UNIT 8 BELT, CHAIN, GEARS AND LAW OF GEARING 8.

1 INTRODUCTION The power is transmitted from one shaft to the other through chains, belts and gears. The ropes and belts are flexible members that are utilized where distance among the two shafts is big. The chains also contain flexibility however they are preferred for intermediate distances. The gears are utilized while the shafts are very close along each other. This kind of drive is known as positive drive as there is no slip. If the distance is slightly larger, chain drive may be utilized for making it a positive drive. Ropes and belts transmit power because of the friction among the belt or rope and the pulley. There is a option of slip and creep and that is why, this drive is not positive drive. Objectives After learning this unit, you must be able to appreciate power transmission derives, understand law of belting and gearing, Find out power transmitted by belt drive, Find out dimensions of belt for given power to be transmitted, understand kinematics of chain drive, categorize gears, and understand gear terminology.

8.2 POWER TRANSMISSION DEVICES Power transmission devices are very normally utilized to transmit power from one shaft to another. Chains, belts and gears are utilized for this reason. While the distance among the shafts is large, belts or ropes are utilized and for intermediate distance chains may be utilized. For belt drive distance may be maximum but this must not be more than ten metres for good results. 8.2.1 Belts In case of belts, friction among the belt and pulley is utilized to transmit power. In practice, there is always some amount of slip among belt and pulleys, thus, exact velocity ratio may not be obtained. That is why; belt drive is not a positive drive. Hence, the belt drive is utilized where exact velocity ratio is not needed. The following kinds of belts illustrated in given figure are most commonly utilized :

(a) Flat Belt and Pulley

(b) V-belt and Pulley (c) Circular Belt or Rope Pulley

The flat belt is rectangular in cross-section as illustrated in Figure (a). The pulley for this belt is slightly crowned to avoid slip of the belt to one side. It uses the friction among the flat surface of the pulley and belt. The V-belt is trapezoidal in section as illustrated in Figure (b). It uses the force of friction among the inclined sides of the pulley and belt. They are preferred while distance is comparative shorter. Various V-belts can also be utilized together if power transmitted is m o r e . The circular belt or rope is circular in section as illustrated in Figure (c). Various ropes also can be utilized together. The belt drives are of the following kinds : (1) (2) Open belt drive, and Cross belt drive.

Open Belt Drive Open belt drive is utilized when sense of rotation of both of the pulleys is similar. It is wanted to keep the tight side of the belt on the lower side to enhance the angle of contact on the pulleys. This kind of drive is illustrated in given Figure.

Cross Belt Drive In cross belt drive, the pulleys rotate in the opposite direction. The angle of contact of belt on both of the pulleys is equivalent. This drive is illustrated in Figure. As illustrated in the figure, the belt needs to bend in two different planes. As a consequence of this, belt wears very fast and thus, this kind of drive is not preferred for power transmission.

As power transmitted by a belt drive is because of the friction, this kind of drive is subjected to slip and creep. Assume d1 and d2 be the diameters of driving and driven pulleys. N1 & N2 is respectively the corresponding speeds of driving and driven pulleys. The velocity of the belt passing over the driver

If there is no slip among the belt & pulley

If thickness of the belt ist, the velocity ratio is

Assume there by total percentage slip S in the belt drive shall be as follows :

The belt moves from the tight side to the slack side and vice-versa, there is some loss of power due to the length of belt continuously extends and contracts and hence, there is relative motion among the belt and pulley. This is known as creep. 8.2.2 Chain The belt drive is not a positive drive due to creep and slip. The chain drive is a positive drive. As belts, chains can be utilized for larger centre distances. They are made of metal and because of this chain are heavier than the belt but they are flexible like as belts. It also needs lubrication from time to time. The lubricant prevents chain from rusting & reduces wear. The chain and chain drive are illustrated in Figure. The sprockets are utilized in place of pulleys. The projected teeth of sprockets fit in the recesses of the chain. The distance among roller centers of two neighbouring links is called pitch. The circle passing through the pitch centers is known pitch circle.

(a)

(b)

(c) Chain and Chain Drive

(d)

Assume be the angle created by the pitch of the chain, and r be the pitch circle radius, then p = 2r sin /2 or, r = p/2 cosec (/2) The power transmission chains are built of hardened and steel to decrease wear. These chains are categorized into three categories (a) (b) (c) Block chain Roller chain Inverted tooth chain (silent chain)

Out of these three categories roller chain illustrated in Figure (b) is most commonly utilized. The construction of this kind of chain is illustrated in the figure. The roller is built of steel and then hardened to decrease the wear. A good roller chain is quitter in operation as compared to the block chain and it contains lesser wear. The block chain is illustrated in Figure (a). It is utilized for low speed drive. The inverted tooth chain is illustrated in Figures (c) and (d). It is also known as silent chain because it runs very quietly even at higher speeds. 8.2.3 Gears Gears are also utilized for power transmission. This is accomplished through the successive engagement of teeth. The two gears transmit motion through the direct contact as chain drive, gears also provide positive drive. The drive among the two gears can be defined by using plain cylinders or discs 1 and 2 with diameters equivalent to their pitch circles as illustrated in Figure. The point of contact of the two pitch surfaces shell contains velocity with the common tangent. Because there is no slip, thus, definite motion of gear 1 may be transmitted to gear 2 or vice-versa. The tangential velocity Vp = 1 r1 = 2 r2 where r1 & r2 are pitch circle radii of gears 1 & 2, respectively.

Gear Drive

o r, N 1 r1 = N 2 r2 o r,

As, pitch circle radius of a gear is proportional to its number of teeth (t).

here t1 & t2 are respectively the number of teeth on gears 1 and 2,. 8.3 LAW OF GEARING The law of gearing states that the general normal at the point of contact of two bodies that are in contact, when transfering motion, must always passes by the means a fixed point known as pitch point on the line joining the centres of rotation of the two bodies. Two bodies may be considered having general shape as illustrate in Figure. Assume point A1 on body (1) be in contact having point A2 of body (2). Points A1 & A2 are coincident points at A. Assume the common normal at point A be n n & common tangent be t t. Assume 1 be angular velocity of body (1) 2 be angular velocity of body (2) VA1 be linear velocity of point A1 VA2 be linear velocity of point A2 VA1 = 1 O1 A1 and VA2 = 2 O2 A2

The direction of V A1 is perpendicular to O1 A1 and the direction of V A2 is perpendicular to O2 A2. The perpendicular may be dropped on n n from O1 & O2 that are O1 C and O2 B, respectively. Assume angle among O1 A1 & O1 C be and angle among O2 A2 & O2 B be . Thus, V A1 & V A2 are inclined to n n respectively by and , as illustrated in Figure. The components of V A1 & V A2 along common normal are respectively V A1 cos & VA2 cos ,.

The relative velocity along n n = V A1 cos V A2 cos . The common normal is line of transmission of motion the relative velocity with this line must be zero to avoid separation or penetration. Thus, VA1 cos VA 2cos = 0 o r, VA1 cos = VA2 cos o r, 1 O1 A1 cos = 2 O2 A2 cos

or 1 O1 C = 2 O2 B o r, 1 = O2 B 2 = O1 C s O1 P C and O2 P B are alike. Thus,

. . . (8.1) Therefore, if it is desired that the velocity ratio among bodies (1) & (2) is to remain constant the location of point P must remain fixed because O1 & O2 already have fixed positions. Hence, while the two bodies (1) & (2) transmit motion, the common normal at the point of contact must always intersect the line joining the centres of rotation at a fixed point to have constant velocity ratio. Velocity of Sliding If the surfaces of the two bodies are in contact, there may be sliding motion among them along with common tangent t t at A. Component of VA1 along common tangent = VA1 sin Component of V A2 along common tangent = VA2 sin Velocity of sliding = VA1 sin VA2 sin

= 1 A 1 C 2A 2 B = 1 ( PC + A1 P) 2 ( PB A2 P) = (1 A1 P + 2 A2 P) + (1 PC 2 PB) As, A1 and A2 are coincident points at A. Thus, A1 P = A2 P = AP Therefore, velocity of sliding = AP (1 + 2 ) + (1 PC 2 PB) From alike triangles O1 PC and O2 PB

Thus, from Eq. (8.1),

o r, 1 PC = 2 PB o r, 1 PC 2 PB = 0 Velocity of sliding = AP (1 + 2 ) . . . (8.2)

From Eq. (8.2), the velocity of sliding is equivalent to sum of angular velocities of two bodies multiplied by distance of point of contact through fixed point P that is called pitch point. 8.4 POWER TRANSMISSION BY BELTS In this section, we will discuss how power is transmitted through a belt drive. The belts are utilized to transmit very small power to the high amount of power. In some of the cases magnitude of the power is negligible however the transmission of speed just may be significant. In such cases the axes of the two shafts might not be parallel. In some of the cases to enhance the angle of lap on the smaller pulley, the idler pulley is utilized. The angle of lap might be defined like the angle of contact among the belt & the pulley. Having the increase in angle of lap, the belt drive may transmit more power. Along with the enhance in angle of lap, the idler pulley also does not permit reduction in the initial tension in the belt. The utilization of idler pulley is illustrated in Figure.

Use of Idler in Belt Drive 8.4.1 Law of Belting The law of belting states that the centre line of the belt like it approaches the pulley, ought to be lie in plane perpendicular to the axis of the pulley in the mid plane of the pulley or else the belt will run off the pulley. But, the point at which the belt leaves the other pulley ought to lie in the plane of a pulley.

The given Figure below illustrates the belt drive in which two pulleys are at right angle to each other. It may be seen that the centre line of the belt approaching larger or smaller pulley lies in its plane. The point at which the belt leaves is contained in the plane of the other pulley. If motion of the belt is reversed, the law of the belting shall be violated. Thus, motion is possible in one direction in case of non-parallel shafts as illustrated in Figure.

8.4.2 Length of the Belt For any kind of the belt drive it is always wanted to know the length of belt needed. It will be needed in the selection of the belt. The length may be estimated by the geometric considerations. But, actual length is slightly shorter. Open Belt Drive The open belt drive is illustrated in Figure. Assume O1 and O2 are the pulley centers and AB and CD are the common tangents on the circles demonstrating the two pulleys. The entirety length of the belt L is given by following L = AB + Arc BHD + DC + Arc CGA Assume r be the radius of the smaller pulley,

R be the radius of the larger pulley, C be the centre distance among the pulleys, and be the angle subtended through the tangents AB and CD with O1 O2.

C J

Draw O1 N parallel to CD to meet O2 D at N. By geometry, O2 O1, N = C O1 J = D O2 K= Arc BHD = ( + 2) R, Arc CGA = ( + 2) r AB = CD = O1 N = O1 O2 cos = C cos sin = R r/ C o r, = sin 1 (R r )/ C

For small value of ; = (R r )/C

It provides approximate length.

Crossed-Belt Drive The crossed-belt drive is illustrated in given Figure. Draw O1 N parallel to the line CD that meets extended O2 D at N. By geometry C O1 J = D O2 K = O2 O1 N L = Arc AGC + AB + Arc BKD + CD Arc AGC = r (+ 2), and Arc BKD = ( + 2) R sin = R + r/c or = sin 1 (R + r)/c For small value of

L = r (+ 2) + 2C cos + R ( + 2) = (+ 2) (R + r ) + 2C cos

For approximate length

8.4.3 Cone Pulleys Sometimes the driving shaft is driven through the motor that rotates at constant speed however the driven shaft is designed to be driven at different speeds. It can be easily completed using stepped or cone pulleys as illustrated in Figure. The cone pulley contains different sets of radii and they are decided such that the similar belt may be utilized at different sets of the cone pulleys.

Assume Nd be the speed of the driving shaft that is constant. Nm be the speed of the driven shaft while the belt is on nth step. rn be the radius of the nth step of driving pulley. Rn be the radius of the nth step of the driven pulley. Where n is an integer i.e., 1, 2, . . . The speed ratio is inversely proportional to the pulley radii

. . . (8.3) For this first step radii r1 and R1 can be selected conveniently. For second pair

, and likewise In order to utilize same belt on all of the steps, the length of the belt must be same i.e. L1 = L2 = .. . = Ln . . . (8.4)

Therefore, two equations are available one provided through the speed ratio and other provided through the length relation & for chosen speed ratio, the two radii may be calculate. Also it needs to be kept in mind that the two pulleys are similar. It is wanted that the speed ratios must be in geometric progression. Assume k be the ratio of progression of speed.

As, both of the pulleys are made alike.

. . . (8.5) If radii R1 and r1 have been selected, the above equations provide value of k or viceversa. 8.4.4 Ratio of Tensions The belt drive is utilized to transmit power from one shaft to another. Because of the friction among the pulley & the belt one side of the belt becomes tight side & other becomes slack side. We needs to first determine ratio of tensions. Flat Belt

Assume tension on the tight side is T1 and the tension on the slack side is T2. Assume be the angle of lap and is the coefficient of friction among the belt and the pulley. Assume an infinitesimal length of the belt PQ that subtends an angle at the centre of the pulley. Assume R be the reaction among the element & the pulley. Consider T be tension on the slack side of the element that is at point P and assume (T + T) be the tension on the tight side of the element.

The tensions T & (T + T) will be applying tangential to the pulley and so normal to the radii OP & OQ. The friction force will be equivalent to R and its action shall be to prevent slipping of the belt. The friction force shall act tangentially to the pulley at the point S. Resolve all of the forces in the tangential direction

. . . (8.6) Resolving out all the forces in the radial direction.

As is very small, by taking limits

Neglecting the product of the two infinitesimal quantities in comparison to other quantities:

that is negligible

Substituting the value of R and T = T o r, T/T = By Taking limits on both of sides as 0 d T/ T = d Integrating among limits, it becomes

1 in Eq. (8.6), we obtain

V-belt or Rope The V-belt or rope make contact on the two sides of the groove as illustrated in fig

(a)

(b)

Assume the reaction be Rn on each of the two sides of the groove. The resultant reaction shall be 2Rn sin . Determine all the forces tangentially in the Figure (b), we obtain

. . . (8.8) Determining all the forces radially, we obtain

As is very small

By neglecting the product of the two infinitesimal quantities

By putting the value of Rn and utilizing the approximation we obtain

Taking the limits and integrating between limits, we get

.........8.9

8.4.5 Power Transmitted by Belt Drive The power transmitted through the belt based on the tension on the two sides and the belt speed. Consider T1 is the tension on the tight side in N T2 is the tension on the slack side in N, and V is the speed of the belt in m/sec. Then power transmitted through the belt is given through

Power P = (T1 T2 ) V = ((T1 T2 ) V)/1000 kW . . . (8.10)

If belt is on the point of slipping.

. . . (8.11)

The maximum tension T1 based on the capacity of the belt to endure force. If permit able stress in the belt is t in Pa, that means N/m2, then T1 = (t t b) N . . . (8.12)

Here t is thickness of the belt in m and b is width of the belt also in m. The above equations may also be utilized to find out b for given power and speed. 8.4.6 Tension due to Centrifugal Forces The belt contains mass and as it rotates along the pulley this is subjected to centrifugal forces. If we suppose that no power is being transmitted and pulleys are rotating, the centrifugal force shall tend to pull the belt as illustrated in Figure (b).

(a)

(b)

Assume TC is the tension because of centrifugal forces or it is also known as centrifugal tension. Consider a small element that subtends an angle at the centre of the pulley. Assume m be the mass of the belt per unit length of the belt in kg/m. The centrifugal force Fc on the element shall be given by following

Here V is speed of the belt in m/sec. and r is the radius of pulley in m. Determining the forces on the element normal to the tangent

As is very small.

By putting for FC

o r, TC = m V 2 . . . (8.13)

Thus, by considering the influence of the mass of the belt the tension on the tight side while power is transmitted is given by following Tension of tight side Tt = T1 + TC and tension on the slack side Ts = T2 + TC .

The centrifugal tension contain an effect on the power transmitted due to maximum tension may be only Tt that is Tt = t t b T1 = t t b m V 2 8.4.7 Initial Tension While a belt is mounted on the pulley some amount of initial tension call T0 is provided in the belt, or else power transmission is not possible due to a loose belt may not sustain difference in the tension. While the drive is stationary the whole tension on both sides shall be 2 T0. While belt drive is transmitting power the entire tension on both of the sides shall be (T1 + T2), here T1 is tension on tight side, and T2 is tension on the slack side. If influence of centrifugal tension is neglected. 2T0 = T1 + T2 o r,

If effect of centrifugal tension is considered, then T0 = Tt + Ts = T1 + T2 + 2TC o r,

....8.14 8.4.8 Maximum Power Transmitted The power transmitted based on the tension T1, angle of lap , coefficient of friction & belt speed V. For a specified belt drive, the maximum tension (Tt), angle of lap and coefficient of friction will remain constant provided that (a) The tension on tight side, that means maximum tension must be equivalent to the maximum permissible value for the belt, and (b) the belt must be on the point of slipping.

Thus, Power P = T1 (1 e ) V As, T1 = Tt + Tc o r, P = (Tt Tc ) (1 e ) V o r, P = (Tt m V 2 ) (1 e ) V dP/dV = (Tt 3m V 2 ) (1 e ) For maxima & minima dP/dv = 0 (Tt 3m V 2 ) (1 e ) = 0 o r, o r, Tt 3m V 2 = 0 Tc = Tt / 3

As well as,

. . . (8.15) At the belt speed specified by the Eq. (8.15) the power transmitted through the belt drive will be maximum. 8.5 KINEMATICS OF CHAIN DRIVE The chain is wrapped round the sprocket as illustrated in Figure (d). The chain in motion is illustrated in Figure. This might be observed that the position of axial line modify among the two position as illustrated by the dotted line & full line. The dotted line meets at B while extended having the line of centres the firm line meets the line of centres at A while extended. The speed of the driving sprocket call 1 will be constant however the velocity of chain shall vary among 1 O1 C and 1 O1 D. Thus,

The variation in the chain speed is responsible for the variation in the angular speed of the driven sprocket. The angular speed of the driven sprocket shall vary between

This variation may be drop off by enhancing number of teeth on the sprocket. 8.6 CLASSIFICATION OF GEARS There are different kinds of arrangement of shafts that are utilized in practice. Accordingly to the relative positions of shaft axes, different kinds of gears are used. 8.6.1 Parallel Shafts In this, the shaft axes lie in parallel planes and keep parallel to one another. The following kind of gears are utilized on these shafts : Spur Gears These gears contain straight teeth along their alignment parallel to the axes. These gears are illustrated in mesh in Figures (a) and (b). The contact among the two meshing teeth is along with a line whose length is equivalent to whole length of teeth. It might be viewed that in external meshing, the two shafts rotate opposite to each of other while in internal meshing the shafts rotate in the similar sense.

(a) External Meshing

(b) Internal Meshing

If the gears mesh externally and diameter of the one of gear becomes infinite, the arrangement becomes Spur Rack and Pinion. This is illustrated in given figure. It changes rotary motion into translatory motion, or vice-versa.

Spur Rack and Pinion

Helical Gears or Helical Spur Gears In this, the teeth make an angle along the axes of the gears that is called helix angle. The two meshing gears contain same helix angle however its layout is in opposite sense as illustrate in given Figure

Helical Gears

The contact among two teeth takes place at a point of the leading edge. The point moves along with a diagonal line across the teeth. This results in slow transfer of load and decrease in impact load and so drop off in noise. The helical gears introduce thrust along with the axis of the shaft that is to be borne by thrust bearings.

Double-Helical or Herringbone Gears A double-helical gear is corresponding to a pair of helical gears with equal helix angle secured together, one along with a right-hand helix and the other a left-hand helix. The teeth of two rows are separated by a groove that is needed for tool run out. The axial thrust that occurs in case of single-helical gears is removed in double helical gears. If the left & right inclinations of a double helical gear meet at a similar apex & groove is removed in it, the gear is called as herringbone gear as illustrated in Figure.

8.6.2 Intersecting Shafts The motion among two intersecting shafts is corresponding to rolling of two conical frustums from kinematical view point. Straight Bevel Gears These gears contain straight teeth that are radial to the point of intersection of the shaft axes. Their teeth differ in cross section throughout their length. In general, they are utilized to connect shafts at right angles. These gears are illustrated in given fig. The teeth make line contact as spur gears.

Straight Bevel Gears Like a special case, gears of the similar size and joining two shafts at right angle to each other are called mitre gears. Spiral Bevel Gears While the teeth of a bevel gear are inclined at an angle to the face of the bevel, these gears are called as helical bevel gears or spiral bevel gears. A gear of this kind is illustrated in Figure (a). They run quitter in action and remain point contact. If spiral bevel gear contain curved teeth but along zero degree spiral angle, it is called as zerol bevel gear.

(a) Spiral Bevel Gear

(b) Zerol Bevel Gear

8.6.3 Skew Shafts These shafts are non-intersecting and non-parallel. The motion of the two mating gears is corresponding to motion of two hyperboloids in contact as illustrated in Figure. The angle among the two shafts is equivalent to the total of the angles of the two hyperboloids. That is following = 1 + 2 The minimum perpendicular distance among the two shafts is equivalent to the total of the throat radii.

Hyperboloids in Contact Crossed-Helical Gears or Spiral Gears They may be utilized for any two shafts at any angle as illustrated in Figure by appropriate option of helix angle. These gears are utilized to drive feed mechanisms on machine tool.

Spiral Gears in Contact

Worm gears This is a special case of spiral gears in which angle among the two axes is normally right angle. The smaller of the two gears is known as worm that has large spiral angle. These are illustrated in Figure.

(a)

(b)

(c) Hypoid Gears

(d)

These gears are approximations of hyperboloids though seem like spiral bevel gears. The hypoid pinion is bigger and stronger than a spiral bevel pinion. They have smooth and quit action and contain larger number of teeth is contact as compared to straight bevel gears. These gears are utilized in final drive of vehicles. They are illustrated in given figure.

Hypoid Gears

8.7 GEAR TERMINOLOGY Before considering kinematics of gears we will define the terms utilized for describing the size, shape and geometry of a gear tooth. Here given definitions are with respect to a straight spur gear. Pitch Circle or Pitch Curve This is the theoretical curve along which the gear rolls out without slipping on the equivalent pitch curve of other gear for transmitting corresponding motion. Pitch Point This is the point of contact of two pitch circles. Pinion This is the smaller of the two mating gears. Usually it is the driving gear. Rack This is part of the gear that has infinite pitch circle diameter. Circular Pitch This is the distance along the pitch circle perimeter among the corresponding points on the consecutive teeth. It is illustrated in given Figure.

Gear Terminology If d refer to diameter of the pitch circle and T is number of teeth, the circular pitch (pc) is given by following p c = d/ T Diamental Pitch This is described as the number of teeth per unit length of the pitch circle diameter. Thus, diamental pitch (pd) may be expressed as pd = T/ d . . . (8.17) . . . (8.16)

From above Eqs. (8.16) & (8.17)

o r,

pc pd =

. . . (8.18)

Module This is the ratio of the pitch circle diameter to the number of teeth. Hence, the module (m) may be expressed as following m = d/ T . . . (8.19)

From above Equations (8.16) pc = m Addendum Circle and Addendum This is the circle passing by the tips of addendum and gear teeth are the radial distance among pitch circle and the addendum circle. Dedendum Circle and Dedendum This is the circle passing by the roots of the teeth and dedendum is the radial distance among pitch circle and root circle. Full Depth of Teeth and Working Depth Full depth is addition of addendum and dedendum and working depth is addition of addendums of the two gears that are in mesh. Tooth Thickness and Space Width Tooth thickness is the thickness of tooth measured along with the space width and pitch circle is the space among two consecutive teeth deliberate along the pitch circle. They are equivalent to each other and compute half of circular pitch. Top Land and Bottom Land Top land is the top surface of and the bottom and the tooth land is the bottom surface among the adjacent fillets. Face and Flank Tooth surface among the top land and pitch surface is known as face while flank is tooth surface among the bottom land and pitch surface. Pressure Line and Pressure Angle The driving tooth exerts a force on the driven tooth along with the common normal. This line is known as pressure line. The angle among the pressure line and the common tangent to the pitch circles is called pressure angle. Path of Contact The path of contact is the locus of a point of contact of two mating teeth from the starting of engagement to the ending of engagement. . . . (8.20)

Arc of Approach and Arc of Recess Arc of approach is the locus of a point on the pitch circle from the starting of engagement to the pitch point. The arc of recess is the locus of a point through pitch point up to the ending of engagement of two mating gears. Arc of Contact This is the locus of a point on the pitch circle from the starting of engagement to the ending of engagement of two mating gears. Arc of Contact = Arc of Approach + Arc of Recess Angle of Action Angle of action is the angle turned by a gear from starting of engagement to the ending of engagement of a pair of teeth. Angle of action = Angle turned throughout arc of approach + Angle turned during arc of recess Contact Ratio It is equivalent to the number of teeth in contact and this is the ratio of arc of contact to the circular pitch. This is also equal to the ratio of angle of action with pitch angle.

Gear Terminology

Example 8.1 An open flat belt drive is needed to transmit 20 kW. The diameter of one of the pulleys is 150 cm with speed equivalent to 300 rpm. The minimum angle of contact can be taken as 170o. The permissible stress in the belt can be taken like 300 N/cm2. The coefficient of friction among pulley and belt surface is 0.3. Find out (a) Width of the belt neglecting influence of centrifugal tension for belt thickness equivalent to 8 mm. (b) Width of belt letting the effect of centrifugal tension for the thickness equivalent to that in (a). The density of the belt material is equal to 1.0 gm/cm3. Solution In the question it is given that: Power transmitted (p) = 20 kW Diameter of pulley (d) = 150 cm = 1.5 m Speed of the belt (N) = 300 rpm Angle of lap () = 170o = (170/180) = 2.387 radian Coefficient of friction () = 0.3 Permissible stress () = 300 N/cm2 (a) Thickness of the belt (t) = 8 mm = 0.8 cm

Assume higher tension is T1 and lower tension is T2. T1/ T2 = e = e0.3 2.387 = 2.53

The maximum tension T1 is controlled through the permissible stress.

Where b is in mm Hence,

Velocity of belt V =

Power transmitted p=

o r,

(b)

The density of the belt material () = 1 gm/cm3

Mass of the belt material/length m = b t 1 metre

= 8b 10 3 kg/m Centrifugal tension TC = m V2 or, TC = 8b 10 3 (23.5)2 = 4.418b N Maximum tension (Tmax) = 24b N T1 = Tmax TC = 24b 4.418b = 19.58b

Power transmitted P =

Also P = 20 kW o r, 460.177b /1000 = 20 b = 45.4 mm

The effect of the centrifugal tension enhanced the width of the belt needed. Example 8.2 An open belt drive is needed to transmit 15 kW from a motor running at 740 rpm. The diameter of the motor pulley is equal to 30 cm. The driven pulley runs at 300 rpm and it is mounted on a shaft that 3 metres away from the driving shaft. Density of the leather belt is equal to 0.1 gm/cm3. Permit able stress for the belt material 250 N/cm2. If coefficient of friction among the pulley and belt is equal to 0.3, find out width of the belt needed. The thickness of the belt is equal to 9.75 mm. Solution It is given that: Power transmitted (P) = 15 kW Speed of motor pulley (N1) = 740 rpm Speed of driven pulley (N2) = 300 rpm Diameter of motor pulley (d1) = 30 cm Density of the belt material () = 0.1 gm/cm3 Distance between shaft axes (C) = 3 m Allowable stress () = 250 N/cm2 Coefficient of friction () = 0.3 Assume the diameter of the driven pulley be d2 N1 d1 = N2 d2 d2 = N1 d1/N2 = (740 30) /300 = 74 cm Sin = (d2 d1)/2C o r, = 0.0734 radian = sin1 (74 30) / (2 300)

= 2= 2.94 rad

Mass of belt m = b t one metre length

Here b is width of the belt in mm o r, m = 0.975 10 3 b kg/m

Active tension T = Tmax TC Velocity of belt V =

o r,

V = 11.62 m/s

TC = m V 2 = 0.975 10 3 b (11.62)2 = 0.132 b N T1 = 24.375 b 0.132 b = 24.243 b

Power transmitted P =

e = e0.3 2.94 = 2.47

165/100 b = 15 or

b = 9 1 mm

Example 8.3 An open belt drive contains two pulleys with diameters 1.2 m & 0.5 m. The pulley shafts are parallel to each other having axes 4 m apart. The mass of the belt is equal to 1 kg per metre length. The tension cant exceed 2000 N. The larger pulley is driving pulley and it rotates at 200 rpm because of the belt slip. The coefficient of the friction is 0.3. Estimate the following (a) (b) (c) Power transmitted, Power lost in friction, and Efficiency of the drive.

Solution It is given that Diameter of driver pulley (d1) = 1.2 m Diameter of driven pulley (d2) = 0.5 m Centre distance (C) = 4 m Mass of belt (m) = 1 kg/m Maximum tension (Tmax) = 2000 N Speed of driver pulley (N1) = 200 rpm Speed of driven pulley (N2) = 450 rpm Coefficient of friction () = 0.3 (a) 1 = 2 N1 /60 = (2 200)/60 = 20.93 r/s

2 = (2 N2) /60 = (2 450)/60 = 47.1 r/s Velocity of the belt (V) = 20.93 (1.2/2) = 12.56 m/s Coefficient tension (TC) = m V2 = 1 (12.56)2 = 157.75 N Active tension on tight side (T1) = Tmax TC o r, T1 = 2000 157.75 = 1842.25 N

o r,

= 5.015o

= 180 2 = 180 2 5.015 = 169.985o

Power transmitted (P) =

= 13.67 kW (b) Power output =

Power lost in friction = 13.67 12.2 = 1.47 kW (c) Efficiency of the drive = Power transmitted / Power input = 12.2/ 13.67 = 0.89 or 89% .

Example 8.4 A leather belt is mounted on two pulleys. The larger pulley contain diameter equivalent to 1.2 m and rotates at speed equivalent to 25 rad/s. The angle of lap is 150o. The maximum permissible tension in the belt is equal to 1200 N. The coefficient of friction among the belt and pulley is equal to 0.25. Find out the maximum power that can be transmitted by the belt if initial tension in the belt lies among 800 N and 960 N. Solution It is given that Diameter of larger pulley (d1) = 1.2 m

Speed of larger pulley 1 = 25 rad/s Speed of smaller pulley 2 = 50 rad/s Angle of lap () = 150o Initial tension (T0) = 800 to 960 N Let the effect of initial tension be negligible. The maximum tension (T1) = 1200 N

Maximum power transmitted (Pmax) = (T1 T2) V 1.2 Velocity of belt (V) = (d1/2) 1 = (1.2 /2) 25 V = 15 m/s Pmax = (1200 623.6) V = (1200 623.6) 15 = 8646 W or 8.646 kW Example 8.5 A shaft carried a pulley of 100 cm diameter that rotates at 500 rpm. The ropes drive another pulley having a speed reduction of 2: 1. The drive transmits 190 kW. The groove angle is equal to 40o. The distance among pulley centres is equal to 2.0 m. The coefficient of friction among ropes and pulley is 0.20. The rope weighs is equal to 0.12 kg/m. The allowable stress for the rope is given as 175 N/cm2. The initial tension in the rope is restricted to 800 N. Find out: (a) (b) Number of ropes & rope diameter, and Length of each rope.

Solution It is given: Diameter of driving pulley (d1) = 100 cm = 1 m Speed of the driving pulley (N1) = 500 rpm Speed of the driven pulley (N2) = 250 rpm Power transmitted (P) = 190 kW Groove angle () = 40o Centre distance (C) = 2 m Coefficient of friction () = 0.2 Mass of rope = 0.12 kg/m Allowable stress () = 175 N/cm2 Initial tension (T0) = 800 N The velocity of rope = ( d1 N1) /60 = ( 1 500)/60 = 26.18 m/s Centrifugal tension (TC) = 0.12 (26.18)2 = 82.25 N

o r,

= sin 0.25 1 = 14.18

Angle of lap () = 2 = 151o or 2.636 radian

o r,

T1 = 4.67 T2 (T1 + T2 + 2Tc)/2 = 800

Initial tension (T0) = o r,

T1 + T2 = 1600 2 82.25 = 1600 164.5 = 1435.5 N 4.67 T2 + T2 = 1435.5 T2 = 253.1 N T1 = 4.67 T2 = 1182.0 N

Numbers of ropes required (n) = 190 /24.32 = 7.81 or can say 8 ropes, Maximum tension (Tmax) = T1 + TC = 1182 + 82.25 = 1264.25 N

o r,

d = 2.03 cm

It is open belt drive, thus, formula for length of rope is given by

8.9 KEY WORDS Spur Gears of shaft. : They contain straight teeth along teeth layout parallel to the axis

Helical Gears : They contain curved or straight teeth and its inclination having shaft axis is known as helix angle. Herringbone Gears : It is a double helical gear with right and left inclinations that meet at a common apex and there is no groove in between. Bevel Gear : They contain teeth radial to the point of intersection of the shaft axes and they differ in cross-section throughout their length.

Spiral Gears : They contain curved teeth that are inclined to the shaft axis. They are utilized for skew shafts. Worm Gears : shafts is 90o. this is special case of spiral gears where angle among axes of skew

Rack and Pinion : Rack is individual case of a spur gear whose pitch circle diameter is infinite and it meshes along a pinion. Hypoid Gears : These gears are approximations of hyperboloids however they seem like spiral gears. Pitch Cylinders: A pair of gears in mesh may be replaced through a pair of imaginary friction cylinders which by pure rolling motion transmit the similar motion as pair of gears. Pitch Diameter : this is diameter of pitch cylinders.

Circular Pitch : This is the distance among corresponding points of the consecutive teeth along with pitch cylinder. Diametral Pitch cylinders. Module Addendum Dedendum : This is the ratio of number of teeth to the diameter of the pitch

: This is the ratio of diameter of pitch cylinder to the number of teeth. : This is the radial height of tooth above pitch cylinder. : This is the radial depth of tooth below pitch cylinder.

Pressure Angle : this is the angle among common tangent to the two pitch cylinders and common normal at the point of contact among teeth (pressure line).