Development of lightweight fiber-reinforced composite pins for heavy load long pitch roller chains

Abstract

This article highlights the design and development of lightweight composite pins using carbon prepreg through the filament winding molding and heat-shrinkage fitting processes for heavy load long pitch roller chains. A structural analysis is performed to confirm the stress distribution of this composite pin based on the lamination structure. The stresses on the plates and pins of the roller chain are analyzed. The structural analysis was performed at maximum load, and the results endorsed the design of a pin with an inner diameter of 20 mm and an outer diameter of 34 mm to be optimum. According to the analysis results, prototypes are fabricated, and fiber volume fraction and porosity of the composite pin were evaluated. The composite pin was inserted into the steel hollow tube using heat shrinkage fitting process, and the damping ratios and weights of these pins were measured. The composites with a fiber volume of 60% and a porosity of 0.52% demonstrated a significant increase in damping ratio (27%) and an 18.6% reduction in weight compared to the steel pin. Overall, inserting the composite pin into steel chain is established as a novel approach to improve the structural design of the heavy load long pitch roller chain for attaining effective durability.