College of Engineering

Mechanical Engineering Department

Subject : PME2-M MACHINE DESIGN 2 (Lecture)

Credit : 2 units
Day/Time : T 06:00PM - 09:00PM
Course/Section : BSME-4E-M

Lecture No. 05:

FLAT BELT DESIGN PROCEDURES
NOTE: WORK IN PROGRESS

Lecturer: Mr. Rodelio T. Padrique

FAIRES APPROACH FOR FLAT BELT DESIGN
1. K is constant; it depends on the material and size of the belt as well as the speed of the
belt. 𝒆fθ − 𝟏 𝟏𝟐𝝆𝒃𝒕𝒗𝒔 𝟐
𝒘𝒗𝒔 𝟐
𝑭𝟏 − 𝑭𝟐 = (𝑭𝟏 − 𝑲) 𝑲= =
𝒆fθ 𝒈𝒐 𝟑𝟐. 𝟐
2. Choose a certain design stress “s” (in psi) that will compute for the safe value for F1
such that If F1 = sA = sbt, A = bt is the cross section in sq. inches.

𝟏𝟐𝝆𝒗𝟐𝒔 𝒆fθ − 𝟏 Net Belt Pull,

𝑭𝟏 − 𝑭𝟐 = 𝒃𝒕(𝒔 − ) lbf
𝟑𝟐. 𝟐 𝒆fθ
3. Typical value for  is:

Many agreed with Faires’s claim that his enhanced Worley’s belt simplified theory is impeccable.

REF: 2
ALBA PROCEDURE (DOCUMENTED BY FAIRES)
▪ Use of Rating Tables and Experience Factors
▪ Use Tables 17.1 and 17.2 for flat leather belt. Interpolate between speeds as recommended by the
Author.

𝒉𝒑
𝒉𝒑 = ( , 𝑻𝒂𝒃𝒍𝒆 𝟏𝟕. 𝟏)(𝒃𝑪𝒎 𝑪𝒑 )(𝑪𝒇𝟏 𝑪𝒇𝟐 … )
𝒊𝒏

Parameter Description
b Belt Width, in.
𝑪𝒎 Correction factor for type of drive. Use 𝐶𝑚 = 1 (if not electric motor)
𝑪𝒑 Correction of size of smallest pulley; smaller pulley have greater flexure.
𝑪𝒇𝒊 Correction factors for environmental conditions. Example: Vertical drive,
dusty atmosphere, shock load condition will give Cf = (0.83)(0.74)(0.71)

REF: Page 449. Design of Machine Elements, by Faires. 4th Edition. 3

3
RATED CAPACITY OF THE BELT
Table 17.1 Leather Belt Rating Capacity (HP/in. of Width)

No. of Plies
Thickness t (in)
Service Duty
Belt Speed, fpm
The value you’re
looking for!

Double ply, t = 20/64 in, medium

service, at 1,000 fpm belt speed.

Notes:
1. For belt speed over 6000 fpm, consult
catalogues.
2. t = average belt thickness

REF: Page 449. Design of Machine Elements, by Faires. 4th Edition. 4

4
Minimum Pulley Diameter for the use of Table 17.1

Table 17.1

REF: Page 449. Design of Machine Elements, by Faires. 4th Edition. 5

5
 Experience [Correction] Factors (Table 17.2)

Factor due to Type of Drive Factor due to Pulley Size Factor due to Operating Conditions
Type of Drive Cm Pulley Size, inches Cp Operating Conditions Cf
4 or less 0.5
Any except electric motor 1.00 Oily, wet or dusty atmosphere 0.74
4 1/8 to 8 0.6
Squirrel cage, compensator starting 0.67 9 to 12 0.7 Vertical drives 0.83
13 to 16 0.8
Squirrel cage, line starting motor 0.50 Jerky loads 0.83
17 to 30 0.9
Slip ring, and high starting torque 0.40 Over 30 1.0 Shock and reversing loads 0.71

WE WILL PROVIDE A SIMPLIFIED, PROCEDURE TO APPLY OUR SIMPLIFIED WORLEY MODEL IN THE NEXT
LECTURE!

REF: Page 450. Design of Machine Elements, by Faires. 4th Edition. 6

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MARK’S ME HANDBOOK: RUBBER BELTING
▪ Rubber belting is made from fabric or cord impregnated and bound together by
vulcanized rubber compounds.
• Cotton or rayon fabric
• Nylon fabric
• Steel cord
• Steel cable.
▪ Advantages are high tensile strength, strength to hold metal fasteners
satisfactorily, and resistance to deterioration by moisture.
▪ Best rubber fabric construction for most service is made from hard or tight-
woven fabric with a “skim coat” or thin layer of rubber between plies.
▪ The cord type of construction allows the use of smaller pulley diameters than
the fabric type, and also develops less stretch in service.
▪ It must be used in the endless form, except in cases where the oil-field type of
clamp may be used.

REF: 7
MARK’S ME HANDBOOK: RUBBER BELTING

▪ Ultimate tensile strength: 280 to 600 lb per inch width per ply.
▪ Weight: 0.02 to 0.03 or more lb/in width/ply. Belts with steel reinforcement are
considerably heavier.
▪ Initial tension: 15 to 25 lb/ply/in width. Otherwise, shafts or bearings will overload.
▪ General rule to achieve initial tension:
• A common rule is to cut belts 1 percent less than the minimum tape-line measurement around the
pulleys.
• For heavy loads, a 1 1/2 percent allowance is usually required, although, because of shrinkage,
less initial tension is required for wet or damp conditions.
• Provide take-up of 2 to 4 percent to allow for length variation as received and for stretch in service.

▪ Maximum safe tight-side tensions for rubber belts:

Duck weight, oz 28 32 32.66 34.66 36
Tension, lb/ply/in width 25 28 30 32 35
REF: 8
MARK’S ME HANDBOOK: RUBBER BELTING
Formula to Calculate Horsepower per inch of belt width as follows:

hp/in = (demanded hp x S)/(K x W)

where:
Demanded hp = horsepower required by the job at hand;
S = service factor
K = arc factor
W = proposed belt width (determined from pulley width). [b]

▪ One enters a belt manufacturer’s catalog with hp/in, belt speed, and small pulley
diameter, then selects that belt which has a matching maximum hp/in rating.
▪ Use Table 8.2.46a, b, c, and d for typical values of S, K, hp/in ratings, and minimum
pulley diameters, respectively.

REF: 9
MARK’S ME HANDBOOK: RUBBER BELTING

REF: 10
MARK’S ME HANDBOOK: RUBBER BELTING
Table 8.2.46b Arc of Contact Factor K—Rubber Belts.

REF:Mark’s ME Hdbk. P8-52 11

MARK’S ME HANDBOOK: RUBBER BELTING
Table 8.2.46c Horsepower Ratings of Rubber Belts (hp/in of belt width for 180 degrees wrap)

REF: 12
12
MARK’S ME HANDBOOK: RUBBER BELTING
Table 8.2.46d Minimum Pulley Diameters—Rubber Belts

REF: 13
13
CHILDS’ PROCEDURE
No. Task Remarks
1. Define the operating Nominal power to be transmitted, rotational speeds of shafts, space, layout
conditions. environmental conditions, etc.
2. Determine the service Service factors are used to down-rate the transmission capability listed by
factor. belt suppliers to account for practical applications vs. test conditions.
3. Get design power. This is the product of the nominal power and the service factor.
4. Select the belt type. Use Manufacturer’s Chart.
5. Select a belt. Select specific belt based on design power and speed from manufacturer.
6. Select pulley diameters Use standard sizes. Choose sizes that give desired speed ratio.
7. Set the center distance Depends on the application. Note: C > D2.
8. Choose the belt length. Available in standard lengths. Make iterations as necessary.
9. Apply correction factors. Apply manufacturer’s guide to correct power (speed ratio, belt geometry,etc.)
10. Determine the Hp/in. Get Design Power from manufacturer. For other belts, it may be Hp/belt.
11. Determine the number The number of belts is given by dividing the design power by the allowable
of belts. power per belt and rounding up to the nearest integer.
REF: 14
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

1. Determine the drive parameters. TO BE FURTHER SYNTHESIZED. PLEASE VISIT THE ORIGINAL
TEXT BY MARRS AND RECOMMEND
• Typical parameters are: IMPROVEMENTS/CORRECTIONS AS NECESSARY!

✓ Drive horsepower (or kW) or flat belt linear speed

✓ Shaft diameters
✓ Preferred speeds of both shafts
✓ Preferred distance between shaft centers

• Recommended belt speeds: 2500 ft/min (12.7 m/s) to 7500 ft/min (38.1 m/s).

• If starting from scratch, set initial linear belt speed of 4000 ft/min (20.3 m/s) and
calculate drive geometry from the belt speed.

REF: 15
15
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

2. Select a flat belt type and thickness.

• Choose belt type and material based on desired characteristics or operating
conditions like coefficient of friction.

• Calculate Belt Thickness

• Option 1: Determine the Design Power: Drive Power x Service factor S x
Safety Factor. Check references for S and other factors. Note: Belt
thickness is typically selected based on calculated design power.
• Option 2: Determine Rated Power or allowable tension per unit width.
Calculate based on tight side tension. [ALBA Procedure]

• Note: If belt width b is not yet known, so leave that term in the solution for now
and solve for it in subsequent steps.
REF: 16
16
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

3. Select the Sizes of the Pulleys.

• Select a standard size for one pulley. Using its pitch diameter, calculate the
diameter of the other pulley. Typical approach:
• Calculate the diameter of other pulley using the formulas.
• Select the nearest size from Manufacturer’s data.

• Verify the selected pulley sizes if the calculated speed ratio is achievable.
• If not, adjust current values of pulley speeds or diameters.
• Redo the affected calculations.

• Suggestion: Do not use a pulley that is below the minimum stock size for
selected belt to avoid exceeding the recommended bending stress on the belt.

REF: 17
17
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

4. Select or calculate a center distance and belt length.

• Based on the selected pulley diameter, Select the manufacturer’s recommended center
distance closest to your desired center distance. Also get the belt length from the manufacturer
based on selected C and pulley diameters.

• If no data tables are available, the calculate a new C using the formula:
𝑩 + 𝑩𝟐 − 𝟑𝟐(𝑫𝟐 − 𝑫𝟏 )𝟐 𝑩 = 𝟒𝑳 − 𝟐𝝅(𝑫𝟐 + 𝑫𝟏 )
𝑪=
𝟏𝟔
• Maximum C should be less than 20 times the D1. For high speeds, minimum C must be meet
the condition:

• For flat belts: that belts be specified 1% shorter than nominal to account for installation tension.
Verify with the manufacturer’s data.

REF: 18
18
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

5. Verify that the angle of wrap on the smaller pulley is greater than 120°.
• Use formula for wrap angle (or angle of contact).

6. Check the belt linear speed.

• Calculate belt linear speed. It must not exceed the maximum value set by the
manufacturer.

7. Check the belt bending frequency.

• Calculate bending frequency. It must be within an acceptable range set by the
manufacturer.

REF: 19
19
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

8. Choose a belt width.

• Option 1: Procedure (based on Mark’s ME Handbook)
• Get the Rated [Design] Power per unit width from manufacturer’s data.
• Equate Rated Power to desired Power and get the nominal belt width.
• Select the belt size closest to the nominal belt width. Get the final belt width.
• Verify: the final Rated Power must be higher than the target power.
• Option 2: Calculation based on Stress Analysis
• Get the equations for centrifugal hoop tension (Fc) and Tight-side Tension Force
(F1) as a function of belt width.
• Substitute Fc and F1 into slip equation and solve for b.
• Select the belt size with a width that exceeds the calculated b.
• If calculated b is not satisfactory, recalculate using a different belt thickness.
• A thicker belt will handle more stress per unit width.

REF: 20
20
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

9. Determine the installation and takeup allowance.

• The allowance, or a formula to calculate allowance, is usually provided by
the manufacturer.

10.Determine the required initial belt tension.

• Usually provided by the manufacturer as a value or through formula. If not,
use formula to calculate initial tension.
• Calculate static shaft load due to belt tension using formula. This
calculation ignores the shaft load due to pulley weight.

REF: 21
21
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

11. Validate the Shafting Involved.

• Check if the shaft diameters are sized properly for the power and speed
requirement.
• Every shaft should be designed according to professional standards.
• Verify the shaft design and calculation, including loads caused on shafts by
belt drives.
• If drive pulley is directly attached to an electric motor, use the NEMA standards
for shaft diameter sizing as necessary.

12. Fit the pulleys to your shaft diameters.

• Check for integral hubs, add bushings, etc.
• Make proper bore size and attachment features into the pulleys.

REF: 22
22
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

YOU MAY CONVERT THESE FORMULAS USING OUR NOMENCLATURE.

REF: 23
23
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

YOU MAY CONVERT THESE FORMULAS USING OUR NOMENCLATURE.

REF: 24
24
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

YOU MAY CONVERT THESE FORMULAS USING OUR NOMENCLATURE.

REF: 25
25
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

YOU MAY CONVERT THESE FORMULAS USING OUR NOMENCLATURE.

REF: 26
26
FLAT BELT DESIGN BASED ON MARRS MD HANDBOOK

YOU MAY CONVERT THESE FORMULAS USING OUR NOMENCLATURE.

REF: 27
27
MARRS’ SUGGESTED REFERENCES

▪ Collins, Busby, Stabb, Mechanical Design of Machine Elements and Machines, 2nd
Ed., John Wiley & Sons, Inc., Hoboken, NJ, 2010
▪ R. Mott, Machine Elements in Mechanical Design, 5th Ed., Pearson/Prentice Hall,
Inc., Upper Saddle River, NJ, 2012
▪ Oberg, Jones, Horton, Ryffel, Machinery’s Handbook, 28th Ed., Industrial Press,
New York, NY, 2008
▪ Shigley, Mischke, Brown, Standard Handbook of Machine Design, 3rd Ed.,
McGraw-Hill Inc., New York, NY, 2004
▪ Shigley, Mischke, Budynas, Mechanical Engineering Design, 7th Ed., McGraw-Hill
Inc., New York, NY, 2004
▪ “The Complete Guide to Chain” Website: www.chain-guide.com
▪ American Chain Association Website: www.americanchainassn.co
REF: 28
28
SHIGLEY’S PROCEDURE

INITIAL TASKS
1. Calculate Nominal Power, H:

Note: forces are in lbf and V is in ft/min.

2. Get the belt allowable tension Fa (or stress

sall) in per unit width from manufacturer’s data.

3. Get Pulley Correction Factor, Cp. It reflects the

severity of flexing at the pulley affecting its life.

4. Get Velocity Correction Factor, Cv. It reflects

the effect of speed over 600 ft/min on life.
- For polyamide and urethane belts use Cv = 5.1.
- For leather belts see Fig. 17–9.

REF: 29
29
SHIGLEY’S PROCEDURE

5. Calculate Design Power, Hd: OTHER USEFUL EQUATIONS:

where:
Ks = Service Factor; nd = safety factor
6. Calculate Combined, Allowable Largest
Tension (F1)a:

REF: 30
30
SHIGLEY’S PROCEDURE

MAIN DESIGN TASKS

REF: 31
31
Notes on the Procedures on Design and Problem Solving
ON DESIGN OF BELTS:
▪ No universal standard procedure! Two (2) Main Approaches are:
• Based on Actual Stress Analysis
• Based on Manufacturer’s Data
▪ No superior approach: Experience and practice are the key!
▪ Design is an art! No exact solution. But there are more superior designs in terms of
cost, long life, and service guarantee.
▪ Stick to one approach to avoid getting lost in the design.
ON PROBLEMS RELATED TO BELTS:
▪ Use your instinct in maneuvering the equations.
▪ Sometimes, mixing the two approaches may be necessary.
▪ Understanding the requirements and use of practicalities will lead to a more
reasonable solution.
REF: 32
GENERAL CONSIDERATIONS

Apply the arts of

creative thinking!

REF: 33
GENERAL FRAMEWORK

▪ G1. Analyze the requirements of the application and known specifications.

• Tabulate all known information (dimensions, speed, power transmitted, service or environmental
conditions, preferred belt type, belt material to be used, etc.).
▪ G2. Select or validate the type of belt drive to be used.
• Type of belt drive must conform with the given application.
• Check the velocity ratio (𝑉𝑅), belt speed (𝑣𝑠 ), the center distance (𝐶), etc. vs. type of belt used.
NOTE: If leather belting is decided, ALBA procedure can be implemented first before detailed stress analysis.

▪ G3. Geometry and Kinematic Analysis.

• Apply suitable geometric and kinematic equations. Calculate values of parameters if possible.
• Take note of parameters that cannot be directly calculated.
▪ G4. Conduct Force and Stress Analysis.
• Apply suitable equations involving F1, F2, K (Fc), maximum stress on the belt, etc. Calculate
the values of these parameters if possible.
• Take note of parameters that cannot be directly calculated.
REF: RTP 34
34
GENERAL DESIGN FRAMEWORK

▪ G5. Make Design Decisions.

• Combine equations from G3 and G4 to calculate the solvable parameters.
• Use Refer to Manufacturer’s Data (Tables and Charts) and other references to choose (or
complete the choice of) the required materials and specifications. Apply sound judgement as
designer for the remaining unknown parameters based on these references. This is your main
accountability as the designer. You’re putting you career on the line!
• Make an interim tabulation of all design variables and other parameters (geometric, kinematic,
force, stress, strain, etc.)
▪ G6. Validate the Design.
• Validate G2. Also recalculate after making changes on materials, dimensions or sizes, etc.
• Iterate the process if you are still not confident of the resulting design.
▪ G7. Document your final design.
• Completely describe the requirements, assumptions made, the design methodology adopted,
and prepare the final table of the belt specifications and other design variables.
• Enumerate your advice on cost, installation and operation involving you proposed design.
REF: RTP 35
35
RETURN TO BASIC: LAW OF BELTING

▪ Law of Belting: The center line of the belt as

it approaches the pulley must:
1) lie in a plane perpendicular to the axis of
that pulley; or,
2) lie in the plane of the pulley.
Otherwise, the belt will run off the pulley.

Illustration: The two pulleys are at right angle to each other. The center line
of the belt approaching larger or smaller pulley lies in its plane. The point at
which the belt leaves is contained in the plane of the other pulley.

If motion of the belt is reversed, the law of the belting will be violated.
Therefore, motion is possible in one direction in this case.
REF: 36
36
EXAMPLE: FAIRES PLEASE WORK ON THIS EXAMPLE.

Problem:
A belt drive is to be designed for F1/ F2 = 3, while transmitting 60 hp at 2700 rpm of
the driver D1; mw = 1.85 ; use a medium double belt, cemented joint, a squirrel-
cage, compensator-motor drive with mildly jerking loads; center distance is
expected to be about twice the diameter of larger pulley.
(a) Choose suitable iron-pulley sizes and determine the belt width for a maximum
permissible s = 300 psi.
(b) How does this width compare with that obtained by the ALBA procedure?
(c) Compute the maximum stress in the straight port of the ALBA belt.
(d) If the belt in (a) stretches until the tight tension F1 = 525 lb, what is F1/F2?

REF: Faires 37
37
EXAMPLE: SHIGLEY PLEASE WORK ON THIS EXAMPLE.

▪ Problem:
A polyamide A-3 flat belt 6 in wide is used to transmit 15 hp under light shock conditions where
Ks 5 1.25, and a factor of safety equal to or greater than 1.1 is appropriate. The pulley
rotational axes are parallel and in the horizontal plane. The shafts are 8 ft apart. The 6-in driving
pulley rotates at 1750 rev/min in such a way that the loose side is on top. The driven pulley is
18 in in diameter. See Figure. The factor of safety is for unquantifiable exigencies.
(a) Estimate the centrifugal tension Fc and the torque T.
(b) Estimate the allowable F1, F2, Fi and allowable power Ha.
(c) Estimate the factor of safety. Is it satisfactory?

REF: Ex. 17-1 Shigley 38

38
 DESIGN WORKSHEET LAYOUT
DEPARTMENT: Design Sheet No.:
NAME OF DESIGNER: Standards Adopted:
NAME OF DESIGN ACTIVITY: 1
START DATE: 2
COMPLETION DATE: 3

TRY CREATING A WORKSHEET FOR THE TWO EXAMPLES.

A. DESCRIPTION: B. SKETCH/SCHEMATIC DIAGRAM:
State the problem to be solved or the requirements to be fulfilled. Insert figure with proper labels.

C. FORMULAS:
Insert the formulas to be used.

Translate the
formula into the
D. CALCULATIONS Cells. E. CONCLUSIONS AND RECOMMENDATIONS
No. Parameter Description Symbol Formula Value Unit Remark
1 Variable 1 Given
2 Variable 2
3 Variable 3 Given

… F. REFERENCES/SOURCES OF DATA
n-2 Variable n-2 See Formula 1 1
n-1 Variable n-1 See Formula 2 2
n Variable n See Formula 3 3

REF: 39
39
END OF LECTURE NO. 10
NEXT: EXAMPLES OF FLAT BELT DESIGN. V-BELT
ANALYSIS.

01/02/2021 40