Design calculations of chain drive

A chain drive consists of an endless chain wrapped around two sprockets as shown in Fig. 1. A chain can
be defined as a series of links connected by pin joints. The sprocket is a toothed wheel with a special
profile for the teeth. The chain drive is intermediate between belt and gear drives. It has some features
of belt drives and some of gear drives.

Fig 1 chain drive

Important tables required for the chain selections & design from design data book.

Table 1 Power rating of simple roller chain

Table 2 Dimensions and breaking loads of roller chains
 Table 3 Service factor (Ks)

Table 4 Tooth correction factor (K2)

 Table 5 Multiple strand factor (K1)

Given data

Torque acting on the motor is T= 10 kg= 98.06 N.m,

RPM = 100rpm

*Design of chain-sprocket

Number of teeth = Z1= 20 (sprocket)

The number of teeth for the both sprocket are same because we will have to transmit same power to
another axis.

Tooth correction factor (K) for the both sprocket K2 = 1.18

From the table 4 (tooth correction factor)

Multiple strand factor for strand 1) k1=1

From table 5 (Multiple strand factor)

From the table 2 (service factor)

For smooth chain & DC motor Ks=1.0

*We required power transmitted for the further calculations

2𝜋𝑛𝑇
POWER (P) P=
60

2𝜋∗100∗98.06
P= 60

P=1026.63 W
(power to be transmitted)∗Ks
KW Rating of Chain = 𝐾1∗𝐾2
 (1026.63)∗1.0
= 1.18∗1.18

Power rating= 737.31 W= .737 KW

Nearest value for 100 rpm in table 14.2 is 0.64

For 100 rpm & Power 0.64KW

From table 1 Power rating of simple roller chain

The Power rating at 08 B is 100rpm & .64 KW power

Therefore chain number 08B is selected.

From table 2

For chain number 08B

*Dimensions

Pitch (P) P=12.70 mm

Roller diameter (d1) d1=8.51 mm (max.)

Width (b1) b1=7.75mm

Transverse Pitch (Pt) Pt=13.92mm

Breaking load

Simple = 17800 N

Duplex = 31100 N

Triplex = 44500 N

*Pitch Circle diameter of driving & driven shaft (PCD)

𝑃 12.70
D1= 180 = 180 = 81.41 = 85 mm
sin( ) sin( )
𝑧 20

For driving sprocket D1= 85mm

For driven sprocket D2= 85mm

*Number of chain link (Ln)

The central distance between sprocket wheels should between 30P to 50 P

By taking the minimum value

Approximate central distance (a) a= 30P

a=30*12.70

a=393.23

=395mm

𝑎 𝑧1+𝑧2 𝑧2−𝑧1 𝑃
Ln = 2 * (𝑃) + [ 2
] + [ 2𝜋 ]2 ∗ (𝑎 )

395 20+20 20−20 12.70

= 2 * (12.70) + [ 2
] + [ 2𝜋 ]2 ∗ 395

395 40 12.70
= 2 * (12.70) + [ 2 ] + 0 ∗ 395

= 82.20

No of links are 83

Correct central distance

𝑍1+𝑍2 20+20
[ Ln -( )] = [83-( )] = 63
2 2

𝑃 𝑍1+𝑍2 𝑍1+𝑍2 2 𝑍2−𝑍1 2

a= 4 {[ Ln − ( 2
)] + √[ Ln − ( 2
)] − 8[ 2
] }

12.70
a= 4
{63 + √63}

a= 400 mm

To provide small sag, for allowing the chain links to take the best position on the sprocket teeth, the
centre distance is reduced by (0.002a). Therefore, the correct centre distance is given by

a= 0.998*400

a=399mm
To calculate tension in chain

The chain velocity is given by

𝑍1 𝑃𝑛1
𝑣=
60 ∗ 103
20∗12.7∗100
V= 60∗1000

V= 0.423 m/s

The chain tension is given by

1000 ∗ 𝐾𝑊
𝑇1 =
𝑣
1000 ∗ .737.31
𝑇1 =
0.423

𝑇1 = 1743.05 𝑁

Factor of safety
17800
FS=
1743.05

FS=10.21
Shaft design

Material of shaft is Mild steel

Material properties of mild steel

Yield strength Syt 150MPa , N/mm2

Factor of safety FS 2
Poisons ratio 𝜇 .303
𝜃 180°

For chain drive max tension

𝑇1 = 1743.05 𝑁 =1.75KN

Permissible shear stress

𝑆𝑦𝑠 0.5 ∗ 𝑆𝑦𝑡

𝜏= =
𝐹𝑆 𝐹𝑆
0.5 ∗ 150
𝜏=
2

𝜏 = 37.5𝑁/𝑚𝑚2

Torsion moment

𝑇1 = 1743.05 𝑁 =1.75KN

𝑇1
= 𝒆𝝁𝜽
𝑇2
𝑇1
= 𝒆𝟎.𝟑𝟎𝟑∗П
𝑇2

𝑇2 = 672.82 𝑁

Torque supplied to the shaft is given by

Mt=(T1-T2)* 85

=(1743.05-672.82) *85

= 90970N.mm
Bending moment

Also (T3-T4)* 100

(1743.05-672.82) *85

= 90970N.mm

𝑇3
= 𝒆𝟎.𝟑𝟎𝟑∗П
𝑇4

T3=1743.05N

T4=672.82N

Both sprockets are same

Neglecting the wt of sprocket

Force on sprocket 1 at pt B

f= T1+T2

= 1743.05+671.82

=2414.87 N

Similarly force on the other sprocket at pt c

f= T3+T4

= 1743.05+671.82

=2414.87 N

Bending moment at pt B

(Mb)B=2414.87*37

=89350.19 N.mm

Bending moment at pt c

(Mb)c==2414.87*37

=89350.19 N.mm
Bending moment at pt a & d

(Mb)a,d=0 N.mm

Shaft diameter ,

16
2𝜏𝑚𝑎𝑥 = √(𝑀𝑏 )2 + (𝑀𝑡 )2
𝜋𝑑3

16
2*37.5=𝜋𝑑3 *√(89.350.19 )2 + 90.97^2

D=8.66mm

Taking safe value diameter of shaft is 10mm