278

Part TWO  Design of a Mechanical Drive

3
n3(idler)
n1(input) n2(output)

1 2

(a)

4 Belt
tensioner
n4(tensioner)

n2 n3 n 4 n5 n6

2 3 4 5 6

1
n1(input)

Belt
(b)
tensioner

Figure 7–32  Serpentine belt drive configurations

7–6  CHAIN DRIVES

A chain is a power transmission element made as a series Working strand (tight side)
of pin-connected links. The design provides for flexibility Chain
while enabling the chain to transmit large tensile forces. pitch
See References 1–3 and Internet sites 1, 4, 6–12, 14, and 15
for more technical information and manufacturers’ data. Driving
When transmitting power between rotating shafts, sprocket
the chain engages mating toothed wheels, called sprock-
ets. Figure 7–33 shows a typical chain drive.
The most common type of chain is the roller chain, Driven
in which the roller on each pin provides exceptionally sprocket
low friction between the chain and the sprockets.
Roller chain is classified by its pitch, the distance Slack strand
between corresponding parts of adjacent links. The pitch
is usually illustrated as the distance between the cen-
ters of adjacent pins. U.S. Standard roller chain carries a Figure 7–33  Basic arrangement of an industrial chain
size designation from 40 to 240, as listed in Table 7–11. drive

M07B_MOTT1184_06_SE_C07.indd 278 3/13/17 4:15 PM

 chapter SEVEN   Belt Drives, Chain Drives, and Wire Rope 279

See Reference 2. The digits (other than the final zero) tension pull applications. See Reference 3 and Internet
indicate the pitch of the chain in eighths of an inch, as in sites 7, 9, 14, and 15 for more information on metric-
the table. For example, the no. 100 chain has a pitch of style chains and for manufacturers’ data.
10/8 or 1 14 in. A series of heavy-duty sizes, with the suffix Another ISO document that is closely related to U.S.
H on the designation (60H–240H), has the same basic roller chain sizes is ISO 10823 and those designations are
dimensions as the standard chain of the same number shown in Table 7–12. The designations are very similar
except for thicker side plates. In addition, there are the to those listed in Table 7–13 from ISO 606, except the
smaller and lighter sizes: 25, 35, and 41. letter following the number is A instead of B.
The average tensile strengths of the various chain Other types of chains include multiple strand designs,
sizes are also listed in Table 7–12. These data can be used heavy series chains, double-pitch chains, and double-pitch
for very-low-speed drives or for applications in which conveyor chains as shown on the left side of Figure 7–34.
the function of the chain is to apply a tensile force or to A wide variety of attachments are available to facilitate the
support a load. It is recommended that only 10% of the application of roller chain to conveying or other material
average tensile strength be used in such applications. For handling uses. Usually in the form of extended plates or
power transmission, the rating of a given chain size as a tabs with holes provided, the attachments make it easy to
function of the speed of rotation must be determined, as connect rods, buckets, parts pushers, part support devices,
explained later in this chapter. or conveyor slats to the chain. The right side of Figure 7–34
ISO standards define several different chain types, shows some attachment styles.
data for three of which are listed in Table 7–13. One Figure 7–35 shows a variety of chain types used
commonly used style from ISO-606 has basically the especially for conveying and similar applications. Such
same design dimensions as for many of the standard U.S. chain typically has a longer pitch than standard roller
roller chains. Then the pitch and dimensions for sprocket chain (usually twice the pitch), and the link plates are
features and bore sizes are listed in the metric unit of mm heavier. The larger sizes have cast link plates.
making it more convenient to integrate familiar chain
designs into an all-metric piece of equipment. ISO-3512
includes eight sizes of chain used for heavy-duty power Design of Chain Drives
transmission and lifting equipment. Some of the pitches The rating of chain for its power transmission capacity
for these chains are also equal to common U.S. sizes. considers three modes of failure: (1) fatigue of the link
Agricultural equipment such as tractor accessories, plant- plates due to the repeated application of the tension in
ers, harvesters, and mowers employ many chain drives to the tight side of the chain, (2) impact of the rollers as
actuate moving systems. ISO-487 defines eight S-designa- they engage the sprocket teeth, and (3) galling between
tions that cover a wide range of power transmission and the pins of each link and the bushings on the pins.
The ratings are based on empirical data with a
smooth driver and a smooth load (service factor = 1.0)
TABLE 7–12  U.S. Roller Chain Sizes and with a rated life of approximately 15 000 h. The
important variables are the pitch of the chain and the
Chain Average tensile size and rotational speed of the smaller sprocket. Lubri-
number ISO 10823 Pitch (in) strength (lb) cation is critical to the satisfactory operation of a chain
25 4A 1/4 925 drive. Manufacturers recommend the type of lubrication
35 6A 3/8 2100
method for given combinations of chain size, sprocket
size, and speed. Details are discussed later.
41 1/2 2000
Tables 7–14 to 7–16 list the rated power for three
40 8A 1/2 3700 sizes of standard chain: no. 40 (1/2 in), no. 60 (3/4 in),
50 10A 5/8 6100 and no. 80 (1.00 in). These are typical of the types of
60 12A 3/4 8500 data available for all chain sizes in manufacturers’ cata-
logs and can be used for problems in this book. When
80 18A 1 14 500
making final designs and specification, you should con-
100 20A 1 14 24 000 sult the catalog data for the particular manufacturer you
120 24A 1 12 34 000 are using. Notice these features of the data:
140 28A 1 34 46 000 1. The ratings are based on the speed of the smaller
sprocket and an expected life of approximately
160 32A 2 58 000
15 000 h.
180 36A 2 14 80 000
2. For a given speed, the power capacity increases with
200 40A 2 12 95 000 the number of teeth on the sprocket. Of course, the
240 48A 3 130 000 larger the number of teeth, the larger the diameter of
the sprocket. Note that the use of a chain with a small
Reference: ANS1 Standard B29.1.
pitch on a large sprocket produces the quieter drive.

M07B_MOTT1184_06_SE_C07.indd 279 3/13/17 4:15 PM

 280 Part TWO  Design of a Mechanical Drive

TABLE 7–13  Metric Roller Chain Sizes and Strength Ratings

General-Purpose power transmission

ISO-606

Chain Pitch Breaking strength Alternate

number in mm lb kN designation

04B 0.250 6.350 — — —

05B 0.315 8.000 989 4.4 —
06B 0.375 9.525 2 001 8.9 Metric 35
08B 0.500 12.700 4 002 17.8 Metric 40
10B 0.625 15.88 4 991 22.2 Metric 50
12B 0.75 19.05 6 497 28.9 Metric 60
16B 1.00 25.40 9 510 42.3 Metric 80
20B 1.25 31.75 14 501 64.5 Metric 100
24B 1.50 38.10 22 010 97.9 Metric 120
28B 1.75 44.45 29 002 129.0 Metric 140
32B 2.00 50.8 37 995 169.0 Metric 160
40B 2.50 63.5 58 993 262.4 Metric 200
48B 3.00 76.2 89 996 400.3 Metric 240
56B 3.50 88.9 122 010 542.7 —
64B 4.00 101.6 160 004 711.7 —
72B 4.50 114.3 202 001 898.5 —

Heavy-Duty power transmission Power transmission for agricultural uses

ISO-3512 ISO-487

Chain Pitch Breaking strength Chain Pitch Breaking strength

number in mm lb kN number in mm lb kN
2010 2.500 63.5 58 903 262.0 S32 1.150 29.2 1 799 8.0
2512 3.067 77.9 84 982 378 S42 1.375 34.9 6 003 26.7
2814 3.500 88.9 116 007 516 S45 0.843 21.4 4 002 17.8
3315 4.073 103.5 133 993 596 S52 1.500 38.1 4 002 17.8
3618 4.500 114.3 183 004 814 S55 1.630 41.4 4 002 17.8
4020 5.000 127.0 236 960 1054 S62 1.650 41.9 6 003 26.7
4824 6.000 152.4 341 951 1521 S77 2.297 58.3 10 004 44.5
5628 7.000 177.8 464 928 2068 S88 2.609 66.3 10 004 44.5

Notes: Not all suppliers offer all sizes.

Breaking strength data must be verified with specific supplier.

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 chapter SEVEN   Belt Drives, Chain Drives, and Wire Rope 281

Standard roller chain,

single strand
(a) Slats assembled to attachments to
form a flat conveying surface

Standard roller chain,

two-strand (also available
with three and four strands)

(b) V block assembled to attachments to

convey round objects of varying diameters

Heavy series roller chain

Double-pitch drive chain

(c) Attachments used as spacers to convey and

Double-pitch conveyor chain position long objects

(a) (b)

Figure 7–34  Other roller chain and examples of attachments

3. For a given sprocket size (a given number of teeth),

the power capacity increases with increasing speed up DESIGN GUIDELINES FOR CHAIN DRIVES ▼
to a point; then it decreases. Fatigue due to the tension
in the chain governs at the low to moderate speeds; The following are general recommendations for designing chain
drives:
impact on the sprockets governs at the higher speeds.
Each sprocket size has an absolute upper-limit speed 1. The minimum number of teeth in a sprocket should be 17
due to the onset of galling between the pins and the unless the drive is operating at a very low speed, under
bushings of the chain. This explains the abrupt drop 100 rpm.
in power capacity to zero at the limiting speed. 2. The maximum speed ratio should be 7.0, although higher
ratios are feasible. Two or more stages of reduction can be
4. The ratings are for a single strand of chain. Although
used to achieve higher ratios.
multiple strands do increase the power capacity, they
do not provide a direct multiple of the single-strand 3. The center distance between the sprocket axes should be
approximately 30 to 50 pitches (30–50 times the pitch of
capacity. Multiply the capacity in the tables by the the chain).
following factors.
4. The larger sprocket should normally have no more than
Two strands: Factor = 1.7 120 teeth.

Three strands: Factor = 2.5 5. The preferred arrangement for a chain drive is with the cen-
terline of the sprockets horizontal and with the tight side
Four strands: Factor = 3.3 on top.
6. The chain length must be an integral multiple of the
5. The chain manufacturer’s ratings are for a service
pitch, and an even number of pitches is ­recommended.
factor of 1.0. Specify a service factor for a given The center distance should be made adjustable to
application as shown in Table 7–16. The combina- ­accommodate the chain length and to take up for toler-
tion of the nature of the driving member and the ances and wear. Excessive sag on the slack side should
driven machine permit the selection of the service be avoided, especially on drives that are not horizontal.
A convenient relation between center distance (CD),
factor. Then compute the design power, Pdes, from,
chain length (Lc), number of teeth in the small sprocket
(N1), and number of teeth in the large sprocket (N2),
Pdes = SF(P) expressed in pitches, is

where P is the power delivered to the chain drive.

M07B_MOTT1184_06_SE_C07.indd 281 3/13/17 4:15 PM

 282 Part TWO  Design of a Mechanical Drive

➭ Chain Length in Pitches ➭ Pitch Diameter of Sprocket

N2 + N1 (N2 - N1)2 p
Lc = 2CD + + (7–18) PD = inches or mm(7–20)
2 4p2CD sin(180°/N)

The center distance for a given chain length, again in 8. The minimum sprocket diameter and therefore the mini-
pitches, is mum number of teeth in a sprocket are often limited by
the size of the shaft on which it is mounted. Check the
➭ Center Distance in Pitches sprocket catalog.
9. The arc of contact, u1, often called the angle of wrap, of the
1 N2 + N1
CD = JL -  chain on the smaller sprocket should be greater than 120°.
4 c 2
N2 + N1 2 8(N2 - N1)2 ➭ Angle of Wrap Smaller Sprocket
+ J Lc - d - R (7–19)
C 2 4p2 u1 = 180° - 2sin-1[(PD2 - PD1)/2CD](7–21)
The computed center distance assumes no sag in either 10. For reference, the arc of contact, u2, on the larger
the tight or the slack side of the chain, and thus it is a sprocket is
maximum. Negative tolerances or adjustment must be
provided. Adjustment for wear must also be provided.
➭ Angle of Wrap Large Sprocket
7. The pitch diameter of a sprocket with N teeth for a chain
with a pitch of p is u2 = 180° + 2sin-1[(PD2 - PD1)/2CD](7–22)

Figure 7–35  Conveyor chains (Rexnord Industries, LLC, Milwaukee, WI)

M07B_MOTT1184_06_SE_C07.indd 282 3/13/17 4:15 PM

 TABLE 7–14  Horsepower Ratings—Single-Strand Roller Chain No. 40

0.500-in pitch Rotational speed of small sprocket, rev/min

No. of
teeth
10 25 50 100 180 200 300 500 700 900 1000 1200 1400 1600 1800 2100 2500 3000 3500 4000 5000 6000 7000 8000 9000

M07B_MOTT1184_06_SE_C07.indd 283
11 0.06 0.14 0.27 0.52 0.91 1.00 1.48 2.42 3.34 4.25 4.70 5.60 6.49 5.57 4.66 3.70 2.85 2.17 1.72 1.41 1.01 0.77 0.61 0.50 0.00
12 0.06 0.15 0.29 0.56 0.99 1.09 1.61 2.64 3.64 4.64 5.13 6.11 7.09 6.34 5.31 4.22 3.25 2.47 1.96 1.60 1.15 0.87 0.69 0.57 0.00
13 0.07 0.16 0.31 0.61 1.07 1.19 1.75 2.86 3.95 5.02 5.56 6.62 7.68 7.15 5.99 4.76 3.66 2.79 2.21 1.81 1.29 0.98 0.78 0.00
14 0.07 0.17 0.34 0.66 1.15 1.28 1.88 3.08 4.25 5.41 5.98 7.13 8.27 7.99 6.70 5.31 4.09 3.11 2.47 2.02 1.45 1.10 0.87 0.00
15 0.08 0.19 0.36 0.70 1.24 1.37 2.02 3.30 4.55 5.80 6.41 7.64 8.86 8.86 7.43 5.89 4.54 3.45 2.74 2.24 1.60 1.22 0.97 0.00
16 0.08 0.20 0.39 0.75 1.32 1.46 2.15 3.52 4.86 6.18 6.84 8.15 9.45 9.76 8.18 6.49 5.00 3.80 3.02 2.47 1.77 1.34 0.00
17 0.09 0.21 0.41 0.80 1.40 1.55 2.29 3.74 5.16 6.57 7.27 8.66 10.04 10.69 8.96 7.11 5.48 4.17 3.31 2.71 1.94 1.47 0.00
18 0.09 0.22 0.43 0.84 1.48 1.64 2.42 3.96 5.46 6.95 7.69 9.17 10.63 11.65 9.76 7.75 5.97 4.54 3.60 2.95 2.11 1.60 0.00
19 0.10 0.24 0.46 0.89 1.57 1.73 2.56 4.18 5.77 7.34 8.12 9.66 11.22 12.64 10.59 8.40 6.47 4.92 3.91 3.20 2.29 0.09 0.00
20 0.10 0.25 0.48 0.94 1.65 1.82 2.69 4.39 6.07 7.73 8.55 10.18 11.81 13.42 11.44 9.07 6.99 5.31 4.22 3.45 2.47 0.00
21 0.11 0.26 0.51 0.98 1.73 1.91 2.83 4.61 6.37 8.11 8.98 10.69 12.40 14.10 12.30 9.76 7.52 5.72 4.54 3.71 2.65 0.00
22 0.11 0.27 0.53 1.03 1.81 2.01 2.96 4.83 6.68 8.50 9.40 11.20 12.99 14.77 13.19 10.47 8.06 6.13 4.87 3.98 2.85 0.00
23 0.12 0.28 0.56 1.08 1.90 2.10 3.10 5.05 6.98 8.89 9.83 11.71 13.58 15.44 14.10 11.19 8.62 6.55 5.20 4.26 3.05 0.00
24 0.12 0.30 0.58 1.12 1.98 2.19 3.23 5.27 7.28 9.27 10.26 12.22 14.17 16.11 15.03 11.93 9.18 6.99 5.54 4.54 0.87 0.00
25 0.13 0.31 0.60 1.17 2.06 2.28 3.36 5.49 7.59 9.66 10.69 12.73 14.76 16.78 15.98 12.68 9.76 7.43 5.89 4.82 0.00
26 0.13 0.32 0.63 1.22 2.14 2.37 3.50 5.71 7.89 10.04 11.11 13.24 15.35 17.45 16.95 13.45 10.36 7.88 6.25 5.12 0.00
28 0.14 0.35 0.67 1.31 2.31 2.55 3.77 6.15 8.50 10.82 11.97 14.26 16.53 18.79 18.94 15.03 11.57 8.80 6.99 5.72 0.00
30 0.15 0.37 0.72 1.41 2.47 2.74 4.04 6.59 9.11 11.59 12.82 15.28 17.71 20.14 21.01 16.67 12.84 9.76 7.75 6.34 0.00
32 0.16 0.40 0.77 1.50 2.64 2.92 4.31 7.03 9.71 12.38 13.66 16.30 18.89 21.48 23.14 18.37 14.14 10.76 8.54 1.41
35 0.18 0.43 0.84 1.64 2.88 3.19 4.71 7.69 10.62 13.52 14.96 17.82 20.67 23.49 26.30 21.01 16.17 12.30 9.76 0.00
40 0.21 0.50 0.96 1.87 3.30 3.65 5.38 8.79 12.14 15.45 17.10 20.37 23.62 26.85 30.06 25.67 19.76 15.03 0.00
45 0.23 0.56 1.08 2.11 3.71 4.10 6.06 9.89 13.66 17.39 19.24 22.92 26.57 30.20 33.82 30.63 23.58 5.53 0.00
Type A Type B Type C
Type A: Manual or drip lubrication
Type B: Bath or disc lubrication
Type C: Oil stream lubrication

283

3/13/17 4:15 PM
 284
TABLE 7–15  Horsepower Ratings—Single-Strand Roller Chain No. 60

No. of 0.750-in pitch Rotational speed of small sprocket, rev/min

teeth 10 25 50 100 120 200 300 400 500 600 800 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500 5000 5500 6000

11 0.19 0.46 0.89 1.72 2.05 3.35 4.95 6.52 8.08 9.63 12.69 15.58 11.85 9.41 7.70 6.45 5.51 3.94 3.00 2.38 1.95 1.63 1.39 1.21 0.00

M07B_MOTT1184_06_SE_C07.indd 284
12 0.21 0.50 0.97 1.88 2.24 3.66 5.40 7.12 8.82 10.51 13.85 17.15 13.51 10.72 8.77 7.35 6.28 4.49 3.42 2.71 2.22 1.86 1.59 1.38 0.00
13 0.22 0.54 1.05 2.04 2.43 3.96 5.85 7.71 9.55 11.38 15.00 18.58 15.23 12.08 9.89 8.29 7.08 5.06 3.85 3.06 2.50 2.10 1.79 0.00
14 0.24 0.58 1.13 2.19 2.61 4.27 6.30 8.30 10.29 12.26 16.15 20.01 17.02 13.51 11.05 9.26 7.91 5.66 4.31 3.42 2.80 2.34 0.41 0.00
15 0.26 0.62 1.21 2.35 2.80 4.57 6.75 8.90 11.02 13.13 17.31 21.44 18.87 14.98 12.26 10.27 8.77 6.28 4.77 3.79 3.10 2.60 0.00
16 0.27 0.66 1.29 2.51 2.99 4.88 7.20 9.49 11.76 14.01 18.46 22.87 20.79 16.50 13.51 11.32 9.66 6.91 5.26 4.17 3.42 1.78 0.00
17 0.29 0.70 1.37 2.66 3.17 5.18 7.65 10.08 12.49 14.88 19.62 24.30 22.77 18.07 14.79 12.40 10.58 7.57 5.76 4.57 3.74 0.00
18 0.31 0.75 1.45 2.82 3.36 5.49 8.10 10.68 13.23 15.76 20.77 25.73 24.81 19.69 16.11 13.51 11.53 8.25 6.28 4.98 4.08 0.00
19 0.33 0.79 1.53 2.98 3.55 5.79 8.55 11.27 13.96 16.63 21.92 27.16 26.91 21.35 17.48 14.65 12.50 8.95 6.81 5.40 0.20 0.00
20 0.34 0.83 1.61 3.13 3.73 6.10 9.00 11.86 14.70 17.51 23.08 28.59 29.06 23.06 18.87 15.82 13.51 9.66 7.35 5.83 0.00
21 0.36 0.87 1.69 3.29 3.92 6.40 9.45 12.46 15.43 18.38 24.23 30.02 31.26 24.81 20.31 17.02 14.53 10.40 7.91 6.28 0.00
22 0.38 0.91 1.77 3.45 4.11 6.71 9.90 13.05 16.17 19.26 25.39 31.45 33.52 26.60 21.77 18.25 15.58 11.15 8.48 0.00
23 0.40 0.95 1.85 3.61 4.29 7.01 10.35 13.64 16.90 20.13 26.54 32.88 35.84 28.44 23.28 19.51 16.66 11.92 9.07 0.00
24 0.41 0.99 1.93 3.76 4.48 7.32 10.80 14.24 17.64 21.01 27.69 34.31 38.20 30.31 24.81 20.79 17.75 12.70 9.66 0.00
25 0.43 1.04 2.01 3.92 4.67 7.62 11.25 14.83 18.37 21.89 28.85 35.74 40.61 32.23 26.38 22.11 18.87 13.51 10.27 0.00
26 0.45 1.08 2.09 4.08 4.85 7.93 11.70 15.42 19.11 22.76 30.00 37.17 43.07 34.18 27.98 23.44 20.02 14.32 10.90 0.00
28 0.48 1.16 2.26 4.39 5.23 8.54 12.60 16.61 20.58 24.51 32.31 40.03 47.68 38.20 31.26 26.20 22.37 16.01 0.00
30 0.52 1.24 2.42 4.70 5.60 9.15 13.50 17.79 22.05 26.26 34.62 42.89 51.09 42.36 34.67 29.06 24.81 17.75 0.00
32 0.55 1.33 2.58 5.02 5.98 9.76 14.40 18.98 23.52 28.01 36.92 45.75 54.50 46.67 38.20 32.01 27.33 19.56 0.00
35 0.60 1.45 2.82 5.49 6.54 10.67 15.75 20.76 25.72 30.64 40.39 50.03 59.60 53.38 43.69 36.62 31.26 1.35 0.00
40 0.69 1.66 3.22 6.27 7.47 12.20 18.00 23.73 29.39 35.02 46.16 57.18 68.12 65.22 53.38 44.74 38.20 0.00
45 0.77 1.86 3.63 7.05 8.40 13.72 20.25 26.69 33.07 38.39 51.92 64.33 76.63 77.83 63.70 53.38 12.45 0.00
Type A Type B Type C
Type A: Manual or drip lubrication
Type B: Bath or disc lubrication
Type C: Oil stream lubrication

3/13/17 4:15 PM
 TABLE 7–16  Horsepower Ratings—Single-Strand Roller Chain No. 80

No. of 1.000-in pitch Rotational speed of small sprocket, rev/min

teeth 10 25 50 75 88 100 200 300 400 500 600 700 800 900 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500

M07B_MOTT1184_06_SE_C07.indd 285
11 0.44 1.06 2.07 3.05 3.56 4.03 7.83 11.56 15.23 18.87 22.48 26.07 27.41 22.97 19.61 14.92 11.84 9.69 8.12 6.83 4.96 3.77 3.00 2.45 0.00
12 0.48 1.16 2.26 3.33 3.88 4.39 8.54 12.61 16.82 20.59 24.53 28.44 31.23 26.17 22.35 17.00 13.49 11.04 9.25 7.90 5.65 4.30 3.41 2.79 0.00
13 0.52 1.26 2.45 3.61 4.21 4.76 9.26 13.66 18.00 22.31 26.57 30.81 35.02 29.51 25.20 19.17 15.21 12.45 10.43 8.91 6.37 4.85 3.85 3.15
14 0.56 1.35 2.63 3.89 4.53 5.12 9.97 14.71 19.39 24.02 28.62 33.18 37.72 32.98 28.16 21.42 17.00 13.91 11.66 9.96 7.12 5.42 4.30 3.52
15 0.60 1.45 2.82 4.16 4.86 5.49 10.68 15.76 20.77 25.74 30.66 35.55 40.41 36.58 31.23 23.76 18.85 15.43 12.93 11.04 7.90 6.01 4.77 0.00
16 0.64 1.55 3.01 4.44 5.18 5.86 11.39 16.81 22.16 27.45 32.70 37.92 43.11 40.30 34.41 26.17 20.77 17.00 14.25 12.16 8.70 6.62 5.25 0.00
17 0.68 1.64 3.20 4.72 5.50 6.22 12.10 17.86 23.54 29.17 34.75 40.29 45.80 44.13 37.68 28.66 22.75 18.62 15.60 13.32 9.53 7.25 0.00
18 0.72 1.74 3.39 5.00 5.83 6.59 12.81 18.91 24.93 30.88 36.79 42.66 48.49 48.08 41.05 31.23 24.78 20.29 17.00 14.51 10.39 7.90 0.00
19 0.76 1.84 3.57 5.28 6.15 6.95 13.53 19.96 26.31 32.60 38.84 45.03 51.19 52.15 44.52 33.87 26.88 22.00 18.44 15.74 11.26 0.36 0.00
20 0.80 1.93 3.76 5.55 6.47 7.32 14.24 21.01 27.70 34.32 40.88 47.40 53.88 56.32 48.08 36.58 29.03 23.76 19.91 17.00 12.16 0.00
21 0.84 2.03 3.95 5.83 6.80 7.69 14.95 22.07 29.08 36.03 42.92 49.77 56.58 60.59 51.73 39.36 31.23 25.56 21.42 18.29 13.09 0.00
22 0.88 2.13 4.14 6.11 7.12 8.05 15.66 23.12 30.47 37.75 44.97 52.14 59.27 64.97 55.47 42.20 33.49 27.41 22.97 19.61 14.03
23 0.92 2.22 4.33 6.39 7.45 8.42 16.37 24.17 31.85 39.46 47.01 54.51 61.97 69.38 59.30 45.11 35.80 29.30 24.55 20.97 15.00
24 0.96 2.32 4.52 6.66 7.77 8.78 17.09 25.22 33.24 41.18 49.06 56.88 64.66 72.40 63.21 48.08 38.16 31.23 26.17 22.35 15.99
25 1.00 2.42 4.70 6.94 8.09 9.15 17.80 26.27 34.62 42.89 51.10 59.25 67.35 75.42 67.20 51.12 40.57 33.20 27.83 23.76 8.16
26 1.04 2.51 4.89 7.22 8.42 9.52 18.51 27.32 36.01 44.61 53.14 61.62 70.05 78.43 71.27 54.22 43.02 36.22 29.51 25.20 0.00
28 1.12 2.71 5.27 7.77 9.06 10.25 19.93 29.42 38.78 48.04 57.23 66.36 75.44 84.47 79.65 60.59 48.08 39.36 32.98 28.16 0.00
30 1.20 2.90 5.64 8.33 9.71 10.98 21.36 31.52 41.55 51.47 61.32 71.10 80.82 90.50 88.33 67.20 53.33 43.65 36.58 31.23
32 1.28 3.09 6.02 8.89 10.36 11.71 22.78 33.62 44.32 54.91 65.41 75.84 86.21 96.53 97.31 74.03 58.75 48.08 40.30 5.65
35 1.40 3.38 6.58 9.72 11.33 12.81 24.92 36.78 48.47 60.05 71.54 82.95 94.29 105.58 111.31 84.68 67.20 55.00 28.15 0.00

40 1.61 3.87 7.53 11.11 12.95 14.64 28.48 42.03 55.40 68.63 81.76 94.80 107.77 120.67 133.51 103.46 82.10 40.16 0.00

45 1.81 4.35 8.47 12.49 14.57 16.47 32.04 47.28 62.32 77.21 91.98 106.65 121.24 135.75 150.20 123.45 72.28 0.00
Type A Type B Type C
Type A: Manual or drip lubrication
Type B: Bath or disc lubrication
Type C: Oil stream lubrication

285

3/13/17 4:15 PM
 286 Part TWO  Design of a Mechanical Drive

TABLE 7–17  Service Factors for Chain Drives

Type of driver

Internal combustion engine

Load type Hydraulic drive Electric motor or turbine with mechanical drive

Smooth
Agitators; fans; generators; grinders; centrifugal pumps; 1.0 1.0 1.2
rotary screens; light, uniformly loaded conveyors
Moderate shock
Bucket elevators; machine tools; cranes; heavy conveyors; 1.2 1.3 1.4
food mixers and grinders; ball mills; reciprocating pumps;
woodworking machinery
Heavy shock
Punch presses; hammer mills; boat propellers; crushers; 1.4 1.5 1.7
reciprocating conveyors; rolling mills; logging hoists;
dredges; printing presses

Lubrication TABLE 7–18 Recommended Lubricant

It is essential that adequate lubrication be provided for for Chain Drives
chain drives. There are numerous moving parts within
Ambient Recommended
the chain, along with the interaction between the chain temperature lubricant
and the sprocket teeth. The designer must define the
lubricant properties and the method of lubrication. °F °C

20 to 40 - 7 to 5 SAE 20
Lubricant Properties.  Petroleum-based lubricating
oil similar to engine oil is recommended. Its viscosity 40 to 100 5 to 38 SAE 30
must enable the oil to flow readily between chain sur- 100 to 120 38 to 49 SAE 40
faces that move relative to each other while providing 120 to 140 49 to 60 SAE 50
adequate lubrication action. The oil should be kept clean
and free of moisture. Table 7–18 gives the recommended
lubricants for different ambient temperatures.
feed lubrication, oil is fed directly onto the link plates of
Method of Lubrication.  The American Chain Asso- each chain strand.
ciation recommends three different types of lubrication
depending on the speed of operation and the power Type B.  Bath or disc lubrication: The chain cover pro-
being transmitted. See Tables 7–14 to 7–16 or manufac- vides a sump of oil into which the chain dips continuously.
turers’ catalogs for recommendations. Refer to the fol- Alternatively, a disc or a slinger can be attached to one of
lowing descriptions of the methods and the illustrations the shafts to lift oil to a trough above the lower strand of
in Figure 7–36. chain. The trough then delivers a stream of oil to the chain.
The chain itself, then, does not need to dip into the oil.
Type A.  Manual or drip lubrication: For manual lubri-
cation, oil is applied copiously with a brush or a spout Type C.  Oil stream lubrication: An oil pump delivers a
can, at least once every 8 hours of operation. For drip continuous stream of oil on the lower part of the chain.

Example Problem Figure 7–37 shows a drive for a heavily loaded conveyor for use in the fields of a large commercial
7–5 produce farm to take heavy containers of potatoes from the field onto trucks that will transport them to
the processing plant. The conveyor is to be driven by a gasoline engine delivering 15.0 hp at a speed of
900 rpm. The conveyor pulley speed is to be 230 to 240 rpm. Design the chain drive.

Solution Objective Design the chain drive.

Given Power transmitted = 15 hp to a heavily loaded produce conveyor

Speed of motor = 900 rpm; output speed range = 230 to 240 rpm

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 chapter SEVEN   Belt Drives, Chain Drives, and Wire Rope 287

Oil filler cap

Sight-feed lubricator

lit
sp
g
sin
Ca
Wick-packed distributing pipe

Oil level

Oil gage Drain plug

(a) Drip feed lubrication (Type A) (b) Shallow bath lubrication (Type B)

Support
clip
Flexible metal Oil filler cap Casing split
hose

Oil filler cap Gasket

lit
sp
g
sin
Ca

Oil disc Oil collector

plate Support
Oil level
clip
Oil gutter Sight
Oil
Oil flow Valve gage
Drain Motor Oil Drain Oil spray
Oil gage
plug Oil pump strainer plug pipe

(c) Disc or slinger lubrication (Type B) (d) Oil stream lubrication (Type C)

Figure 7–36  Lubrication methods

Conveyor
Driven sprocket

Engine

Driving sprocket

Figure 7–37  Chain drive for a heavy-duty conveyor for Example Problem 7–5

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 288 Part TWO  Design of a Mechanical Drive

Analysis Use the design data presented in this section. The solution procedure is developed within the ­Results
section of the problem solution.

Results Step 1. Specify a service factor and compute the design power. From Table 7–17, for moderate
shock from the loads applied to the heavy-duty conveyor and a gasoline engine drive, use a service
factor of SF = 1.4. Then,

Design power = Pdes = SF(P) = 1.4(15.0 hp) = 21.0 hp

Step 2. Compute the desired ratio. Using the middle of the required range of output speeds, we have

Ratio = (900 rpm)/(235 rpm) = 3.83

Step 3. Refer to the tables for power capacity (Tables 7–14 to 7–16), and select the chain pitch. For
a single strand, the no. 60 chain with p = 3/4 in seems best. A 17-tooth sprocket is rated at 21.96 hp
at 900 rpm by interpolation. At this speed, Type B lubrication (oil bath) is required.
Step 4. Compute the required number of teeth on the large sprocket:

N2 = N1 * ratio = 17(3.83) = 65.11

Let’s use the integer: 65 teeth.

Step 5. Compute the actual expected output speed:

n2 = n1(N1/N2) = 900 rpm(17/65) = 235.3 rpm (Okay! The speed is within the specified range.)
Step 6. Compute the pitch diameters of the sprockets using Equation (7–20):

p 0.75 in
PD1 = = = 4.082 in
sin(180°/N1) sin(180°/17)
p 0.75 in
PD2 = = = 15.524 in
sin(180°/N2) sin(180°/65)

Step 7. Specify the nominal center distance. Let’s use the middle of the recommended range,
40 pitches.
Step 8. Compute the required chain length in pitches from Equation (7–18):

N2 + N1 (N2 - N1)2
Lc = 2CD + +
2 4p2CD
65 + 17 (65 - 17)2
Lc = 2(40) + + = 122.5 pitches
2 4p2(40)

Step 9. Specify an integral number of pitches for the chain length, and compute the actual theoreti-
cal center distance. Let’s use 122 pitches, an even number. Then, from Equation (7–19),

1 N2 + N1 N2 + N1 2 8(N2 - N1)2
CD = JLc - + JLc - d - R
4 2 C 2 4p2

1 65 + 17 65 + 17 2 8(65 - 17)2
CD = J122 - + J122 - d - R
4 2 C 2 4p2

CD = 39.766 pitches = 39.766(0.75 in) = 29.825 in

Step 10. Compute the angle of wrap of the chain for each sprocket using Equations (7–21) and
(7–22). Note that the minimum angle of wrap should be 120°.
For the small sprocket,

u1 = 180° - 2sin-1[(PD2 - PD1)/2CD]

u1 = 180° - 2sin-1[(15.524 - 4.082)/(2(29.825))] = 158°

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 chapter SEVEN   Belt Drives, Chain Drives, and Wire Rope 289

Because this is greater than 120°, it is acceptable.

For the larger sprocket,

u2 = 180° + 2sin-1[(PD2 - PD1)/2CD]

u2 = 180° + 2sin-1[(15.524 - 4.082)/(2(29.825))] = 202°

Comments Summary of Design

Figure 7–38(a) shows a sketch of the design to scale.

Pitch: No. 60 chain, 3/4-in pitch

Length: 122 pitches = 122(0.75) = 91.50 in

Center distance: CD = 29.825 in (maximum)

Sprockets: Single-strand, no. 60, 3/4-in pitch

Small: 17 teeth, PD = 4.082 in

Large: 65 teeth, PD = 15.524 in

Type B lubrication is required. The large sprocket can dip into an oil bath.

CD = 29.825

PD = ¤15.524

PD = ¤4.082 in

158° 202°

(a)

CD = 15.272
PD = ¤10.349

PD = ¤2.721

151° 209°

(b)

Figure 7–38  Scale drawings of layouts for chain drives for Example Problems 7–5 and 7–6

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 290 Part TWO  Design of a Mechanical Drive

Example Problem Create an alternate design for the conditions of Example Problem 7–5 to produce a smaller drive.
7–6
Solution Objective Design a smaller chain drive for the application in Example Problem 7–5.

Given Power transmitted = 15 hp to a conveyor

Speed of motor = 900 rpm; output speed range = 230 to 240 rpm

Analysis Use a multistrand design to permit a smaller-pitch chain to be used to transmit the same design power
(21.0 hp) at the same speed (900 rpm). Use the design data presented in this section. The solution
procedure is developed within the Results section of the problem solution.

Results Let’s try a four-strand chain for which the power capacity factor is 3.3. Then the required power per
strand is
P = 21.0/3.3 = 6.36 hp
From Table 7–14, we find that a no. 40 chain (1/2-in pitch) with a 17-tooth sprocket will be satisfac-
tory. Type B lubrication, oil bath, can be used.
For the required large sprocket,
N2 = N1 * ratio = 17(3.83) = 65.11
Let’s use N2 = 65 teeth.
The sprocket diameters are

p 0.500 in
PD1 = = = 2.721 in
sin(180°/N1) sin(180°/17)
p 0.500 in
PD2 = = = 10.349 in
sin(180°/N2) sin(180°/65)

For the center distance, let’s try the minimum recommended: C = 30 pitches.
30(0.50 in) = 15.0 in
The chain length is

65 + 17 (65 - 17)2
Lc = 2(30) + + = 102.9 pitches
2 4p2(30)

Specify the integer length, Lc = 104 pitches = 104(0.50) = 52.0 in. The actual maximum center
distance is

1 65 + 17 65 + 17 2 8(65 - 17)2
CD = J104 - + J104 - d - R
4 2 C 2 4p2
CD = 30.54 pitches = 30.54(0.50) = 15.272 in

Compute the angle of wrap of the chain for each sprocket using Equations (7–21) and (7–22). Note that
the minimum angle of wrap should be 120°.
For the small sprocket,

u1 = 180° - 2sin-1[(PD2 - PD1)/2C]

u1 = 180° - 2sin-1[(10.349 - 2.721)/(2(15.272))] = 151.1°

Because this is greater than 120°, it is acceptable.

For the larger sprocket,

u1 = 180° + 2sin-1[(PD2 - PD1)/2C]

u2 = 180° + 2sin-1[(10.349 - 2.721)/(2(15.272))] = 208.9°

Comments Summary
Figure 7–38(b) shows the new design to the same scale as the first design. The space reduction is
significant.

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 chapter SEVEN   Belt Drives, Chain Drives, and Wire Rope 291

Chain: No. 40, 1/2-in pitch, four-strand, 104 pitches, 52.0 in length
Sprockets: No. 40–4 (four strands), 1/2-in pitch
Small: 17 teeth, PD1 = 2.721 in
Large: 65 teeth, PD2 = 10.349 in
Maximum center distance: 15.272 in
Type B lubrication (oil bath)

Spreadsheet for Chain Design The user enters data shown in italics in the gray-shaded
Figure 7–39 shows a spreadsheet that assists in the design of cells. Refer to Tables 7–11 to 7–17 for required data.
chain drives using the procedure developed in this section. Results for Example Problem 7–6 are shown in the figure.

CHAIN DRIVE DESIGN

Initial Input Data: Example Problem 7–6—Multiple strands

Application: Coal conveyor

Drive/type: Engine-mechanical drive
Driven machine: Heavily loaded conveyor
Power input: 15 hp
Service factor: 1.4 Table 7–17
Input speed: 900 rpm
Desired output speed: 235 rpm

Computed Data:

Design power: 21 hp
Speed ratio: 3.83

Design Decisions—Chain Type and Teeth Numbers:

Number of strands: 4 1 2 3 4
Strand factor: 3.3 1.0 1.7 2.5 3.3
Required power per strand: 6.36 hp
Chain number: 40 Table 7–14, 7–15, or 7–16
Chain pitch: 0.5 in
Number of teeth—driver sprocket: 17
Computed no. of teeth—driven sprocket: 65.11
Enter: Chosen number of teeth: 65

Computed Data:

Actual output speed: 235.4 rpm

Pitch diameter—driver sprocket: 2.721 in
Pitch diameter—driven sprocket: 10.349 in

Center Distance, Chain Length, and Angle of Wrap:

Enter: Nominal center distance: 30 pitches 30 to 50 pitches recommended

Computed nominal chain length: 102.9 pitches
Enter: Specified no. of pitches: 104 pitches Even number recommended
Actual chain length: 52.00 in
Computed actual center distance: 30.545 pitches
Actual center distance: 15.272 in
Angle of wrap—driver sprocket: 151.1° Should be greater than 120°
Angle of wrap—driven sprocket: 208.9°

FIGURE 7–39  Spreadsheet for chain design

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