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DESIGN PROCEDURE OF CHAIN DRIVES

STEP-1: Selection of transmission ratio (i)

Select a preferred transmission ratio (i) from PSG 7.74.

STEP-2: Selection of number of teeth (Z1)

Select the no. of teeth on the pinion’s sprocket.
NOTE:
Where the space is a problem, Z1min=7.

STEP-3: Determination of number of teeth (Z2)

Determine the no. Of teeth on the driven sprocket by using transmission ratio(i).
Z 2= i x Z 1 .
Z2 should not be greater than Z2max .Z2max=100 to 120.

STEP-4: Selection of standard pitch (p)

Determine the range of chain pitch using the formula,
Optimum centre distance, a = (30 to 50)p PSG 7.74
From the pitch range obtained, consulting table, obtain max.
Speed of the rotation of the pinion W1max. PSG 7.74

STEP-5: Selection of chain

Assume any chain from PSG 7.71-7.73

STEP-6: Calculation of total load, PT.

Total load on the driving side of the chain,
PT = Pt + PC + PS.
Where,
Pt=tangential force due to power transmission.
Pt=1020N/v N.
N-transmitted power in kW.
v-chain velocity in m/s.
Pc-centrifugal tension=mv . 2

m -mass of chain per m PSG 7.71 to 7.73

v -velocity of chain.
Ps-tension due to sagging.
Ps=k x W x a N.
K - co-efficient of sagging PSG 7.78
W- weight per m length if chain.
1. centre distance.

STEP-7: Calculation of service factor, ks.

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Ks=k1 x k2 x k3 x k3 x k4 x k5 x k6. PSG 7.76 & 7.77.
Where,
k1 - load factor.
k2 - factor for distant regulation.
k3 - factor for centre distance of sprocket.
k4 - factor for position of sprocket.
k5 - lubrication factor.
k6 - rating factor.

STEP-8: Calculation of design load and checking

Calculate the design load,
Design load= total load on chain x service factor.
For the selected chain, the breaking load Q is obtained from PSG7.71 to 7.73.
Actual factor of safety = Q / design load.
This actual F.O.S should not be lesser than the recommended f.O.S given in PSG7.77.
If it is not satisfactory, one more chain may be added to the existing one or increase the
pitch.

STEP-9: Check for bearing stress

Check for bearing stress in the roller using formula,
 = Pt x kS / A
Where, A-bearing area taken from PSG 7.71 to 7.73.
This  is compared with permissible value given in PSG7.77.

STEP-10: Calculation of length of chain

Calculate the length of the chain in terms of no. Of links (correct to even number).
lp = 2ap+(Z1Z2/2)+((Z2-Z1)/2𝜋)2/ap.
Also calculate the final centre distance corrected to an even no. of links using the equation.
a = ((+√(2-8m)) x p/4. PSG 7.75.
m = ((Z2-Z1)/2𝜋) 2.

 = lp-((Z1-Z2)/2)

STEP-11: Calculate diameter of sprocket PSG 7.78

Dia. of small sprocket, d1=p / (sin (180/Z1))
Dia. of largest sprocket, d2=p / (sin (180/Z2)).

Sprocket outside diameter, do=d+0.8dr.

dr -diameter of roller. PSG 7.71-7.73

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Design a chain drive to run a compressor from 11Kw electric motor, running at
970rpm the compressor being 330rpm. The compressor operates 16hours/day.
The centre distance should be approximately 500mm. the chain tension may be
adjusted by shifting the motor slides

STEP 1: Given Data

Power (p) =11Kw

Motor speed =970rpm

Compressor speed = 330 rpm

Center distance (a) = 500mm

motor speed
Transmission ratio (i) = = 2.939
compressor speed

STEP 2: selection of number of teeth on the pinion (Refer the PSG pg.no: 7.74)

Recommented z1, for i= 2-3

No. of teeth on the sprocket z1, = 25

STEP 3: selection of number of teeth on the sprocket (Refer the PSG: 7.74)

Z2 = z1, * i

= 2.94 * 25 =75

STEP 4: optimum center distance.(a) (Refer the P.S.G pg.no: 7.74)

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a = (30 to 50)p

If 30 is used
500
pmax = =16.66
30

500
pmin = =10
50

always select larger pitch value

standard pitch is 15.875 is choosed (Refer the PSG pg.no: 7.74)

pitch p=15.875

STEP 5: selection of chain (Refer the PSG pg.no: 7.74)

Assume the chain to be duplex.

The chosen chain number is 10A-2/DR50

STEP 6: Total load on the driving side of the chain (Refer the P.S.G 7.78)

PT = Pt +Pc +Ps

1020𝑁
Pt = (tangential force due to power transmission)
𝑣

no of teeth on the sprocket ∗pitch ∗speed 25∗15.875∗970

v= =
60 60

v =6416.14mm/s =6.42m/s
1020∗11
Pt = =1747.66 N
6.42

𝑚𝑣 2
w.k.t Pc = (centrifugal tension ) (Refer the PSG pg.no: 7.78)
𝑔

for mass m to be found for selected during fine mass per unit length
1.78∗10
( ) m=1.78
10

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Pc =1.78*6.4162 =73.273N

w.k.t Ps =k.W.a (Refer the PSG pg.no: 7.78)

Assuming horizontal position k=6 ,W=1.78x10 =17.8N/m , a= 500mm

Ps = 6x17.8x.5 =53.4 N

PT =1748.75+73.273+53.4 = 1875.423N

STEP 7: service factor (ks) (Refer the PSG pg.no: 7.76 to 7.77)

ks= k1 x k2 x k3 x k4 x k5 x k6

k1 =1(load factor)

k2 ( factor for distance regulation) =1.25 assuming center distance

k3 ( factor for center distance of sprocket) =1 for (30 to 50)p

k4 ( factor for the position of sprocket) =1

k5 (lubrication factor ) =1.5

k6( rating factor) =1.25

ks=1 x 1.25 x 1 x 1 x 1.5 x1.25 =2.343

STEP 7: Design load (from the PSG pg.no: 7.72)

Design load = pt x ks = 1875.423 x 2.343 =4394.116N

Q = 4440 x 10 = 44400
44400
Actual factor of safety = =10.10
4394.116

Recommended FOS is obtained (from P.S.G pg.no: 7.77)

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The recommended FOS for the speed of rotation of small sprocket for
330rpm is 8.55

The actual FOS > recommended FOS

So the design is safe

STEP 9: check for the bearing stress

the bearing stress is found by using the formulae

σ =pT x ks/A

A = bearing area (from the PSG pg.no: 7.71 to 7.73)

A = 1.40 cm2 = 1.40x 10-4 mm2

4394.116
σ= = 31.39 N/mm2
1.40𝑥10−4

The permissible allowable stress calculated (from the P.S.G pg.no: 7.77)

Permissible allowable stress=2.87 x10 =28.7 N/mm2

STEP 10: calculate the length of chain (from the PSG pg.no: 7.72)

length of chain in terms of link connected to even numbers

𝑧 −𝑧 2
𝑧1 + 𝑧𝑎 ( 1 2)
2𝜋
lp =2ap + +
2 𝑎𝑝

𝑎𝑝 =a0/p = 31.50

lp=115mm
𝑒+√(𝑒 2 −8𝑚)𝑝
a=
4

𝑧1 + 𝑧𝑎
e =ip - = 65mm
2

a = 31.49 x 15.875 =499.98mm

STEP 10: calculate the pitch circle diameter:

𝑝
Dia of the small sprocket (d1) = 180 =126.66mm
sin( )
𝑧1

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𝑝
(d2) = 180 =379.10mm
sin( )
𝑧2

(d0) = d +.8 dr (from the PSG pg.no: 7.72)

(dr) =10.16mm

(d0) = d1 +.8 dr =126.66+8.128= 134.79mm

(d0) = d2 +.8 dr = 387.23mm

STEP 10 : SPECIFICATION:
Power (p) =11Kw

Motor speed =970rpm

Compressor speed = 330 rpm

Center distance (a) = 500mm

motor speed
Transmission ratio (i) = = 2.939
compressor speed

z1, = 25

z2, = 75

pitch p=15.875

The choosen chain number is 10A-2/DR50

PT = 1875.423N

Ks=2.343

Design load = 4394.116N

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