Stress Analysis

1. Determining Allowable Contact Stresses [σH]

In a fatigue analysis, the maximum contact stresses [σH] that may be allowed
in long time operation are calculated as
The factor of safety SH: is taken as
 1.1 with normalizing, martempering, and full hardening and
 1.2 with surface hardening and casehardening.
 For critical drives whose failure may have grace consequences, SH is usually increased
by 15 %.
 The durability factor KHL: takes care of the service life and loading condition of a
given drive

Where, is the number of repeated stress cycles to be sustained in contact

is the design number of stress cycles that the gear can sustain under constant load
2. Determining the Allowable Bending Stresses
The allowable bending stress can given by the following formula

is the factor of safety in being ranging between 1.7 and 2.2 ( the
greater value is taken for cast gear blanks).
takes care of load reversal ( it is taken equal to 1 with unidirectional
loading and from 0.7 to 0.8 with reversal loading)
YR accounts for the roughness of the transition surface of the teeth (Y R
=1.05 with case hardening, carbonitriding and nitriding, Y R=1.2 with
martempering and normalizing, YR=1.05 to 1.2 with induction
hardening, the greater value being specified for full hardening)
KbL is the durability factor and is determined as :
 For BHN ≤ 350

 For BHN >350

Where, Nbo =4*106 is the number of repeated stress cycles to be

sustained in bending for all steels

Nb is the design number of stress cycles that the gear can
sustain under constant load
σ 0 b lim b : is the endurance limit of the teeth in bending corresponding to the
number of repeated stress cycles to be sustained
Helical Gearing
Dimension Analysis
In helical gear, the spacing of the teeth may be measured in the direction t-t or in the direction n-n.
Therefore, two circular pitches, namely the transverse circular pitch Pt (usually called the circular

pitch) in the former case and the normal circular pitch Pn in the latter case, are generally specified.
Accordingly, two modules, notably the transverse module m t =Pt/ π and the normal module mn=Pn/ π
are distinguished.

Pt=Pn/cosβ
mt=mn/cosβ , where β is the
helix angle and ranges from
80 to 150 and sometimes 200
 Pitch diameter
d=dw= mtz= mnz/cosβ
 Addendum
ha= mn
 Dedendum
hf=1.25mn
 Clearance
C=0.25mn
 Diameters of concentric circles
da=d+2mn
df=d-2.5mn
 Center distance
aw= (d1+d2)/2=mn(z1+z2)/ (2cosβ)
Force Analysis

 Tangential force
Ft=2T1/d1

Where, T1 is the applied torque

d1 is the pitch diameter

 Radial force
Fr= ( Ft/cosβ) tanαw
 Axial force
Fa=Ft tanβ
 Chapter 3
Design of Belt, Rope and Chain Drives
Introduction
Types of Drive
Drives may categorized into two groups:- friction drive and engagement
drive.

Friction drive:- power is transmitted by means of friction. Eg. Belt drive

and rope drive

Engagement drives:-power transmission occurs by means of successive

engagement and disengagement of two solid parts. Eg. Gear drive and chain
Transmission of power by Belt and Rope drives

Introduction
⚫ The belts 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 :
i. The velocity of the belt.
ii. The tension under which the belt is placed on the pulleys.
iii. The arc of contact between the belt and the smaller pulley.
iv. The conditions under which the belt is used.
Types of Belt Drives

The belt drives are usually classified into the following

three groups:
1.Light drives. These are used to transmit small powers at
belt speeds upto about 10 m/s as in agricultural machines
and small machine tools.
2.Medium drives. These are used to transmit medium
powers at belt speeds over 10 m/s but up to 22 m/s, as in
machine tools.
3.Heavy drives. These are used to transmit large powers at
belt speeds above 22 m/s as in compressors and generators
Types of Belts
⚫ Though there are many types of belts used these days, yet
the

 Used where a • Used where a great

• Used where a great
moderate amount of amount of power
amount of power is to be is to be
power is to be transmitted, from one
transmitted, from one transmitted, from
pulley to another, one pulley to
pulley to another • when the two another,
 when the two
pulleys are • when the two
pulleys are not pulleys are more
more than 8 metres very near to each than 8 metres apart
apart. other.
Material and Working Stresses in Belts
1. Leather belts
2. Cotton or fabric belts
3. Rubber belt
4. Balata belts

⚫The ultimate strength of leather belt varies from

21 to 35 MPa and a Factor of safety may be
taken as 8 to 10.
⚫However, the wear life of a belt is more
important than actual strength.
Belt Speed
⚫A little consideration will show that when the
speed of belt increases, the centrifugal force also
increases which tries to pull the belt away from the
pulley.
⚫This will result in the decrease of
power transmitted by the belt.
⚫ It has been found that for the efficient
transmission of power, the belt speed 20 m/s to
22.5 m/s may be used.
Types of Flat Belt Drives

Open belt drive Crossed or twist belt drive.

Velocity Ratio of a Belt Drive
• It is the ratio between the velocities of the driver and the follower or
driven. It may be expressed, mathematically, as:
Let
d1 = Diameter of the driver, d2 = Diameter
of the follower,
N1 = Speed of the driver in r.p.m., N2 = Speed of
the follower in r.p.m.,

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

The velocity ratio of a belt drive may also be obtained as

Selection of a Belt Drive

The following are the various important factors upon

which the selection of a belt drive depends:
1. Speed of the driving and driven shafts,
2. Speed reduction ratio,
3. Power to be transmitted,
4. Centre distance between the shafts,
5. Space available
Length of an Open Belt Drive

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22
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Length of a Cross Belt Drive

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25
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 Power Transmitted by a Belt

Let T1 and T2 = Tensions in the tight side and slack side of the belt respectively
in newtons,
r1 and r2 = Radii of the driving and driven pulleys respectively in metres, and
ν = Velocity of the belt in m/s.
The effective turning (driving) force at the circumference of the driven pulley
or follower is the difference between the two tensions (i.e.T1 – T2).
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While determining the angle of contact, it must be remembered that it is the angle of contact at
the smaller pulley, if both the pulleys are of the same material.We know that

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 Example

1. Find the power transmitted by a belt running over a pulley of 600 mm diameter at 200
r.p.m. The coefficient of friction between the belt and the pulley is 0.25, angle of lap
160° and maximum tension in the belt is 2500 N.
Solution:
Given: d = 600 mm = 0.6 m ; N = 200 r.p.m. ; μ = 0.25 ; Ө= 160° = 160 × π/ 180 = 2.793
rad ; T1 = 2500 N
We know that velocity of the belt,

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Con………..

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 V-belt drive


V-belt is mostly used in factories and workshops
where a great amount of power is to be transmitted
from one pulley to another when the two pulleys are
very near to each other.
Advantages of V-belt drive

⚫ The V-belt drive gives compactness due to the small distance between centres of

pulleys.
⚫ The drive is positive, because the slip between the belt and the pulley groove is

negligible.
⚫ Since the V-belts are made endless and there is no joint trouble, therefore

the drive is smooth.

⚫ It provides longer life, 3 to 5 years.

⚫ It can be easily installed and removed.

⚫ The operation of the belt and pulley is quiet.

 Disadvantages of V-belt drive
⚫ The V-belt drive can not be used with large centre distances, because of larger weight per
unit length.
⚫ The V-belts are not so durable as flat belts.

⚫ The construction of pulleys for V-belts is more complicated than pulleys of flat belts.

⚫ Since the V-belts are subjected to certain amount of creep, therefore these are not suitable for

constant speed applications such as synchronous machines and timing devices.

⚫ The belt life is greatly influenced with temperature changes, improper belt tension and

mismatching of belt lengths.

⚫ The centrifugal tension prevents the use of V-belts at speeds below 5 m / s and above 50 m

/ s.
Con………
 The V belts are made of fabric and cords moulded in rubber and covered with fabric
and rubber as shown in Fig. (a). These belts are moulded to a trapezoidal shape and
are made endless. These are particularly suitable for short drives.
 A clearance must be provided at the bottom of the groove as shown in Fig. (b), in
order to prevent touching of the bottom as it becomes narrower from wear.
 The V-belt drive may be inclined at any angle with tight side either at top or bottom.
 In order to increase the power output, several V-belts may be operated side by side. I

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Con………
The following table shows the Dimensions of standard V-belt

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 Rope Drives
 The rope drives are widely used where a large amount of power is to be
transmitted, from one pulley to another, over a considerable distance.
 The ropes drives use the following two types of ropes :
1. Fibre ropes, and
2. Wire ropes.
 The fibre ropes operate successfully when the pulleys are about 60 metres
apart, while the wire ropes are used when the pulleys are upto 150 metres
apart.
 Fibre Ropes

 The ropes for transmitting power are usually made from fibrous materials
such as hemp, manila and cotton.
 Since the hemp and manila fibres are rough, therefore the ropes made from
these fibres are not very flexible and possesses poor mechanical properties.
In order to minimise this defect, the rope fibres are lubricated with a tar,
tallow or graphite.
 The lubrication also makes the rope moisture proof. The hemp ropes are
suitable only for hand operated hoisting machinery and as the ropes for
lifting tackle, hooks etc.
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Sheave for Fibre Ropes

The fibre ropes are usually circular in cross-section as shown in Fig. (a). The sheave for
the fibre ropes, is shown in Fig.(b). The groove angle of the pulley for rope drives is
usually 45°.

The grooves in the pulleys are made narrow at the bottom and the rope is pinched
between the edges of the V-groove to increase the holding power of the rope on the
pulley. 38
Advantages of Fibre Rope Drives

The fibre rope drives have the following advantages:

1. They give smooth, steady and quiet service.
2. They are little affected by outdoor conditions.
3. The shafts may be out of strict alignment.
4. The power may be taken off in any direction and in fractional parts of
the whole amount. 5. They give high mechanical efficiency.

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 Wire Ropes
 When a large amount of power is to be transmitted over long distances from one pulley
to another (i.e. when the pulleys are upto 150 metres apart), then wire ropes are used.
 The wire ropes are widely used in elevators, mine hoists, cranes, conveyors, hauling
devices and suspension bridges.
 The wire ropes are made from cold drawn wires in order to have increase in strength and
durability.
 The various materials used for wire ropes in order of increasing strength are wrought
iron, cast steel, extra strong cast steel, plough steel and alloy steel. For certain purposes,
the wire ropes may also be made of copper, bronze, aluminium alloys and stainless
steels.
Advantages of Wire Ropes
The wire ropes have the following advantages as compared to fibre ropes.
1. These are lighter in weight,
2. These offer silent operation,
3. These can withstand shock loads,
4. These are more reliable,
5. These are more durable,
6. They do not fail suddenly,
7. The efficiency is high, and
8. The cost is low.

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Designation of Wire Ropes
 The wire ropes are designated by the number of strands and the number of wires in
each strand. For example, a wire rope having six strands and seven wires in each
strand is designated by 6 × 7 rope. Following table shows the standard designation of
ropes and their applications:

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Construction of Wire Ropes
The wires are first given special heat treatment and then cold drawn in order to have high
strength and durability of the rope. The steel wire ropes are manufactured by special
machines. First of all, a number of wires such as 7, 19 or 37 are twisted into a strand and
then a number of strands, usually 6 or 8 are twisted about a core or centre to form the rope
as shown in Fig. The core may be made of hemp, jute, asbestos or a wire of softer steel.

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 Assignment
Write a review on Chain drive
Your review must include a detail description of chain drive. And include your
reference
Thank you!

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