Chapter One

Damages of Belts
Introduction

Belts are used to transfer power from one shaft to another through pulleys that rotate at the same
or different speeds. The driver pulley is responsible for transferring power, while the driven
pulley is responsible for receiving it. Automobiles, home appliances such as washing machines,
toys, manufacturing industries and other similar things all employ belt drive. Two or more
pulleys are coupled with a belt in tension in a belt drive system. Because of the frictional grip
between the belt and the pulley surface, mechanical power or rotary motion is conveyed from the
driving pulley to the driven pulley. The belt have two sides the slack side and the tight side. It is
made up of two pulleys that are connected by an unending belt. The difference in tension
between the slack and tight sides determines the belt's effective pulling force, which causes the
driven pulley to rotate. Because the tight and slack sides of the belt have different tensions
depending on the angle of contact, the belt drives must be set up so that the slack side comes
above the pulleys and the tight side comes below.

In the event of wide belts and large pulleys, it can supply great power at high speeds. However,
because these wide-belt-large-pulley drives are bulky, take up a lot of space, and require high
tension, resulting in high loads, they are not well suited to close-centers applications. As a result,
V-belts have largely replaced flat belts for short-distance power transmission, and longer-
distance power transmission is rarely done with belts at all. Leather or fabric were used to make
flat belts in the past. Individual electric motors are currently used in industry machines, for
example. Flat belts were commonly employed in line shafting to convey power in factories in the
19th and early 20th centuries. Flat belts are still in use today, but not nearly as much as they were
when line shafts were employed. The flat belt is a simple power transmission technology that
worked effectively in its day. The flat belt was the most frequent type of belt.
Types of belts

Belts have many types. Use of a particular types of belt depends on power to be transmitted and
types of service. Among them flat belt, V-belt, Grooved belt, Ribbed belt and Circular belt.

1. Flat belt

A flat belt is a belt with a flat surface, usually evenly textured on both sides, used in a
pulley system. Historically, flat belts were often used for transmission of power from
flywheels to other parts of machinery, and today, they are commonly seen in use as
conveyor belts or parts of belt arrays, where the flat surface makes it easy to move products
along the top of the belt. Numerous companies design machines intended to work with such
belts, and sell replacement belts and belt sections made from a variety of materials.

Leather was one of the original materials used in belt construction. Today, nylon and other
tough synthetics are commonly used because they hold up longer. Rubber, metal, and other
materials may be involved in the construction of a flat belt, and some are reinforced with
especially strong materials to address concerns about structural integrity. When a flat belt
is used as part of a transmission, sometimes the belt is twisted to create a Mobius Strip so it
will wear evenly through use, lengthening the time between replacements.

figure 1: flat belt

2. V-belt

A V-belt is a wedge-shaped belt manufactured out of a rubber compound, reinforced with a

tensile cord specifically engineered to transmit power into movement. V-belts can be found
in driving mechanisms, such as engines in air compressors, fans, and pumps.

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 Figure 2: V-belts

The general working principles of belts

Belts are commonly used in various machines and systems to transfer power or motion between
rotating shafts. The general working principles of belts involve friction, tension, and the
transmission of power. Here is a detailed explanation of how belts work:

1. Friction: Belts work based on the principle of friction. When a belt is wrapped around
two pulleys, one or both of which are powered, friction between the belt and the pulleys
enables the transfer of power. The friction between the belt and the pulleys prevents
slipping, allowing the belt to drive the driven pulley.
2. Tension: Proper tension in a belt is crucial for its efficient operation. The tension in the
belt maintains the contact between the belt and the pulleys, ensuring that power is
transmitted without slipping. Tension can be adjusted using tensioners to account for
wear or to optimize performance.
3. Transmission of Power: As the driving pulley rotates, it causes the belt to move, which
in turn rotates the driven pulley. This transfer of motion transmits power from the driving
pulley to the driven pulley. The speed of the driven pulley is determined by the ratio of
the diameters of the two pulleys and the speed of the driving pulley.

Historical developments of V-belts

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The V belt was developed in 1917 by John Gates. These are endless, and their cross-sectional
shape is trapezoidal. They reduce the slippage and alignment problem. They provide the best
combination of power transmission, speed of movement, load of the bearings, and long service
life. The belt tends to wedge into the groove, as the load increases. Greater the load, more is the
wedging action, thus improving the torque transmission and need lesser width and tension than
flat belts. The preferred center distance is larger than the largest pulley diameter, but less than
three times the sum of diameter of both the pulleys. Optimal belt speed range is 5–35 m/s.

V belts have long life (3–5 years) and offer quiet operation and low maintenance. These are most
commonly used in industry and are available in standard cross-sectional sizes and lengths. They
offer more speed than flat belts. The best speed for V belts is between 8 and 30 m/s. V belts are
made in two sizes: conventional and narrow. Ideal speed for standard belt is 23 m/s and for
narrow belts it is 50 m/s.

The use of V-belts in belt transmissions dates back to the beginning of the 20th century,
however, in the last dozen or so years, thanks to intensive development of the chemical industry,
many new materials used in the production of drive and transport belts have been developed. The
development of belt transmissions concerns new materials, geometric forms of belts. The source
of incorrect operation of belt transmissions can be inaccuracies in the, pulleys and intermediary
drive transmission elements assembly of machines and devices, unbalance and shape of
elements in rotary motion, wear and tear of elements, change of belt transmission temperature.

The working principles of V-belts

V-belts are normally used to transfer power between two shafts whose axes are parallel and some
distance apart.

Figure 3 figure 4
The belt is mounted on pulleys that are attached to the driving and driven shafts and the drive
relies on friction between the belt and the pulleys for its operation. The belt sits in the groove of
the pulley and makes contact with the sides of the groove as shown figure 4.
In order to be able to transmit power, the belt must be under tension so that it is forced down into
the groove. The belt is squeezed and friction develops between the sides of the belt and the sides
of the groove. The depth of the groove is always greater than the thickness of the belt, however,
and the belt should never bottom in the groove. The operation of the belt and its ability to

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transmit power depend on the size of the friction force and the arc of contact of the belt. The
greater the arc of contact the more power the belt can transmit.

As well as performing its primary function of transmitting power, a

V-belt can be used to change the speed of the driver output and
hence the torque transmitted to the driven unit.

Figure 5: arc of contact

V belt construction and materials

Each component has a vital role to play in how well V-belts perform and how long they last.
Different materials and configurations can influence belt performance characteristics in specific
applications.

The tensile cord is the load-carrying component of a V-belt. Most V-belts are made with
polyester cords. In a well-engineered V-belt, the tensile cords and rubber body of the belt are
chemically bonded to form one unit, allowing for equal load distribution and longer belt life.
Tensile cords are supported by rubber stocks, both above (over cord) and beneath (under cord).
Various synthetic rubber stocks are used by different manufacturers to provide heat resistance
and reduce wear. Some high-performance synthetic rubber compounds, such as ethylene,
significantly extend a belt's operating temperature range and resist hardening, cracking, and
premature failure.

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Adhesion gum is the element that forms a strong chemical bond between the tensile cord and the
rubber stock. It bonds the belt together so that it acts as a single unit. The gum also absorbs cord
stresses and avoids cord pullout. The notches in a notched V-belt are designed to increase belt
flexibility and reduce bending stresses, especially on small sheaves.

To protect the core of the belt from destructive environmental forces such as oil, grime and heat,
as well as from general wear and tear, some V-belts have a fabric cover, or band ply. In a well-
engineered belt, this flexible fabric is treated to form a chemical bond with the belt core
materials, allowing it to withstand the stress of constant bending over time and prolonging cover
life.

Sheaves are essential V-belt drive components. As noted earlier, how well a V-belt fits into the
sheave determines how much power the belt drive can transmit and how efficiently it operates.
Proper fit is a function of both the belt and the metal sheave. A well-engineered belt and a well-
machined, matching sheave provide the optimal combination.

Damage types of V belts

V-belts, commonly used in machinery to transfer power, can experience various types of damage
that can affect their performance and longevity. Some common types of V-belt damage include:

1. Cracking:

Cracks on V-belts can form due to a variety of reasons. One common cause is age-related
deterioration, where the rubber material of the belt becomes brittle over time. Excessive heat
can also accelerate this process, as high temperatures can cause the rubber to harden and
crack. In addition to this exposure to certain chemicals or oils can degrade the belt material,
leading to cracks. Cracking weakens the structural integrity of the belt, making it more prone
to failure and reducing its overall lifespan.

2. Glazing: Occurs when the surface of the V-belt becomes smooth and shiny, usually as a
result of excessive slipping or inadequate tension. When a belt slips on the pulleys due to

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 insufficient tension or excessive load, friction generates heat that can polish the belt
surface, creating a glazed appearance. Glazing reduces the belt's ability to grip the pulleys
effectively, leading to further slipping and potential damage to the belt and pulley
surfaces. Proper tensioning is essential to prevent glazing and ensure efficient power
transmission.
3. Chunking: Chunking involves the formation of small pieces or chunks breaking off from
the belt material. This type of damage is often caused by factors such as overheating,
contamination with foreign materials like oil or grease, or running the belt under
excessive load conditions. When chunks break off from the belt, it can lead to uneven
distribution of force along the belt's length, potentially causing further damage and
reducing the belt's overall reliability.

4. Cupping: Cupping refers to the development of small cups or dents on the surface of the
V-belt. This damage is typically caused by pulley misalignment or uneven belt tension.
When the belt is not aligned correctly with the pulleys or when tension is unevenly
distributed, it can cause the belt to wear unevenly, leading to the formation of cups or
dents. Cupping can result in decreased belt performance, increased noise, and premature
failure if not addressed promptly.

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5. Edge wear: edge wear occurs when the edges of the V-belt become frayed, worn out, or
damaged. This type of damage is often a result of misalignment between the belt and the
pulleys or inadequate support for the belt edges. When the edges of the belt are not
properly supported or aligned, they can experience increased friction and wear, leading to
edge damage. Edge wear weakens the belt's structure and can eventually cause the belt to
fail prematurely if left unattended.
6. Belt elongation: Belt elongation refers to the stretching or elongation of the V-belt over
time. This can occur due to factors such as excessive load, improper tensioning, or
normal wear and tear. When a belt elongates, it loses tension and may slip on the pulleys,
leading to reduced power transmission efficiency. Monitoring belt tension and replacing
elongated belts promptly is crucial to maintaining optimal performance and preventing
equipment downtime.
7. Belt pilling: Belt pilling is a type of damage where fibers on the belt surface start to form
small balls or pills. This can happen due to friction between the belt and other
components, leading to the fibers breaking down and forming these small clusters. Pilling
can reduce the belt's smoothness and flexibility, impacting its performance and
potentially causing additional wear and tear on the belt and pulleys.
8. Chemical damage: Chemical damage occurs when V-belts are exposed to substances
that degrade the belt material. Certain chemicals, oils, or greases can weaken the rubber
material of the belt, causing it to deteriorate and lose its strength and flexibility. Chemical
damage can lead to cracks, swelling, or softening of the belt material, ultimately affecting
the belt's ability to transmit power efficiently. Avoiding exposure to harmful chemicals
and ensuring proper maintenance can help prevent chemical damage to V-belts.
9. Abrasion: Abrasion damage on V-belts results from the rubbing or scraping of the belt
surface against other components or contaminants. Abrasion can wear down the outer
layer of the belt, exposing the underlying material and weakening the belt's structure.
Factors such as misalignment, improper tensioning, or the presence of abrasive particles
can contribute to abrasion damage. Regular inspection and maintenance to address
sources of abrasion can help prolong the lifespan of V-belts and prevent premature
failure.