Beruflich Dokumente
Kultur Dokumente
Important Note
Software is also available allowing convenient initial designs to be complete.. A very useful
design package is obtained from Mitcalc.com (ref links below) this covers everything that is
provided below :.. better and more comprehensively
Introduction
The roller chain is used to transmit motion between rotating shafts via sprockets mounted
on the shafts. Roller chains are generally manufactured from high specification steels and
are therefore capable of transmitting high torques within compact space envelopes.
Compared to belt drives the chain drives can transmit higher powers and can be used for
drives with larger shaft centre distance separations. In European /ISO standards the chains
are normally rated on a standard 15000 hours life. Service factors on the drive and driven
wheels are used to adjust the rating for non-standard conditions.
Chain Details
Relevant Standards
Chain Description
Duplex Chain
The range of pitch sizes can vary between 4mm, (0.158 inch) to 114.3mm, (4.500 inch).
The European/ISO chain standards have large pin diameter compared to the US standards,
especially for the larger pitch sizes. This results in better wear resistance due to the
greater bearing area.
The ISO standard has a simple form of part numbering, for example: 1/2 inch pitch duplex
chain would be 06B-3. The first two digits are the pitch size in 1/16?s of an inch, therefore
06 = 6/16 or 3/8 inch. The letter ?B? indicates European Standard. The suffix 3 indicates the
number of strands in the chain, in this case a triplex chain.
The maximum number of teeth on the larger wheel should not exceed 150 and generally the
number of teeth is restricted to 114 providing a normal maximum ratio of about 6:1
The angle of contact of the chain and the smallest wheel should exceed 120 o. This provides
practical limitation on the size of the larger wheel or results increased center distance
separation. Larger wheel diameters tend to result in reduced chain life.
It is good practice on low ratio chain drives to ensure that the number of teeth on both
wheel when added do not exceed 50. A 1:1 drive should therefore have a maximum of 25
teeth on each wheel.
The large sprockets on high ratio drives are generally made of cast iron because the teeth
have reduced chain engagements over time with consequent reduced fatigue and wear.
For more arduous service conditions the larger sprockets may be made from cast steel or
steel plate. The smaller sprockets when highly loade are generally made from steel type
which allow the body to be heat treated for toughness while the teeth are hardened to resist
wear e.g. case hardened. Heat treatment is generally required when :
The speed is above 0,7 time max speed when fully loaded
The speed is above 0,5 time max speed when fully loaded, under medium
impulsive load
Typical maximum speed are listed in the chain properties table below
For lower duties sprockets are generally machined from steel bar stock.
Idler sprockets
hen the drive and driven sprockets centres are fixed it may be desireable to include idlers
sprockets to take up the slack in the chain. Idler sprockets should preferably be located
against the slack side of the chain within the chain envelope - diverting the chain
outwards. Idler sprockets are subject to continuous impact from the chain and are subject
to wear if only small sprockets are used and if the chain speed is high.
A large number of roller chains are designed to provide a power transmission between two
sprockets with minimum/no regular lubrication and under conditions of high levels of
contamination. My bicycle chain drive has worked successfully for over 25 years ( including
one replacement of the wheel sprocket and one replacement of the chain). The bicycle is
used at least three journeys per week for an average journey time of about 20 minutes.
Motor cycle chain drives work in similar operating conditions...
Industrial chain drives are generally designed to operate in enclosed cases with installed
lubrication systems.
Chains rarely fail because they do not have sufficient tensile strength. They most often fail
in wear or fatigue. In practice sprocket teeth wear allowing the chains to jump the
teeth. Manufacturers specify the chains based on the following parameters
Chain systems are designed with correction coefficients to compensate from the difference
from these design conditions
It is important when designing chain drives to ensure good alignment of the sprocket
shafts. It is also important to minimise chain slackness and if the centres can not be
adjusted then it may be necessary to use idler sprockets.
Chain Lubrication
Chain drive lubrication provides similar benefits to bearing journal lubrication. The benefits
include reduced friction, cooling, impact resistance at higher chain speeds. The chain
supplier generally provides recommendations for the lubrication requirements for each
chain drive. If suitable lubrication is not provided the then capacity of the chain drive is
reduced.
Oil Mist lubrication...This is used for high speed chain drive and is based on
the chain case being filled with a oil mist.
There is continuous development in chain drives and self-lubricated chains are available
which do not require continuous lubrication and have similar performance to lubricated
chain drives.
Plastic chains are also available which do not require lubrication. Plastic chain drives
obviously have much reduced operating characteristics compared to steel chains.
Nomenclature
1. Specify the Drive speed , Driven speed and the power to be transferred
2. Identify the operating characteristics of the drive and driven shafts (smooth,
rough, shock
3. Select the approximate shaft centre distance
4. Calculate the speed ratio using table of standard sprockets (minimum No of
teeth normally 19
5. Calculate the appropriate design factors
6. Calculate the design power
7. Select a chain which has a higher power capacity than the design power.
This will involve some iteration
8. Confirm that there is sufficient safety on the tensile strength of the chain
and the wear/fatigue strength of the bushing.
T1 = P1 .9,549 / n
T2 = P1 . 9,549 / n
Chain Velocity
Pd = P.K1.K2.K3.K4.K5.K6.K7.
Normally the drive is a reduction drive and the driver sprocket is the
smallest. This is normally selected as a 19 tooth wheel unless a high speed
smoother drive is required then a 23 (or higher) tooth wheel is selected.
Tooth factor ft = 19 / z1
This allows for the difference in ratio from the 3:1 ratio normally used in
determining the design power for chain drives...
Driver Characteristics
Some shock
Smooth Running, Loading..IC Heavy shock
Electric Motors, IC engines , Electric Loading IC engines
engines with motors with with less than six
hydraulic couplings frequent cylinders
stops/starts
Driven machine
characteristics
Smooth running
.Office 1 1,1 1,2
Machines,Generators
Light duty ..Fans,
pumps,
compressors,printing
1,2 1,3 1,4
machines, uniformly
loaded conveyors,
machine Tools
Moderate
shock..concrete
mixing , non- 1,4 1,5 1,7
uniformly loaded
conveyors, mixers.
Heavy shock
loading.. Planars, 1,6 1,7 1,9
presses, drilling rigs.
Centre Distance Factor (K4)
This allows for chain designs with sprocket centre distances other than optimum= C/p = 40.
C/p 20 40 60 80 =<160
K4 1,2 1 0,9 0,85 0,7
This factor involves some judgement and the notes below are provided for
guidance.
The design power as evaluated by the above process should be less than the lower of the
chain capacity associated with the link or the bush as calculated below...Note:
Manufacturers and suppliers generally simplify this process by providing tables or charts to
make this process more convenient. A typical graph is shown below Chain Power graph....
The dynamic load on a chain includes for the tensile load for transmitting the power and the
centrifugal load resulting from the chain rotating on the sprocket.
For normal speed applications only the direct load due to the tensile load is relevant.
Ft = P 1*1000 / v..(N)
Note this is derived in principle in the webpage for flat belt drives.. Flat belts
Fc = Mm.v2..(N)
Fr = F t + F c
The value Fr is divided into the breaking strength of the chain Fb to obtain the static Factor of
Safety of the Chain
Ss = Fr /F b
This value of Ss is divided by the Application factor K3 to arrive at the dynamic Factor of
Safety
Sd = Fr / (Fb * K3)
The graphs below show (very approximately) the range of recommended static and dynamic
safety factors.
Chain Bearing Stress
The bearing stress is the resultant tensile stress / the bearing area B a. Values for the bearing
area are provided in the chain properties table below...
B s= T r / B a
The calculated bearing stress should be less than the acceptable bearing pressure
The specific pressure and the friction coefficents are obtained from the charts below:
Pitch Diameter
The pitch diameter of a chain sprocket can be obtained from the formula
D = P / sin ( / z)
Table below identifies the pitch diam for sprockets with chain pitch of 25,4mm . for other
chain pitches the diameter will be proportional e.g for 12,7mm chain pitch the diameters will
be half the tabled values.
There are practical limitations for the minimum distance between the chain sprocket centres
to prevent interference of the sprocket teeth. To provide a reasonable chain operating life is
necessary to ensure good spacing and a minimum wrap of 120 o. The drive layout will
determine the actual centre distance. A recommended value is about 40 time the chain
pitch.
When the chain centre distance can be adjusted to suit the chain length then the length (L)
of the chain in (pitches) can be used to determine the centre distance between sprockets
(C) using the following formula
Chain Length
The length of the driving chain is normally required in numbers of double pitches because a
complete link includes the inner and the outer link which covers two pitches.
The Chain length (L) in pitches (p) is given (to sufficient practical accuracy ) by the formula
Chain Properties
Note: I have hand sketched this based on a typical manufactures chart.. Please use it with
care and ,better still, get a the information from a chain supplier..
Chain suppliers each produce graphs similar to the one below to enable convenient
selection of a suitable chain for a specific duty. This is compared to the design power which
is the required power corrected by appropriate factors. The main factors to be considered
are the tooth factor and the service factor...