Design of Flexible Machine Elements

Belt and Rope Drives

3.1 Introduction

Machine elements such as belts, ropes or chains are frequently used whenever
power has to be transmitted from one shaft to another.
The belts and rope drives are used to transmit power from one shaft to another by means
of pulleys which rotate at the same speed or at different speeds. The amount of power
transmitted depends upon the following factors.

1. The velocity of belt

2. The tension under which the belt is placed on pulleys.
3. The arc of contact between the belt and the smaller pulleys.
4. The conditions under which the belt is used.

3.2 Selection of a belt drive

The selection of a belt drive depends upon the following factors:

1. Speed of the driving and driven shafts

2. Speed reduction ratio
3. Power to be transmitted
4. Positive drive requirements
5. Shafts layout

3.3.1 Velocity ratio of belt drive

It is the ratio between the velocities of the driver and the follower or driven.

Let d1 = Diameter of the driver d2 = Diameter of the driven

N1= Speed of driver in rpm N2 = Speed of follower in rpm

Length of belt that passes over the driver in one minute =  d1 N1

Length of belt that passes over the follower in one minute =  d2 N2

 Since the length of belt that passes over the driver in one minute is equal to the length of
the belt that passes over the follower in one minute,

 d1 N1 =  d2 N2

N 2 d1
Or Velocity ratio = =
N1 d 2

N 2 d1 + t
When thickness is considered =
N1 d 2 + t

where t is the thickness of the belt.

3.4 Slip of belt: Sometimes, the frictional grip becomes insufficient for the power
transmission between the belt and the pulley. This may cause some forward motion of
the driver without carrying the belt with it. This is called slip of the belt and expressed as
percentage.

3.5 Creep of belt: When the belt passes from the slack side to the tight side, a certain portion
of the belt extends and it contracts again when the belt passes from the tight side to the
slack side. Due to these changes of length, there is a relative motion between the belt and
pulley surfaces. This relative motion called creep. The net effect of creep is to reduce
slightly the speed of the driven pulley or follower.

Fig.4.1. Open Belt drive

(Source: Machine Design by R.S.Khurmi and J.K.Gupta)

3.6 Ratio of driving tensions for flat belt drives

Consider a driven pulley rotating in the clockwise direction. Let T1 be the tension in the
belt on the tight side. Let T2 be the tension in the belt on the slack side.

Fig.4.2. Close up view of tensions on tight and slack sides

(Source: Machine Design by R.S.Khurmi and J.K.Gupta)

Considering a small portion of the belt PQ subtending an angle of  at the centre of pulley
as shown, the belt PQ is in equilibrium under the following forces:

1. Tension T in the belt at P

2. Tension (T+  +  T ) in the belt at Q
3. Normal reaction RN

4. Frictional force F =  RN where μ is the coefficient of friction between the belt and

pulley.
Resolving all the forces horizontally,

 
RN = (T +  T ) sin + T sin (Equation 3.1)
2 2
 
Since the angle  is very small, sin =
2 2

   
RN = (T +  T ) +T =T +T = T  (Equation 3.2)
2 2 2 2

 T  
(Neglecting small term )
2
 Now resolving the forces vertically,

F=  RN = (T +  T ) cos  − T cos  (Equation 3.3)

2 2


Since angle  is very small, take cos =1
2

T
Therefore F =  RN = (T+ δT)-T = δT (Or) RN = (Equation 3. 4)


T T
Equating equations 2 and 4 for RN, T  = (Or) = 
 T

Integrating the above equation between the limits T2 and T1 and from 0 to θ,


T
T1


T2
T
=   
0

T1 T1
log e [ ]= μθ (or) = eμθ
T2 T2

Maximum tension in the belt Tt = ft b t where b.t is the cross-sectional area of

rectangular belt.

T1
Note: Ratio of tensions = = eμθ (Neglecting TC)
T2

T1 − TC
Ratio of tensions = = eμθ (Considering centrifugal tension TC)
T2 − TC

3.7 Condition for the transmission of maximum power

The power transmitted by a belt P = (T1-T2)  (Equation 3. 5)

T1 T1
We know that = eμθ (or) T2 = (Equation 3.6)
T2 e 

Substituting equation 4.6 in 4.5,

  1 

T1
P = (T1 − 
) = T1 1 −  P = T1 C (Equation 3.7)
e  e

1
where C= and T1 = Tt - Tc (Equation 3.8)
e 

Substitute equation 4.4 in 4.3,

P = (Tt – Tc)  C = (Tt - m 3) C (Equation 3.9)

For maximum power conditions, differentiate equation 2.5 with respect to  ,

(Tt − m 3 ) C  = 0
dP d
=0 and
d d  

Tt
Tt = 3m 2 =0 or Tt = 3Tc or Tc = (Equation 3.10)
3

Tt Tt
m 2 = or =
3 3m

where  is the belt speed for maximum power conditions.

3.8 Initial Tension (To)

The tension of a belt when it is fitted to a pair of stationary pulleys is termed as the initial
tension of the belt (To).

T1 + T2
Initial tension (To) = +T (Equation 3.11)
2

T1 + T2
Initial tension (To) = (neglecting TC) (Equation 3.12)
2

3.9 Effect of Centrifugal Tension on Power Transmitted:

Tension on tight side Tt = T1 + TC

Tension on slack side Ts = T2 + TC

 Power transmitted P = ( Tt − Ts )  = ( T1 + TC ) − (T2 + TC )  = (T1 − T2 ) 

Hence centrifugal tension has no effect on power transmitted.
Problem 1: A leather belt 9 mm x 250 mm is used to drive a cast iron pulley 900 mm in diameter
at 336 rpm. If the active arc on the smaller pulley is 120 degrees and the stress in the tight side
is 2 MPa, find the power capacity of the belt. The density of leather may be taken as 980 kg/m3
and the coefficient of friction of leather on cast iron is 0.35.

Data: t = 9 mm=0.009 m b=0.25 m d=900 mm = 0.9 m


N = 336 rpm θ = 120˚ = 120  = 2.1 rad  = 2MPa

 = 980kg / m3 μ = 0.35
 dN   0.9  
Velocity of belt  = = = 15.8m / sec
60 
Cross-sectional area of belt A = b.t= 9x250=2250 mm2

Maximum or total tension in the tight side of the belt =Tt =   b  t = 4500 N
Mass of the belt per metre length m = Area x length x density = b.t.l. 

= 0.25 x 0.009 x 1 x 980 = 2.2 kg/m length

Centrifugal tension TC = mv2 = 2.2 (15.8)2 = 550 N

Tt = T1+ TC or T1 = 4500 – 550 =3950 N

T1
= eμθ = 2.085 T2 = 1895 N
T2

Power capacity of the belt P = (T1-T2)  = (3950-1895)15.8 = 32,470 W

P = 32.47 kW

Problem 2: A flat belt is required to transmit 30 kW power from a pulley of 1.5 m effective
diameter running at 300 rpm. The angle of contact is spread over 11/24 of the circumference.
The coefficient of friction between the belt and pulley surface is 0.3. Determine taking
centrifugal tension into account the width of the belt required. It is given that the belt thickness
is 9.5 mm; density of the belt material 1100 kg/m3 and the related permissible working stress
is 2.5 MPa.

Problem 3: A belt 100 mm wide and 10 mm tick is transmitting power at 1000 m/min. The net
driving tension is 1.8 times the tension on the slack side. If the safe permissible stress on the
belt section is 1.6 MPa, calculate the power that can be transmitted at this speed. Assume
 density of leather as 1000 kg/m3. Calculate the maximum power that can be transmitted by this
belt and the speed at which this can be transmitted.

Problem 4: Two pulleys, one 450 mm diameter and the other 200 mm diameter, on parallel
shafts 1.95 m apart are connected by a crossed belt. What power can be transmitted by the
belt when the larger pulley rotates at 200 rev/min, if the maximum permissible tension in the
belt is 1 kN, and the coefficient of friction between the belt and pulley is 0.25?

References:

1. Shigley’s Mechanical Engineering Design by Budynas and Nisbett, eighth edition,

Mc-Graw Hill publications, 2006.
2. Fundamentals of Machine Component Design by Robert C. Juvinall and Kurt M.
Marshek, third edition John Wiley & Sons, 2003.
3. Machine Design by R.S.Khurmi and J.K.Gupta, fifth edition, S.Chand &
Company, 2005.

4.10 V-Belt Drives

4.10.1 Ratio of tensions for V-Belt drives

Fig.4.3 V-Belt Drives

(Source: Fundamentals of Machine Component Design by Robert Juvinall)

 Fig.4.3 Cross-section of V-belt drive

(Source: Machine Design by R.S.Khurmi and J.K.Gupta)

T1
= e  '
T2
where 2β is pulley groove angle.

'=
sin 

Problem 5: A compressor, requiring 90 kW, is to run at about 250 r.p.m. The drive is by V-belts
from an electric motor running at 750 r.p.m. The diameter of the pulley on the compressor shaft
must not be greater than 1 meter while the centre distance between the pulleys is limited to 1.75
meter. The belt speed should not exceed 1600 m/min. Determine the number of V-belts required
to transmit the power if each belt has a cross-sectional area of 375 mm2, density 1000 kg/m3 and
an allowable tensile stress of 2.5 MPa. The groove angle of the pulleys is 35°. The coefficient of
friction between the belt and the pulley is 0.25.

Problem 6: Find the maximum power (Pmax) that can be transmitted by the V-belt drive shown in
figure below under the following conditions: smaller pulley speed = 4000 rpm, smaller pulley
radius = 100 mm, β = 18°, θ = 170°, µ = 0.20, belt maximum tension = 1300 N, and belt unit weight
= 1.75 N/m and number of V-belts = 3.
 Figure 4.4 V-Belt Drives (Source: Fundamentals of Machine Component Design by Robert
Juvinall)

Maximum Power/belt Pmax = (T1 − T2 )vmax

Tt 1300
TC = = = 433 N
3 3
Tension on tight side T1 = Tt − TC = 1300 − 433 = 867 N → Equation (a)
T1  0.2
= e   where  ' = = = 0.647
'
Ratio of tensions
T2 sin  sin18

T1 0.647170 
=e 180
= 6.82 → Equation (b)
T2

T1
From equations (a) and (b), T2 = = 127 N
6.82
w 1.75
mass of belt m = = = 0.178 kg/m length
g 9.81
Tt 1300
 max = = = 49.28 m/sec
3m 3  0.178

 Maximum Power/belt (Pmax ) = (T1 − T2 ) max = (867 − 127)  49.28 = 36.46 kW

Maximum Power for 3 belts = 3  36.46 = 109.4 kW
Problem 7: The following data is given for a V-belt connecting 20 kW motor pulley to a
compressor.

Parameters Motor Pulley Compressor Pulley

Speed 1440 rpm 900 rpm
Pitch Diameter (mm) 300 900
Coefficient of friction 0.2 0.2

The centre distance between the pulleys is 1 m. Cross-section of the belt is trapezoidal with
parallel sies being 12 mm and 22 mm respectively and the depth is 14 mm. The density of the
composite belt is 0.97 gm/cc and the allowable tension in the belt is 850 N. Determine the number
of belts required for this application.

ℎ 14(22+12)
(Hint: area of belt a = (𝑏1 + 𝑏) = = 238 𝑚𝑚2 )
2 2

Problems for Practice

Problem 1: The layout of a leather belt drive transmitting 15 kW power is shown in figure below.
The centre distance between the pulleys is twice the diameter of the bigger pulley. The belt should
operate at a velocity of 20 m/sec approximately and the stresses in the belt should not exceed
2.25 N/mm2. The density of leather is 0.95 gm/cc and the coefficient of friction is 0.35. The
thickness of belt is 5 mm. Calculate:

(i) The diameters of pulleys (ii) The width of belt and (iii) The belt tensions
[Answer: (i) d1 = 270 mm and d2 = 810 mm (ii) b = 127 mm (iii) T1 = 1429 N; T2 = 692 N]
 Fig. 4.5 (Source: Design of Machine Elements by V.B. Bhandari)

Problem 2: Determine the maximum power (Pmax) that can be transmitted by a V-belt for the
following particulars: Effective diameter of smaller pulley = 1.2 m; Number of grooves (belts) = 10
and groove angle = 45º; Angle of contact = 160º and coefficient of friction µ = 0.28; Maximum
permissible tension in the belt = 960 N and mass of belt = 1.2 kg/m length.

[Answer: Pmax for 10 belts = 91 kW]

Problem 3: Power is transmitted between two shafts by a V-belt whose mass is 0.9 kg/m length.
The maximum permissible tension in the belt is 2.2 kN. The angle of lap is 170º and the groove
angle is 45º. If the coefficient of friction between the belt and pulley is 0.17, find (i) Velocity of the

belt for maximum power ( max ) (ii) Power transmitted at this velocity (Pmax). [Answer: (i)  max

= 28.54 m/sec (ii) Pmax = 30.6 kW]

Problem 4: Determine the number of V-belts required to transmit 40 kW power under the
following conditions:

Parameters Smaller Pulley Larger Pulley

Speed 1120 rpm 280 rpm
Diameter 225 mm 900 mm
Pulley groove angle 34º 34º

Maximum working load per belt = 560 N Co-efficient of friction = 0.15

Centre distance between pulleys = 875 mm Mass of belt = 0.3 kg/m length
References:

Text Books:

1. Fundamentals of Machine Component Design, Third Edition by Robert. C.Juvinall

and Kurt. M. Mashrek, John Wiley & Sons Publications, 2003.
2. Machine Design by R.S. Khurmi and J.K.Gupta, Fourth Edition, S.Chand
Publications, 2005.

Reference Books:

1. Shigley’s Mechanical Engineering Design, Eighth Edition by Budynas−Nisbett,

McGraw Hill Publications, 2006.
2. Mechanical Design by Peter.R.N.Childs, Second Edition, Elsevier Butterworth Heinmann
Publications, 2004.
3. Design of Transmission Systems by Dr.P.Kannaiah, Scitech Publications (India) Pvt.Ltd,
2007.