Power or Energy produced in one machine can be transmitted to another machine (or) between two members of a machine by means

of some intermediate mechanism called drives or power transmission systems.

(UNIT I) FLEXIBLE ELEMENTS (BELT, CHAIN AND ROPES)

(UNIT II) SPUR AND PARALLEL AXIS HELICAL GEARS (UNIT III) BEVEL, WORM AND CROSSED HELICAL GEARS (UNIT IV) DESIGN OF GEAR BOXES (UNIT V) DESIGN OF CAM, CLUTCHES AND BRAKES

Classification of Mechanical drives

According to physical condition

Friction drives (Belt and Rope drives)

Toothed drives (Gears and chain drives)

According to method of linking

Direct contact drives (Gear drives)

Drives with intermediate link (Belt, rope and chain drives)

Classification of Belt Drives

Based on power transmission

Belt materials

Light duty drives About 5 kW power, velocity up to 10 m/s Ex: Pumps

Leather (Oak tanned or chrome tanned) fabrics (Canvas or woven cotton ducks) rubber (Canvas or cotton duck impregnated with rubber, For greater tensile strength, the rubber belts are reinforced with steel cords or nylon cords) plastics (Thin plastic sheets with rubber layers )

medium duty drives 5 kW to 20 kW power, velocity up to 20 m/s Ex: punch and printing machinery
Heavy duty drives More than 20 kW power, more than 20 m/s Ex: Turbines

Based on centre distance

For long distance about 5m to 20m Flat belts For short distance less than 5m V belts, toothed belts etc.

Based on cross section

Flat belts

V belts ( single V belt, multiple V belt ribbed belt)

Toothed or timing belt Round belt

Power to be transmitted Service conditions Factors considered for selection of belt drives Based on wear resistance, durability, strength, flexibility & coefficient of friction Speed of the machinery shaft

Space availability for installation

Center distance

Velocity ratio

Advantages: long distance power transmission, withstand shock and vibration, adjusting misalignment between driving and driven machine, simple in design, low cost Disadvantages: large space, belt slipping, exert heavy load on the shaft and bearings, power loss due to friction, shorter life

Flat belt joints

Cemented joints

Laced joints

Hinged joints

Open belt drives

Cross belt drives

No crossing between belts, Pulleys are rotating in same direction,

Vibration due to long centre distance, slip due to low frictional grip

Pulleys are rotating in opposite direction due to crossing, More angle of contact
Belts rubs during crossing leads to wear, bending in two different planes

Friction between the belt and the pulley is responsible for transmitting power from one pulley to the other. Due to the presence of friction between the pulley and the belt surfaces, tensions on both the sides of the belt are not equal.

Relationship between belt tensions

Free body diagram of a belt segment

The length of the belt segment frictional force N

Centrifugal force due to the motion of the belt

Important terms

The motion of the belt and pulley assuming a firm frictional grip between
the belts and pulleys. Sometimes, the frictional grip becomes insufficient and may cause forward motion of a pulley without carrying the belt. This is called slip of the 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 slack side. Due to these changes of length, there is a relative motion between the belt and the pulley surfaces. This relative motion is termed as creep.

Flat belt drive

Packing Depot
Baggage Handling

Coal industry

 The belt thickness can be built up with a number of layers. The number of layers is known as ply.

Typical Belt drive specifications Material No. of ply and Thickness Maximum belt stress per unit width Coefficient of friction of the belt material Density of Belt material

Centrifugal Tension in the Belt

When a belt runs over a pulley, some centrifugal force is caused, whose effect is to increase tension on both tight side and slack

side of the drive. This tension caused by centrifugal force is

known as centrifugal tension.
At high speed greater than 10 m/s, effect of centrifugal force is

considerable .

If the effect of centrifugal tension is considered, Then, the total tension in the tight side Tmax = T1 + TC Total tension in the slack side Tmin = T2 + TC Where, T1 = Tension in the tight side of the belt T2 = Tension in the slack side of the belt TC = Centrifugal tension

Therefore, centrifugal tension has no effect on the power transmission.

Condition for Maximum Power Transmission

when the power transmitted is maximum, 1/3rd of the maximum tension (T) is absorbed as centrifugal tension (TC) .

Crowning of Pulley
Pulleys are provided with a slight conical shape or convex shape in their outer rim surface to prevent the belt from running off the pulley due to

centrifugal force. This is known as crowing of pulley.

Usually crowning height may be 1/96 th of the pulley width.

Sag in the belt drive

In horizontal belt drive, loose side is usually kept on the top. On the

upper side, the sag of the belt due to its own weight slightly increases the
arc of contact with the pulleys and increases the efficiency of the drive. If the lower side is slack side, then sag will reduce the angle of contact with the pulleys. This has to be avoided to gain the power transmission. In case of vertical belt drive, due to gravitational force on the belt, it will try to fall away from the lower surface of the lower pulley. This causes slip and reduces the efficiency of the drive. To run such a drive, the belt has to run with excessive tension with consequent increase in bearing reactions and reduced belt life.

Timing belt or Ribbed belt

Timing belt has toothed shape in their inner surface. Their engagement with toothed pulley will provide positive drive without any belt slip where as in the case of ordinary V belts chances for slip are more. Hence toothed shape belts ( i.e. timing belts) are always superior than V belts.

Initial tension not required reduces the bearing action high strength to weight ratio costlier than the V and flat belts more sensitive to misalignment

Timing belt or Ribbed belt

Timing belt or Ribbed belt

Round Belts
Round belts are made of leather, canvas and rubber. The diameter of the round belts are usually 3 to 12 mm. They are suitable for , 90 twist, reverse bending or serpentine applications. Round belts are limited to light duties dish washer drives, sewing machines, vacuum cleaner, light duty textile machinery.

Trapezoidal groove

Half round groove

Quarter turn Belt Drive

The quarter turn belt drive (also known as right angle belt drive) as is used with shafts arranged at right angles and rotating in one definite direction. In order to prevent the belt from leaving the pulley, the width of the face of the pulley should be greater or equal to 1.4 b, where b is width of belt. when the reversible motion is desired, then a quarter turn belt drive with a guide pulley, may be used.

Design of V Belt Drive

In case of V belt drive, power is transmitted by the wedging action between the belt and the v groove in the pulley or sheave.
A clearance should be provided at the bottom of the groove to prevent touching of the bottom as it becomes narrower from wear. To increase the power transmission, multiple V belts can be operated side by side. All the belts should stretch at the same rate so that the load is equally shared between them. When one of the set of belts break, the entire set should be replaced at the same time. If only one belt is replaced, the new unworn and unstretched belt will be more tightly stretched and will move with different velocity.

Forces acting on an element of V Belt

The force components T, T+ dT and Centrifugal force are same as like flat belt element. But the normal reaction which act on the sides of the V belt.

Different failures in belt drives

Design of Wire rope

Wire rope is a type of rope which consists of several strands of metal wire twisted into a helix. Lighter in weight silent operation withstand shock loads do not fail suddenly more reliable Applications: Elevators - mine hoists cranes conveyors - hauling devices suspension bridges

Left-hand Lang's lay (RHLL) wire rope Strands are twisted into a left hand side

Right-hand Lang's lay (RHLL) wire rope Strands are twisted into a right hand side

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 meters apart), then wire ropes are used.

Rope construction 6x7

Wire diameter dw
where d = rope diameter

Area of cross section (Approx. 0.38 d2

0.106 d

6 x 19 6 x 37
8 x 19

0.063 d 0.045 d
0.05 d

0.38 d2 0.38 d2
0.38 d2

Cross or regular lay ropes direction of twist of wires in the strands is opposite to the direction of twist of the stands Parallel or lang lay ropes direction of twist of the wires in the strands is

same as that of strands in the rope

Composite or reverse laid ropes wires in the two adjacent strands are

twisted in the opposite direction

Stresses in Wire Ropes

Direct stress due to axial load lifted and weight of the rope

Bending stress when the rope winds round the sheave or drum The approximate value of the bending stress in the wire as proposed by Reuleaux

Equivalent bending load on the rope

Load on the whole rope due to bending

Impact load and stress during starting

Effective stresses in the wire rope at different situations

Impact Loading: The load which is rapidly applied to the machine component is known as impact load.

Impact stress = Twice the stress produced by gradual load

Thimble with four or five wire tucks

Wire rope socket with zinc

Regular thimble with clips

Special offset thimble with clips

Three bolt wire clamps

Design of Chain Drives

Positive drive No slip No Creep high temperature service Easier to install compact than belt drives

Classification of Chains

Hoisting and hauling chains

Used for suspending, raising or lowering loads in material handling equipments Chain with oval links

Conveyor chains Used for carrying materials continuously in conveyors by sliding Detachable or hook joint type chain

Chain with square links

Closed joint type chain

Power transmitting chains Roller chain

Used for transmitting power from one shaft to another shaft

Types of roller chain

Silent chain
Inverted tooth chain formed by laminated steel plates each plate has two teeth with space to accommodate tooth of the sprocket for high speed applications silent operation

Breaking load: The maximum tensile

load which if applied will result in chain

failure is known as breaking load.