Notes on Sprockets and Chains Page 1

Notes on Sprockets and Chains

A sprocket is a toothed wheel upon which a chain rides. Contrary to popular opinion, a sprocket is not a gear.

Chain Construction
Chains have a surprising number of parts. The roller turns freely on the bushing, which is attached on each end to the inner plate. A pin passes
through the bushing, and is attached at each end to the outer plate. Bicycle chains omit the bushing, instead using the circular ridge formed
around the pin hole of the inner plate.

Chain Dimensions
Chain types are identified by number; ie. a number 40 chain. The rightmost digit is 0 for chain of the standard dimensions; 1 for lightweight
chain; and 5 for rollerless bushing chain. The digits to the left indicate the pitch of the chain in eighths of an inch. For example, a number 40
chain would have a pitch of four-eighths of an inch, or 1/2", and would be of the standard dimensions in width, roller diameter, etc.

The roller diameter is "nearest binary fraction" (32nd of an inch) to 5/8ths of the pitch; pin diameter is half of roller diameter. The width of the
chain, for "standard" (0 series) chain, is the nearest binary fraction to 5/8ths of the pitch; for narrow chains (1 series) width is 41% of the pitch.
Sprocket thickness is approximately 85-90% of the roller width.

Plate thickness is 1/8th of the pitch, except "extra-heavy" chain, which is designated by the suffix H, and is 1/32" thicker.

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Notes on Sprockets and Chains Page 2

ANSI Standard Chain Dimensions

Chain No. Pitch Roller Diameter Roller Width Sprocket thickness Working Load
25 1/4" 0.130" 1/8" 0.110" 140 lbs
35 3/8" 0.200" 3/16" 0.168" 480 lbs
40 1/2" 5/16" 5/16" 0.284" 810 lbs
41 1/2" 0.306" 1/4" 0.227" 500 lbs
50 5/8" 0.400" 3/8" 0.343" 1400 lbs
60 3/4" 15/32" 1/2" 0.459" 1950 lbs
80 1" 5/8" 5/8" 0.575" 3300 lbs

Bicycle and Motorcycle Chain Dimensions

Chain No. Pitch Roller Diameter Roller Width Sprocket thickness

Bicycle, with Derailleur 1/2" 5/16" 1/8" 0.110"
Bicycle, without Derailleur 1/2" 5/16" 3/32" 0.084"
420 1/2" 5/16" 1/4" 0.227"
425 1/2" 5/16" 5/16" 0.284"
428 1/2" 0.335" 5/16" 0.284"
520 5/8" 0.400" 1/4" 0.227"
525 5/8" 0.400" 5/16" 0.284"
530 5/8" 0.400" 3/8" 0.343"
630 3/4" 15/32" 3/8" 0.343"

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Notes on Sprockets and Chains Page 3

Selecting a Chain
Two factors determine the selection of a chain; the working load and the rpm of the smaller sprocket. The working load sets a lower limit on
pitch, and the speed sets an upper limit.

Maximum Pitch = (900 ÷ rpm ) 2/3

The smaller the pitch, the less noise, wear, and mechanical losses will be experienced.

Sprockets
There are four types of sprocket;

Type A: Plain Plate sprockets

Type B: Hub on one side
Type C: Hub on both sides
Type D: Detachable hub

Sprockets should be as large as possible given the application. The larger a sprocket is, the less the working load for a given amount of
transmitted power, allowing the use of a smaller-pitch chain. However, chain speeds should be kept under 1200 feet per minute.

The dimensions of a sprocket can be calculated as follows, where P is the pitch of the chain, and N is the number of teeth on the sprocket;

Pitch Diameter = P ÷ sin (180° ÷ N)

Outside Diameter = P × (0.6 + cot ( 180° ÷ N) )

Sprocket thickness = 0.93 × Roller Width - 0.006"

Proceedure for Laying Out a Sprocket

The first thing you need to know to lay out a sprocket is the dimensions of the chain which is to run upon it, specifically the pitch, roller
diameter, and the roller width of the chain. The second thing you need to know is the number of teeth in the sprocket, which will depend entirely
on your application. From these numbers, the outside diameter and thickness of the required blank can be calculated.

You'll also need to know the angle between teeth - this is simply the 360° divided by the number of teeth.

1. Start by drawing a three radial

lines from the center of the blank to
the edge, separated by an angle
equal to the angle between teeth.

2. Draw lines parallel to these

lines, at a distance equal to the
pitch of the chain.

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Notes on Sprockets and Chains Page 4

3. A roller will be located at each

intersection of the parallel lines
and the pitch circle. Draw a circle
equal to the roller diameter of the
chain.

4. Draw lines between the roller

centers.

5. Draw circles around the roller

centers, that pass through the
intersection of the other roller and
the line between centers.

6. The tooth profile is as shown.

The sprocket teeth are usually truncated one chain pitch above the bottom of the seat; this is not shown here. Note that this shape is not the only
one that will work - bicycles in particular use various tooth shapes for different circumstances.

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Application
Sprockets should be accurately aligned in a common vertical plane, with their axes parallel. Chain should be kept clean and well lubricated with
a thin, light-bodied oil that will penetrate the small clearances between pins and bushings.

Center distance should not be less than 1.5 times the diameter of the larger sprocket, nor less than 30 times the chain pitch, and should not
exceed 60 times the chain pitch. Center distance should be adjustable - one chain pitch is sufficient - and failing this an idler sprocket should be
used to adjust tension. A little slack is desirable, preferably on the bottom side of the drive.

The chain should wrap at least 120° around the drive sprocket, which requires a ratio of no more than 3.5 to 1; for greater ratios, an idler
sprocket may be required to increase wrap angle.

References:
The Complete Chain Guide
Ryle Sprocket

Back

January 1, 1970 GMT

© 2003 W. E. Johns

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