Higher Technological Institute HTI

Belt Drive System

Dr. Ahmed Nabhan M. Elkholy

Associate Professor
Faculty of Engineering - Minia University
 Lecture slides to accompany

A Textbook of
Machine Design

by
R. S. Khurmi
J. K. Gupta
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Belts represent the major types of flexible power transmission elements.
Remember, for a given power transmission, the torque is increased in
proportion to the amount that rotational speed is reduced. So .some speed
reduction is often desirable. The high speed of the motor makes belt drives
somewhat ideal for that first stage of reduction. A smaller drive pulley is
attached to the motor shaft, while a larger diameter pulley is attached to a
parallel shaft that operates at a correspondingly lower speed. Pulleys for
belt drives are also called sheaves.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Selection of a Belt Drive
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. Centre distance between the shafts, 4. Power to be transmitted,
5. Positive drive requirements, 6. Shafts layout,
7. Space available, and 8. Service conditions.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 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 up
to 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.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Types of Belts
Though there are many types of belts used these days, yet the following are
important from the subject point of view:
1. Flat belt. The flat belt as shown in Fig. (a), is mostly used in the factories
and workshops, where a moderate amount of power is to be transmitted,
from one pulley to another when the two pulleys are not more than 8
meters apart.
2. V- Belt. The V-belt as shown in Fig. (b), is mostly used in the 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.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 3. Circular belt or rope. The circular belt or rope as shown in Fig. 5.2 (c) is
mostly used in the factories and workshops, where a great amount of
power is to be transmitted, from one pulley to another, when the two
pulleys are more than 8 meters apart.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Material used for Belts
The material used for belts and ropes must be strong, flexible, and durable.
It must have a high coefficient of friction.
• Leather belts. The most important material for flat belt is leather. The
best leather belts are made from 1.2 meters to 1.5 meters long strips cut
from either side of the backbone of the top-grade steer hides. The hair
side of the leather is smoother and harder than the flesh side, but the
flesh side is stronger. The fibers on the hair side are perpendicular to the
surface, while those on the flesh side are interwoven and parallel to the
surface.
• Cotton or fabric belts. Most of the fabric belts are made by folding canvass
or cotton duck to three or more layers (depending upon the thickness
desired) and stitching together.
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 • These belts are woven also into a strip of the desired width and
thickness. They are impregnated with some filler like linseed oil in order
to make the belt water-proof and to prevent injury to the fibers. The
cotton belts are cheaper and suitable in warm climates, in damp
atmospheres and in exposed positions. Since the cotton belts require
little attention, therefore these belts are mostly used in farm machinery,
belt conveyor etc.
• Rubber belt. The rubber belts are made of layers of fabric impregnated
with rubber composition and have a thin layer of rubber on the faces.
These belts are very flexible but are quickly destroyed if allowed to
encounter heat, oil or grease. One of the principal advantage of these
belts is that they may be easily made endless. These belts are found
suitable for sawmills, paper mills where they are exposed to moisture.
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 • Balata belts. These belts are like rubber belts except that balata gum is
used in place of rubber. These belts are acid proof and waterproof and it
is not affected by animal oils or alkalis. The balata belts should not be at
temperatures above 40°C because at this temperature the balata begins
to soften and becomes sticky. The strength of balata belts is 25 per cent
higher than rubber belts.

Material of belt Mass density in kg / m3

Leather 1000
Convass 1220
Rubber 1140
Balata 1110
Single woven belt 1170
Double woven belt 1250

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Coefficient of Friction between Belt and Pulley
The coefficient of friction (μ) for oak tanned leather belts on cast iron
pulley, at the point of slipping, is given by the following relation, i.e.
4.26
𝜇 = 0.54 −
152.6 + 𝜈
Where ν = Speed of the belt in meters per minute.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Types of Flat Belt Drives
Open belt drive. The open belt drive, as shown in Fig., is used with shafts
arranged parallel and rotating in the same direction. In this case, the driver
A pulls the belt from one side (i.e., lower side RQ) and delivers it to the
other side (i.e., upper side LM). Thus, the tension in the lower side belt will
be more than that in the upper side belt. The lower side belt (because of
more tension) is known as tight side whereas the upper side belt (because
of less tension) is known as slack side.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Crossed or twist belt drive. The crossed or twist belt drive, as shown in Fig.,
is used with shafts arranged parallel and rotating in the opposite directions.
In this case, the driver pulls the belt from one side (i.e., RQ) and delivers it
to the other side (i.e., LM). Thus, the tension in the belt RQ will be more
than that in the belt LM. The belt RQ (because of more tension) is known as
tight side, whereas the belt LM (because of less tension) is known as slack
side.
A little consideration will show that at a point where the belt crosses, it
rubs against each other and there will be excessive wear and tear. In order
to avoid this, the shafts should be placed at a maximum distance of 20 b,
where b is the width of belt, and the speed of the belt should be less than 15
m/s.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Quarter turn belt drive. The quarter turn belt drive (also known as right
angle belt drive) as shown in Fig. (a), 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. In case the pulleys cannot be
arranged as shown in Fig. (a) or when the reversible motion is desired, then
a quarter turn belt drive with a guide pulley, as shown in Fig. (b), may be
used.
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Belt drive with idler pulleys. A belt drive with an idler pulley (also known as
jockey pulley drive) as shown in Fig., is used with shafts arranged parallel
and when an open belt drive cannot be used due to small angle of contact on
the smaller pulley. This type of drive is provided to obtain high velocity ratio
and when the required belt tension cannot be obtained by other means.
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Stepped or cone pulley drive. A stepped or cone
pulley drive, as shown in Fig., is used for changing
the speed of the driven shaft while the main or
driving shaft runs at constant speed. This is
accomplished by shifting the belt from one part of
the steps to the other.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Fast and loose pulley drive. A fast and loose pulley drive, as shown in Fig., is
used when the driven or machine shaft is to be started or stopped
whenever desired without interfering with the driving shaft. A pulley which
is keyed to the machine shaft is called fast pulley and runs at the same
speed as that of machine shaft. A loose pulley runs freely over the machine
shaft and is incapable of transmitting any power. When the driven shaft is
required to be stopped, the belt is pushed on to the loose pulley by means
of sliding bar having belt forks.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Belt drive kinematics
• Open Belt Drive
In case of an open belt drive, both the pulleys rotate in the same direction as
shown in Fig.

Let r1 and r2 = Radii of the larger and smaller pulleys,

x = Distance between the centers of two pulleys (i.e., O1O2), and
L = Total length of the belt.
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 The contact angle of driver pulley, θ1, can be calculated
𝜃1 = 180° + 2 𝛼
Form triangle O1O2M
𝑀𝑂1 𝑟1 − 𝑟2
sin 𝛼 = =
𝑂1 𝑂2 𝑥
So, the contact angle of driver pulley, θ1
° −1
𝑟1 − 𝑟2
𝜃1 = 180 + 2 𝑠𝑖𝑛
𝑥
By the similar way, the contact angle of driver pulley, θ2
° −1
𝑟1 − 𝑟2
𝜃2 = 180 − 2 𝑠𝑖𝑛
𝑥
Length of an Open Belt Drive, L
𝑟1 − 𝑟2 2
𝐿 = 2𝑥 + 𝜋 𝑟1 + 𝑟2 +
Production Engineering and Mechanical Design Department 𝑥
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 • Cross Belt Drive
In case of a cross belt drive, both the pulleys rotate in the opposite directions
as shown in Fig.

Let r1 and r2 = Radii of the larger and smaller pulleys,

x = Distance between the centers of two pulleys (i.e., O1O2), and
L = Total length of the belt.
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 The contact angle of driver pulley, θ1, can be calculated
𝜃1 = 180° + 2 𝛼
Form triangle O1O2M
𝑀𝑂1 𝑟1 + 𝑟2
sin 𝛼 = =
𝑂1 𝑂2 𝑥
So, the contact angle of driver pulley, θ1
° −1
𝑟1 + 𝑟2
𝜃1 = 180 + 2 𝑠𝑖𝑛
𝑥
By the similar way, the contact angle of driver pulley, θ2
° −1
𝑟1 + 𝑟2
𝜃2 = 𝜃1 = 180 + 2 𝑠𝑖𝑛
𝑥
Length of a Cross Belt Drive, L
𝑟1 + 𝑟2 2
𝐿 = 2𝑥 + 𝜋 𝑟1 + 𝑟2 +
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University
𝑥 Dr. Ahmed Nabhan M. Elkholy
 Power Transmitted by a Belt
Let T1 and T2 = Tensions in the tight and slack side of the belt respectively in N,
r1 and r2 = Radii of the driving and driven pulleys respectively in meters,
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).
∴ Work done per second = (T1 – T2) ν N-m/s
And power transmitted = (T1 – T2) ν Watt. (1 N-m/s = 1Watt)

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Ratio of Driving Tensions
For Flat Belt Drive
Consider a driven pulley rotating in the clockwise direction as shown in Fig.
Let T1 and T2 = Tensions in the tight and slack side of the belt
θ = Angle of contact in radians (i.e.. angle subtended by the arc AB, along
which the belt touches the pulley, at the center).

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Now consider a small portion of the belt PQ, subtending an angle δθ at the
center of the pulley as shown in Fig. The belt PQ is in equilibrium under the
following forces:
• 1. Tension T in the belt at P,
• 2. Tension (T + δT) in the belt at Q,
• 3. Normal reaction RN, and
• 4. Frictional force F = μ × RN, where μ is the coefficient of friction
between the belt and pulley

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 The tension ratio for the flat belt
𝑇1
= 𝑒 𝜇𝜃
𝑇2
Centrifugal Tension
Since the belt continuously runs over the pulleys, therefore, some centrifugal
force is caused, whose effect is to increase the tension on both the tight as
well as the slack sides. The tension caused by centrifugal force is called
centrifugal tension. At lower belt speeds (less than 10 m/s), the centrifugal
tension is very small, but at higher belt speeds (more than 10 m/s), its effect
is considerable and thus should be considered.
TC = Centrifugal tension acting tangentially
𝑇1 − 𝑇𝑐
= 𝑒 𝜇𝜃
𝑇2 − 𝑇𝑐
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 For V-Belt Drive
The tension ratio for the V-belt
𝑇1
= 𝑒 𝜇𝜃 𝑐𝑜𝑠𝑒𝑐 𝛽 = 𝑒 𝜇𝜃/ 𝑆𝑖𝑛 𝛽
𝑇2
Centrifugal Tension
𝑇1 − 𝑇𝑐
= 𝑒 𝜇𝜃/ 𝑆𝑖𝑛 𝛽
𝑇2 − 𝑇𝑐
Where 2β is the groove angle.
The groove angle in degree [32, 34, 36, 38]

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Maximum Tension in the Belt
A little consideration will show that the maximum tension in the belt (T) is
equal to the total tension in the tight side of the belt (T1).
Let σb = Maximum safe stress,
A = Cross section area of the belt
We know that the maximum tension in the belt,
T1 = Maximum stress × Cross-sectional area of belt = σb*A
For the flat belt
T1 = σb.b.t
Where b = Width of the belt, and
t = Thickness of the belt.

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Table 5.1 Standard lengths of Endless-manufactured flat belts (DIN 387)

250 355 500 710 1000 1400 2000 2800 4000 5000 8000
265 375 530 750 1060 1500 2120 3000 4250 6000 8500
280 400 560 800 120 1600 2240 3150 4500 3600 9000
315 450 630 900 1250 1800 2500 3550 5000 7100 10000
335 475 670 950 1320 1900 2650 3750 5300 7500

Table 5.2 Standard belt widths (b), pulley widths (B) and height (h):

b 16 20 25 32 40 50 70
90 110 125 140
B 20 25 32 40 50 63 80
100 125 140 160
h 0.5 0.5
b 160 180 200 220 250 280 315 355 400 450 500 560
B 180 200 220 250 280 315 355 400 450 500 650 630
h 1.0 1.5 2.0

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 For the V-belt
T1 = σb. A
The Cross-sectional area of belt is according table 5.3

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Table 5.3 Endless normal V-belts (DIN 2215) and cut V-belts (DIN 2216)

b 5 6 8 10 13 17 20 25 32 40 50
t 3 4 5 6 8 11 12.5 16 20 25 32
f 6 7 8 10 12 15 18 22 27 34 42
e 6 8 10 12 16 20 24 30 38 46 58

Determination of the required number of belts for a drive with a nominal

power
𝑝
z=
𝑝₁𝑐₁𝑐₂
Where Z = number of belts
p1 = power rating of one belt at optimum conditions
C₁ = contact angle correction factor
C₂ = service factor

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Table 5.4 Contact angle correction factor C₁

Contact angle 180 170 160 150 140 130 120 110 100 90 80 70
Endless belts C₁ 1 .98 .95 .92 .89 .86 .82 .78 .73 .68 .63 .58
Cut belts C₁ 1 .98 .95 .91 .87 .82 .77 - - - - -

Table 5.5 Service factor C₂

less than 600rpm more than 600rpm

Working hrs. per days 10 15 20 10 15 20

Light service centrifugal pumps ,
conveyors , ventilators 1.0 0.9 0.8 0.9 0.8 0.75
Medium service stirrers , m/c tools ,
0.9 0.8 0.75 0.8 0.75 0.7
pressures , shears, printing machines
Heavy service reciprocated
compressors , elevators , textile 0.8 0.75 0.7 0.7 0.65 0.6
machines , hammer-saw mills
Extreme heavy service store crushers
0.75 0.7 0.65 0.65 0.6 0.55
,dredgers , hoists , cranes , mixers

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Horsepower rating of a single v-belt at optimum conditions p1 can be calculated from
Table 5.5
b (mm) 5 6 9 10 13 17 20 22 25 32 40 50
υ (m/s)
2 .024 .05 .10 0.19 0.37 0.7 1.0 1.1 1.5 2.4 3.9 6.0
4 .047 .10 .19 0.37 0.74 1.3 1.9 2.3 3.0 4.7 7.4 12.0
6 .068 .15 .28 0.55 1.1 1.9 2.8 3.4 4.8 7.0 11.0 18.0
8 .086 .19 .36 0.72 1.4 2.5 3.9 4.4 5.7 9.2 14.0 23.0
4.5 5.9 6.9 .43 0.87 1.7 3.1 4.6 5.1 6.6 11.4 17.0 28.0
12 .11 .25 .48 1.0 2.0 3.6 5.2 6.4 8.0 12.8 20.0 32.0
14 .11 .26 .52 1.1 2.2 4.0 5.8 7.0 9.0 14.4 22.0 36.0
16 .11 .27 .55 1.2 2.4 4.3 6.3 7.5 9.8 15.7 24.0 39.0
18 .10 .26 .56 1.2 2.6 4.6 6.7 9.0 10.4 16.6 26.0 42.0
20 .08 .24 .54 1.3 2.7 4.8 6.9 8.2 10.7 17.1 27.0 43.0
22 .05 .21 .49 1.2 2.7 4.8 7.0 8.3 10.9 17.3 27.0 44.0
24 - .15 .42 1.1 2.6 4.7 6.8 8..2 10.9 17.0 26.0 48.0
26 - .08 .30 1.0 2.5 4.5 6.5 7.2 10.9 16.4 25.0 49.0
28 - - .18 0.9 2.3 4.1 6.0 7.0 9.9 14.8 23.0 37.0
30 - - - - 2.0 3.6 6.0 6.0 8.0 15.0 20.0 38.0

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
 Table 5.3 Endless normal V-belts (DIN 2215) and cut V-belts (DIN 2216)

b 5 6 8 10 13 17 20 25 32 40 50
t 3 4 5 6 8 11 12.5 16 20 25 32
f 6 7 8 10 12 15 18 22 27 34 42
e 6 8 10 12 16 20 24 30 38 46 58

Face width (B) = (n – 1) e + 2 f

Production Engineering and Mechanical Design Department

Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy
Production Engineering and Mechanical Design Department
Faculty of Engineering - Minia University Dr. Ahmed Nabhan M. Elkholy