Session 10

Lecture notes Design of Transmission System

Problem on Design of Chain Drive

Design a chain drive to run a compressor from a 11kW electric motor running at 9970
rpm, the compressor speed being 330 rpm. The compressor operates 16 hours / day. The centre
distance should be approximately 500mm .The chain tension can be adjusted by shifting the
motor on slides.
Solution:
1.Selection of transmission ratio:
i =9790 / 330 = 2.94
2. Selection of no. of Teeth on the driver sprocket :
Z1 =25 ( for i = 2to 3 )
3. Determination of no. of teeth on the driven sprocket :
Z2 = i x Z1 =2.94 x 25 = 74

( Z2 max = 100 to 120 )

4. Selection of standard pitch (p)

a = (30 50 ) p

a = 500 mm ( given)

pmax = a / 30 = 500 /30 = 16.6mm

pmin = a /50 = 500 /50 = 10 mm.
Assume a standard pitch closer to pmax

p = 15.875 mm (std) is chosen.

5. Selection of the Chain :

From table for p =15.875 , Assume the chain to be duplex. Chosen chain number
is 10A-2/DR50
6. Calculation of total load on the driving side of the Chain (P T )
PT = { tangential force due to power transmission} + { Centrifugal tension due to
speed of the chain} + {tension due to chain sagging}
1

2
3

Tangential load (Pt ) = 1020N/v

where v = no.of teeth on the sprocket x pitch x rpm / ( 60 x 1000)
v = 25 x 15.875 x 970 / ( 60 x 1000) = 6.42 m/s
Pt = 1020 x 11 /6.42 = 1748 N.
Pt = 1748N.
Centrifugal tension ( Pc ) = wv2 /g = mv2
Pc = 1.78 x 6.422 = 75 N.
Tension due to sagging (Ps ) = k.w.a
[ k = 6 for horizontal drive ; w= mg ; a= 0.5 m ]
Ps = 6 x 17.8 x 0.5 = 53.4 N.

P =P + P + P = 1748 + 75 + 53.4 = 1876.4N.

T
t
c
s

7. Calculation of Service Factor(ks)

ks = k1 x k2 x k3 x k4 x k5 x k6
Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Session 10
Lecture notes Design of Transmission System
k1 = 1.25 ( for variable loads with mild shocks)
k2 = 1 ( for adjustable supports )
k3 = 1 ( ap = (30 to 50 ) p )
k4 = 1 ( drive is horizontal )
k5 = 1 ( for drop lubrication )
k6 = 1.25 ( for 16 hrs. /day working )
ks = k1 x k2 x k3 x k4 x k5 x k6
ks = 1.25 x 1 x 1 x1 x1 x 1.25 = 1.5625 = 1.6.
8. Calculation of Design Load :
Design Load = PT xks = 1876.4 x 1.6 =3002 N.
9. Calculation of Working Factor of Safety (Fsw )
Fsw = Breaking load from table / Design load = 44400 /3002 = 14.79
10. Check for factor of safety
we find for smaller sprocket speed of 1000 rpm and pitch 15.875 mm, the
required factor of safety is 11.We find that the actual factor of safety is greater and hence
the design is satisfactory.
Fsw> n (table value)
14.79 > 11
11. Check for the Bearing stress on the rollers
Induced stress = Pt xks /A
= 1748 x 1.6 /140 = 19.97 N/mm2
(induced) < (allowable from table value)
19.97 < 22.4 N/mm2 ( for small sprocket speed 1000 and pitch 15.875mm)
12. Calculation of actual length of Chain (L)
lp =2ap + [ Z1 + Z2 ]/2 + { [ Z2 - Z1 ] /2 }2 / ap
( whereap= a0 / p = 500 /15.875 = 31.49 mm )
lp =2(31.49) + [ 25 + 74 ]/2 + { [ 74 - 25 ] /2 }2 / 31.49
lp = 114.4
lp = 116 links ( rounded off to an even number ).
Actual length of chain = 116 x p
= 116 x 15.875
= 1.842 m
13. Calculation of Exact center distance:
Exact center distance , a ={ [ e + (e2 -8M) ] / 4 } x p
e = lp [ Z1 + Z2 ]/2 = 116 - [ 251 + 74 ]/2 = 66.5
M = { [ 74 - 25 ] /2 }2 = 60.8

Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Session 10
Lecture notes Design of Transmission System

a =512.91mm.

14. Calculation of Pitch circle diameters of sprockets

PCD

of smaller sprocket ,d1 = p / ( sin (180/z1 ) )

= 15.875/ (sin (180/25))
= 126.66mm.

PCD

of larger sprocket ,d2 = p / ( sin (180/z2 ) )

= 15.875 / ( sin (180/74 ) )
= 374.034mm.

Two marks
1. What is chordal action in chain drives? [Dec 2012]
Chordal action results in a pulsating and jerk motion of a chain. In order to reduce the
variation in chain speed, the number of teeth on the sprocket should be increased.
2. What is a silent chain? In what situations, silent chains are preferred?
Inverted tooth chains are called silent chains because of their relatively quiet operation.
Silent Drives are preferred for high-power, high-speed, and smooth operation.
3. What are the possible ways by which a chain drive may fail?
The four basic modes of chain failure are:
a) Wear
b) Fatigue
c) Impact and
d) Galling.
16 Marks
Problem:-Design a chain drive to actuate a compressor being 250 rpm. Minimum center distance
should be 500 mm. The chain tension may be adjusted by shifting the motor on rails. The
compressor is to work 8 hrs. /day. [ Nov/Dec-2009]
Answer:
a) Selection of transmission ratio(i):
Transmission ratio (i): = Z2/Z1 = n1/n2
(Preferred transmission ratio in PSG data book page no 7.74)

Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Session 10
Lecture notes Design of Transmission System
b) Selection of no. of Teeth on the driver sprocket :( 2marks)
To select Z1 in PSG data book page no 7.74 based on Transmission ratio (i)
c) Determination of no. of teeth on the driven sprocket :
Transmission ratio (i): = Z2/Z1 = n1/n2
d) Selection of standard pitch (p) ( 2marks)
a = (30 -50) p
To select the pitch in PSG data book page no 7.72 based on minimum to
maximum pitch value
e) Selection of the Chain : ( 2marks)
To select the chain in PSG data book page no 7.72 based on pitch value
f) Calculation of total load on the driving side of the Chain (PT ) (2 marks )
PT =Pt + Pc + Ps
*Tangential force = Pt =1020 N/v [page No: 7.78]
v =(No of teeth on the sprocket x pitch x speed) / (60 x1000)
*Centrifugal tension =Pc= mv2 [page No: 7.78]
*Tension due to sagging = Ps= k.w.a [page No: 7.78]
*To take k value in PSG data book page no 7.78 based on position of chain
derive
g) Calculation of Service Factor(ks)
ks =k1.k2.k3.k4.k5.k6[ PSG Data book page No 7.76]
* k1 - load factor To take k1 value inPSG Data book page No 7.76 based
on types of load on the chain drive
* k2 distance requlation factor To take k2 value inPSG Data book page
No 7.76
* k3 Centre distance factor To take k3 value inPSG Data book page No
7.76 based on Centre distance
* k4 position of the sprockets factor To take k 4 value inPSG Data book
page No 7.77
* k5 Lubrication factor To take k5 value inPSG Data book page No 7.77
* k6 Rating factor To take k6 value inPSG Data book page No 7.77
h) Calculation of Design Load : ( 2marks)
Design load = total load (PT) x Service Factor(ks)
i)

Calculation of Working Factor of Safety (Fsw ) ( 2marks)

Fsw =Breaking load / design load
To take bearing load inPSG Data book page No 7.72 based on chain type

j) Check for factor of safety

To check factor of safety inPSG Data book page No 7.77 based on speed of smaller
sprocket
k) Check for the Bearing stress on the rollers ( 2marks)
*Induced stress = = (PT x ks) /A
Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Session 10
Lecture notes Design of Transmission System
*Allowable stress () To take Allowable bearing stress () value in PSG
Data book page No 7.77 based on speed of smaller sprocket and pitch value
*To Compare the Induced stress with Allowable stress ()
l)

Calculation of actual length of Chain (L)

L = lp x Numer of link
lp =2 ap + [(z1+z2) /2] + [ ((z 2 z1) /2)2/ap]

(PSG Data book page

No 7.75)
m) Calculation of Exact center distance (a): ( 2marks)
a = [(e +

e2 +8 m

) / 4] x P

e = lp [(z1 +z2)/2]
m = [(z2-z1)/2]2

[PSG Data book page No 7.75]

[PSG Data book page No 7.75]

[PSG Data book page No 7.75]

n) Calculation of Pitch circle diameters of sprockets

*Diameter of smaller sprocket, d1 = p/ [sin (180o /Z1)]

[PSG Data book page No 7.78]

*Diameter of large sprocket, d2 = p/ [sin (180o /Z2)]

[PSG Data book page No 7.78]
Quiz
1. The main types of chains used to transmit-power are..........
a. silent chain and bush
b. bush,roller and silent chain
d. wire, roller
2. The linear distance between the centers of consecutive roller is called As
b. pitch of pinion

c. roller chain

d. chain

3. The linear distance between the centers of consecutive roller is called As

a. roller chain

b. chain

d. pitch of pinion

4. localised compressive stress at the area of contact between two members is known as
a. bending stress

b. shear stress

c. bearing stress

d. tensile stress

5. localised compressive stress at the area of contact between two members is known as
a. bearing stress

b. bending stress

c. tensile stress

d. shear stress

Application

Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology

Session 10
Lecture notes Design of Transmission System

Motor bike

Prepared byMr.M.Subramanian ASP, & Mr. B.Charles, AP, Department of Mechanical Engineering
Adithya Institute of Technology