Calculation of Artificial Friction Conveying Coefficient f,

and a Comparison between I S 0 and CEMA

lshwar 6. Mulanl*

In conveyor design, theFrst step is capacity and the second step is belt width and speed. The third step is
decision on 'ff," where distinction arises between DIN/ISO and CEMAfor calculating resistances. Then
again, both the methods are virtually similar. This topic helps in understanding D m design style and its
comparison to CEMA.
This topic isfrom the book Engineering Science and Application Design for Belt Conveyor wherein the
issue has been analysed in detaiL It presents a workable calculation model to calculate the value off in
design office, based on conveyor parameters.
CEMA uses IOr, Ky and 0.01 5 instead off. Thus, f is a sum effect of Kx, Ky and 0.01 5. Hence, knowledge
on f is also applicable to Kx and Ky. This helps to understand their relationship.
decrease f will also increase/decrease Kx, Ky and 0.015.
Thus information in this topic will also help to consider a
better value for CEMA parameters, their understanding,
and clarity about comparative aspects. This topic indirectly promotes the interchangeability of both of the
concepts to the advantage of both methods. This topic is
taken from the international book Engineering Science
and Application Design for Belt Conveyors by Ishwar G .
Mulani from Pune, India. The author has contributed to
this topic.
For such a calculation model to be of ~racticalvalue. it
needs to be in conjunction with commercially acceptable
standards and norms. Therefore, this calculation procedure considers the guidelines of DIN/ISO as a basis. The
calculation model further analyzes the issue and provides
a calculation model so that the designer can calculate the
right value off, as a design input in the DIN/ISO method.
Thus, the proposed calculation method helps for better
design in conformity with DIN/ISO.
The readers who are used to USA practice will also find
this topic very useful to get new insight into the subject
and to comply with the respective standards in a more
exact and easy manner. This is due to the fact that
although calculation style could be different, the underlying considerations and principles are the same.
Although this article is pertaining to design issue, its
information is equally interesting and useful to plant
engineers, because it explains the intrinsic phenomenon

PREFACE

This topic explains the design procedure for calculation

of "artificial friction coefficient for conveying f" abbreviated as "conveying friction coefficient f" for ease of
writing. The value of f is very important for calculating
main resistance FH,while designing belt conveyors as per
European standards. The belt conveyors all over the
world are designed by two methods: (1) DIN/ISO style,
and (2) CEMA style. The choice is often mentioned by
the buyer. Therefore, it is essential that the engineers
concerned with conveyor design are equally competent
in both of the methods to promote business needs.
The CEMA publication provides specific values for
factors corresponding to f, so design as per CEMA has
easy input. However, DIN/ISO publications do not
mention the direct value of f, which is left to the
designer. Hence, the designer often finds himself partly
guessing on this crucial value, without which he cannot
proceed in design. Also, this issue becomes somewhat
disputable because the value marginally differs from
person to person. This topic provides a unique calculation model, the first of its kind, suitable for use in a
design office that is setup to calculate the value of f.
Thus, this topic will be of great help to engineers who
need to design belt conveyors as per DIN/ISO style.
The CEMA method uses the f i n different forms: Kx, Ky
and 0.015. The f is the sum effect of Kx, Ky and 0.015 of
CEMA. Therefore, knowledge of f is equally relevant to
CEMA factors. The conveyor parameters which increase/

" Pune, India

55

56

CONVEYOR BELT OPERATING TENSIONS FOR DESIGN

in conveying and effect of conveyor features on power

consumption, particularly for longer conveyors.
INTRODUCTION

This article deals with the calculation of conveying friction coefficient f, which is required for calculating the
"main resistance" while designing belt conveyor, as per
European practices. This unique calculation model is the
first of its kind to calculate value off in design office setup. The reader may want to become familiar with DIN
22101/ISO 5048 for easier understanding of the subject.

MAIN RESISTANCE

The belt conveyor resistance is made up of many resistances such as main resistance, slope resistance, skirt
board resistance, scraper resistance, pulley rotational
resistance, etc. As the name implies, main resistance is
one of the most significant resistances in a belt conveyor.
The main resistance is defined as the resistance to belt
travel due to the "motion alone" on idlers (accounting for
misalignment in installing the idlers but not accounting
for fonvard/backward tilt of idlers). The carrying run
belt travels along with material whereas the return run
belt travels without material. The belt travel encounters
three types of friction resistances, namely: (1) idler rotational resistance, (2) belt flexure resistance, and
(3) material flexure resistance.
The aforesaid resistances are frictional in nature and
their total value is main resistance. The clear understanding of each of these frictional resistances is necessary for correct calculation of an artificial friction
coefficient for conveying.
Idler Ratatlonal Resistance

The belt travel compels the idlers to rotate, and hence, the
belt is subjected to rotational resistance of idlers. The rotational resistance is a sum of the following three resistances.
Bearing frictional resistance. One of the rotational resistances is due to bearing frictional resistance
which is pF, where p is the friction coefficient of the
bearing and "F" is radial force. The typical values for the
coefficient of friction are 0.0015 for ball bearings 6200/
6300, and 0.0018 for taper roller bearings 30200, as
referred to bearing bore radius/diameter. The rotation
effort F1 at periphery is given by the following fonnula:
bearing bore
roller diameter

bearing bore
roller diameter
The bracketed portions signify the friction coefficient,
referred to as roller periphery, and their typical values for
rollers of 139.7 outer diameter fitted with 6205 or 30205
bearings are 0.0015 x 25 + 139.7 = 0.0027 or 0.0018 x
25 + 139.7 = 0.00034. In general, this can be safely taken
as 0.0004 considering variations in ratio of bearing bore
and idler diameter. This amounts to only 2% of the basic
value of the conveying coefficient f = 0.02.
Idler misalignment or sliding resistance. The other
main cause for rotational resistance is due to the inherent
visible/nonvisible misaligned position of idlers. This
results in very passive (slow) sliding of belt on idlers, and

Value of 0 is exaggerated

FIGURE 1

thereby this resistance. It is also proportional to weight of

the belt and material resting on idlers.
The idlers need to be installed such that their axis of
rotation is exactly perpendicular to the belt travel path.
The misalignment (mostly invisible) would be present
within the permissible limits in accordance with the tolerances for structural fabrication, erection, etc. Figure 1
shows the exaggerated misaligned position of the idler
with respect to belt path by an angle 8.Belt velocity v can
be replaced by two vector components OA + AB as shown
in the figure. Component v cos 8 is perpendicular to the
idler axis and causes the idler rotation. Component v sin 8
is parallel to the idler axis and cannot cause any rotation.
The belt is sliding in the direction of OA on the idler, therefore, the idler will apply sliding friction force F on belt in
the direction of AO, i.e., OD.
Force F on belt, direction OD = po M g where p, is
the sliding friction coefficient between belt and idler. M
is the mass of belt plus material if any is carried by it.
Resolving "F" along and across the belt,
Force OC = F .cos 0 = p,+ MI g- cos 0
i.;

(This force results into side thrust on the belt.)

ForceCD=F.sinO=h.-Ms.glsinO

This force is acting against the belt travel and causes

hidden sliding resistance as a part of rotational resistance.
Therefore, the resistance to belt motion = (yo * sin 8)
M:.gN.
The value (pot sine) signifies equivalent sliding friction
coefficient for the belt on the idlers. Now, sin 8 = "offset
gradient" of idlers.
Therefore,
Equivalent sliding frictioncoefficient = (b)(offset
gradient)

The value of p, is nearly up to 0.4 for the rubber belt

on the idler shell (steel). The offset/misalignment is
considered at the rate of 3 mm for 1,000 mrn length of
idler base. "From actual belt path," as the tentative
average aggregate of all idlers, the typical value of the
equivalent sliding friction coefficient is
Equivalent sliding friction coefficient = (po-sin 0) =
(po) (offset gradient) = 0.40 x 3 +1,000 = 0.0012
The idler sliding coefficient is applicable to the moving
mass of the belt plus material (but not for idlers rotating
mass). For further details, refer to the book Engineering

CALCULATION OF ARTIFICIAL FRICTION CONVEYING COEFFICIENT

Belt (thickness exaggerated)

'Y

Vertical sag (exaggerated)

-

FIGURE 3
L- Denting (exaggerated)

FIGURE 2

Science and Application Design for Belt Conveyors,

authored by Ishwar G. Mulani.
Seal resistance. The idler rotation causes shearing
cum churning of grease. This shearing/churning force
increases with shearing speed (rotational speed). The
smaller diameter idler needs to rotate faster for the same
belt speed and will encounter more resistance to rotation. The value will be less for bigger diameter. This
resistance is independent of load on the idler.
Some of the seals are contact type. This contact area
creates frictional resistance, which is independent of load
and speed. The grease churning/shearing resistance plus
seal contact resistance are together named as sealing
resistance.
The seal resistance is not related to radial load (idler
load), and hence, its value is constant whether the
conveyor is running at full load or empty.
The idler rotational total resistance is the sum effect of
aforesaid frictions sections, which can be expressed as
under.
Idler rotational resistance = (combined coefficient for
bearing and sliding resistance) x (load) + (sealing
resistance of constant magnitude)
The effect of seal resistances at roller periphery is
inversely proportional to roller diameter. The typical
values with reference to roller periphery can range from
1N to 4 N per roller (3 N to 12 N total for three rollers of
an idler set) depending upon design.
Belt Flexure Resistance

The belt is supported on spaced idlers and is hanging

freely between the idlers. As the belt travels on idlers, it
is subjected to two types of flexing actions repetitively:
flexing of its thickness and flexing of its shape. The
flexing of its thickness is denting (or indenting) flexure
and flexing of shape is bending flexure (shape can only
change by bendindunbending of the belt).
Belt denting is shown in Figure 2. Any point on the belt
gets dented when on the idler and it gets undented the
moment it leaves the idler. Suppose a belt is moving at
2.5 mps on idlers spaced at 1.25-m pitch, then every
point on the belt will be subjected to one dentingundenting cycle every half second.
The bending flexure of the belt occurs due to sag of the
belt and slight opening of the belt between the idlers as it
travels. Figure 3 shows concave and convex bending of
the belt on a longitudinal axis as it travels. In addition,
the belt is also subjected to bending flexure along its
width as shown in Figure 4. Both of the above
phenomena cause bending flexure of the belt. Its
frequency is the same as that for denting flexure.
All the energy input during denting and bending is not
recovered during undenting and unbending (reverse
bending), but some energy is lost in these repetitive

u
Top view of belt (exaggerated)

FIGURE 4

Schematic depiction of material flexure

(exaggerated)
FIGURE 5

flexing cycles. This is synonymous to internal friction of

belt texture and opposes the cause, which is belt travel.
The belt flexure resistance is proportional to magnitude of belt flexure and thereby it is influenced by the
following parameters.
The belt denting flexure is effected by hardness and
thickness of belt texture (structure). The hard and
thin texture will have less depth of dent and would
cause less drag.
The higher tension in the belt keeps it straight with
less sag and less variation in shape. Therefore, a
belt with higher tension has less bending flexure
and moves easily on the idlers.
In a given conveyor of specific belt construction
and belt tension, the magnitude of belt flexures and
thereby its resistance is proportional to material
weight + belt weight.
Materlal Flexure Resistance

The material has a concave shape between the idlers and

a convex shape directly on the idler, as shown in
Figure 5. This causes subtle relative oscillating motion of
material particles among themselves and also on the belt,
in longitudinal direction. This is known as longitudinal
flexure of material.
Likewise, when seen from the top, the belt shape along
with material slightly opens between the idlers and
slightly closes near the idlers. This causes internal
rubbing within material and also on belt in transverse
direction. This phenomenon is known as transverse
flexure of material.

57

58

1 CONVEYOR BELT OPERATING TENSIONS FOR DESIGN

Thus belt travel causes longitudinal as well as transverse flexure of material, which is frictional in nature. The
friction opposes the cause, which is belt travel. Therefore,
the belt travel encounters the material flexure resistance,
which is influenced by the following parameters.
The higher tension in the belt keeps it straight with
less sag and less variation in shape. Therefore,
material flexure resistance is remarkably less when
it is conveyed by belt under higher tension.
Contrarily, more effort is needed to move a slack
belt loaded with material.
The material of rough surface and/or interlocking
shapes causes more intense friction and hence
more flexure resistance. The smooth and rounded
lumps/particles have less flexure resistance.
For a given belt conveyor with specific material and
belt tension, the material flexure resistance is
proportional to material weight per meter on the
belt. (The quantity as well as intensity of friction,
which is occurring in the body of bulk material, is
proportional to material weight.
BASIS FOR ARTIFICIAL FRICTION COEFFICIENT
OF CONVEYING f

As described in the foregoing sections, the main resis-

tance is comprised of frictional resistances: (1) idler rotational resistance, (2) belt flexure resistance, and (3)
material flexure resistance.
The above frictional resistances are related to the
following moving masses: (1) idler rotating mass per
meter length of conveyor, (2) belt mass per meter length
of conveyor, and (3) material mass per meter length of
conveyor.
These moving masses' relation to earlier said frictional
resistances is not one to one, but it is cumulative in
effect as below.
The idler bearing supports the weight of rotating
parts + belt + material resting on the belt. Hence, in
a broad sense the idler rotating resistance is
proportional to the sum total weight of all three
masses.
The magnitude of belt flexure is effected by the
belt's own weight + material weight resting on a
belt. Therefore, belt flexure resistance is
proportional to the sum total weight of belt mass +
material mass.
The material flexure resistance depends upon
material self-weight only, as it is at the top.
Figure 6 shows the equivalent model for the depiction of
the above.
Thus there could be three different friction coefficients
applicable to three different values of mass. However, to
avoid complexities, the practice is to use single value of
artificial/hypothetical friction coefficient f applied to the
total moving mass force to calculate main resistance FH.
The complete mass is assumed to be moving on the
bearing inner race and is multiplied by the artificial friction coefficient f to give same frictional resistance as
occurring actually. The above depiction of mass forces
shows direct addition. In fact, these are to be added as

Motion

1
Tractive pull

Material mass (Mm)

Belt mass (2Mb)

Idler rotating mass (Mc + Mr)

FIGURE 6

vector quantities to account for conveyor inclination,

which makes slight difference.
The main resistance,
where L is conveyor length.
DIN/ISO STIPULATIONS I N BRIEF FOR VALUE OF
f, CONVEYOR WITH POSITIVE POWER

Referring to the DIN/ISO standard, the basic value of

conveying friction coefficient is f = 0.02. This value can
be used for conveyors of positive power in the following
situations.
The material being conveyed has average flexure
resistance.
2. Belt sag between the carrying idlers is limited to a
maximum of 1.0% at any point along conveying
route.
3. The standard aligned stationary conveyors with
good maintenance conditions.
4. All idlers are equipped with antifriction bearings.
The carrying idlers are of 3 roller type, with troughing angle up to 35".
5. The idler diameter is not less than 108 mm.
6. The maximum pitch of carrying idler and return
idler is 1.5 m and 3.0 m, respectively.
7. Calculation of main resistance when the capacity is
in the range of 70% to 100%.
8. Belt speed is nearly 5.0 mps.
9. For ambient temperature of 20C and above (if we
ignore 4% increase in f for 0C to 20C, then basic
value 0.02 can also be considered for temperature
0C and above).
L

The value increases/decreases as per actual conditions. Refer to the respective standard for specific information. The above stipulations are unquantified. The
following exercise provides quantified effect.
DIVISION OF f INTO CONSTITUENT
COEFFICIENTS
Relatlve Proportion of Mwlng Masses

It is necessary to establish relative proportion of moving

masses applicable to average conveyors, for use in the
next section. Following are the average reference values
for moving masses.
Mm + Mb = 77% of (Mm + 2Mb + Mc + Mr)
Mm + 1.5 Mb = 81%of (Mm + 2Mb + Mc + Mr)

CALCULATION OF ARTIFICIAL FRICTION CONVEYING COEFFICIENT

The basis for the above has not been included here due to
space limitations. One can also use the exact proportion
applicable to his/her specific calculation, if need be.
DerivsHon of Average Proportlom Value of
Consmuents of f

This topic derives the proportion of constituents of f for

usual application needs. Referring to the amcle by
C. Spaans in a Trans Tech publication Belt Conveyor Technology, the formula for FH using a constituent of f is as
below:

FH = Roller resistance + (fdc+ fbc + fm ) (Mb + Mm) g

+ (f& fb,) .Mb .g
+

where fdc, fbc and fm are friction coefficients for belt

denting flexure, belt bending flexure, and material
flexure, respectively, for carrying run. The aforesaid
value of main resistance is per meter of conveyor.
fdr and fbr are friction coefficients for belt denting
flexure and belt bending flexure, respectively, for
return run.
Using the above formula and its pertaining information, the following calculation model has been created by
this exercise to enable the calculation off in design office
set-up.
~ i r i t l ~this
, exercise decides roller resistance, belt
flexure resistance and material resistance, as a proportion (percentage) of the total value, as a general basis.
Subsequently, the quantified effect on f has been calculated under the Quantified Effect on f section which
follows, due to various parameters of the conveyor. Rearranging the formula,
FH = Roller resistance + (fdc,. Mb + fdc ,, Mm+ fdr ,. Mb +
fbc..Mb+fh..Mm+fbr..Mb+fm.-Mb+fm-.Mm)'g

The next step is to see the approximate relationship

between fdcand f&, and fbcand fbr. The general formula
for belt denting flexure coefficient is

As can be seen, the nature of the formula ensures a

nearly stable relation between fdc and fh. This is considered here as fdr = 0.6 fdc. This marginal variation in relationship does not have an effect on the final result
because fdr is multiplied to only Mb whereas the fdc is
multiplied to (Mm + Mb) and is governing.
The relationship between fbcand fbris in direct proportion to average sag on the carrying side and average sag
on the return side. In general, this average sag can be
considered in the ratio 2: 1.
Therefore fbr = 0.5 fbc. There could be some variation
in this relation but its effect on the total result is not
significant because fb, is multiplied to only Mb whereas
fk is multiplied to both (Mm + Mb) and is governing the
result. Now, substituting the value of fd, in t e r n of fdc,
and fbr in terms of fk,
... FH = Roller mistance + [fdc (Mm + 1.6 Mb) + fk
(Mm + 1.5 Mb) + fm (Mm + Mb)] g

Now,
Roller resistance = 0.0004 (Mm + 2Mb + MC+ Mr) g +
seal resistance + yl sin 8 (Mm + 2Mb) g

For this analysis, considering seal resistance equal to

1.5 times the bearing resistance and sin 0 = 3 + 1000:
Roller resistance = 0.001 (Mm + 2Mb + MC + ~ r .g) +
0.0012 x (Mm + 2Mb) g

FH = 0.001 (Mm + 2Mb + Mc + Mr) g + 0.0012 x (Mm

+ 2Mb) .g + [fdc . (Mm + 1.6 Mb) + fbc . (Mm + 1.5 Mb)
+ fm (Mm + Mb)] .g
Now,
Equating this with the above FHvalue, the equation for f
is as below:

+ 2Mb + Mc + Mr) x g
:. f = 0.001( Mx m(Mm
+2Mb+Mc+Mr)xg
where cl is constant, D is roller diameter, and lr is the
belt and idler contact length. All parameters are identical
for carrying and return run except load per meter and
idler pitch.

In general, the ratio of p, and p, can be considered 2.5.

The ratio of load per meter on carrying and return could
be in the range of 8:l to 20:l.
For ratio 8:1,
1

= 1.5 i.e.,
fdr

For ratio 20: 1,

fdr

= 0.66 fdc

0.0012 x (Mm + 2Mb) x g

(Mm+2Mb+Mc+Mr)xg

fdcx (Mm + 1.6Mb) x g

(Mm+2Mb+Mc+Mr)xg

fbc x (Mm + 1.5Mb) x g

(Mm+2Mb+Mc+Mr)xg

Using various proportion values from the Relative

Proportion of Moving Masses section:
f = 0.001 + 0.0012 x 0.85 + 0.83 fdc + 0.81 fbc
+ 0.77 h
Typical values for fdc = 0.012, fk = 0.0035 and fm= 0.008
for sag less than 1% at any point on carrying run.
:. f = 0.00202 + 0.83 x 0.012 + 0.81 x 0.0035
+ 0.77 x 0.008

59

60

CONVEYOR BELT OPERATING TENSIONS FOR DESIGN

TABLE 1

Belt Width
(mm)
h-35'

Material Depth (mm)/% Increase

h -40"

Average considered

h 450

8%

16%

:. f = 0.00202 + 0.00996 + 0.00283

+

0.00616 = 0.02097

Roller resistance coefficient = 0.00202 + 0.02097 =

0.096 i 9.5% of total value off
Belt denting flexure resistance coefficient = 0.00996 +
0.02097 = 0.475 r 47% of total value off
Belt bending flexure resistance coefficient = 0.00283 +
0.02097 = 0.135 z 13.5% of total value off
Material flexure resistance coefficient = 0.00616 +
0.02097 = 0.2937 ;
30% of total value off
We can use the previous proportions to assess the
implication on f due to variation in application condition.
If need be, the designer can follow the procedure to find
out actual proportion and consequent implications.
QuantWed Effect on f (Calculatlan for f)

Various standards mention only effect (unquantified)

on the value of f for deviation from base conditions.
Therefore, it leaves the value of f open to judgement/
manipulations. This calculation model provides quantified effect, and hence values of f, in accordance with
specific features of the belt conveyor. Analysis depth has
been limited up to engineering needs for the solution.
Increment in f for material difficult to flexure. It has
been considered that very difficult material has a 66%
increase in material flexure resistance. Accordingly, the
revised percentage figures are 9.5 + 47 + 13.5 + (30 x
1.66) = 119.8. Therefore increase has been mentioned as
20% in basic value 0.02.
Increment in f for deeper troughing angle. The 40"
and 45" trough idlers are normally of deep trough type.
The comparative depth of material for 3S0, 40" and 45'
idlers are as per Table 1 for 15" surcharge angle. Other
parameters being constant, the material flexure resistance increases in proportion to the square of material
depth on the belt.
The % of f constituents, 40" troughing = 9.5 + 47 +
13.5 + (30 x 1.08 x 1.08) = 105%; i.e., 5% increase in f.
The % of f constituents, 45" troughing = 9.5 + 47 +
13.5 + (30 x 1.16 x 1.16) = 110%; i.e., 10% increase in f.
In addition, the deeper troughing angle also affects the
force on side roller, and thereby the denting flexure. This
exercise is not presented due to space limitation. Its
result is as below:
For 40" trough idlers: 9.5 + (47 x 1.009) + 13.5 + 30 =
100.423; i.e., 0.42% increase. (This is ignored).
For 45" trough idlers: 9.5 + (47 x 1.020) + 13.5 + 30 =
100.94; i.e., 0.94%, say 1% increase. Accordingly, total
implications in f = 0.02 are 5% for 40" trough idlers and
10 + 1= 11% for 45" trough idlers.

Increment in f for smaller diameter idlers. The other

parameters being unchanged, the idler diameter will
primarily affect the belt denting coefficient. The formula
for denting flexure coefficient is as below (where c2 is
constant and D, is idler diameter):

... f,

for roller 88.0 mm

f, for roller 108.0 mm

108.0
- - 88.9

Therefore, roller diameter of 88.0 mm instead of 108 mm

would change the f constituent as below,
9.5+(47x1.14)+13.5+30=106.6;i.e.,6.6%.Smd
diameter also increases the roller rotational coefficient
slightly. Therefore total implication has been considered
as 7.5%.
Increment i f f d u e t o poorly aligned stationar
conveyor. For p r l y aligned stationary conveyor, a d i tional misalignment offset gradient is considered as 5/
1,000; i.e., 5 mm offset for 1,000 mm length of idler
base. This results in additional rotational resistance due
to more sliding. Looking from the top, the belt will be in
shallow wavy line, which tends to reduce idler misalignment with respect to the actual path of the belt. Considering deviation from the actual belt path as 80% of
dimensional deviation,
(A) Additional resistance due to sliding = (Equivalent
sliding friction coefficient) (mass) - g

= {pl (offset gradient)) (Mm + 2.Mb) g

= (0.4. (0.80 x 5 + 1000)) (0.85 (Mm + 2.Mb

Mc

Mr)) .g

(B) Basic resistance force = f (Mm+ 2.Mb + Mc + Mr ) g

=0.02-(Mm+2.Mb+Mc+Mr).g
Ratio of increase for resistance = (additional resistance,
A) (basic resistance force, B) = 0.068
This means, say, 6.5% increase in basic value of f =
0.02, for poorly aligned conveyor.
From the above generalized formula for percentage
increase in f = (0.4 x 0.85 i0.02) x (offset gradient
increase) x 100 = 1,700 x (offset gradient increase).
The aforesaid increase in offset gradient is with respect
to the actual path of the belt.
Increment in f due to poor ali nment in shiftable
conveyor. The shiftable conveyor fength is made up of
modules, placed side by side, as shown in Figure 7. It will
have more misalignment affecting f.
The AB is the conveying line. The "true p a t h of the
belt will be lying somewhere in between the straight line
AB and modules orientation, in a very shallow wavy
form. The idler misalignment affecting the tractive pull is
with reference to the actual path of the belt. The approximate implication on "f" due to misalignments is as
below. The misalignment gradient 3 + 1,000 is already
counted in the basic value off.
Arrangement-X. This arrangement is statistically
the least possible and hence has not been analysed.
Arrangement-Y. The misalignment with reference
to belt line is considered as 80% of dimensional misalignment. Accordingly, additional gradient = (0.8 x 100 +

CALCULATION OF ARTIFICIAL FRICTION CONVEYING COEFFICIENT

Frame
module

for average shiftable conveyors, and approximately

17.5% for a poorly used system.
Increment in f due to belt sag. The belt sag between
two carrying idlers (and also between two return idlers)
is to be limited within 1% of respective idler spacing at
any point along conveyor route. It is essential to design
all high-performance conveyors according to this sag
value. If the designer opts for higher sag value, its likely
effect is as below.
The belt sag average value along conveyor length
affects the belt bending flexure and material flexure coefficients. Now, average sag wiU be proportionate to allowable design sag. Hence, it can be said that belt bending
flexure and material flexure relation to design sag wiU be
the same as for average sag.
While assessing the response of a particular conveyor
to sag, all other conditions are identical and only sag
values are manipulated.
For all other conditions being constant except sag, the
relation between fb and sag % is as below.
fb = c3 (sag %), where c3 is constant. Therefore,
increase in fb is 50% for 1.5% sag instead of 1%. Similarly, increase in fb is 100% for 2% sag instead of 1%.
Now sag also affects the material flexure coefficient.
All other conditions being identical, the relationship
between f, and sag is as below.
[ I value also increases with sag, which is approximately
accounted by 50% addition into the first part result.

li

6,250

BI

BI

,:

= c, .

hipie

function of sag

%I-

Arrangement-X Arrangement-Y Arrangement-Z

...f, for 1.5% sag - -A3 =

Arrangement-X: Statistically least probable

~rrangement-Y:statistically
Arrangement-Z: Statistically probable
(Exaggerated)

f,forl.O%sag

i.e., 22.5

11= 33.5%

increase in f,

-O
..f, for 2.0% sag - -K

FIGURE 7

f,,, for 1.0% sag

6,250) - (3 1,000) = 0.0098. Therefore, % increase in

= 1,700 x 0.0098 = 16.6667, say 17%.

Arrangement-Z. The 50% of modules have proper

placement and 50% of modules have misaligned placement. As the belt will be in wavy line, even properly
placed modules will contribute to the misalignment
gradient, which is considered as 20% of the dimensional
misalignment. For balance 50% of modules, it is considered 80% of the dimensional gradient. Accordingly, for
50% of modules, the increase in offset gradient = 0.0098
(as per Y).
Percentage increase in f for these modules = 1,700 x
0.0098 = 16.6667

For balance 50% of modules, increase in offset gradient

= (0.20 X 100

1.225

KO

6,250)

- 0.003 = 0.0002.

Percentage increase in f for this 50% of modules =

1,700 x 0.0002 = 0.34

Hence,
the average mean effect = 0.5 x (16.66

0.34) = 8.5%

This explains the effect on f in shiftable conveyors. In

general, one can consider a 12.5% increase in value of "f"

i.e., 41 + 20.5

= 61.5%

KO
increase in f,

The implication in f for 1.5% sag instead of 1.0% sag =

9.5 + 4 7 . 0 + (13.5 x 1.5) + ( 3 0 x 1.335) = 116.8; i.e.,
increase, say 15% to 19%.
The implication in f for 2.0% sag instead of 1.0% sag =
9.5 + 47.0 + (13.5 x 2.0) + (30 x 1.615) = 131.9; i.e.,
increase, say 27% to 34% increase.
The aforesaid increase is 50% for 3% sag. The decrease
is 10% for sag value 0.65%.
Increase in f due to thicklsoft rubber cover on belt.
The belt denting flexure is occurring on the carrying as
well as the return run. The belt denting flexure on the
carrying run plays a dominant part because the same is
getting multiplied to a much larger quantity (Mm + Mb),
and it has been considered for analysis.
The belt denting flexure on the carrying run is affected
the by the bottom cover. The denting flexure will
increase due to the combined effect of hardness as well
as thickness of the bottom cover. If the belt cover is soft
(less hard) but it is thin, the depth of dent will be less and
it may not affect the denting flexure. Also, if rubber has
usual hardness but much thicker cover, it results in a
deeper dent and affects flexure resistance. This exercise
has not been presented here due to space limitation;

61

62

CONVEYOR BELT OPERATING TENSIONS FOR DESIGN

however, the end result is as below (increase in basic

value f = 0.02).
Nil
5.5%
11%
Nil
5.5%
11%

Bottom cover thickness less than 2 rnm

Bottom cover thickness 2 mm to 3 mm and
rubber hardness 65 shore A
Bottom cover thickness more than 3 mm and
rubber hardness 65 shore A
Bottom cover thickness up to 4 mm and rubber
hardness 75 shore A
Bottom cover thickness 5 mm to 6 mm and
rubber hardness 75 shore A
Bottom cover thickness 8 mm above and rubber
hardness 75 shore A

Incremenvdecrementfor belt speed. The conveying

friction coefficient value f = 0.02 can be decreased for
conveyor speed lesser than 5.0 mps. These reduction
factors with respect to speed are based on a ContiTech
Germany publication (slightly changed here for safety in
design):
10%reduction on 0.02 for 2.75 rnps < v <3.75 rnps
15% reduction on 0.02 for 2.0 rnps < v <2.75 rnps
17.5% reduction on 0.02 for v 12.0 rnps
Increment in f for narrow belt width. The exercise
for this is not presented here due to space limitation. The
increment values are as below; to account for dominant
effect of seal resistance:
20% increase in basic value 0.02, for belt width up to
650 mm
10%increase in basic value 0.02, for belt widths up to
750 mm and 800 mm
Noteworthy features of this calculation model. The
procedures suggested here adopt rational approach and
practically eliminate the element of speculation in
deciding one of the most important parameters in
conveyor design. While calculating the implication by
particular feature, only that feature becomes variable,
whereas all other features become nonvariable. This
method gives correct implication due to specific feature
alone and also simplifies the assessment.
Engineering judgment is present only in assessment of
material flexure resistance, i.e., it can alter basic value of
f in the range of 0.02 to 0.024. Also the error will be due
to the difference between judged value and actual value.
Therefore, if the error in judgment is, say, 20h, the
overall error will be 0.0008. Please note that while
deciding the design value of "f ", apply all + implication to
basic value off = 0.02 only. The design value off should
not be taken less than 0.017 for conveyors of positive
power (to comply with DIN).
EXAMPLES

Example 1

Select the value of 'If" for an 800-mm belt width x 30-m

center-to-center horizontal conveyor for conveying
broken granite of (-)75-mm size, at 1.8 rnps speed in a
quarry. The conveyor is equipped with 114.3 mm 0.d. x 3
roll x 30" trough carrying idlers. The idlers' pitch is 1.0 m
and 3.0 m for carrying and return run, respectively. The
design capacity of the conveyor is 500 mtph. Ambient
temperature is 2C to 40" C.

Solution. The designer analyzes the requirement

and makes the following decisions:
Belt speed is 1.8 mps, which is less I 2.0 mps.
Therefore, the implication is -17.5% on f.
The belt width being 800 mm, consider +10%
increase in basic value off.
The material is broken granite, which is difficult to
flexure. Hence, +20% increase in basic value off.
Idler diameter and troughing angle do not have any
implication.
The expected maintenance quality is likely to be
poor. Consider +6.5% implication in basic value off.
The conveyor has simple screw take-up. Therefore,
user will not be able to maintain the correct tension
all the time. Hence, design for max sag of 1% but
contingency for 2%. The increase is +27% in basic
value.
Belt cover thickness and hardness do not have any
implication.
Condition can be considered clean and hence,
implication nil. No implication due to temperature.
The evaluated value off is
0.02
-0.0035
+0.002
+0.004
4.0013
+0.0054

basic value
-17.5% for belt speed
+10?/0 for belt width
+20% for material flexure
+6.5% for maintenance
+27%for 2% sag

The total of above is 0.0292. The design can be done

with f = 0.03.
Example 2

Select value of "f" for a 1,200-mmbelt x 300-m centerto-center inclined (up) conveyor for conveying (-135mm size coal having a bulk density of 800 kg/m3. The
conveyor design capacity is 1,200 mtph and is operating
at 3.15 rnps speed. The conveyor is equipped with 152.4
mm 0.d. x 3 roll x 3.5" trough carrying idlers. The idlers'
pitch is 1.20 m and 3.0 m for carrying and return run,
respectively. Ambient temperature is -5C to 35C. The
conveyor location is in power station.
Solution. The designer analyzes the requirement
and makes following decisions:
Belt speed 2.75 <: v = 3.15 rnps < 3.75 mps.
Therefore, the implication is -10% on f.
The belt width is more than 800 rnm. Therefore, no
implication for belt width.
The material being conveyed is coal, which is
average for flexure. Hence, no implication for
flexure.
Idler diameter and troughing angle do not have any
implication.
The expected maintenance quality is likely to be
excellent. Hence, no implication for maintenance.
Conveyor will have gravity take-up and design sag
of 1%. Therefore, implication nil.
The temperature is -5C. The implication is +5%by
interpolating the data.

CALCULATION OF ARTIFICIAL FRICTION CONVEYING COEFFICIENT

Belt cover thickness and hardness do not have any

implication.
Condition can be considered clean and hence,
implication nil.
The evaluated value of f = 0.02 basic value - 0.002 ten
percent for belt speed + 0.001 five percent for temp.
The total of this is 0.019. The design can be done with
f = 0.019 or 0.02.
Example 3

Select value of f for a 1,000-mm belt x 3,500-m long

inclined (up) conveyor for conveying (-175-mm limestone, bulk density 1,350 kg/m3, from mine to plant. The
conveyor design capaaty is 1,325 mtph and speed
3.5 mps. It has 152.4 mm 0.d. x 3 roll x 35" trough
carrying idlers, at 1.5 m pitch. The return idler pitch is
3.0 m. The ambient temp. is 2C to 45C. The conveyor
has steel cord belt of cover thickness 8 and 5 mm.
Solution. The designer analyzes the requirement
and makes following decisions:
Belt speed 2.75 < v = 3.5 mps < 3.75 mps.
Therefore, the implication is -10% on f.
The belt width is more than 800 mm. Therefore, no
implication for belt width.
Limestone is somewhat difficult for flexure.
Therefore, the implication is +lo% on f.
Idler diameter and troughing angle do not have any
implication. Also no implication due to
temperature.
The maintenance quality is likely to be average,
hence consider increase of half of +6.5%; i.e.,
+3.25%.
Conveyor will include a reliable take-up device for
the correct tension all the time. For such a long
conveyor, the design sag is likely to result in less
than 0.65%. Accordingly, 10% reduction in basic
value off.
For belt bottom cover thickness 5 mm and rubber
hardness around 75 shore-A, the increase is +5.5%.
The evaluated value of f = (0.02 basic value) - (0.002
decrease 10% for speed) + (0.002 increase 10% for material flexure) - (0.002 decrease 10% for sag) + (0.00065
increase 3.25% for maintenance) + (0.0011 increase
5.5% for thick rubber cover). The total of this is 0.01975.
The design can be done with f = 0.02.
T H I S CALCULATION M O D E L A N D C E M A

CEMA calculates the "main resistance" of DIN/ISO in the

following form (notations Kx, Ky, 0.015, Wm & Wb are
as per CEMA).
Carrying idlers' rotation resistance is accounted for by
factor Kx. However, the difference with respect to f is
that Kx also includes multiplication by (Wb + Wm).

Carrying run belt flexure + material flexure resistance

is accounted for by factor Ky.
Return run idlers' rotational resistance + belt flexure
resistance is accounted for by factor 0.015 (CEMA stipulations, reference 2nd edition, are at variance whether
return idlers' rotational resistance is part of 0.015 or Kx.
If it is part of Kx, then the calculation of return belt
tension at various points will not be feasible. Hence,
return idler rotation resistance is mentioned as part of
0.015).
The aforesaid information provides basic comparison.
Further elaboration is not included due to space limitation. The article helps to understand various phenomena
and their implications. It can be useful while choosing/
adjusting the values of Kx, Ky and 0.015 for calculation
by CEMA method. For example, if idlers' alignment is
poor in a specific case, the designer can think of taking
somewhat more of a value of Kx. Likewise, while
choosing a specific value of Ky, one can take into consideration issues such as troughing angle, belt cover thickness, cover hardness, sag, etc., which will have parallel
effects (although magnitude/percentage increase in f are
not to be used directly for Ky, as its multiplier is Wb +
Wm instead of total mass).
Following are the commonly used engineering symbols
in this article:
General notation for force, N
General notation for coefficient of friction
General notation of mass, kg
Earth surface gravity acceleration, 9.81 m/2
Inclination for conveyor or conveyor portion, as
applicable, degree
Artificial friction coefficient for conveying, or
conveying friction coefficient
Belt speed, m/s
Belt mass (either of carry or return), kg/m
Carry side idler set rotating mass, per meter of
conveyor length, kg/m
Material mass (which is on belt), kg/m
Return idler sets rotating mass per meter length of
conveyor, kg/m
Carry side 3 roller idler set troughing angle
Notations other than the above are clarified wherever
they are mentioned in the article.
REFERENCES

Conveyor Equipment Manufacturers Association (CEMA). Belt

Conveyors for Bulk Materials. 2nd ed. Boston, Mass. CBI
Publishing Company, Inc.
Mulani, Ishwar G. 2001. Engineering Science and Application
Design for Belt Conveyors. Pune, India: Ishwar G. Mulani.
Spaans, C. 1991. Calculation of the Main Resistance of Belt
Conveyors. In Belt Conveyor Technology. Vol. 1/94. Edited
by Reinhard H. WoNbier. TransTech Publications.
Standards: DIN 22101 and IS0 5048.

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