AIM: To study the power transmission systems.

THEORY:
The power is transmitted by different modes. One of these modes is mechanical drive. It
comprises different elements depending on the requirements which are as under:
1) Shaft or Shafting. 2) Belt.
3) Pulley. 4) Gear.
5) Chain. 6) Bearings and bearing blocks.

Shaft:

It is a one of the most essential element for power transmission. It is supported and runs in
bearings the other elements like pulleys, gears are mounted on shaft for transmit the motion.
The power transmitted by shaft can be given by,
2πNT
P=
60 ,000
Where P = Power kW
N = angular speed of shaft rpm
T = Torque on shaft N.m
Belt:
A belt is a flexible element running over pulleys. Which are used mostly in belt drives. They are
made with different cross section and from different materials depending on amount of torque
which is going to be transmit, the center distance between the driving and driven shaft.
Types of Belt
a) Flat belt
They are rectangular in cross section with standard width and thickness. They are available in the
form of long strap which can be join by suitable type of joint with require length. Mostly used
when distance between two shafts as large as 10 meters. Through this type of belts we can get
the clutch action by shifting it from loose to tight pulley.
The materials for flat belt are leather, rubber, canvas etc.

b) V-belt
They are trapezoidal in cross section with standard dimensions and available in endless form in
standard length. They are run in v-grooves made pulleys. The number of belts used is depends on
the amount of torque, which is to be transmitting. By using this types of belts slip can be reduce.
They are mostly used to connect shafts, which have center distance less than or equal to 5
meters. By this, types of belts speed ratio can be achieve up to seven. The material for v-belts is
fabric-vulcanized rubber with cotton or nylon cord tension element.
c) Timing belt
These belts are basically flat belt with teeth molded on inner side. They are available in standard
endless length, pitch and width. They are also known as positive drive belts. Mostly used for
short center distance arid for higher power transmission. They are comparatively costlier. The
material used for these types of belts is high quality rubber reinforced with the high tensile fabric
cords.
d) Rope
It is also one kind of circular belt which is used mostly in factories and workshops, when the
distance between shafts is running from 8mtrs. to 30 meters. The materials used for these are
leather, cotton, fabric and rubber and metal Wires. The fiber ropes are used when the pulleys are
about 60 meters. Apart, while wire ropes are used when the pulleys are up to 150 meters apart.
Pulleys:

The function of this element is to transmit the power from one shaft to the belt which running
over it, by giving motion in virtue of friction. They are generally made from C.I, Cast steel,
wrought iron and aluminum alloys, wood, nylon, plastics, fibers etc.

Constructional Details:

The main parts of pulleys are as under:

a) Rim: Is an outer most part of pulley. It may flat or grooved or convex on which belt is runs.
The convex feature preventing the slipping of belt and it keep in tension to the belt.
b) Hub or Boss: A Central hollow cylindrical portion of pulley called hub, in which shaft is
inserted and to prevent relative motion between them by different methods.
c) Arm: It joining the hub and the rim. They may be straight or curved have various cross
section like circular or elliptical etc.
d) Rib: It is a circular disc like portion of pulley joining the hub and the rim. Smaller diameter's
pulley provided with it.
Types of Pulley
a) Cone pulley (Stepped pulley)
Mostly made from C.I., having several steps of different diameters, it used to get varying
velocity ration of power transmission between parallel shafts by simple shifting the belt from one
step to other. The driving and driven pulley are placed opposite manner and diameter of the
corresponding steps are such that same belt can be used.
b) Guide pulley
Used to guide the belts connecting nonparallel intersecting or nonintersecting shafts. It is also
keeps the belt in proper plane.
c) Jockey (Rider) pulley
It increases the arc of contact and also keeps the belt in tension. It mounted near the smaller of
the two-transmission pulleys in a belt drive and always positioned to ride on the slack side of the
belt.
d) Grooved pulley
It has a groove at rim and cross section of it depends on the cross section of belt or rope.
Generally made from C.I. Because of groove, comparative friction is higher so can be used for
transmitting higher torque.
e) Fast and loose pulley
Pair of pulley mounted on the shaft out of which one is provided with brass or gunmetal bush
and it rotates freely where as other is keyed to shaft. The arrangement enable a machine shaft to
be started or stopped at will without stopping the running of the belt by shifting the belt from
loose pulley to fast pulley or fast pulley to loose pulley by a suitable belt shifter.
Chain:
It consists of several rigid links hinged together to provide on endless flexible loop passing over
the driving and driven wheel called sprockets. Sprockets have projecting teeth, which fit into
recesses in the link of chain enabling a positive drive.
The pitch can be given by following formula,
 P = d . Sin (180°) where, d = Diameter
Z Z = Number of teeth on sprocket

Roller chain commonly used for power transmission. In bicycles, motor cycles, textile
machineries and agricultural equipment the roller chains are frequently used. In context of stands
they can be classified like simplex, duplex or triplex chain.

Gear:

Gear is a toothed member (link), which is used to transmitting the motion by means of
successively engaging teeth from a rotating shaft to another, which rotates, or from a rotating
shaft to a body which translates. They are used to transmit power between shafts that are parallel,
intersecting or neither parallel nor intersecting by the use of various types of tooth gears.
Types of Gears
a) Spur gear
Used where the power is transmitted between parallel shafts. The teeth may be internal or
external. These gears have very wide applications like in watches, measuring instruments,
machine tools, automobiles etc. In this types teeth are parallel to shaft axis.
b) Helical gear
These are similar to spur gear except that their teeth are not straight to the shaft axis but follows
a helical path, with either left hand helix or right hand helix. They are used to connect parallel
shaft as well as nonparallel shaft, nonintersecting shaft. Properly designed helical gears run more
smoothly and quietly at high speeds. In this types of gears teeth are gradually engaged with each
other because of this, the noise pollution and impact load is low compare to spur gears. The draw
back of these gears is axial thrust experience during motion. The solution of this problem can be
solved by double helical (Herringbone) gear.
c) Spiral gear
Skewed gears are used to connect two nonparallel, nonintersecting shafts. Their teeth are like
helical gear cut along helical path on the wheel periphery. The teeth have point contact. Suitable
for small power transmission.
d) Bevel gear
They have their blanks conical in shape and having varying in cross section along the tooth
width. They are mostly used where two axis of shaft intersecting in a plane, they may be at right
angle or may not be. The bevel gears having angle between shafts at 90° are called miter gears
and other then 90° is called bevel gears. Depending on their shape of teeth they may be classified
as straight tooth type, spiral or skew or hypoid bevel gears. Spiral has smoother running action.
Hypoid bevel gears are used in automobile differential gear box.
e) Worm gear
These are special forms of helical gear in which teeth have line contact and axes of driving and
driven shaft are at right angle and nonintersecting. A smaller gear is called worm and large one
called worm wheel. This combination use for very large velocity ratio and for law space. The
noise and vibration are cooperative low. Their common application are in lath, drilling, milling
etc. They are also used in reduction gearbox.
f) Rake and pinion
This may consider as a pair of spur gear having one of the gear having infinite pitch circle
diameter (PCD) is called rack. Where as other small gear is known as pinion. These are used to
transmit circular motion into rectilinear motion and vice- versa. They are fitted in lathe, drill,
planner etc. to convert rotary motion into transitory motion.

Power transmission drives:

As we know power is transmitted by different type of drives which are framed in following
tree diagram.

MECHANICAL DRIVE

Frictional drives Positive drives/Mesh drives

Belt drive Rope drive Chain drive Gear drive

Frictional drive:

In this type the power is transmitted by the virtue of friction. If the distance between source and
utilization place is small than direct drive is used other wise flexible drive is used.

Belt and rope drive

To transmit the power from one shaft to another shaft, pulleys are mounted on two shafts. Which
are connected by belt or a rope depends upon the requirement. The belt /rope should be in
tension so that motion of one pulley is transmitted to other. Through this system constant
velocity ratio can not be maintained because of slipping and straining of belt/rope. Diameters of
driving and driven pulley are the controlling parameter for the velocity ratio and their relation
can be written as under,
N 2 D1
=
N1 D2

Where, N1, N2 = speed of pulleys.

Dl , D2 = respective diameter of pulleys.
With respect to belt position and relation between axes of the shaft, belt drive can be classified.
a) Open belt drive
When shaft axes are parallel and rotates in same direction. In this case driver pulls the belt from
one side and delivers it to other side. Thus the tension in the lower side will be more than that in
upper side. The lower side known as tight side where as upper side called slack side.
b) Cross belt drive
Used where the shaft axes are parallel but direction of rotation of two shafts is in opposite
direction. In this case driver pulls the belt from one side and delivers to other side.
c) Quarter turn drive
Used for nonparallel non-intersecting shafts. Provided that the center line of the belt when
approaches a pulleys lies in the mid plane of that pulley.
d) Right angle drive
Used when axes of shaft are at right angle. In this one additional suitable guide pulley used.
Which is directing and can be connect to belt.
Positive drive:

To avoid slipping and for getting constant velocity ratio this type is used. In this projecting
portions (tooth) are mash with corresponding recesses. This constrained to move together
without slipping and ensure perfect velocity ratio (V.R). Under this class chain drive and gear
drives are falling which are discuss as under:

Gear trains:
An assembly of gear wheels by means of which motion is transmitted from one shaft to another
shaft is called gear train. It may include any or all kinds of gears, depends on the relative axial
relationship between the shafts and the require V.R .The ratio of rpm of driver (1st) gear to rpm
of the driven (last) gear is known as speed ratio or V.R of gear train. It will be positive if
direction of rotation 1st and last is same and negative in case of opposite. As we have seen that
depending on the gear arrangement different type of gear train can be framed as under,
a) Simple gear train
A series of gears, capable of receiving and transmitting motion from one gear to another is called
simple gear train. In it, all the gear axes remain fixed relative to the frame and each gear is on
separate shaft. In this type,
1) A pair of mating external gear always moves in opposite direction and move in same direction
in case of one internal gear (annular) and one external pair.
2) All odd number gears are move in one direction and all even number gear move in the
opposite direction.
3) Shaft axes are parallel to each other.
4) Intermediate gear does not effect on V.R and therefore they called as idlers. Some time idler
may use to change the direction of driven gear. Their formulas are as under,
Train value = Rpm of driven = Number of teeth of driving
Rpm of driving Number of teeth of driven
V.R. = 1
Train value
b) Compound gear train
When two or more than two gear are mounted on common shaft it is known as compound gear. It
gives compact layout. The train value of type can be denoted as under,

Train value = Product of number of teeth of driving gears

Product of number of teeth of driven gears
c) Reverted gear train
First and last gears run at same axis, it is also one kind of compound train. Very large reduction
ratio can be achieve in compact place by this type. The speed ratio and their pitch circle radius
relation can be written as under,
Train value = Product of number of teeth of driving gears
Product of number of teeth of driven gears
Rl + R2 = R3 + R4
Where, Rl = radius of driving gear
R4 = radius of driven gear
R2, R3 = Intermediate gears
d) Epicyclic gear train
When there exists a relative motion of axis in gear train, it is called a planetary or epicyclic gear
train, thus in an epicyclic train the axis of at least one of the gear also moves relative to the
frame. If the arm is fixed, the gear train becomes a simple gear train. Large speed reduction is
possible with this type and if the fixed wheel is annular a more compact unit could be obtained.
Important applications of epicyclic gear train are in transmission, computing devices etc.

Part - II

AIM: To study the different types of couplings, clutches & brakes.

THEORY:
In practice, it is rare that power generation and power utilization at the same place. It is
transformed in different mode. Here we are limiting our discussion up to mechanical mode.
Transmission nature is a preferential and with respect to this different elements are used.
When mechanical power transmitted by continues rotating motion and input & out put members
require acting as same unit in that situation members are joint couplings. Where as requirement
is discontinue / continue and with limiting extremity power flow. In that constrains mostly
clutches are used and for control over power value on input or output member brakes are used,
They are used to slow down, stop or hold a load or release a load and control its speed.
Couplings:

Most common power transmitting member is shaft, which limited by manufacturing and
shipping requirements. The elements which joint two shafts are know as couplings, which
transmit power one to another. On the bases of axial relationship between two shafts, different
types of couplings are developed which are as under:

1. Sleeve coupling:

It consist of sleeve or hollow cylinder normally made from cast iron, which receives end of two
shafts made to butt together inside the sleeve. Sleeve and shaft are keyed by sunk key, which
normally made from same shaft material. Some time two keys may be a used. Torque is
transmitted from driver shaft to sleeve and from sleeve to driven shaft. It has no projected parts
and simple constructional features still require careful fitting.

2. Split muff coupling:

It is a improved form of sleeve coupling. In this sleeve is split into two halves and connected by
bolts. Here key also used as in sleeve coupling to create a pressure between the surface of shaft
and the sleeve there is some clearance at joining of to sleeve halves. So tightening of the bolts
causes frictional force between the surfaces. Because of this it can be used for heavy-duty work.
3. Flange coupling:
It is most widely used from medium to heavy duty. It consists of two coupling halves keyed to
two shafts, which are coupled by bolts. When bolt heads and nuts protrude beyond the flat
surfaces of flanges, the coupling called as unprotected type, which is dangerous. To over come
this flange is provided with a shroud or an annular projection, which shelter the bolt heads and
nuts. To ensure true alignment, one shaft may entered into other flange or projected portion of
one flange fit into the corresponding recess of other flange.
1. Bush pin type flange coupling:
It is a modified form of protected type flange coupling. There is a cushioning effect due to
leather/rubber bush in one of the flange. In which enlarged diameter of pins are inserted and
other end of bolt is fastened by nut in other flange. This feature is offering a small axial
movement and takes care of shock and slight misalignment. It is mostly used for direct
connection of electric motor.
5. Oldham coupling:
It is used in connecting two parallel shafts whose axes are at small offset. It consist of three
members, two flanges and one intermediate disc, both flange have diametrical slot at right angle
to each other, where as intermediate disc has replica of that slots on respective either sides. The
rotation of drive shafts causes the rotation and sliding of circular disc, which transmit the power
to the driven shaft.
6. Universal coupling:
It is used where the axes of shafts are intersecting to each other and during operation; angle
between the axes may slightly very. It consists of forks keyed to the ends of either shaft and they
are pin joined to a center block, which has two arms at right angles to each other. This is widely
used in automobiles to connect propeller shaft and also in machine tools.

Clutches:

Element which used to connect the one rotational part to another stationary, which later is to be
set into motion and transmit as well as control the limit of flow of mechanical power, where the
power at driven may be required to start or stop frequently. There are four categories: 1)
mechanical type 2) electromagnetic type 3) pneumatic type 4) hydraulic type.

Mechanical type clutches:

Jaw and toothed type clutch

Positive clutches used to connect driven shaft to prime mover when it is not objectionable to start
the driven suddenly and where the connected load (including inertia resistance) is not so great,
which is also not so harmful to the prime mover it self. It consists of segmental projection or
dogs on one side flange and corresponding recesses on other side flange on the driven shaft. In
this driving flange is rigidly attached where as driven flange is keyed by feather key so it can
slide on that shaft. Some time involute teeth also provided.
Frictional clutch
Power transmitted by virtue of friction between the surfaces. These are important when
engagement must be made under load and prime mover is to be protected against sudden load.
Apart from this, shafts running at different speed are to connect, without stopping. These features
make them suitable for vehicles, process machineries, machine tool and where the frequently
power cut-off either partial or completely required. Frictional surfaces may be flat, conical or
cylindrical and they are named with respect to that.
a) Disc clutch: In this type, one flange is rigidly keyed to driving shaft. Where as other is fitted
on driven by splines or feather key so it can move along the axis of shaft. During working
movable flange is pressed by mechanism so the torque is transmitted by friction through the disc,
which is between two flanges. In this type of clutches the amount of transmitted torque will be
depends on axial pressure, contact area of surfaces and coefficient of friction. On the bases of
number of disc frictional clutches can be classified like single disc clutches, multi disc clutches.
When large torque is to be transmitted at that time multi disc clutches is preferable, because of
higher number of contact surfaces.
b) Cone clutch: In this contact surfaces of flange are in conical shape. The slop of cone is
varying from 8° to 15°, the clutch parts (cones) are held together by springs, which produce axial
force. In this type of clutches the excessive axial pressure is not required.
c) Centrifugal clutch: They are used in a wide variety of application to connect drives (electric
motor, I.C.engines etc.) In this type of clutches power flow is possible only after reaching certain
amount of speed of driving shaft. The engagement of shoes with the inner lining of drum will
take place when centrifugal force becomes greater than spring force. This engagement will cause
the transmission of torque from driving to driven.

BRAKES:

It is a element whose primary purpose is to absorb a kinetic energy by way of frictional

resistance. Which are generally used for slow or stopping the moving parts, there are some
brakes which are used to with hold conversion from potential to kinetic energy of the object as
they are lowered by hoists elevators etc. Other main function is to hold a body in rest of uniform
motion against accelerating forces/ couples and preventing unwanted reversal of the direction of
rotation. The major functional different between clutch and brake is that unlike a brake, which
connects a moving member to a stationary frame, a clutch connects a rotating member to another
rotating member. In brakes absorbed energy dissipate in form of heat.
They are used in automobile, trains, vehicles, hoists elevators, press and in machines.
Their different classes are:Mechanical type brakes, electrical type brakes, hydraulic type brakes
and some other types.
Here our discussion is limited up to mechanical types.

Types of Brakes:
a) Block brake: This brake consists of block, which are pressed against the rim of revolving
brake wheel or drum, which faced with frictional material. The block are made of soft material
compare to drum or wheel, like wood or soft metal.

These types of brakes are mostly used in railway trains, tram cars etc. Prony brake is also
belongs to this class.
b) Band brake: It consists of flexible bend of leather of steel lined with friction material, which
embraces a part of the circumference of brake drum. In context of interrelated position between
band ends and fulcrum, band brake may be simple or differential type band brake. When force is
applied at lever end the friction is generated between band and drum surfaces, which cause speed
reduction or stopping of wheel.
The band and block type brake is improved type of band brake, which consists of number of
wooden blocks fixed to a steel band.

Properties required for brake linings

1) High mechanical strength.

2) High coefficient of friction.

3) Law wear rate.

4) High heat dissipation capacity.

5) Should not affect by moisture or oils.

Examples: wood, leather, asbestos and ferrodo.

c)Internal expanding shoe brake: Widely used in automobiles. Which may be operated by
mechanically or hydraulically. It consists of two shoes lined with some friction material, pivoted
at one ends about a fixed fulcrum. The shoes are housed inside the rotating drum. Under release
condition there is a gap between shoes and inner surface of the drum by spring, when shoes are
expanded by mechanically /hydraulically. The friction between shoes and the drum produce a
braking torque and hence reduces the speed of the drum. These types of brakes are mostly used
in automobiles.