are used in the same

applications as spur gears and helical gears. The herringbone gear
appears as two opposite-hand helical gears butted against each
other. This complex configuration counterbalances the thrust force of
a helical gear.

Herringbone Gear
c. Rack and Pinion-A rack is a special case of spur gear
where the teeth of the rack are laid flat, not formed around
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a circle as spur gears. The rack can be perceived as a

spur gear with an infinitely large diameter. When the rack
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mates with a spur gear, translating motion is produced.

Rack and Pinion

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
2. Gears for connecting intersecting shafts

a. Straight bevel gears have teeth formed on a conical surface

and are used to transmit motion between nonparallel shafts.
Although most of their applications involve connecting
perpendicular shafts, bevel gears can also be used in
applications that require shaft angles that are both larger and
smaller than 90°. As bevel gears mesh, their cones have a
common apex. However, the actual cone angle of each gear
depends on the gear ratio of the mating gears. They are Straight Bevel Gears
designed as a set, and replacing one gear to alter the gear ratio
is not possible

b. A spiral bevel gear is a bevel gear with helical teeth. The main
application of this is in a vehicle differential, where the direction of
drive from the drive shaft must be turned 90 degrees to drive the
wheels. The helical design produces less vibration and noise than
conventional straight-cut or spur-cut gear with straight teeth.

A spiral bevel gear set should always be replaced in pairs i.e. both
the left hand and right hand gears should be replaced together since Spiral Bevel Gear
the gears are manufactured and lapped in pairs.

3. Neither parallel nor intersecting shafts

a. Crossed-helical gears are used to transmit power and motion

between non-intersecting and non-parallel axes. They can stand a
small change in the center distance and the shaft angle without any
impairment in the accuracy of transmitting motion, the arrangement
saves space and results in more compact and more balanced
designs.
Where axial space is limited compared to radial space, angular
drives are preferred despite their higher initial cost. Crossed Helical Gear

b. Hypoid gears are cone shaped gears similar to spiral bevel

gears except they transmit motion between non-
intersecting shafts. The small gear shaft (hypoid pinion
side) is offset from the larger gear shaft (hypoid gear
side). With proper offset amount, the pinion shaft and large
gear shaft can pass each other without interference,
enabling the shafts to be supported securely on both ends.
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Generally, compared with bevel gears, hypoid gears can Crossed Helical Gear
obtain higher speed reduction. Their large contact ratio allows
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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 c. A worm drive is a gear arrangement in which
a worm (which is a gear in the form of a screw) meshes
with a worm gear (which is similar in appearance to a spur
gear). The two elements are also called the worm
screw and worm wheel. The terminology is often confused
by imprecise use of the term worm gear to refer to the
worm, the worm gear, or the worm drive as a unit.

A worm drive is used to reduce rotational speed or transmit

higher torque. One advantage is that motion can
transferred with 90-degree shaft angle.
Worm Drive

NOMENCLATURE OF SPUR GEAR

GEAR TRAINS
A gear train is a mechanical system formed by mounting gears on a frame so the teeth of
the gears engage.
Gear teeth are designed to ensure the pitch circles of engaging gears roll on each other
without slipping, providing a smooth transmission of rotation from one gear to the next. [1]
Features of gears and gear trains include;
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o the ratio of the pitch circles of mating gears defines the speed ratio and the mechanical
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advantage of the gear set,

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 o a planetary gear train provides high gear reduction in a compact package,
o it is possible to design gear teeth for gears that are non-circular, yet still transmit torque
smoothly, and
o the speed ratios of chain and belt drives are computed in the same way as gear ratios.

Types of Gear Trains

Gear trains are composed of two or more meshing gears with the purpose of transmitting power
from one shaft to another. The nature of the train used, depends upon the velocity ratio required
and the relative position of the axes of shafts. A gear train may consist of spur, bevel or spiral
gears.

The Following are the different types of gear trains, with respect to the arrangement of
wheels:
o Simple gear train,
o Compound gear train,
o Reverted gear train, and
o Epicyclic gear train.

1. Simple Gear Train

When there is
only one gear on
each shaft, as
shown, it is
known as simple
gear train. The
gears are
represented by
their pitch
circles.
When the distance between the two shafts is small, the two gears 1 and 2 are made to
mesh with each other to transmit motion from one shaft to the other, as shown in Fig (a).
Since the gear 1 drives the gear 2, therefore gear 1 is called the driver and the gear 2 is
called the driven or follower.

2. Compound Gear Trains

When there are more than one gear on a shaft, as shown in Fig. it is called a compound
train of gear. The idle gears, in a simple train of gears do not effect the speed ratio of the
system.
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The idler gears are useful in bridging over the space between the driver and the driven,
whenever the distance between the driver and the driven or follower has to be bridged over
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by intermediate gears and at the same time a great ( or much less ) speed ratio is require.

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 The advantage of intermediate gears is intensified by providing compound gears on
intermediate shafts. In this case, each intermediate shaft has two gears rigidly fixed to it so
that they may have the same speed.

3. A simple reverted gear train consists of two shafts each of

which carry multiple compound spur gears. A compound gear
consists of two gears of different pitch diameters attached to
one another. This reverted gear train consists of 4 double spur
gears each with a gear ratio of 3:1. This assembly has two
configurations. The 1st configuration allows the user to convert
a a slow shaft input speed to a fast output speed. The 2nd
configuration allows the user to convert a fast shaft input speed
to a slow output speed. The user can change from config. 1 to
config. 2 simply by dis-engaging the crank component from one shaft and re-engaging it to
the opposite shaft. This device teachers the user the fundamental engineering principles of
shaft speed ratios, gear ratios, and torque.
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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
4. In epicyclic gear trains, the axes of the shafts
on which the gears are mounted may move
An epicyclic gear train (also known
as planetary gear) consists of
two gears mounted so that the center of one
gear rotates around the center of the other. A
carrier connects the centers of the two gears and
rotates to carry one gear, called the planet
gear or planet pinion, around the other, called
the sun gear or sun wheel. The planet and sun
gears mesh so that their pitch circles roll without
slip. A point on the pitch circle of the planet gear
traces an epicycloid curve. In this simplified
case, the sun gear is fixed and the planetary
gear(s) roll around the sun gear.
An epicyclic gear train can be assembled so the
planet gear rolls on the inside of the pitch circle
of a fixed, outer gear ring, or ring gear,
sometimes called an annular gear. In this case,
the curve traced by a point on the pitch circle of
the planet is a hypocycloid.
The combination of epicycle gear trains with a planet engaging both a sun gear and a ring gear
is called a planetary gear train. In this case, the ring gear is usually fixed and the sun gear is
driven.

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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Topic exercises

o What is train value?

o Explain the arrangement and mounting on shafts of gears on a simple gear train.
o What are the reasons in using simple gear trains?
o Explain the arrangement and mounting on shafts of gears on compound gear train.
o Reasons why compound gear trains are used?
o Uses of reverted gear trains.
o Explain the arrangement of

Topic Questions

o Explain the constitution, the different types of gears and gear trains.
o Explain the advantages and disadvantages of having different tooth geometric profiles of
the following:
a. spur gear;
b. helical gear;
c. crossed helical gears;
d. hypoid gear;
e. straight bevel gear;
f. helical bevel gear;
g. worm and worm gears;

o Write a technical report about emerging new technologies in gear manufacturing.

References

o https://cdn.thomasnet.com/insights-images/embedded-images/99f2f999-0133-4767-
9694-9ce8a8af4147/74e5efdf-1f3b-4c67-96ab-311201e1acc2/FullHD/internal-external-
gear-pair.jpg
o https://cdn.thomasnet.com/insights-images/embedded-images/99f2f999-0133-4767-
9694-9ce8a8af4147/fbfd5e4e-4a3f-48b2-af80-6a9389331792/FullHD/different-types-of-
gears.jpg
o Design of Machine Elements by VB Bhandari
o Mechanical Engineering Design by J.E. Shigley
o Analysis and Design of Machine Elements by V.K.
o J. J. Uicker, G. R. Pennock, and J. E. Shigley, Theory of Machines and Mechanisms,
Fifth Ed., Oxford University Press, 2016
o L. W. Tsai, Mechanism Design: Enumeration of Kinematic Structures According to
Function, CRC Press, 2000
o
21

Bernard J. Hamrock, Steven R. Schmid, Bo O. Jacobson McGraw-Hill Higher Education,

2007 - Technology & Eng Fundamentals of Machine Elements
Page

engineering.uco.edu › Courses › ENGR3153 › Lectures › Chapter1

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Videos
o https://youtu.be/EGvFMOlnch4
o https://youtu.be/MJ9xyIU9QIU
o https://youtu.be/M9CnxXCsGTw
o https://youtu.be/DjMaDN3EtWc
o https://youtu.be/r_sYNL4vKqc
o https://youtu.be/ARd-Om2VyiE
o https://youtu.be/Al5RrMZOUlE

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Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
MODULE 4: BELTS AND PULLEYS
OVERVIEW

BELT DRIVES
Belt drives are simple, inexpensive, and do not require axially aligned shafts. They help protect
machinery from overload and jam, and damp and isolate noise and vibration. Load fluctuations are
shock-absorbed (cushioned). They need no lubrication and minimal maintenance. They have high
efficiency (90–98%, usually 95%), high tolerance for misalignment, and are of relatively low cost if
the shafts are far apart. Clutch action is activated by releasing belt tension. Different speeds can be
obtained by stepped or tapered pulleys.
The angular-velocity ratio may not be constant or equal to that of the pulley diameters, due to slip
and stretch. However, this problem has been largely solved by the use of toothed belts. Working
temperatures range from - 35°C to 85°C. Adjustment of center distance or addition of an idler pulley
is crucial to compensate for wear and stretch.
A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most often
parallel. Belts may be used as a source of motion, to transmit power efficiently or to track relative
movement. Belts are looped over pulleys and may have a twist between the pulleys, and the shafts
need not be parallel.
In a two pulley system, the belt can either drive the pulleys normally in one direction (the same if on
parallel shafts), or the belt may be crossed, so that the direction of the driven shaft is reversed (the
opposite direction to the driver if on parallel shafts). As a source of motion, a conveyor belt is one
application where the belt is adapted to carry a load continuously between two points. The belt drive
can also be used to change the speed of rotation, either up or down, by using different sized pulleys.
Belts are the cheapest utility for power transmission between shafts that may not be axially aligned.
Power transmission is achieved by purposely designed belts and pulleys. The variety of power
transmission needs that can be met by a belt-drive transmission system are numerous, and this has
led to many variations on the theme. Belt drives run smoothly and with little noise, and provide shock
absorption for motors, loads, and bearings when the force and power needed changes. A drawback
to belt drives is that they transmit less power than gears or chain drives. However, improvements in
belt engineering allow use of belts in systems that only formerly allowed chain drives or gears.

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Flat Belt with Crown Pulley V-Belt with Sheave as Pulley

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Objectives of the Module
After successfully comprehending module 2, you should have gained the ability to:

o proficient in using computer simulation programs in designing belt and pulley systems;
o identify the different types belt and pulley systems that are appropriate for the respective
applications;
o proficient in
o expert in the choosing the right type of belt and pulley system for different loads;
o explore other possibilities in the use of belt drive systems.

BELTS

The function of a belt drive is to transmit rotational motion and torque from one shaft to another,
smoothly, quietly, and inexpensively.

Belt drives provide the best overall combination of design flexibility, low cost, low maintenance,
ease of assembly, and space savings.

Compared to other forms of power transmission, belt drives have these advantages:

o less expensive than gear or chain drives;

o have flexible shaft center distances, where gear drives are restricted;
o operate smoothly and with less noise at high speeds;
o can be designed to slip when an overload occurs in the machine;
o require no lubrication, as do chains and gears;
o can be used in more than one plane. They are easy to assemble and install and have
flexible tolerances;
o require little maintenance; and
o do well in absorbing shock loading.

Belts are typically made of continuous construction of materials, such as rubberized fabric,
rubberized cord, reinforced plastic, leather, and fabric (i.e., cotton or synthetic fabric).

TYPES OF BELTS

1. A flat belt is the simplest type but is typically limited to low-torque applications because the
driving force is restricted to pure friction between the belt and the pulley.
2. V-belt is the most widely used type of belt, particularly in automotive and industrial
machines. The V shape causes the belt to wedge tightly into the pulley, increasing friction
and allowing higher operating torque
3. Multi-V-belt design is identical to several V-belts placed side by side but is integrally
connected. It is used to increase the amount of power transferred.
4. Cog belt is a belt design similar to a V-belt but has grooves formed on the inner surface. This
24

feature increases belt flexibility, allowing the belt to turn smaller radii. Thus, it can be used on
Page

smaller pulleys, reducing the size of the drive.

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 5. Timing belt has gear-like teeth that engage with mating teeth on the pulleys. This arrangement
combines the flexibility of a belt with the positive grip of a gear drive. This belt is widely used in
applications where relative positioning of the respective shafts is desired.

Toothed Belt and Pulley Geometry

Pulleys, more appropriately referred to as sheaves, are the wheels that are connected to the shafts and
carry the belt. The pulleys have a groove around the outside, with a shape to match that of the belt. A V-
belt sheave is shown Industrial sheaves are machined from steel or

25

Cross Section of a V-Belt

Page

Cross Section Sheave

Flat Belt and Pulley

Geometry

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Topic Exercises

1. Show the geometric representation of the following systems of or

system parts and give the reason/s for their respective configurations:

Open belt drive system

Crossed belt drive System
Quarter turn belt drive system
Constant velocity transmission system

2. Compare systems/ system parts in question no. 1 as to their

respective application/s, advantage/s and disadvantage/s of one
over the others.

Topic Questions

o Explain how power is transmitted from one shaft to another in a belt and pulley system.
o Can the sense of rotation on chain drive be opposite? Explain your answer?
o Explain the respective industrial uses of belt drives systems, and give at least five (5)
applications of each system.
o Explain how Constant Variable Transmission (CVT) system works.

Links for Suggested Reading Video Viewing

o https://youtu.be/4PsJkXO70Xc?t=65
o https://youtu.be/zlVBJKcQsMg
o https://youtu.be/zcxCOqKP7Fc
o https://youtu.be/fJISKOtCPtk
o

References

o https://www.powertransmission.com/articles/0619/Advanced_Belt_Drive_Systems/
o https://www.powertransmission.com/issues/0617/vbeltsfig3.jpg
o Design of Machine Elements by VB Bhandari
o www.brainkart.com › article › Selection-of-V-belts-and-p..
o Mechanical Engineering Design by J.E. Shigley
o Analysis and Design of Machine Elements by V.K.
o J. J. Uicker, G. R. Pennock, and J. E. Shigley, Theory of Machines and Mechanisms,
Fifth Ed., Oxford University Press, 2016
o L. W. Tsai, Mechanism Design: Enumeration of Kinematic Structures According to
Function, CRC Press, 2000
26

o Bernard J. Hamrock, Steven R. Schmid, Bo O. Jacobson McGraw-Hill Higher Education,

Page

2007

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Videos
o https://youtu.be/ZSTZdTAB_As
o https://youtu.be/hkIyGrLDy3A
o https://youtu.be/CKyG-68BNJQ
o https://youtu.be/PEq5_b4LWNY?t=4
o https://youtu.be/PEq5_b4LWNY
o https://youtu.be/HSxg97m8lLA

27
Page

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
MODULE 5: CHAINS AND SPROCKETS
Overview
Chain drive is a way of transmitting mechanical power from one place to another. It is often used to
convey power to the wheels of a vehicle, particularly bicycles and motorcycles. It is also used in a
wide variety of machines besides vehicles.
Most often, the power is conveyed by a roller chain, known as the drive chain or transmission
chain, passing over a sprocket gear, with the teeth of the gear meshing with the holes in the links of
the chain. The gear is turned, and this pulls the chain putting mechanical force into the system.
Another type of drive chain is the Morse chain, invented by the Morse Chain Company of Ithaca,
New York, United States. This has inverted teeth.[2]
Sometimes the power is output by simply rotating the chain, which can be used to lift or drag objects.
In other situations, a second gear is placed and the power is recovered by attaching shafts or hubs
to this gear. Though drive chains are often simple oval loops, they can also go around corners by
placing more than two gears along the chain; gears that do not put power into the system or transmit
it out are generally known as idler-wheels. By varying the diameter of the input and output gears with
respect to each other, the gear ratio can be altered. For example, when the bicycle pedals' gear
rotate once, it causes the gear that drives the wheels to rotate more than one revolution.

Chain Drive Systems

Chain drives, gear drives and belt drive systems are all effective power transmission choices.
Each offers advantages and disadvantages with respect to the other.

The advantages of chain drive systems are as follows:

o Shaft center distances are relatively unrestricted. Whereas gear drive center-to-center
distances are restricted to specific dimensions for a given set of gears, the center distances
between two chained sprockets can vary anywhere from 50% to 300% or more of their
pitch diameters.
o Chain Drive are relatively easy to install. Assembly tolerances are not as restrictive as
those for gear drives. Chain drives are a better choice for less experienced builders
working with a minimum of machine tools.
o Chain drives can be readily redesigned and reconfigured in comparison to gear drive
systems.
o Chains perform better than gears under shock loading conditions
o Chain drives spread operating loads over many teeth whereas the operating loads acting
on gear drives are concentrated on one or two teeth.
o Chain drives do not require tension on the slack side (Belt drives do) thus bearing loading
is reduced
o Chain drives require less space for a given loading and speed condition than pulleys and
belts.
o Chain drives systems are (usually) less costly to build and maintain than an equivalent gear
28

drive
Page

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
TYPES OF CHAINS

o Hoisting Chains
-Oval Link Chains
-Stud-Link Chains
o Conveyor Chains
o Power transmission Chain
-Block Chain
-Roller Chain
-Silent Chain or Inverted Tooth Chain

Hoisting Chains

A hoist is a mechanical device which is used to lift loads from one place to another place in a
workstation, these chains are quite strong to handle heavyweight

- Oval-Link Chains
It is one of the common types of chain used in
hoist, it consists of many oval links attached to
each other. These types of chains are also called
Coil Chains. Links of this type of chain is oval.
However, there are square link types of chains
that are also available., but the kinking is
occurred easily due to high loading.

- Stud-Link Chains The stud-link chains used to

minimize the deformation and link or tangle easily. In
this type of chain, a round bar or stud is used to fit
inside the oval-link chains to provide more strength
to the chain. It is used in Ship to up and down the
anchor of the ships, and some crane hoist where we
need to lift a very high amount of load.

Conveyor Chains

It is a mechanical device system that is used to move the materials from one place to another.
This type of chain is well shaped that it can easily run over the sprocket. Generally, this type of
chain is made of malleable cast iron and used in Low-Speed Machinery approx 2 m/s.
29
Page

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Conveyor Chains types

o Detachable or Hook Joint types Conveyor chain.

o Closed-end pintle type conveyor chain.

- Detachable or Hook Joint types Conveyor chain: Detachable or Hook Joint types
Conveyor chains are used in a conveyor where the length between power transmission
is short.
- Closed-end pintle type conveyor chain: This type of chain is consists of a barrel and link
and made in a single casting, then the chain is heat-treated to provide higher strength.

Power Transmission Chains

This type of chain is made of steel and sometimes it heats treated to minimize wear and tear.
This type of chain has greater accuracy and can easily run over the sprocket.

Power Transmission Chains types

o Block Chain
o Roller Chain
o Silent Chain or Inverted tooth Chain

- Block Chain This type of chain is used in low-speed areas and will produce noise due to
the sudden contact between sprocket and chain; however, this is used in some low-
speed conveyor machines.
- Roller Chain: This type of chain is constructed by:

 A bush
 Inner Link
 A pin
 Outer Plate
 Inner plate
 Rollers

In this type of chain, a bush along with

the roller is fitted inside both the plates
then a pin is passed through both the
end of the roller to fasten it.

The rollers are free to rotate inside the

bush so that when it contacts between
the sprocket the wear tear would be
minimized. Generally, it is made of
steel. It is soundless and wears less as
compared to the block chains and used in
any circumstances and this type chains
30

gave much service area if proper

lubrication is maintained.
Page

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
 - Silent Chain or Inverted Tooth Chain: The operation of this type of chain is quite silent and
can be used in high-speed power transmissions areas. This type of chain does not have
any roller, it is accurately shaped that it can easily sit over the sprocket.

ADVANTAGES OF CHAIN DRIVE

o Low maintenance.
o Greater efficiency up to 97 percent.
o Slipping is negligible
o Chain drive can operate in wet conditions too.
o It can withstand abrasive conditions, easy to install.
o Initial tension is not required.
o Even in fire hazards it does not faces any bad problem.
o Multiple shafts can be driven from a single chain drive.
o Chain drive requires less space and it is more compact than belt drive.
o It produces less stress on the shaft because the sprockets are lighter than pulleys.
o Transmit higher power compared to belt drive.
o Chain drive, the speed ratio is good as compared to belt drive.
o It can be used in reversing drives.
o It can be operated at a high temperature Like a belt which cants not operate at high
temperatures.
o Chain drive can be used up to 3 m in distances between small and large centers.

DISADVANTAGES OF CHAIN DRIVE

o The major disadvantages are here it requires more and frequent lubrication otherwise
rust problem comes.
o It cannot be used where there is a requirement of slips.
o We can’t keep chain drive-in open. It needs housing or covering.
o It cannot be used for précised motion requirements.
o It is noisy and therefore there is a problem of vibration too.
o The installation or initial cost is more.
o The velocity fluctuation is more.

APPLICATIONS OF CHAIN DRIVE

o Chain drive used for transmission of power.

o It is used for lifting loads and also used to carry material.
o This is also used in woodworking machinery.

INDUSTRIAL USED OF CHAIN DRIVE

o Transportation Industry.
o Agriculture Machinery.
o Material Handling Equipment.
31

o Building construction.
Page

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila
Topic Exercises

3. Show the geometric representation of the following systems of or

system parts and give the reason/s for their respective configurations:

Hoisting Chains
-Oval Link Chains
-Stud-Link Chains
Conveyor Chains
Power transmission Chain
-Block Chain
-Roller Chain
-Silent Chain or Inverted Tooth Chain

4. Compare systems/ system parts in question no. 1 as to their

respective application/s, advantage/s and disadvantage/s of one
over the others.

Topic Questions

o Explain how power is transmitted from one shaft to another in a chain drive sytem.
o Can the sense of rotation on chain drive be opposite? Explain your answer?
o Explain the respective industrial uses of chain drives, and give at least five (5)
applications of each system.

Links for Suggested Reading Video Viewing

o https://youtu.be/4PsJkXO70Xc?t=65
o https://youtu.be/zlVBJKcQsMg
o https://youtu.be/zcxCOqKP7Fc
o https://youtu.be/fJISKOtCPtk

References

o Design of Machine Elements by VB Bhandari

o Mechanical Engineering Design by J.E. Shigley
o Analysis and Design of Machine Elements by V.K.
o J. J. Uicker, G. R. Pennock, and J. E. Shigley, Theory of Machines and Mechanisms,
Fifth Ed., Oxford University Press, 2016
o L. W. Tsai, Mechanism Design: Enumeration of Kinematic Structures According to
Function, CRC Press, 2000
o Bernard J. Hamrock, Steven R. Schmid, Bo O. Jacobson McGraw-Hill Higher Education,
2007
32
Page

Prepared by Prof. Eduael G. Usal, Faculty, M. E. Dept. College of Eng’g, P. U. P., Manila