Sheave Design

Design of Bearing Seat and Sheave Groove

Due to the low coefficient of friction of cast nylon, sheaves can
Types of Bearing Seats be installed without anti-friction bearings in applications with light
loads (Type 4 and Type 5). Please refer to the section “Sheaves
without bearings” later in this brochure. If the load in the bearing
seat exceeds the maximum permissible load for running directly
1 2 3 4 5

on the shaft, anti-friction bearings should be installed. Several

installation methods are available (Types 1, 2 and 3).

The groove diameter of a cast nylon sheave should exceed the

1 2 3 4 5
wire rope diameter by about 5%. This allows for the tolerance in
the rope diameter and assures good support for the wire rope. The
groove depth should be at least 1.5 times the rope diameter to
prevent “jumping”. A groove angle (throat angle) of between 30°
and 45° assures the best support for the wire rope. When using
Width (B) stranded cables, the root diameter should not be a whole number
Throat Angle (w) multiple of the length of lay of the cable.

Rope Rope Diameter Groove Radius m

Diameter (d)
Groove Depth (h)

(inches) (inches) (inches)

1/8 0.066 0.079
(m) 1/4 0.131 0.118
3/8 0.197 0.177
1/2 0.263 0.197
Groove Radius (r) 5/8 0.328 0.236
3/4 0.394 0.276
7/8 0.459 0.276
h = Groove depth (1.5 • d) minimum
w = Throat angle
1 0.525 0.315
d = Wire rope diameter 1-1/4 0.656 0.394
r = Groove radius (see Figure 1 or (d+5%) / 2) 1-1/2 0.788 0.433
m = Minimum flange width 1-3/4 0.919 0.492
B = Minimum width of sheave = d • 2.5
2 1.050 0.492
Maximum permissible fleet angle is 4°
Figure 1: Recommended Groove Dimensions

Determining Line Pull

Certain calculations involving line pull (Fs) and the wrap angle (α)
The following formula determines the actual must be completed when designing a sheave. For circumferential
load based on line pull and wrap angle:
loads, the wrap angle α influences the load on the groove and on
α
Fres = 2 • Fs • sin { 2 } the center bore or bearing. Wrap angle is defined as the angle
formed between the entry and exit points of the wire rope on the
sheave, as seen from the center of the sheave.

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 Groove Pressure
Two criteria must be observed, but as a general rule, if the D:d ratio (sheave tread diameter : wire rope diameter) is 18:1
or greater, the calculations for groove pressure can be ignored. The calculated value of the maximum continuous service
load (p’) resulting from the use of the formulas given below, must be equal to or less than the values given in Figure 3
and Figure 4.

1. Sheave under circumferential load, or sheave under point load. 2. Stranded wire rope, or armored cable
Circumferential Load Point Load Open Stranded Cable

(d)
(d1) Strand

Line pull Fs Load F (Wheel Pressure)

Open Cable, circumferential load Open Cable, point load

3 3
X X
p’ = p’e•
Z
with p’e = 650 • [(2 • r) - d1 ] • Fres
2 • r • d1 • D
in psi
p’ = p’e •
Z
with p’e = 505 •
[1 - 2d r + dD ]
•
1 1
•
F
(d1)2
in psi

d1 = Strand diameter in inches Specific Pressure (Pe) Correction Factor

D = Root diameter of sheave in inches (in psi) (X)
X = Correction factor taken from Figure 2
≤ 7,250 Z
r = Groove radius in inches
F = Load (wheel pressure) in lbs
22,000 6
Fres = Total load in lbs (see previous page) 43,500 4
Z = Number of strands ≤ 62,250 2.5
2
psi N/mm
Figure 2
psi N/mm2

70°F

Maximum p’
120°F

Maximum p’
165°F

210°F

m/s m/s
ft/min 100 200 300 400 500 600 ft/min

Figure 3: Maximum Continuous Loading Figure 4: Maximum Continuous Loading

p’ for Circumferential Loads p’ for Point Loads

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 Armored cable, point contact

p’ = Expected area pressure between cable and groove

a = (2/d) - (1/r)
b = 2/D
3
d = Cable OD in inches p’ = 765 • (a + b)2 • F in psi
D = Root diameter of sheave in inches z
F = Load (wheel pressure) in lbs
r = Groove radius in inches
cos v = (a-b) / (a+b)
z = Auxiliary value from Figure 5

Auxiliary value z for various angles

v 90 - 85° 84 - 75° 74 – 65° 64 – 55° 54 – 45° 44 – 35° 34 – 25° 24 – 15° 14 – 5° 4 – 0°
z 1.0 1.007 1.030 1.065 1.124 1.211 1.346 1.541 2.109 0

Figure 5

Armored cable, circumferential load

There is no specific calculation for this application. Please contact
our engineers if your application calls for these conditions.

Bearing press fit tolerance

Minimum recommended press fit for bearing seat with needle roller
or ball bearing. For other roller bearings and bronze bushings,
multiply the press fit undersize by 1.6. Tolerance should be
+/- 0.002 (+/- 0.05 mm).

1 2 3 4 5 6 7 8 10 inches
Press fit undersize (interference)

.
.
per inch or mm OD

.
.
.
.
.

mm
Bearing or Bushing OD

Figure 6

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 Center bore pressure
Besides the pressure between cable and groove, the pressure between center bore and bearing outer race must be
calculated for the proper sheave design.

N/mm2

40

30
Fres

Maximum p’
p=
d1 • L • Y 20

10
d1 = Bearing OD in inches (or mm)
Fres = Total load in Ibs (or N)
Y = Number of bearings
Ambient Temperature (°F)
L = Bearing load carrying width in inches (or mm)
Figure 7: Maximum continuous
center bore pressure p vs. temp.

The calculated area pressure on the bearing outer race must be less than the values given in Figure 7. If the values are
greater, a steel sleeve should be used in the bore. The bearings could then be pressed into the steel sleeve. A decision
to use a cast nylon sheave in a specific application can only be made once both the area pressure in the groove and on
the bearing outer race have been calculated.

Sheaves Without Bearings

The calculation for surface area pressure for bushings (running the sheave on the shaft) is the same as for anti-friction
bearings. However, for a bushing, the area pressure must be multiplied by the speed of the sheave in order to obtain
the PV-value. The PV-value decides whether the sheave can run directly on the shaft

PV-value = Pressure x Velocity in (N/mm2 x m/s)

Sheaves made of Oilamid® (cast nylon + oil) have a maximum PV-value of about 0.1 N/mm2 x m/s when running dry
or 0.6 N/mm2 x m/s when running with lubrication. Anti-friction bearings should be used where these PV-values are
exceeded.
inches

Operating bearing play

in % of shaft diameter
Minimum recommended operating
bearing play for sheaves running
directly on the shaft.

mm

Bushing ID

Figure 8

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 Load Calculation Example

Conditions:
Sheave tread diameter: 23”
Wire Rope: 1” diameter open stranded (1/4” strand diameter, 8 strands)
Load: 20,000 lbs line pull with 120° wrap angle
Bearing: Tapered roller (2) OD 4.375” x 1.5” long (cup length 1.1875”)

Groove pressure:

Fres= 2 • 20000 • sin [120 ] = 34,641 psi Result:

2
The sheave groove can withstand the line pull at line speeds up to about
(2 • 0.525) • 34641 = 44,038 600 ft/min. in ambient temperatures of 70°F or line speeds up to about
p’e = 650 •
2 • 0.525 • 0.25 • 23 300 ft/min. at ambient temperatures up to about 100°F (see Figure 3).
3 These figures are for continuous service. Load capacity for intermittent
p’ = 44038 • = 26,967 psi
8 operation is higher.

Bore pressure:

p= 34641 Result:
= 3334 psi
4.375 • 1.1875 • 2 The sheave bore can hold the load at ambient temperatures up to about
120°F in continuous service (see Figure 7).

Press Fit Undersize of Center Bore (see Figure 6):

4.375 • 0.0033 = 0.014” • 1.6 = 0.0231” Center bore size should be 4.352”
4.375” - 0.0231 = 4.352” Tolerance: +0.000” /- 0.004”

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Worksheet for Sheaves Made of Cast Nylon
Company Name ______________________________________________________________________________

Contact name ________________________________________________________________________________

Address _____________________________________________________________________________________

Telephone____________________________ Fax__________________________ Date ___________________

Sheave information Application Information

Outer Diameter (OD) __________________ Inches Line Pull (Fs) _________________________ lbs
Root Diameter (D) _____________________ Inches Rope Speed (V)_______________________ fpm
Hub Diameter (h) _____________________ Inches Ambient Temperature (Ta) min.___ max___ ˚F
Center Bore Diameter (b) ______________ Inches Wrap Angle (α) _______________________ ˚
Sheave Thickness (B1) ________________ Inches Fleet Angle __________________________ ˚
Hub Thickness (B2) ___________________ Inches Type of Loading † Circumferential † Point
Groove Radius (r) ____________________ Inches
B1

Type of Sheave † Fixed † Free Hanging r

Color † Natural White † Black

Bearing/Bushing Information
Bearing/Bushing OD (d1) ______________ inches

Bearing/Bushing Width (L) _____________ inches

B2
Number of Bearings (Y) _______________

Shaft Diameter (s) ____________________ inches

Type of Bearing † Bushing † Anti-Friction

OD D h b
Supply with † Bearing † Bushing † Neither

Wire Rope Information

Rope Diameter (d) ____________________ inches

Strand Diameter (d1) __________________ inches

Number of Strands (Z) _________________

Type of Rope † Open Wire † Armored Cable

Quantity Requirements
Qty to be quoted ____ Annual Qty Required ____

engineer would be happy

to assist you in your
sheave design.
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