21.

3 FAILURE MODES OF BELT DRIVES

The most common failure mode of belts is a broken belt caused by improper
tensioning. There is a tension at which the belt experiences optimum service life.
Above this tension belt fatigue translates into a decrease in belt life; below this tension
belt slip results in reduced belt life. Table 21-1 presents a summary of failure modes for
belt drives.

Table 21-1. Typical Failure Modes of Belt Drives

FAILURE MODE FAILURE CAUSE FAILURE EFFECT

Improper operating
Installation error Belt failure
tension
Pulley/sheave Sidewall cracking and belt
Installation error
misalignment failure
Belt slippage and rapid wear
Worn pulley/sheave Incorrect tension
rate
Belt slippage, operating Belt hardening and reduced
Temperature extreme
environment life
Chemical Belt wear and eventual
Operating environment
contamination failure
Foreign objects in the Belt wear and eventual
Operating environment
belt drive assembly failure
Excessive heat and wear
Belt slip Insufficient tension generated with reduced belt
life
Belt fatigue Excessive tension Broken belt
Large starting and stopping
Worn belt and
forces greater than 10% Premature belt failure
pulley/sheave,
above operating conditions
Normal wear rate Normal repetitive stressing Eventual belt failure
Heat build-up due to Variation in drive ratio and
Rapid belt deterioration
inadequate ventilation reduced belt life
Improper belt drive Sidewall cracking and belt
Loose pulley/sheave on shaft
operation failure

Misalignment can be caused by non-parallel shafts, offset pulleys, or shafts or

pulleys that have an angular skew at installation. Misalignment causes belts to
Belt arid Chain Drives Revision B
21 -5