Modern Pulley Analysis

Modern Pulley Design Techniques And Failure Analysis Methods
Vinit Sethi and Lawrence K. Nordell

Coneyor Dyna!ics" #nc.
1111 West Holly Street
Bellingham, WA 98225
Published standards and speciications do not ade!uately co"er engineered class pulleys or modern high strength steel
cord belt con"eyors# $his paper discusses the %on"eyor &ynamics, 'nc# (%&') design criteria and stress analysis
techni!ues emphasi*ing the inite element method (+,-), atigue ailure criteria, design limits and manuacturing
re!uirements to ensure successul and sae pulley installations#
#NT$%D&CT#%N
High tension engineered class pulley applications are e.ceeding con"entional /isdom including published industrial and
academic guidelines# Since they are not co"ered by standards or manuacturer0s published inormation, and re!uire
custom engineering, they are classiied as 1engineered class0# 'nstallations beyond 2333 4W (8333 HP) are becoming
commonplace# $he cost o a catastrophic ailure in this po/er range can ha"e gra"e conse!uences on personnel saety
and on the plants proit and loss statement# 5nortunately, no industrial committees, go"ernment bodies, academic or
technical societies ha"e ta4en a leadership role to set orth appropriate instruments to manage the di"ersity o opinions
in this ield# -anuacturers dier on the ollo/ing criteria6
types o stresses that are important, a.
atigue stress range criteria, b.
allo/able stress limits in /elded and non7/elded members, c.
allo/able load limits on the pulley components, d.
material surace inish criteria in critically stressed areas, e.
analytical tools that resol"e the necessary stress actors, f.
materials o construction and their limitations, g.
abrication techni!ues, constructed tolerances and tolerance controls, h.
!uality assurance deinitions and practices, i.
guidelines or cold /eather conditions, j.
appropriate lagging speciications# k.
,ngineered class pulleys are deined as those /hich all into any o the ollo/ing categories6
Shat diameter e.ceeding 253 mm (13 in#) a.
Steel cord belt applications b.
Pulley ace /idth e.ceeds 1285 mm (22 in#) c.
Pulley diameter e.ceeds 1533 mm (23 in#) d.
Pulley load e.ceeds 93,333 4g (22,333 lbs#) e.
Belt modulus e.ceeds 8333 :;mm (<8333 lb;in) f.
Bi4on, =ingeder or other nonstandard connections g.
Stub shat pulleys h.
:ot co"ered by American :ational Standards 'nstitute (A:S') :o# B135#1 i.
$his paper /ill attempt to address some o these issues /ith the introduction o some o %&'0s design and stress criteria,
and pulley stress analysis techni!ues or steel drum pulleys#
Modern Pulley Design Techniques And Failure Analysis Methods http://www.ckit.co.za/secure/conveyor/papers/troughed/modern/moder...
1 of 16 25-02-2014 19:22
D'SC$#PT#%N %F P&LL'( C%MP%N'NTS
$he main components o a pulley or a con"eyor belt application are sho/n in +igure 1#
+igure 1# %=>SS7S,%$'>: >+ P5??,@ ASS,-B?@
Shell) $he belt is /rapped around the shell surace# $he shell is usually constructed by rolling a single lat plate into a
cylindrical shape or by orming t/o hal cylinders in a press# $he shell or rim can be a plate rolled e!ual to the pulley ace
/idth or in a shorter central shell body, /hich is attached to a rim section machined integral /ith the end7dis4 as sho/n
in +igure 1# =un7out tolerances and metal distortions are controlled by machining the shell and line boring the hub ater all
/elding and stress relie"ing are completed#
'nd*dis+ And ,u- Asse!-ly) ,nd7dis4s and hub assemblies o many dierent shapes ha"e been used# $hey can be a
straight plate, tapered, cur"ed or turbine, pencil# shaped etc# as illustrated in +igure 2#
+igure 2# &'++,=,:$ ,:&7&'SA B,>-,$=',S
$he end7dis4s can be made o cold rolled plate, casting, orging, machined plate or abricated pieces# $he turbine shape
reduces the dis4 stiness /hile optimi*ing the distribution o end7dis4 bending stresses# At a gi"en end7dis4 cross7
section, the sign () o the bending stress alternates rom the hub to the shell, as sho/n in +igure 9# $he proiled or
turbine end7dis4 ta4es ad"antage o the bending stress crossing through *ero# :ear this point, the end7dis4, metal
thic4ness can be signiicantly reduced /ithout ad"ersely aecting the end7dis4 load capacity# 'n eect, the optimal
proiled or turbine shape closely ollo/s the magnitude o the bending stress# %ontact stresses at the connection o the
loc4ing de"ice /ith the shat and the hub are reduced by the increased le.ibility# 'n addition, a smaller loc4ing mechanism
may be used due to the reduced end7dis4 moment#
2 of 16 25-02-2014 19:22
+igure 9# B,:&':B S$=,SS &'S$='B5$'>: >+ ,:&7&'SA %=>SS S,%$'>:
$he most common types o end7dis4 construction are sho/n in +igure <# +igure <a sho/s a pulley /ith a plate type
end7dis4 that is /elded to both the shell and the hub# ?arge alternating bending stresses combined /ith possible /eld
inclusions, high stress risers in /elded suraces, and other la/s in the hub;end7dis4 ma4e it a !uestionable design# All
/elded sections ha"e reduced metal atigue strength as /ill be described later# Weld *ones in pulleys are inherently more
ailure prone# $hereore, or engineered class pulleys, +igure <b sho/s that /elding is minimi*ed by integrating the hub
and turbine shaped end7dis4 rom a common metal plate# +igure <c sho/s the shell outer section is incorporated into the
hub7end7dis4 rom a single metal orm in more ad"anced designs# $his eliminates all illet /elds# +illet /elds ha"e a
signiicantly lo/er allo/able atigue stress range than does nati"e metal, typically 99C DBritish Standard BS5<33 Part 13,
19831 o the metal0s atigue rating# $he end7dis4 hub to dis4 illet /elds are subEected to usually compressi"e alternating
stresses due to the loc4ing de"ice e.pansion# $he absence o tensile stresses reduces the li4elihood o crac4
propagation# Alternati"e designs such as the one sho/n in +igure 2e are being in"estigated as cost eecti"e alternati"es,
due to the reduced machining re!uirements#
+igure <# &'++,=,:$ $@P,S >+ ,:&7&'SA W,?& %>:S$=5%$'>:
Loc+ing Mechanis!) ,ngineered class pulley assemblies are typically astened to the supporting shat /ith a non74eyed
loc4ing de"ice# $he non74eyed loc4ing de"ice uses pressure and riction to secure the pulley to its shat# $his eliminates
the 4ey/ay and its stress risers, thereby increasing the shats load capacity, by as much as 23C DBi4on ?oc4ing
Assemblies %atalogF#
Bi4on and =ingeder are manuacturers o the t/o most commonly used riction7style loc4ing mechanisms or con"eyor
pulley applications# $he Bi4on (+igure 5) or =ingeder style loc4ing mechanisms use the /edge principle to translate
clamp loads rom loc4ing scre/s into radial contact pressures on the shat and hub bore creating a mechanical
intererence it# $hese de"ices can be easily installed or remo"ed, can transmit high tor!ues, thrust loads and bending
moments# $here is ho/e"er a stress concentration created at the edge o a loc4ing de"ice due to notch eects created
by the loc4ing pressure, shat bending moment, and reaction to the resultant belt orces# $his can be reduced by the use
o a raised Eournal on the shat on /hich the loc4ing de"ice /ill sit# $he raised Eournal e.tends about 1 mm (3#3<3
inches) abo"e the shat /ith generous illet radii, 'ts length is 172mm (3#3<373#383 inches) less than the loc4ing de"ice
collar# $he purpose is to allo/ the loc4ing de"ice edge to plastically deorm the edge at the shat raised Eournal# $his
produces a more uniorm load pattern across the shat contact *one similar to cro/ning cylindrical rollers o a modern
bearing assembly# $he raised section can be eliminated i the loc4ing mechanism manuacturers pro"ide appropriate
corner radii#
3 of 16 25-02-2014 19:22
+igure 5# S%H,-A$'% >+ ?>%A':B -,%HA:'S-
'n 1985, a high capacity con"eyor (2833 4W) ta4e7up pulley ailed ater about three months o ser"ice# >ur in"estigation
reported that a combination o a sti end7dis4 and le.ible loc4ing de"ice caused a high local stress riser on the shat that
caused the atigue ailure# $he ailed pulley is sho/n in +igure 2# $he %&' loc4ing de"ice selection criteria /ere ormulated
rom this ailure data#
+igure 2 SHA+$ +A$'B5, +A'?5=, A$ ?>%A':B &,G'%, SH>5?&,=
'n 1982, a large 2233 4W (9533 hp) do/nhill con"eyor /as analy*ed using the %&' criteria $he con"eyor had been in
operation or about t/o years# We reported to the client that the design /as theoretically in danger o a catastrophic
atigue shat ailure# $he client in"estigated the pulley and ound our assessment to be true# $he pulley assembly /as
4 of 16 25-02-2014 19:22
remo"ed rom ser"ice and rebuilt using a /ider loc4ing de"ice /hich signiicantly reduced the loc4ing de"ice edge stress#
Similar indings ha"e been made on other con"eyor systems#
Sha.t) Pulley shats are subEected to a combination o bending stresses due to the belt loading, torsional stresses rom
motor dri"ing tor!ue and high local contact pressure due to the compressi"e action o the loc4ing mechanism# &ri"es
/ith shat mounted reducer;motor assemblies can impose additional bending orces /hich are superimposed on the
basic orces# $he e.tent o shat bending is dependent on the le.ibility o the end7dis4s and its loc4ing de"ice and on the
shat sectional modulus# ' the loc4ing de"ice and end7dis4s are !uite sti, then the shat /ill bend mainly outside o the
pulley# Highly le.ible end7dis4 arid loc4ing de"ice assemblies re!uire a sti, high sectional modulus shat, bet/een the
pulley end7dis4s, to gain design economy# Some manuacturers use a secondary internal shell or drum (double drum) to
increase the apparent shat sectional modulus# We do not recommend this procedure or shats o"er 933 mm (12 in#)
diameter# $he /eld connection o this e.tra drum to the end7dis4 hub presents design problems /hich ha"e not been
sol"ed to date (i#e# more capacity is assumed than can be achie"ed)# We ind that the e.tra drum cannot deli"er all o
the e.tra sectional modulus inherent in the secondary drum0s cross7section# $he end7dis4 then becomes o"erstressed at
the hub connection leading to obser"ed atigue ailure o the end7dis4#
Stub shat studies are in progress to de"elop special sti end7dis4 designs that /ill pro"ide better economy and;or better
shipping, handling, erection and maintenance o large pulley systems# A number o designs are in re"ie/# $/o concepts
are illustrated in +igure 8#
+igure 8# S$5B SHA+$ P5??,@ &,S'B:S
Lagging) ?agging is a co"ering that is applied to the surace o the shell to impro"e perormance in certain applications#
'n the case o a dri"e pulley, the use o lagging can increase the coeicient o riction bet/een the belt and the pulley
pre"enting slipping e"en /ith lo/er belt tensions# ?agging reduces rapid shell /ear in mining applications in"ol"ing
abrasi"e materials li4e iron ore# ?agging is usually made o an elastomer or ceramic# $he lagging can ha"e dierent
patterns depending on the application# $he herring7bone or diamond groo"e patterns are used or their ability to allo/
/ater to escape in /et applications# %&' recommends the diamond pattern because o its superior compression
characteristic# >ther patterns are used to impro"e belt7trac4ing# $he depth and spacing o groo"ing ha"e ta4en many
orms# $he speciications are dependent on applications# A discussion on si*es and pattern o groo"ing, and material
properties re!uires more discussion than can be pro"ided in this paper#
=ecently, t/o large con"eyor systems (<533 4W and 8133 4W) suered rom lagging damage# =e"ie/ o international
literature, internal in"estigation and material testing sho/ed that e.isting hot "ulcani*ing material speciications and
groo"ing patterns must be upgraded# 'n the case o the abo"e noted con"eyors, cold bonded lagging /as successully
applied in place# $he tensile strength, tear strength, and abrasi"e inde. are superior /ith the ne/ cold bonded lagging,
and /ith special polyurethane lagging, than /ith today0s con"entional hot "ulcani*ed lagging#
%eramic lagging has sho/n beneit /ith increased riction and /ear resistance# 'nsuicient data e.ists to recommend its
use in dri"e pulleys abo"e 9333 4W#
C%NV'(%$ D(NAM#CS" #NC. D'S#/N C$#T'$#A
5 of 16 25-02-2014 19:22
%&' has established certain stress and manuacturing criteria /ith /hich to compare and e"aluate "arious pulley designs
/ith respect to ris47ree long term operation# $he stress criteria comprise o static and atigue strength analyses# $hese
stress criteria consist o setting limits on both the ma.imum stresses and on the stress range that can occur in dierent
components o the pulley (shell, dis4, hub and shat)# $he three dimensional stress ield consists o radial, tangential and
a.ial stresses, /hich are analy*ed in the pulley#
Static Strength Criteria
While e"aluating ductile materials, yield strength o the material is usually used as the ailure criteria 'n the case o brittle
materials, li4e cast iron, /hich do not ha"e a yield point, the ultimate strength o the material is used as the ailure
criteria# %&' uses the &istortion ,nergy $heory DShigley, H#,#, 1982F or perorming static strength analyses# $his theory
is meant or ductile materials as it predicts the initiation o yield#
$he Gon -ise0s stress 3e is used in the theory# +or a tria.ial stress state, the Gon -ises stress is deined in terms o the
principal stresses 31, 32 and 39 as6
I
e
J D3#5K L(I
1
7 I
2
)
2
M (I
2
7 I
9
)
2
M (I
9
7 I
1
)
2
NF
3#5
Principal stresses aO# a2 and 39 are normal stresses that act on planes that do not carry any shear stress# -a.imum
and minimum principal stresses act on mutually perpendicular planes, and are the algebraically largest and algebraically
smallest normal stresses to be ound at a paint in a gi"en stress ield# $hese stresses are not to be conused /ith the
radial, tangential and a.ial stresses#
'n regions such as the shell /here only the tangential and the a.ial or bending stresses are dominant, a bia.ial stress
state can be assumed or simplicity# +or a bia.ial stress state, the Gon -ise0s stress is obtained by substituting 39J3 in
the abo"e e!uation to get6
I
e
J D3#5K L(I
1
2
7 I
1
I
2
M I
2
2
F
3#5
According to this theory, yielding occurs /hen the Gon -ises stress e!uals the yield stress# ,.periments ha"e sho/n that
the distortion7energy theory predicts yield /ith the greatest accuracy amongst the accepted stress theories# $he %&'
criteria uses the &istortion ,nergy theory /ith a multiplier o 3#8 /hich accounts or probabilistic conditions such as
"ariations in metallurgy, metal porosity, inclusions, and other uncertain conditions# $his multiplier o 3#8 is slightly higher
than the 3#2 to 3#22 multiplier used or /elded structures DShigley, H#,#, 1982F# $hus the ma.imum acceptable Gon
-ise0s stress in the shat, end7dis4 and shell is (3#8 P yield stress o the component)#
Fatigue Strength Criteria
'n the case o most pulleys, the largest range stresses in the shell are usually in the tangential or hoop direction and
occur close to the centerline o the pulley# Pulleys /ith /ide shell aces may ha"e the largest range stress in the a.ial
direction due to bending in a region close to the shell;dis4 connection# $he British Standard BS5<33 Part 13 is used to
determine the allo/able stress ranges or the circumerential and seam /elds in the shell or ininite atigue lie as sho/n
in +igure B#
+igure 8# %'=%5-+,=,:$'A? A:& AP'A? W,?& %?ASS'+'%A$'>:S
Shell Circu!.erential 0elds ha"e an allo/able a.ial stress range o 88 -Pa (11125 psi) (%lass % /eld) and allo/able
hoop stress range o 133 -Pa (1<533 psi) (%lass B /eld)# $hese "alues apply i the /elds are ull penetration and ha"e
been ground lush and pro"en ree o deects# ' they are not ground lush and pro"en ree o deects, the allo/able a.ial
stress range reduces to 55 -pa (8985 psi) (%lass & /eld) and the hoop stress range to 88 -Pa (11125 Ps) (%lass %
6 of 16 25-02-2014 19:22
/eld)#
Shell A1ial Sea! 0elds ha"e an allo/able a.ial stress range o 133 -Pa (1<533 psi) (%lass B /eld) and hoop stress
range o 88 -Pa (11125 psi) (%lass % /eld) i they are ull penetration and ha"e been ground lush and pro"en ree o
deects# ' not, the allo/able a.ial stress range reduces to 88 -Pa (11125 psi) (%lass % /eld) and hoop stress range to
55 -Pa (8985 psi) (%lass & /eld)#
$hese allo/able stress ranges are or 13 million load cycles /ith a 98C conidence le"el# =adiographic and;or a ull
ultrasonic inspection must be perormed to e"aluate the /elds#
Dis+) +or most pulleys, the largest luctuating or range stresses in the dis4 are in the radial direction and are due to
end7dis4 bending# $he atigue strength criteria used here is that the ma.imum stress should not e.ceed the endurance
stress, Se, or ininite lie# $he endurance stress, 5eO is dependant on numerous actors including material type, surace
inish, stress concentration eects, type o loading, ailure mode, etc# A conser"ati"e endurance stress o <3C o yield
stress (23C or shear) is used or ductile materials to account or the ollo/ing possibilities, some o /hich are diicult to
!uantiy6
5nlimited number o starts and stops a.
&ynamic loads b.
'rregularities in lagging thic4ness c.
-aterial buildup d.
>"erloading o the con"eyor e.
Sha.t) As the pulley rotates, the shat contact pressure under the loc4ing de"ice changes at the inside and outside
shoulders# $he alternating stress introduced due to this can lead to atigue ailure i the range is large# $hereore limits are
placed on ho/ large this range stress can be, $his range stress should not e.ceed the limits imposed in the modiied
Boodman diagram as sho/n in +igure 9#
$he modiied Boodman diagram can be constructed to deine the sae operating en"elope or end7dis4 and shat
stresses# $he ma.imum and minimum "alues o all stress components at a gi"en point must lie /ithin the en"elope
deined by the dar4 lines to be acceptable rom a atigue lie standpoint# $he en"elope can be deined using the ollo/ing
e!uations6
Bi"en6
I
u
6 5ltimate tensile stress o material
I
s
6 @ield stress
S
e
6 ,ndurance stress
I
ma.
6 -a.imum calculated stress (radial, tangential, a.ial)
I
min
6 -inimum calculated stress (radial, tangential, a.ial)
I
mean
6 -ean stress J (I
ma.
M I
min
);2
Allo/able stress range or 3 Q I
mean
Q I
yield
is gi"en by6
Ima. Q Imean K (I 7 Se);Iu M Se
IminR Imean K (Iu M Se);Iu 7 Se
' Imean Q 3, then Imean 7 Se Q I Q Imean M Se
7 of 16 25-02-2014 19:22
+igure 9# ->&'+',& B>>&-A: &'AB=A-
$able 1 sho/s a design e"aluation o t/o sample pulleys using the abo"e static strength and atigue ailure criteria $he
shat, end7dis4 and shell ha"e been e"aluated in dierent sections /ith both the allo/able limits and the calculated
stresses listed# Such an approach pro"ides a comparison o dierent pulley designs /ith the obEecti"e being to determine
the best design or an application# $he stresses /ere calculated using programs de"eloped at %&' that are described
later#
&esign S1 S2
?oc4ing &e"ice B'A 1315 =+: 8312
S,AFT
5ltimate Stress 158333 123981
@ield Stress 195333 89929
:ominal ?oc4ing &e"ice Pressure 28313 19233
a# -a.imum ?oc4ing &e"ice Pressure
%riteria6 Q (@ield) 195333 89929
%alculated 9951< 95592
b# -inimum ?oc4ing &e"ice Pressure
%riteria6 R 13C (=) ; 2C (S) o :ominal 2831 1923
%alculated 2353< 283<
c# =ange J (-a.imum 7 -inimum)
%riteria6 Q (3#< . @ield) 5<333 95929
%alculated 19338 92892
d# Boodman +atigue ?imit Q 1#3 3#29 1#38
e# Bending -oment %apacity J (Bending -oment ; $ors# %apacity)K133 (C)
$orsional %apacity 531933 28351<
%alculated &is4 Bending -oment 81238 52152
%riteria6 Q 92C (1315) ; <<#5C (=+: 8315) ; 19#5C (=+: 8312) Q 92 B'A
Q 19#5 =+:
Q <<#5 =+:
%alculated 1< 21
Acceptable ; :ot Acceptable @es :o (e)
'ND*D#SK
5ltimate Stress 93333 89929
@ield Stress ( R 92333 PS') 23333 <3191
a# -a.imum Gon -ises Stress
%riteria6 Q (3#8 . @ield) <2333 <219<
%alculated 9<812 1523<
8 of 16 25-02-2014 19:22
b# -a.imum Shear Stress
%riteria6 Q (3#5 . @ield) 93333 93392
c# -a.imum =ange Stress
%riteria6 Q (3#< . @ield) 2<333 2<382
%alculated (-a.# J =adial) 15<19 1<391
d# Boodman +atigue ?imit Q 1#3 3#89 3#59
Acceptable ; :ot Acceptable @es @es
S,'LL
@ield Stress ( R 9233 PS') 53333 <9511
a# -a.imum Gon -ises Stress
%riteria6 Q (3#8 . @ield) 95333 93<58
b# -a.imum Shear Stress
%riteria6 Q (3#5 . @ield) 25333 21852
c# -a.imum =ange Stress
%riteria6 Q 1<533 (=) ; 21853 (S) 1<533 1<533
%alculated (-a.# J Hoop) 992< 992<
Acceptable ; :ot Acceptable @es @es
$able 1 SA-P?, ,GA?5A$'>: >+ A?$,=:A$'G, P5??,@ &,S'B:S
Manu.acturing Criteria
Shell) $he shell outside diameter should be machined /ith respect to its bearing Eournals /ithin 3#85 mm (3#393 inches)
$#'#=# ($otal 'ndicator =eading) or non7dri"e pulleys, and 3#53 mm (3#323 inches) $#'#=# or dri"en pulleys# $hese
tolerances minimi*e e.cessi"e local stresses in the steel cord belt splice due to eccentric action and load changes o the
motor rom the "ariation in belt speed# With dri"e pulleys, a snub pulley or second dri"e is usually located close by /here
the "ariation in tolerances can interact# $o illustrate this sensiti"ity the ollo/ing e.ample is gi"en6
&ri"e pulley diameter 1333 mm (99#98 inches)
&ri"e motor electrical slip 1#5C T 133C tor!ue
&ri"e U Snub diameter tolerance 3#53 mm (3#323 inches)
$hereore, the diameter "ariation bet/een dri"e pulleys can be (3#53 M 3#53) 1#3 mm (3#3<3 inches)#
$he luctuation in their belt surace speeds is in proportion to their dierence in diameters, causing a
number o reactions /hich ollo/ the speed change# $his results in a motor tor!ue luctuation o 8C (1
mm ' 1333 mm . 133C tor!ue ; #315 slip J 2#28C), and belt line related stress conditions# Pulley
lagging anomalies are additi"e to this increase# With similar tolerance de"iation on the lagging the motor
tor!ue luctuation /ould also double# $his produces added stresses on the shell#
Belt misalignment produces asymmetric orces on the pulley# -a.imum acceptable belt misalignment, about 2C o its
/idth, can produce about a 13C increase in the bearing reaction on one side# $his increase added to the manuacturing
tolerance, noted abo"e, necessitates an e!ui"alent belt line orce increase o 13C#
$he shell should ha"e a near uniorm plate thic4ness ater machining# >ur criterion is no more than a 13C dierence
bet/een minimum and ma.imum thic4ness# $he minimum thic4ness should meet the stress criterion# $his criterion is set
to control the step de"iation bet/een the end7dis4 rim section, /hich has been machined, and the rolled or ormed main
shell body, as sho/n in +igure 9c# We urther re!uired the inside circumerential /eld be ground lush and tapered
smooth at least one ull metal thic4ness beyond the /eld in both directions, as sho/n in +igure 13#
9 of 16 25-02-2014 19:22
+igure 13# +':'SH %='$,='A >+ SH,?? %'=%5-+,=,:$'A? W,?&
$he illustrations belo/ in +igure 11 demonstrate the type o ailure /hich resulted rom a step bet/een end7dis4 and
inner rolled shell that /as not correctly inished#
+igure 11# SH,?? +A$'B5, +A'?5=, A$ &'SA;SH,?? %'=%5-+,=,:$'A? W,?&
:o interior shell stieners are allo/ed on inal assembly# Any use o stieners during abrication must be remo"ed# Some
manuacturers claim that the stieners gi"e the shell added strength# 'n theory, under some circumstances, this is true,
pro"ided ull penetration /elds are made or the complete circumerence on both sides o the stiening ring# :o
manuacturer can demonstrate through rigorous analysis that the methods used come close to meeting acceptable
criteria (i#e# incorporating proper theory and accepted /elding standards)# $hereore, the stiener rings should be lightly
/elded or later remo"al and ground inishing# Historically, a number o pulleys ha"e ailed along these stieners# $he
manuacturers ha"e reduced the shell stress allo/ance to compensate or ma4ing the ring thic4er#
Balancing /eights are not permitted on the shell interior bet/een the end7dis4s# $hese result in high local stress risers
/hich lead to shell ailure# $his /as recently /itnessed on a large belt eeder pulley in %hile# %&' recommends the balance
/eights be astened to the shell inside diameter e.tension outside o the end dis4# $he /eights must not be astened or
/elded on the illet radius region#
,nd7dis4 and Hub Assembly6 ,nd7dis4 design is oten described as 1le.ible1 or 1rigid1# $he terms reer to the end7dis4
thic4ness re!uired to meet the acceptable combined stress le"el sho/n in +igure 12#
10 of 16 25-02-2014 19:22
+igure 12# ,:&7&'SA S$=,SS,S GS# P?A$, $H'%A:,SS
't is prudent to design a le.ible end7dis4, i all hub design criteria can be met# $he si*e o /elds is then minimi*ed# $he
loc4ing de"ice bending moment magnitude is minimi*ed and shat contact stress is minimi*ed#
$he end7dis4 hub si*e is oten speciied larger than necessary# the hub contains the loc4ing de"ice# $he loc4ing de"ice
orce e.pands the hub, /hich in turn e.pands the end7dis4 and rim# 5sing classical ?am e!uations and +,-, it can be
sho/n that the end7dis4 and rim pro"ide considerable restraint on the hub0s e.pansion# $hereore, the analysis should
include the end7dis4 and shell stiness in the hub analysis# the hub stresses are not allo/ed to e.ceed the Gon -ises
yield criterion#
,nd7dis4 connection at the hub and shell should ha"e ample illet radii# +illet radii should e!ual the metal thic4ness at the
respecti"e connections# $he illet radii should ha"e a metal inish o 29 =-S (micro inches) /hether /elded or machined#
$he general metal inish outside the illets is speciied to e!ual or e.ceed 125 =-S#
$he end7dis4 /eld termination , sho/n in +igure <a, re!uires ull length /elding on the inside and outside o the end7dis4,
Welding only rom the outside produces a signiicant stress riser at the root o the /eld# We ha"e obser"ed a number o
shell ailures due to this condition#
$he end7dis4 hub should be bored ater /elding and stress relie"ing# $he shat should then be mounted, i possible, and
the inal machining completed on the shell#
$he balancing /eights should not be /elded to the end dis4# $hey may produce unacceptable stress risers and reduced
end7dis4 load capacity#
Loc+ing Mechanis!) $he Bi4on (et# al#) style loc4ing mechanism adds signiicantly to the le.ibility o the end7dis4, $he
manuacturers do not publish the elastic spring constants o their loc4ing de"ices# $hereore, a theoretical approach is
re!uired# $he same theoretical principles used to analy*e the end7dis4 and hub ha"e been applied to the loc4ing de"ice#
5sing thic47/all theory, narro/ and /ide loc4ing mechanism beha"ior is incorporated in the %&' analysis# :arro/ loc4ing
mechanisms (Bi4on <333 and =ingeder 8312 series) can contribute o"er 53C o the end7dis4 le.ibility# Wide loc4ing
mechanisms (Bi4on 1312V 1315 and =ingeder 8315 series) normally contribute 13793C o the end7dis4 le.ibility#
Se"en criteria go"ern the %&' selection o the most appropriate loc4ing de"ice in combination /ith the other pulley
dimensions6
$ransmission o t/ice motor nameplate tor!ue connected to the dri"en side o pulley# 1.
$ransmission o bending moment, bet/een shat and end7dis4, is gi"en as a unction o loc4ing de"ice torsional
capacity and is rated by the manuacturers (i#e# Bi4on <333 series Q22C, 1315 series Q92C 1312 series
Q95C, and =ingeder or all series in published tables range rom 12C to 23C)# Bi4on allo/s momentary loads
up to 83C#
2.
-inimum pressure under the loc4ing de"ice must e.ceed 13C o nominal pressure or normal running orces,
and 2C o nominal pressure or momentary o"erloads (i#e# staing)# $his protects against retting corrosion#
3.
11 of 16 25-02-2014 19:22
-a.imum shat pressure must not e.ceed the Gon -ises yield criterion as noted in this paper# 4.
Shat pressure combination o mean and alternating stress cannot e.ceed Boodman criteria as noted in this
paper in +igure 9#
5.
$he bolt tor!ue should e.ceed 85C o the catalog rating or non7dri"en pulleys# 6.
$he loc4ing de"ice inner ring load capacity should be "eriied by the manuacturer# 7.
Sha.ting) $he shating should ha"e an o"erall surace inish e.ceeding 253 =-S# All suraces should be inished 1bright,1
remo"ing all scale and surace la/s#
All illet radii should be inished to 29 =-S#
$he loc4ing mechanism Eournal should be inished at 125 =-S or optimal clamping eect# A iner inish reduces the
surace asperity# 't is theori*ed that the reduced asperity causes the mounting lubricants to be trapped as the clamping
action is applied, thereby reducing the eecti"e riction# A coarse inish o 253 =-S and higher ma4es it more diicult to
control manuacturing tolerances#
?oc4ing de"ice Eournal dimensions /ere mentioned earlier# $he illet radii should e.ceed the Eournal step by at least a
actor o three#
-any design criteria reer to the shat delection limitations# $he delection reers to the angle made by the loaded shat
o its neutral unloaded centerline at the pulley end7dis4 centerline# 't is normally e.pressed in a dimensionless slope or
tangent o the angle# $he typical "alue o the slope or engineered class pulleys is 3#3315# $he "alue is !uoted as a ree
shat delection /ithout end7dis4 assembly restraint# $he "alue originally /as deri"ed in practice# $his /as the "alue
ound /here the pulley tapered bushing (loc4ing de"ice) /ould not /al4 or mo"e on its shat# $he criterion stated in the
1?oc4ing -echanism1 section is usually more stringent, 't also is more rele"ant to the loc4ing mechanism design#
All shat steps or turndo/n sections rom the pulley hub diameter to bearing Eournal diameter ha"e illet radii in the step
transition si*ed to control the stress risers# $he %&' criterion or stress risers is based on the published /or4 0Stress
%oncentration +actors1 by =# ,# Peterson (198<)#
ST$'SS ANAL(S#S T'C,N#2&'S
Finite 'le!ent Method 3F'M4 5ased Methods
Descri6tion) $he inite element techni!ue has been successully used to design and analy*e con"eyor belt pulleys# >ne
o the commonly used reerences o this application is by ? ?indner (1985)# A %&' pulley stress analysis program has
been de"eloped based on the A:S@S inite element sol"er, Gersion <#<A DS/anson Analysis Systems, 'nc#, 1989F# $his
program is ully parametric and can handle most pulley designs and loadings# An a.isymmetric geometry is modeled /ith
non7a.isymmetric loading to conorm /ith the non7a.isymmetric belt tensions# $he eect o the loc4ing de"ice
e.pansion is included in the analysis# $he nominal loc4ing pressure at the hub is pro"ided as an input to the program
along /ith the belt tensions, orientation o the belt tension "ectors and pulley geometry# A "ariety o end7dis4 designs
can be modeled# $hese capabilities ha"e been added o"er a period o time and the program continues to gro/ in its
capabilities# $he end7dis4s that can be modeled include straight, straight tapered, cur"ed, double cur"ed and splines# +lat
and tapered hubs can be modeled and so can stepped and straight shats# >nce the input ile has been entered, the
A:S@S program generates the geometry, meshes it /ith a mi.ture o !uadrilateral and triangular elements ha"ing
mid7sided nodes# A sample o the type o mesh structure used in the analysis is sho/n in +igure 19#
12 of 16 25-02-2014 19:22
+igure 19# W5A&=A:$ S,%$'>: 7 +':'$, ,?,-,:$ -,SH
$he non7a.isymmetric loading is modeled /ith a combination o +ourier terms# $he program runs each case /ith one
+ourier term and then superposes the solution together to arri"e at the composite solution# >"erhung loads can also be
accounted or in the inite element analysis# A +ourier loading is also used to model the o"erhung loads#
Selection o. nu!-er o. Fourier ter!s) $he errors associated /ith appro.imation in an a.isymmetric analysis are
introduced in the appro.imation o the applied loading on the pulley /ith a +ourier series# Since the solution time is
almost directly proportional to the number o +ourier terms in the series, it /as necessary to perorm an in"estigation
into the inluence o number o +ourier terms on the solution# An increase in the number o +ourier terms used to model
the loading leads to an increase in the accuracy /ith /hich the applied loading matches the desired loading# Ho/e"er,
there is a point ater /hich the large increase in solution time out/eighs the small incremental increase in accuracy# 't
/as ound that or /rap angles o close to 183 degrees, the increase in accuracy in going rom 15 +ourier terms to 95 is
marginal (less than 1C)# $his is sho/n in +igure 1<# With /rap angles less than 23 degrees, more than 95 +ourier terms
are re!uired to maintain the same le"el o accuracy#
13 of 16 25-02-2014 19:22
+igure 1<# ,++,%$ >+ :5-B,= >+ +>5=',= $,=-S >: ?>A&':B APP=>P'-A$'>:
%ut6ut .ro! the Finite 'le!ent Analysis Progra!) $he output rom the program consists o a "ariety o stress plots
o the entire !uadrant section or o any subset o that A "isual representation o the ma.imum, minimum and range
stresses can be obtained in the orm o colored contour plots# A sample plot o the ma.imum Gon -ise0s stress is sho/n
in +igure 15# $his is a blac4 and /hite rendition o a color contour plot and this ma4es some o the stress contours
diicult to discern# Additionally, it is possible to generate P@ plots /hich sho/ the "ariation in a particular stress
component at a speciic location as the pulley rotates# $he program also generates plots o the deormed geometry as
the pulley rotates# $hese are oten "ery useul in determining the cause or a type o stress distribution# +igures 12a7d
sho/ the deormed shape o a pulley# $his pulley had a 183 degree belt /rap angle /hich started at 93 degrees and
e.tended to 283 degrees as sho/n in +igure 12a $he scale o the deormations has been e.aggerated# +igure 1 2a is at
3 degrees (i#e# outside o the /rap region)# $he shat bending due to the resultant belt tensions is ma.imum at 3 and
183 degrees# 't is minimum at 93 degrees and 283 degrees# $he shell starts bending in/ards due to the belt loading
rom about 85 degrees and inally bends out/ards ater the pulley comes out o the /rap region at about 285 degrees#
+igure 15# -AP'-5- G>: -'S,0S S$=,SS P?>$ +igure 12# W5A&=A:$ S,%$'>: &,+>=-,& SHAP,S
Classical Mechanics A66roach * PST$'SS
Descri6tion) PS$=,SS is a proprietary program de"eloped at %&', in 198<, that uses a close7orm appro.imate
analytical method to sol"e or the stresses in a pulley# $his program is based on the /or4 o H# ?ange (1929) and W#
Schmolt*i (198<)# $he theoretical treatment o the loc4ing de"ice and its reaction into the end7dis4, rim and shat are
uni!ue# $hin shell theory is used in the analysis o the shell# $he dimensions o the shell, end7dis4, hub, loc4ing de"ice and
shat along /ith the belt tension loads and loc4ing de"ice pressures are input to the program# 't calculates stresses
including range stresses that can be used or atigue analysis at "arious locations that are pro"ided as input to the
program# $/o +ourier appro.imations are used to describe the loading on the pulley# >ne +ourier series is used to
describe the loading in the tangential direction /hile a second +ourier series is used to appro.imate the loading
distribution in the a.ial direction# $he ad"antages o this program include its ease o use coupled /ith a short e.ecution
time ma4ing it a "aluable design tool allo/ing the designer to re"ie/ the eect o a design change on the stress
distribution in a short period o time# 'ts limitations include a restricted class o end7dis4 designs that can be analy*ed and
loss o accuracy at certain locations such as the end7dis4 ; shell connection due to certain assumptions that had to made
there to ma4e the analytical solution easible# %&' is presently in the process o de"eloping a ne/ analytical pulley stress
analysis program /hich /ill not be restricted by the limitations o the e.isting program#
Co!6arison o. F'M and PST$'SS results .or a 6ulley) A test case pulley is presented using both, the inite element
program and the %&' classical mechanics program PS$=,SS# $he obEecti"e is to demonstrate agreement o the stresses
calculated by the t/o approaches sho/n in +igure 18# $he location selected is the outside o the shell at the pulley
centerline# $his is usually the point o ma.imum shell stress# $he shell and end7dis4 connection, and the stresses in the
end7dis4 are also in reasonable agreement#
14 of 16 25-02-2014 19:22
+igure 18# %>-PA='S>: B,$W,,: +':'$, ,?,-,:$ A:A?@S'S A:& PS$=,SS =,S5?$S
'7P'$#M'NTAL M'T,%DS
Descri6tion) ,.perimental methods used by %&' to measure the stresses in pulleys in operation in"ol"e the installation
o strain gages at "arious locations o interest on the pulley# +or measurement o stresses on the inside o the pulley, i#e#
on the shell, shat and end7dis4, the strain gages must be installed beore the installation o the pulley on a shat# >nce
the pulley is put into operation, the strain gages /ill indicate the total strain range at the location /here they are bonded#
=adio telemetry is used to get the strain data rom the rotating pulley into a 'B- P% based data ac!uisition system#
Battery po/ered transmitters are mounted on the pulley# $hese transmitters modulate the output strain signal rom the
Wheatstone bridge /ith a +- carrier /a"e and transmit it to a sensiti"e signal conditioning;recei"er unit /hich e.tracts
the strain signal and eeds it to the data ac!uisition system# %alibration o the strain gages is perormed by using a shunt
resistance and measuring the output "oltage rom the Wheatstone bridge#
Co!6arison o. e16eri!ental results and F'M .or test 6ulley) An operating pulley /as instrumented at the %ordero
-ine in Wyoming# 't /as tested in conEunction /ith the manuacturer, Precision Pulley, using the procedure described
abo"e# Strains at t/o locations /ere measured and the corresponding stresses calculated# >ne o the strain gages /as
located on the shat in the interior o the pulley by the manuacturer beore it /as mounted on a shat# $he other /as
mounted on the outside o the end7dis4# $he strain gages /ere calibrated by introducing a 4no/n resistance change
along one arm o a Wheatstone bridge circuit# $he stress range that the change in resistance corresponded to /as
calculated# $he "oltage change produced by the resistance change /as recorded, as sho/n in +igure 18# $his pro"ided a
correlation bet/een "oltage and stress# $he purpose o these measurements /as to obtain actual stress inormation
/ith /hich to compare stresses predicted by the +,-# +igure 19 sho/s the measured a.ial stresses in the shat and the
radial stresses in the dis4 as the pulley is rotating# $he a.ial stress range at the shat location /as measured to be 12#8
-Pa (1892 psi)# $he dis4 radial stress range /as 8#9 -Pa (1233 psi)# +rom the estimated belt tonnage, the inite
element analysis predicted the a.ial stress range at the shat location to be 19#8 -Pa (2333 psi) (+igure 23) and the
radial stress range at the dis4 to be 9#2 -Pa (1993 psi) (+igure 21)# $he absolute magnitudes o the predicted "alues are
/ithin 13C o the measured "alues# $he ratios o a.ial to radial stresses are /ithin 2C o measured "alues# $he e.act
tonnage on the con"eyor during the test could not be obtained and this could account or the error, 't /as also possible
to determine the o"erload during a loaded startup rom the radial stress measurements as sho/n in +igure 22# $he
igure sho/s that the pea4 stress range during staing is 152C o the running stress range#
+igure 18# S$=A': BAB, %A?'B=A$'>:
+igure 19# S$=,SS,S -,AS5=,& >: $,S$ P5??,@
+igure 23# +':'$, ,?,-,:$ A:A?@S'S
7 SHA+$ AP'A? =A:B, S$=,SS
+igure 21# +':'$, ,?,-,:$ A:A?@S'S
7 &'SA =A&'A? =A:B, S$=,SS
+igure 22# S$=,SS,S -,AS5=,& >: $,S$ P5??,@ &5=':B ?>A&,& S$A=$5P
15 of 16 25-02-2014 19:22
C%NCL&S#%NS
%&' is an independent engineering consulting company# We ha"e been successully perorming pulley stress and atigue
lie analyses or the last nine years# PS$=,SS /as de"eloped in 198< and has been used to predict many ailures beore
they actually happened and also as a "aluable tool in orensic engineering# $he inite element program /as de"eloped
o"er t/o years ago# $he design criteria and manuacturing notes presented herein are in present use at %&'# We ma4e
no claim that the inormation presented is e.hausti"e and suicient# We do hope the inormation presented may be o
help to initiate a program or better industrial norms# +urthermore, /e /ould be pleased to participate in the
de"elopment o better standards or our industry#
$'F'$'NC'S
British Standard BS 5<33, 1983, 1Steel concrete and composite bridges 7 Part 137 %ode o practice or atigue1# 1.
Bi4on ?oc4ing Assemblies catalog 9A89, Bi4on %orp# 2.
Shigley, H# ,#, 1982, 1-echanical ,ngineering &esign1, -cBra/7Hill# 3.
Peterson, =# ,#, 198<, 1Stress %oncentration +actors1, Wiley7lnterscience# 4.
&eSal"o, B# H# and Borman, =# W#, 1989, A:S@S 5sers -anual or =e"ision <#<1, S/anson Analysis Systems,
'nc#, 1989, Houston, Pennsyl"ania, 5#S#A#
5.
?indner, ?, 1985, 1%onstruction o a %on"eyor Belt Pulley /ith the Aid o the $PS713 +inite ,lement Program1,
Braun4ohle 9, -arch 1985, pp# 81798#
6.
?ange, H#, 1929, 1'n"estigations on Stresses in Belt con"eyor Pulleys1, &octoral $hesis, $echnical 5ni"ersity,
Hanno"er#
7.
Schmolt*i, W#, 198<, 1$he &esign o %on"eyor Belt Pulleys /ith %ontinuous Shats1, &octoral $hesis, $echnical
5ni"ersity, Hanno"er#
8.
16 of 16 25-02-2014 19:22

Modern Pulley Analysis

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Modern Pulley Design Techniques And Failure Analysis Methods

Vinit Sethi and Lawrence K. Nordell

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