“DESIGN AND DEVELOPMENT OF PAN-MIXTURE FOR MIXING AND CRUSHING OF FLY-ASH,CEMENT,SAND AND WATER.”

7/27/2019 DESIGN AND DEVELOPMENT OF PAN-MIXTURE FOR MIXING AND CRUSHING OF FLY-ASH,CEMENT,SAND AND WATE

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TITLE OF SEMINAR/PROJECT REPORT

DESIGN AND DEVELOPMENT OF PAN-MIXTURE FOR MIXING ANDCRUSHING OF FLY-ASH,CEMENT,SAND AND WATER.

Submitted by

DARSHIN MAKVANA(080160119032)

HAMIR BAMBHANIYA(080160119001)

BALDEV VAGHASIA(080160119124)

NITESH KUCHA(080160119027)

In fulfillment for the award of the degree

OfBACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

GOVERNMENT ENGINEERING COLLEGE-MODASA

Gujarat Technological University, Ahmedabad

April, 2012

GOVERNMENT ENGINEERING COLLEGE- MODASA

MECHANICAL ENGINEERING 2011-012


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CERTIFICATE

Date:25/04/2012

This is to certify that the dissertation entitled DESIGN AND

DEVELOPMENT OF PAN-MIXTURE FOR MIXING AND CRUSHING

OF FLY-ASH,CEMENT,SAND AND WATER has been carried out by

MAKVANA DARSHIN ASHOKBHAI under my guidance in fulfillment of

the degree of Bachelor of Engineering in MECHANICAL(7th Semester) of

Gujarat Technological University, Ahmadabad during the academic year

2011-12.

Guides: INTERNAL GUIDE EXTERNAL GUIDE

Prof. K.D. PANCHAL Mr. J.M. UPADHYAY

Head of the Department

Prof. N.K. PANCHAL


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ABSTRACT

DESIGN AND DEVELOPMENT OF PAN MIXTURE FOR MIXINGAND CRUSHING OF FLY ASH, CEMENT, SAND AND WATER.

The main function of Pan Mixture is to mixing and crushing of fly ash,cement, sand and water.

Pan mixture is mostly used to make material fly ash bricks. Any Design work of pan mixture done by industry is not proper, so

humble effort to improve the design work of pan mixture throughout this

project work.

This design process will be done by some assumption and mathematicalrelation.

By proper designing the performance of pan mixture will be improve.


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LIST OF TABLES

TABLE NO. TABLE DISCRIPTION PAGE NO.

TABLE:1 Following data about sand specific gravity 8

TABLE:2 Particle size limits of sand 8

TABLE:3 Approximate composition 9

TABLE:4 bearing of 60 series 25

TABLE. 5 Proportion of stan`parallel , tapered & gib head keys: 34

TABLE 6. selection of bolt 34


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LIST OF FIGURES

FIGURE NO. FIGURE DESCRIPTION PAGE NO.

FIG.1 BASIC DIAGRAM OF PAN 12

FIG.2 MATERIAL FILL IN WHOLE PAN 12

FIG.3 CASE 2 OF DESIGN OF PAN 13

FIG.4 CASE 1 OF DESIGN OF PAN 14

FIG.5 FINAL DIMENTION OF PAN 15

FIG.6 FREE BODY DIAGRAM OF ROLLER ARM 20

FIG.7 FREE BODY DIAGRAM OF ROLLER 21

FIG.8 FRONT VIEW ROLLER FREE BODY 23

FIG.9 TENSION AT ROLLER ARM ( SIDE VIEW) 24

FIG.10 SHOVEL 27

FIG.11 ARRANGEMENT OF SHOVEL. 28

FIG.12 FLANGE COUPLING Courtesy of 32

MECHANICAL HAND BOOK

FIG.13 TOP & FRONT VIEW OF PAN MIXTURE COURTESY

OF NEPTUNE PVT LTD.

FIG.14 3-D VIEW OF PAN-MIXTURE COURTESY OF

FORTUNE PVT.LTD. 37


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LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE

Symbol Abbreviations

Name

M Mass

L Length

Mass densityF Force

T Torque

Vc Volume of cement

Vs Volume of sand

Vf Volume of fly ash

V Total volum

ut Ultimate shear stress

ut

Ultimate bending stress

W Weight

c Crushing strength

s Shear strength

M Bending moment

Z Section of modulus

Angular velocity

P Power

N Revolution per minute

P.C.D Pitch circle diameter

b Bearing stressD Diameter


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TABLE OF CONTENTS

CHAPTER:1 INTODUCTION TO PROJECT WORK

1.1 introduction1.2process study of mixing and crushing.1.3 determination of process parameters.

CHAPTER:2 BRIEF HISTORY OF WORK

CHPTER:3 Literature Survey

3.1 rotamixer forced action rotary

mixer, hd stainless steel pan

3.2 replacement rotamixer stainless

steel pan3.3 electronic mixer timer, for

regulating mix duration

3.4 rmp55 rotamixers

CHAPTER:4 PROJECT WORK

4.1general study of pan mixture

4.2property of cement

4.3calculation of volume of shell:

4.4 design of pan

4.5 functional desing of pan mixture

4.6 design of roller


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4.7 functional design of shovel

4.8 design of shaft:

4.9design of coupling

4.10 design of plate for whole machine

4.11 hydralic gate system design

CHAPTER NO:5 CONCLUSION


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CHAPTER NO:1

INTRODUCTION TO PROJECT WORK

1.1INTRODUCTION

The IDP consists of following two steps. Design of components. Development of existing parts.

Design of components like, Main Vertical shaft (critical component). Roller weight & size. Scrappers. Shovel and shovel arm. Shell. Bearing housing. Rubber bush coupling.

Development of existing parts like, Setting of shovel angle arrangement. Numbers of scrappers & rollers to crushing and mixing.

Solution of this problem is carried out by following steps.

1.2Process study of mixing and crushing.

- As per given data by industry material ratio to be mixed and crushed:

Fly ash: 60%,

Cement: 30%,

Sand: 10%,

Required quality of water to make slurry.

1


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-From the ratio of material volume of each material will be finding out from

V=M=mass of material

=Density of material

-By adding sub volume of each material total volume of material will be find out.

-By giving some allowance in height top holding plate & in radius for bearing

housing shell drum height and radius can be computed.

1.3Determination of process parameters.

- As per information from free body diagram of roller, shovel for ,scrapper total load

can be found out.

- From this load torque on shaft can be found.

- For specific mixing time specific r.p.m of shovel& roller are required which can be

studied from process study of mixing.

- According to this study &torque electric motor is selected.

-To reduce high r.p.m of motor into small required specific type of gear box is

selected.

- From the gear box & motor the total height of mixture is determined .

1.3.1 Basic free body diagram for pan-mixture.

-FBD is best way to study the machinery completely.

-Draw the load diagram of roller& shovel as per process study.

-Free body diagram of critical component also drawn to design the machine.

-Analyze the forces from these load diagrams.


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1.3.2Select the material for safe limit.

-In pan mixture some components have to bear, wear &corrosion.

-So, for that component like,

Roller drum

Roller arm

Shovel plate

Shovel arm

Select the special type of material.

1.3.3Find the dimensions of rollers.

Roller size.

-From civil engineering handbook crushing strength of sand will be determine.

-Crushing strength of cement & fly ash is negligible.

- Determine the weight of roller from the crushing strength of sand.

-Find the dimension of roller as per density of roller material.

1.3.4Find the dimension of shovel.

Shovel size.

-Calculate the shear force of mixture from the property of material as per mixing

requirement.

-Calculate the shear force of fly ash, cement, sand & water by some formula.

-Determine the dimension of four shovel & one scrapper from the shear force ofmixture for safe limit.

Capacity of pan mixture is 1000 kg. Design the outer shell of pan mixture and the base of this machine. Select the gear box as per requirement which is used to transmit the power from

motor to main rotating shaft.

Finally determine the total height of machine from gear box.


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CHAPTER NO:2

BRIEF HISTORY OF WORK

In past bricks were made by mixing fly ash, sand, cement and water by hand. It was very

tedious work and mixing process required lot of time. Another disadvantages of hand mixing

is that the sand should be crushed in crushing machine.

But due to development in infrastructure sector it required drastically demand of bricks so the

designer felt to do automation in bricks and ceramics industry. So from that point pan mixture

machine was invented.

Now , a many types of design and working model available in market according to need of

ceramics industry.

There are ,

Vertical pan,

Horizontal pan,

Inclined pan mixing machines are available.

Also automated and manually operated machines are available.


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CHAPTER NO:3

Literature Survey

Refine Ltd 2004 Telephone: 01202 632270 Fax: 01202 632432 14 Email:

[email protected] Website: www.refina.co.uk

3.1ROTAMIXER FORCED ACTION ROTARY MIXER, HD stainless

steel pan

Stock no Description Power Weight Drum Size Capacity ex VAT

705500 RMP55 1.5kw 80kg 55 ltr 46cm 75kg 995.00

3.2REPLACEMENT ROTAMIXER STAINLESS STEEL PAN

Stock no Description Size Depth ex VAT

323205 mixing pan, 55 ltr 46cm 47cm 189.00

3.3ELECTRONIC MIXER TIMER, for regulating mix duration

Stock no Description ex VAT

802010 electronic timer 189.00

TECHNICAL & APPLICATIONS

3.4RMP55 ROTAMIXERS

Robust forced action mixers

Twin paddles for thorough mix action

No unmixed pockets


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Radial & axial mix, turns & lifts material

Paddles are adjustable

Suitable for up to 8mm aggregate

55 liter stainless steel rust free pan

Easy clean & low maintenance

RMP55 ROTAMIXERS are robust forced action mixers that are designed to mix all

those materials that cant be successfully mixed in a conventional free-fall cement mixer The

mixer uses the same frame as the heavy duty RM65 with a 55 ltr stainless steel pan It is

driven by a 1.5kw, 110 volt high torque motor and sealed gear box; 240 and 415 volt motors

are also available The rotating pan produces a centrifugal mix and the technically designedpaddles generate a radial and axial action; the paddles mix right up to the tub sides The

RMP55 is the ideal mixer for up to 2 bags of repair mortar and grout, epoxy, screed, flooring

latex and self levelers, cements, adhesives and coatings P12 L shaped paddle + P22 rotary

paddle The RMP55 is also available with a 2.2kw motor option and larger gearbox - add

1952 bag, 45 liter capacity output up to 800kg/hr 1.5kw, 110 volt, 22 amps.

RMP55

55 liter stainless steel pan


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CHAPTER NO:4

Project work

4.1General study of pan mixture

Pan mixture is used to mixing and crushing of fly ash, cement , sand and water. Main components for mixing of materials are four shovels. Main component for crushing is two roller. One scrapper is used to clear the wall of shell.

4.1.1Materials which mixed in pan mixture are:

Fly ash -60% Cement -30% Sand -10%

4.1.2Property of sand:

Specific gravity :2.65 to 2.95 Crushing strength:650kg/cm2

The specific gravity Gs of a soil without any Qualification is taken to be

average value for the soil grain in numerical values are given in a discuss where it

may be clear the specific gravity is reffered , the magnitude of the value may indicate

the correct usages since the specific gravity of the soil grains will always be larger

than the bulk specific.


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If one is considering only the soil grains, one Gs as

Gs= Gs=specific gravity,

=Density of material,Ywater= Density of water.

TABLE:1 Following data about sand specific gravity

Type of sand Gs

Sand 2.65-2.67

Silty sand 2.67-2.70

Bulk density of sand =

TABLE:2Particle size limits of sand

Type Range (mm)

Fine gravel 6-2

Corse sand 2-0.6

Medium sand 0.6-0.2

Fine sand 0.2-0.06

Specific gravity of sand: 2.65

Bulk density :1200kg/m3


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4.1.3 Shear strength :The shear strength of a soil may be defined as the maximum

resistance of the sand to shearing stress under any given condition .

Coulombs law and in its simplest form

T=c+tan

T=shear stress

=total compressive stress

c=apparent cohesive stress

=angle of shearing resistance

4.2property of cement

TABLE:3 approximate composition

Silica 20to25%

Aluminum oxide 4to8%

Calcium oxide 60to65%

Ferrous oxide 2to4%

Magnesium oxide 1to3%

4.2.1compression strength of cement:

the dry mixture of cement &sand is added water is given by following

formula.

P= +3.5

P=% of water by weight of dry material


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Pn=%of water required for making cement paste of normal

consistency.

Compressive strength of Portland cement should not less Then

After 3days=115kg/cm2

After 7days=175 kg/cm2

Density of cement: 1290kg/m3

4.2.2Property of fly ash

Density of fly ash: 2100kg/m3

4.3calculation of volume of shell:

here,

fly ash-60%

cement-30%

sand-10%

volume of fly ash:

Vf= m=mass of fly ash

=density of fly ashVf=

=0.2857m3


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volume of cement:Vc=m/

=300/1290

=0.2325m3

volume of sand:Vs=m/

=100/1200

=0.0833m3

Total volume of materials = (0.2857+0.2325+0.0833)105

=6.0137105

cm3

4.4 DESIGN OF PAN

V=r2h

Where,

r=radius of drum

h=height of drum

h=500mm (assume)

r2=0.6015h

=0.60150.5

R =1.0968 m

Now take height 100cm

V= r2h

6.0137105=3.14r2100

r2= 6.013105/1003.14

= 43.76cm


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Take r = 45.00 cm (radius of pan)

Show a figure of pan

H=1000 mm

D=900 mm

FIG.1 BASIC DIAGRAM OF PAN

Now,

All density are taken as minimum value so, any type of material which has any

density can be included in a cylinder of h=1000 mm , r=450 mm.

As per above assumption material fill in cylinder are as below:

H=1000 mm

D=900 mm


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FIG.2 MATERIAL FILL IN WHOLE PAN

As shown in fig. condition is not actually not reliable because for crushing of sand the roller

have to roll on the material and in this condition roller is not perfectly roll on material.

So, we can apply two type of condition:

1. either increase radius of pan2. either increase height of pan.

If increase the height of pan then contact between base of pan and roller is not done

perfectly.

This condition shown in figure below:

Main shaft

roller

H=1000mm

D=900 mm

FIG.3 CASE 2 OF DESIGN OF PAN


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As shown in fig. this condition is not sufficient.

So, we chose the second option increase radius of pan and reduce height of material filling.

For this condition some advantage also:

1.Increase the contact of roller with base.

2. Reduce the H.P of drive motor.

3. Improve the crushing quality.

This condition also shown in fig.

1000 mm

R 150 mm

FIG.4 CASE 1 OF DESIGN OF PAN

So, it seems very advantageous to increase radius of pan for perfect crushing of sand &

mixing the materials.

Suppose ,we fill material at height of h=150 mm

Than, Vold =Vnew

R12H1 = R22H2


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452100 = R2215

R2 = 113.6 cm

Take, R2 = 1140 mm

So, D2=2280 mm

Now, it is also high fill up & we have to take a roller with three times diameter of material fill

up height.

Diameter of roller =3* height of fill up

= 3*15

= 45

It can be seen that roller diameter is higher than the weight of roller also high. So, we have to

reduce material fill-up area.

So, take

H = 100 mm

Than Vold = Vnew

*1142*15 = *R

2*10

R= 1390.62 mm

Take, R=1400 mm

Now final fig. of pan fill up and diameter of pan view

D=2800mm

H=1000mm

H=100mm

FIG.5 FINAL DIMENTION OF PAN

Here extra 900mm height can be eliminated as per requirement and as shown infig final diameter of pan is 2800mm.


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4.5 FUNCTIONAL DESING OF PAN MIXTURE

Now force require ton crush sand particles in to fine sand particle:

F=L(d1-d2)c

Here ,

L=length of roller,

d1=diameter of input sand particles,

d2=diameter of output sand particles,

c=crushing strength.

L=500mm,

d1=6 mm,

d2=1mm,

c=3.5 Mpa

F=500(6-1)3.5

F= 8750 N

Torque acting at shaft

T =F1

r1

+F2

r2

F1,F2=force acting by roller 1&2

r1,r2 =radius of roller 1&2

=87501.05+87500.55

=14000 Nm

T = 14 KNm

Now , Extra 5% torque is taken for shovel friction with material.


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So ,Torque at shaft

T`=1.05T

= 1.0514

T`=14.7kNm

4.5.1 TIME CYCLE

Generally the process cycle of pan-mixture batch is varied from 4-6

minutes per batch .For neglecting the centrifugal force acting on the material it

is recommended that peripherical velocity of roller& shovel should not exceed

2M/s.(from mechanical system design. (R.B.PATIL)

So, angular speed of roller= 2m/s

= N= N=19 R.P.M

Now, power required to do the main function of pan mixture is given below,

P=Torque angular speed

P= 14

= 142

P=28 KW

4.5.2 GEAR BOXNow, generally available electric motor are at 1400 r.p.m. so, it is require to reduction

from 1400 to 19 r.p.m. there are power loss in the reduction of gear box hence taking

extra 90% efficiency of gear box so 10% extra power of motor is required.

P=10% extra of 28kw

P=30.8kw


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Generally 30.8kw rated motor is not available in market. So, it is require to take 31kw

motor with 1440 t.p.m.

So, motor configuration :P=31kw

N=1440r.p.m

Now , gear box configuration:

G=N1/N2

=speed of elect. Motor/speed of roller

= 1440/19

G = 75.78:1

Take G=76:1

4.6 DESIGN OF ROLLER:4.6.1FUNCTION OF ROLLER:

Roller is used for crushing of sand particles in form of powder of small

fine particles.

For that function we have required minimum 2 roller.

Take clearance of 600 mm on both side of main shaft

Now force require ton crush sand particles in to fine sand particle:

F=L(d1-d2)c

Here ,

L=length of roller,

d1=diameter of input sand particles,


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d2=diameter of output sand particles,

c=crushing strength.

L=500mm,

d1=6 mm,

d2=1mm,

c=3.5 Mpa

F=500(6-1)3.5

F= 8750 N

So, mass of roller :

=3.5 Mpa

F= 8750 N

So, mass of roller :

M=

=.

M = 891.94kg

=892 kg

= 6800kg/m3 (for C.I)

so, volume of roller:

V=

=

V= 0.13117m3


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Now roller length L=500mm

V = r2L

0.13117 = 3.14 r20.5

R= 289.05 mm

R = 290 mm (radius of roller)

But holding purpose of roller it is required to hole in roller center so extra radius distance

should be provide to roller.

So, Take

R =300 mm

4.6.2 DESIGN OF ROLLER ARM:Roller arm connect top plate with roller . it is squre in cross section .

Free body diagram of roller arm is shown below:

Arm -1 800mm 300mm Arm -2

700mm

700mm

1000mm

FIG.6 FREE BODY DIAGRAM OF ROLLER ARM

But pure tension on arm it is modified as below:


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700mm L

L

300mm

So, length of arm

L=700 300L= 361.57 mm

Free body diagram of roller with arm:

T

mg

FIG.7 FREE BODY DIAGRAM OF ROLLER

Tan =

= 66.80

now from fig.

Tsin= Mg


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T=

=.

.

T= 9520.38N

Now ,

t =

t =

A=.

wb=.

here select cast iron rod of grade FG150 , for square cross-section area

W=b

b2=.

b=7.96 mm


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taking b=10 mm

4.6.3 DESIGN OF ROLLER SHAFT:

Free body diagram of roller shaft:

T/2 T/2

FIG.8 Front view roller free body


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T

Fig.9 tension at roller arm ( Side view)

So, max banding moment of roller shaft,

Mmax = T/2L

= (9520.38500)/2

Mmax= 2380095 Nmm

So, taken circular shaft,

b =

Mmax= /32 bd3

Now taking shaft material FG400(C.I)

b = 400 N/mm2

so,

2380095= = /32400 d3d = 39.28mm

d= 40 mm


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for fitting purpose inner diameter of roller:

d= 41 mm

now two bearings fitted at two ends of roller ,

TABLE:4 BEARING OF 60 SERIES

Bearing

no

Bore(mm) Outside

dia(mm)

Width Static

c0(kN)

Dynamic

C(kN)

Grease

lubrication

Oil

lubrication

6005 25 47 12 6.55 11.2 15000 18000

6006 30 55 13 8.3 13.3 12000 15000

6007 35 62 14 10.2 15.9 10000 13000

6008 40 68 15 11.6 16.8 9500 12000

From manufacturers catalogs selecting bearing . so, we can select

ball bearing from axial & radial load .

Series : 6008

Bore : 40 mm

Outer dia. : 68 mm

Width: 15 mm

Static c0 = 11.60 kN

Dynamic c =16.80 kN

Grease lubrication = 9500 r.p.m

Oil lubrication = 12000 r.p.m

4.7 Functional design of shovel.

Number of shovels

n = 4

So , width of shovel =


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=

=27.5 cm

h

27.5

275mm

h w

Now, equation of projectile motion,

R =

So , taking = 45 for maximum mixing of material at given velocity of shovel.

Now, sin = But, h = height of filling material + allowance

h = 10cm + 1cm

= 11cm


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sin45 =

w = W = 15.5 16 cm

250mm

160mm

FIG.10 shovel

Arrangement of shovel.


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FIG.11 Arrangement of shovel.

Angle between two shovels =

= 90

Angle between two rollers =

= 180

4.8 DESIGN OF SHAFT:

Shaft is a critical component of pan mixture. If it fail working of all machine is stop.

Material of shaft is mild steel, for cost benefits and higher working life. Here shaft is

designed on basis of twisting moment and bending moment. Bending moment is due to

unbalanced force of rollers.

Here ,


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T=14kNm

N=19r.p.m

Now , the unbalanced force acting on shaft is calculated below:

m22r2 m1

2r1

shaft

so, unbalanced force

F= m12r1 - m2

2r2

=(89221.05)-(89220.55)

F= 1784 N

So, bending moment

M=FL

M=17841

M=1784Nm

Now, according to max. shear stress theory

Te = =14000 1784

Te = 14113.2 Nm

But Te=/16d3

Here mild steel of 45 C8 type

So,


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ut=500Mpa

ut =700Mpa

taking factor of safety = 6

so, t = .

= 700/6

, t =116.67 N/mm2

And

= .= 500/6

= 83.34 N/mm2

now according to shear stress theory ,

Te=/16d3

Where,

d=diameter of shaft

14113.21000 =/1683.34d3

d= 95.2 mm

now equivalent bending moment

Me =1/2(M+ )=1/2(M+Te)

=1/2(1784+14113.2)

Me =7948.6

According to max tensile stress theory

Me=/32td3

7948.6= /32166.67 d3

d= 91.37 mm


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but, taking higher value

d= 95.2 mm

taking value

d=96 mm

L=130 mm

4.9DESIGN OF COUPLINGCoupling is used to connect housing shaft to gear box shaft.

Main function of coupling is to provide engagement & disengagement of power drive

from machine.

In this case flange coupling is used.

Specification of coupling is obtain by design.

d = diameter of shaft

= inner diameter of hub

D = outer diameter of hub= 2d

Length of hub, L = 1.5d

=1.595

L = 142.5mm

Pitch circle diameter of bolts,

D1 = 2d

= 295

= 190mm


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FIG.12 FLANGE COUPLING Courtesy of MECHANICAL HAND BOOK

Outer diameter of flange

D2 = D1 + ( D1 D )

= 4d

= 4 95

= 380 mm


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Thickness of flange,

tf = 0.5d= 0.5 95

= 47.5 mm

Selecting material 45C8

ut = 700 MPa

ut = 500MPa

Taking, F.S. = 6

t = ut / F.S

t = 166.67 MPa

= ut /F.S

= 83.34 MPa

design of hub.

T = /16 c c = 450 MPa

c < ut

Design of key.

Material of key 45C8

Length of key,

L = Length of hub

L = 142.5 mm

From the standard table of IS: 2292 and IS: 2293 at 197


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TABLE. 5 Proportion of standard parallel , tapered & gib head keys:

Shaft dia. Upto &

including(mm)

Width(mm) Thicknees(mm)

50 16 10

58 18 1165 20 12

75 22 14

85 25 14

95 28 16

110 32 18

130 36 20

150 40 22

Width = 28 mm

Thickness = 16 mm

Design for bolts.

TABLE 6. SELECTION OF BOLT

Shaft

dia(mm)

35to55 56to150 151to230 231to390 Above390

No.of bolts 4 6 8 10 12

According to IS: 36523 number of bolts required at 95 mm diameter shaft is 6.

n = 6

load on each bolt = /4 btorque transmitted by bolt,

T = /4 b n D1/2For maximum safety we should take steel material,

b = 30 MPa

d1 = 10 mm.


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4.10 Design of plate for whole machine

From, Hertz contact stress theory it is reccomanded that plate should following specification,

Material: stainless steel

Poisson ratio of S.S.:0.27

Poisson ratio of C.I. :0.22

Ys moduls for S.S. : 193GPa

Ys module for C.I. : 170 GPa

And force of upper plate F=8750 N

So, from that data we can find thickness of plate T=10 mm

And side plate thickness=8 mm.

In hertz contect stress theory two components are come in contact

Here in this case two cylindarical surface are come in contact

1. Roller2. Base plate (take its radius infinite.).

So,

Contact stress,

ch =

Where, b=contact space

F=force

L=width of roller.

b=


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= . . . / 1/2

=8.3 mm

Take 10mm. thickness of plate.


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4.11 HYDROLIC GATE SYSTEM DESIGN:

Here empting time of material from pan is 2 minute. In this gatting system hydraulic system

are used so one master cylinder are used . for controlling the motion of gate open & close

there are limit swich are used.

Gate are finally open after completing mixture of material in pan. In 2 minute cycle

1 minute for opening gate.

1 minute for closing gate.

MASTER

CYLINDER

HYDRALIC CYLINDER

GATE

GATE

fulcrum point

end of gate

50

20

400

P

O


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As shown in fig.

Po= distance traveled by point on gate.

=1/3* circumference of gate circle.

= 1/3**400

=418.66 mm

Now speed of point p

=distance/time

=418.67/60

==6.97 mm/sec.

Now from fig.

. =

P1P2=.

P1P2=52.35MM.

So required stroke for second piston =52.32mm

Take 53mm.

p`

p

p2

Q1

Q

Q2

O


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Now bore of piston is 30mm

Then volume displacement per minute v=/4*d2 *L

=/4*302*53

= 37444.5mm3/mm

So, drive motor has to supply above volume of fluid to the second cylinder.

If bore of second cylinder is20mm

So, volume displacement by one revolution

V2=/4*202*20

=6280mm3

So number of stroke frist cylinder require

=v1/v2

=37444.5/6280

=6 (approch).


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4.11 FINAL VIEW OF PAN MIXTURE

FIG.13Top & front view of pan mixture Courtesy of NEPTUNE PVT LTD.


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FIG.14 3-D view of pan-mixture courtesy of fortune pvt.ltd.


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CHAPTER NO:5

Conclusion

5.1 Advantages of design & development of pan mixture.

Prevent the failure of machine To reduce production cost. To improve mixing performance. To improve crushing efficiency. To produce mixing material in laser time. To settle the shovel & roller. To reduce power required of motor.

In any machinery the failure of machine occur due to critical component failure. Thiscan be prevented by proper designing of critical component (in our case vertical

shaft).

Select suitable size of rollers so, selecting the roller not over size or under size.


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Appendices

value of poisson ratio for materials

Sr. no. Material Poissons ratio

1 Steel 0.25 to 0.33

2 Cast iron 0.23 to 0.27

3 Brass 0.32 to 0.42

Values of modulus of rigidity for materials.

Sr.no. Material Modulus of rigidity (GPa)

1 Steel 80 to 100

2 Cast iron 40 to 50

3 Brass 30 to 50

Strength of material as per IS codes.

Sr.no. IS designation Strength in MPa

1 FG400 400

2 FG150 150

3 45C8 700

REFERENCES


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1. Mechanical system design by S.P. PATIL

2.Machine design vol.1&2 by R.B. PATIL

3.Machine design by R.S KHURMI& J.K GUPTA

4. Mechanical hand book by SADHU SINH

5.Catelog of NEPTUNE INDUSTRY PVT. LTD

6.Property of soil by M.J. SMITH


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SPECIMEN

DESIGN AND DEVELOPMENT OF PAN-MIXTURE FOR MIXING ANDCRUSHING OF FLY-ASH,CEMENT,SAND AND WATER.

A PROJECT REPORT

Submitted by

DARSHIN MAKVANA(080160119032)

HAMIR BAMBHANIYA(080160119001)

BALDEV VAGHASIA(080160119124)

NITESH KUCHA(080160119027)

In fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

GOVERNMENT ENGINEERING COLLEGE-MODASA

Gujarat Technological University, Ahmedabad

April, 2012


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Documents

“DESIGN AND DEVELOPMENT OF PAN-MIXTURE FOR MIXING AND CRUSHING OF FLY-ASH,CEMENT,SAND AND WATER.”