Professional Documents
Culture Documents
PMCM DP
PMCM DP
PMCM DP
ii
AKNOWLEDGEMENT
First and above all we would like to express our deep acknowledgement to our instructor Mr. Abiyou Solomon (MSc) for his continuous assistance and advice consultancy. Next, we also express our heartfelt acknowledgement to Mr. Solomon Mulugeta a member of JU research office for his unlimited support and advice. Last but not the list we also acknowledge our group member to their great effort and tolerance.
iii
ABSTRACT
The main purpose of this work is to design pedal meat chopping machine. The work includes design of different machine elements such as design of shaft, gear, keys, screw, and selection of bearing, design of fasteners, tables, forked plate, blades and design of chain drives. This machine is made to be manually input power, in order to be used to the community where electric power is insufficient. This is also aimed at reducing electric power consumption. According to the website http://www.gizmag.com an average human can produce 400W power for two hours and 200W for about 8 hours which is enough to cut a meat.
iv
TABLE OF CONTENTENT
Contents
AKNOWLEDGEMENT ........................................................................................................................ ii ABSTRACT........................................................................................................................................ iii LIST OF FIGURES .............................................................................................................................. vi LIST OF TABLES ................................................................................................................................ vi SPECIFICATION ................................................................................................................................. 1 CHAPTER 1 INTRODUCTION ............................................................................................................. 2 CHAPTER 2 PROBLEM FORMULATION ............................................................................................. 3 2.1 POBLEM STATEMENT OF THE PROJECT ................................................................................. 3 2.2 GOALS AND OBJECIVES OF THE WORK .................................................................................. 3 2.3 SCOPE OF THE WORK ............................................................................................................. 4 CHAPTER 3 LITERATURE REVIEW ..................................................................................................... 5 3.1 BACKGROUND INFORMATION ............................................................................................... 5 CHAPTER 4 PRODUCUCTION DESIGN .............................................................................................. 6 CHAPTER 5 DESIGN OF COMPONENT .............................................................................................. 7 5.1 INTRODUCTION ...................................................................................................................... 7 5.2 DESIGN OF SHAFT .................................................................................................................. 8 5.3 GEAR DESIGN ....................................................................................................................... 36 5.3.1 Introduction .................................................................................................................. 36 5.4 DESIGN OF CHAIN DRIVE...................................................................................................... 41 5.4.1 Roller Chain ................................................................................................................... 41 5.5 Key design ............................................................................................................................ 43 5.6 SELECTION OF SCREW .......................................................................................................... 44 5.6.1 Bolted joints .................................................................................................................. 44 5.6.2 Design for bolts and nuts .............................................................................................. 45 5.7 Selection of Bearing ............................................................................................................. 45 5.7.1 Ball bearing ................................................................................................................... 45
5.7.2 Types of ball bearing ..................................................................................................... 46 5.7.4 Material selection ......................................................................................................... 47 5.7.5 Types of bearing lubrication ......................................................................................... 47 5.7.6 Calculation of bearings.................................................................................................. 47 5.9 DESIGN OF TABLE ................................................................................................................. 48 5.10 DESIGN OF PLATE ............................................................................................................... 48 5.11 DESIGN OF BLADE .............................................................................................................. 49 CHPTER 6 ASSEMBLY AND PARTS OF DRAWING ........................................................................... 50 CONCLUSION.................................................................................................................................. 54 RECOMMENDATION ...................................................................................................................... 54 BIBLOGRAPHY ................................................................................................................................ 55
vi
LIST OF FIGURES
LIST OF TABLES
SPECIFICATION
Specification is important and essential characters tics which states limits that are to be specified. Specification includes parameters which have to be specified us not calculated directly -The following parameters are specified in our design work. - Diameter of the sprocket - Number of teeth on the two sprockets - Diameter of the blade etc. In order to make it easy, we have listed all specification in the following table.
Input power Means of driving Blade diameter Length of shaft-1(blade on it) Length of shaft-2 Number of teeth of smaller sprocket Number of teeth of larger sprocket Speed of smaller sprocket Speed of larger sprocket Table dimension Table height Plate dimension Size of output meat
200W Manually by pedal 200 mm 450 mm 350 mm 21 49 140 60 500 mm X 800 mm 750mm 306 mm X 500 mm 20 mm X 20 mm
CHAPTER 1 INTRODUCTION
As described above the objective the objective of this course s to make students to design their own machine element. Based on what they have learned in a class. Based on this objective we have chosen to design Pedal meat chopping machine. The reason why we choose to design this machine is that in our locality there is no such type of machine. People usually chop meat manually by hand. Which is takes a long time to chop even a single kilogram of meat. We mainly focus on chopping of meat but not to mince it, since there is a machine which is used to mince a meat and usually people need a small amount of minced meat than chopped meat. So we are trying to solve this problem and to show our effort by designing such type of machine which able to solve the community problem as large.
Types of shaft
Shafts are classified as follows according to their industrial application: Line Shaft: It is a shaft which transmits power to several machine elements. Spindle: Stub Shaft: Counter shaft: A spindle is a short revolution shaft. A shaft that is integral with an engine, motor or prime mover. A short shaft that connects a prime mover to a line shaft of a machine.
(i)
Transmission shaft:
These shafts transmit power between the source and the machine and absorbing power. Counter shafts and line shafts are transmission shaft.
(ii)
Machine shafts:
These shafts form an integral part of the machine itself. Example: Crank shaft, stub shaft.
Material
Plain carbon steels C 07 320 - 400 200 C 10 340 - 420 210 C15 370 - 490 240 C20 440 - 520 260 C25 460 - 550 280 C30 500 - 600 300 C40 580 - 680 330 C45 600 - 750 380 C50 660 - 780 380 40 Ni 3 750 - 1050 600 30 Ni4 Crl 1000 - 1150 600 40 Cr 3 Mol V20 1350 1120 40 Crl 700 - 850 540 Table commonly used for shaft and their mechanical properties.
50 mm
250 mm
50 mm
= 13.64Nm=13640 N.mm
10
N - Revolution speed W - Load Assuming that the torque on the gear is same as that of the shaft, the tangential force acting vertically upward on the gear:-
Ft =
=161.42 N
=171.78 N
WVD = WG x cos
=171.78 x cos 200 =161.42 N
Horizontal component:
11
Since the torque on the gear is the same with shaft value (i.e. 13640 N.mm) Mt = (T1 T2) x RD 13640= (T1 T2) x 84.5 mm = T1 (1-T2/T1) x 84.5mm Let we assume tension ratio T1/T2 = 2 Then 13640=T1 (1-1/2) x 84.5 mm 13640=45.25T1 T1=322.84 N T1/T2=2 T2=161.42 N Therefore total vertical load acting downward on the shaft at B T 1+T2+WB (LEFT) And neglecting weight of the sprocket T1+T2=322.84+161.42 =484.26 N Since the sprocket 2 is mounted at 450 inclination the total tension is resolved into X and Y component.
Tt = 484.26
45 45
12
RAH TY B
TX
RBV RBH
Wt Wr
50
mm
250
mm
50
mm
50 mm
250 mm
50 mm
FH =0 RAH + RBH TH + WV= 0 RAH + RBH = TH + WV RAH + RBH = 342.2 161.41 RAH + RBH =180.78 N ------------------------------------ 1 M at A= 0 TH x 50 RBH x 300-WV x 350=0
13
342.2 x 50 RBH x 300 161.42 x 350 =0 17110 RBH x 300 56497=0 RBH x 300 = - 39387 RBH = -131.29 N (downward) ---------------------------- 2 Now inserting 2 into 1 we get RAH + RBH =180.78 N RAH =180.78 (-131.29) = 312.07 N
Bending moment on horizontal
MB at section 1
A RAH
X
=RAH x X =312.07 x X At X=50 , 15603.5 N.mm
MB at section 2
TH A B RAH
X (X-50)
50 mm
14
=312.07x 342.2(x-50) =312.07x 342.2x + 17110 =-30.13x + 17110 At X=50, 15603.5 N.mm At X=300, 8071 N.mm MB at section 3
TH A B RAH
C
x 250 mm
RBH
50 mm
(X-300)
=-30.13x + 17110 131.29(x-300) = -30.13x 131.29x + 17110 + 39387 =-161.42x + 56497 At x=300, 8071 N.mm At x= 350, 0
50 mm
250 mm
50 mm
15
F=0
RAV + RBV TV+ WV=0 RAV + RBV=342.2 + 58.75 RAV + RBV=283.45 N -------------------------- 3
M at A= 0 =TH x 50 RBV x 300 WV x 350 =342.2 x 50 - RBV x 300 58.75 x 350 =17110 20562.5 - RBV x 300 RBV =-11.508 N----------------------------------------------4 4 into 3 Then, RAV + (-11.508 N) =283.45 N RAV =294.9 N Bending moment on vertical axis
A RAV
x
MB at section 1 =RAV x X =294.9 x 50
=14747.9 N-mm
MB at section 2
16
TV A B RAV
X (X-50)
50 mm
=294.6x 342.2 (x-50) =294.6x 342.2x + 17110 =-47.24x + 17110 At X=50, 14747.9 At X=300, 2937.4 MB at section 2
TV A B RAV RBV
C
50 mm
250 mm
(X-300)
=-47.24x + 17110 11.508(x-300) =-58.75x + 3452.5 + 17110 =-58.75x + 20562.5 At x=300, 2937.4 At x=350, 0 Resultant force MH
17
Maximum bending at V=2937.4 Maximum bending at horizontal H=8071 R= = =8588.9 N-mm The resultant bending moment is MB max = 8588.9 N-mm Resultant maximum bending moment = = =21469.6 N-mm
18
B 50 mm 250 mm
15603.5 N-mm
C 50 mm
8071 N-mm
14747.9 N-mm
The shaft material is made from C45 and from standard of PSGDB; the ultimate load is in the range of 600-750 we take the average of the range. i.e 675 N/mm2 and allowable load is y =380 N/mm2 Factor of safety (n) =
= 675/380 = 1.78
Since the machine is not heavy duty machine take s.f n=2 The factor of safety is 2. This factor was chosen by considering Variations in material properties The effect of size of the shaft The type of loading
19
The effect of machining or forming The effect of heat treatment The effect of shear on function The effect of operating environment The specific operating requirements and the concern for human safety
N/mm2
Mte = [(Mt kt )2 + ( Mb kb )2
20
Nature of loading Stationary shaft Stationary applied load Suddenly applied load Revolving shaft Suddenly applied load Minor shock load Heavy shock load
Kb
Kt
1 1.5-2.0
1 1.5-2.0
1 1-1.5 1.5-3.0
Kt and Kb values are 1 because the shafts of natural load is stationary applied load = =45436.06 N-mm Since our shaft material solid and subjected to pure torsional moment M te the shaft diameter can be found from the torsional strength equation given by Shear strength =16Mt /d3 =16Mt /d3 95=
d3 = =2435.83
21
P=T =rF F= where P= power F= force r= radius of the blade = angular velocity
22
Therefore F=
= 0.14 N
Where Mt = torsional moment P= power N = revolution Force analysis for shaft 1 The shaft is made from C45, from PSGDB y =380 N/mm2 According to maximum shear stress theory y = n is stands for safety factor
N/mm2
23
= 95 N/mm2
Force on shaft
C D E F G H I
J K L M N O
WV
68 mm 50 mm
WH
68 mm
266 mm 22 mm
RAH
RAV
RBH RBV
WH
400 mm 50 mm
RAH
RBH
FH =0 RAH + RBH WH= 0 RAH + RBH = WH RAH + RBH = 85.74 N --------------------- ------- 5
24
Moment at point
M at A = 0 0= RBH x 400 85.75 x 450 RBH = 6 into 5 RAH + RBH = 85.74 N RAH +96.46 =85.74 RAH = -10.66 (downward) = 96.46 N ------------------- 6
RAH
25
RAH
(x-400)
RBH
=-10.66 x X + 96.46(x-400) =85.8 x 38610 At x= 400, -4264 N-mm At x= 450, 0 Vertical force FV = 0 =- RAV + FC + FD + FE + FF + FG + FH + FI +FJ + FK + FL + FM +FN + FO -RBV RAV + RBV = (13 x 0.14 N) +161.24 RAV + RBV = 163.18 N --------------------------------------- 7
M at A = 0 = 0.14(68+90+112+134+156+178+200+222+244+266+288+310+332) +161.42 x 450 RVB x 400 = 337.28 + 72639 - RVB x 400 RVB = 364.04 N ------------------------------------------ 8 7 into 8 RAV + RBV = 163.18 N
26
RAV
=-200.8 x At x=68, -13657.8
Section 2
68 mm
RAV
=-200.8 x 0.14(x-68) =-200.936x +9.248 At x= 68, 13657.8 N-mm At x=90, -18074.9 N-mm Section 3
27
C D
68 mm
22 mm
RAV
=-200.936x + 9.248 0.14(x-90) =-201.072x + 21.488 At x=90, -18074.9 N-mm At x=112, -22498.5 N-mm
Section 4
C D E
68 mm
22
mm
RAV
x
= -201.072 x + 21.488 0.14(x-112) = -201.208x 36.72 At x=112, -22498.9 N-mm At x=134, -26925.152 N-mm
Section 5
28
C D E F
68 mm
22
mm
RAV
x
=-201.208x + 36.72 0.14(x-134) =-201.344x + 54.944 At x=134, -26925.152 N-mm At x=156, -31354.72 N-mm
Section 6
C D E F G
68 mm
22
mm
RAV
=-201.344x + 54.94 0.14(x-156) = -201.48x + 76.156 At x=156, -31354.72 N-mm At x=178, -35787.284 N-mm Section 7
29
C D E F G H
68 mm
22
mm
RAV
x
=-201.48x +76.156 0.14(x-178) =-201.616x + 100.364 At x= 178, -35787.28 N-mm At x= 200, -40222.83 N-mm
Section 8
C D E F G H I
68 mm
22
mm
RAV
=-201.616x + 100.364 0.14(x-200) =-201.752x + 127.564 At x= 200, -40222.8 N-mm At x= 222, -44661.38 N-mm
30
Section 9
C D E F G H I
68 mm
22
mm
RAV
x
=-201.752x + 127.564 0.14(x-22) =-201.868x + 157.756 At x= 222, -44661.38 N-mm At x= 244, -49102.9 N-mm
Section 10
C D E F G H I J K
68 mm
22
mm
RAV
=-201.868x +157.756 -0.14(x-2446) =-202.024 x +190.94 At x= 266, 49102.9 N-mm At x= 288, -57994.96 N-mm Section 11
31
C D E F G H I
J K L
68 mm
22 mm
RAV
=-202.024x +190.94 0.14(x-268) =-202.16x + 227.116 At x= 266, -49102.9 N-mm At x=288, -57994.96 N-mm
Section 12
C D E F G H I J K L M
68 mm
22 mm
RAV
=-202.16x +227.116 0.14(x-288) =-202.296x +266.284 At x=288, -57994.96 N-mm At x=310, -2445.476 N-mm Section 13
32
C D E F G H I
J K L M N
68 mm
22
mm
RAV
= -202.296x + 266.284 0.14(x-310) = - 202.432 x + 308.45 At x= 310, -62445.48 N-mm At x=332, -66398.984 N-mm
Section 14
C D E F G H I
J K L M N O
68 mm
22 mm
RAV
= -202.432x + 308.45 0.14(x-332) = -202.568x + 358.596 At x= 322, -66898.98 N-mm At x=400, -80675.8 N-mm
33
Section 15
C D E F G H I
J K L M N O
68 mm
22
mm
RAV
RBV
34
C D E F G H I J K L M N O
WV
68 mm 50 mm
WH
68 mm
266 mm 22 mm
RAH
RAV
RBH RBV
-13687.8 N-mm
-18074.9 N-mm -26925.1 N-mm -22498 N-mm -35787.2 N-mm -44661 N-mm -31354.7 N-mm -40222 N-mm -53547.4 N-mm -49102.9 N-mm 62445.4 N-mm 57994.9 N-mm 66898.9 N-mm -80675.8 N-mm 80788.4 N-mm
35
Kt and Kb values are 1 because the shafts of natural load is gradually Met = =81931.77 N-mm Since our shaft material solid and subjected to pure torsional moment M te the shaft diameter can be found from the torsional strength equation given by Shear strength =16Mt /d3 =16Mt /d3 95=
d3 = =43350.94 d = =13.37 say 14 mm Checking for ultimate tensile strength = = =25 N/mm2 Since the tensile strength is less than the ultimate tensile strength our design is safe.
36
TERMS USED IN SPUR GEAR The following terms, which will be mostly used in this chapter, should be clearly understood at this stage. 1. Pitch circle. It is an imaginary circle which by pure rolling action, would give the same motion as the actual gear. 2. Pitch circle diameter. It is the diameter of the pitch circle. The size of the gear is usually specified by the pitch circle diameter. It is also called as pitch diameter. 3. Pitch point. It is a common point of contact between two pitch circles. 4. Pitch surface. It is the surface of the rolling discs which the meshing gears have replaced at the pitch circle 5. Pressure angle or angle of obliquity. It is the angle between the common normal to two gear teeth at the point of contact and the common tangent at the pitch
37
point. It is usually denoted by . The standard pressure angles are 14 1 /2 and 20. 6. Addendum. It is the radial distance of a tooth from the pitch circle to the top of the tooth. 7. Dedendum. It is the radial distance of a tooth from the pitch circle to the bottom of the tooth. 8. Addendum circle. It is the circle drawn through the top of the teeth and is concentric with the pitch circle. 9. Dedendum circle. It is the circle drawn through the bottom of the teeth. It is also called root circle. Note: Root circle diameter = Pitch circle diameter cos , where is the pressure angle. 10. Circular pitch. It is the distance measured on the circumference of the pitch circle from a point of one tooth to the corresponding point on the next tooth. It is usually denoted by pc. Mathematically, D= diameter of the pitch circle, and T= number of teeth on the wall A little consideration will show that the two gears will mesh together correctly, if the two wheels have the same circular pitch. Note: If D1 and D2 are the diameters of the two meshing gears having the teeth T1 and T2 respectively; then for them to mesh correctly, Circular pitch, Where
pc =D/T
pc =
or D1/D2 = T1/T2
Given that
d=169 mm, N=143 m= =169/43 = 3.9 say 4 Where: - m module, mm d Pitch diameter, mm
38
Diametral pitch: - Pd =
Spur Gear 5.3.2 Force analysis of spur gear Before beginning the force analysis of gear trains let us agree on the notation to be used. Beginning with the numeral 1 for the frame of the machine, we shall designate the input gear as gear 2, and then number the gears successively 3, 4, etc. Next, there may be several shaft involved and usually one or two gears are mounted on each shaft as well as other elements. We shall designate the shafts, using lowercase letters of the alphabet, a, b, c, etc.
39
40
The free body diagram of the pinion has been redrawn and the forces have been resolved into tangential and radial components. We now define Wt =Ft 32 =161.42 KN As the transmitted load this tangential load is really the useful component, because the radial component Fr32 serves no useful purpose. It does not transmit power. The applied torque and the transmitted load are seen to be related by the equation. T= Wt = x 161.42
= 13,639 Nmm The power H transmitted through a rotating gear can be obtained from H= where Wt transmitted load H Power in kW Next we designate the pitch line velocity by V, V= dn/12 mm where V - pitch-line velocity, ft/min 1ft = 304.8
41
Roller Chain
Length of chain
GIVEN VALUES RATED POWER= 200W N1=140 N2=60 We know that the velocity of chain drive, V.R =
42
Number of teeth for smaller is T1=21 & larger sprocket is T2= 49 Design power = Rated power x service factor The factor Ks=K1 .K2 .K3 = 1.5 x 1 x 1.25=1.875 And the design power= 200 x 1.875=375W According to ISO: 2403-1991 the pitch for chain number 10B is p=15.875 and the roller diameter d=10.16mm, breaking load (WB) =22.2Kn minimum roller width w =9.65mm We know that pitch circle diameter for the smaller sprocket is d1 = p cosec (
v1 =
= 0.78m/s
= 255 N
The minimum center distance between the smaller and larger sprockets should be 30 to 50 times of the pitch. Therefore we take 30 times of the pitch Center distance x= 30 15.875 =476.25 mm
In order to accommodate initial sag in the chain, the value of center distance is reduced by 2 to 5 mm. Therefore Correct center distance
X=476.25 4= 472 mm
43
+ +
+( +(
)2 )2
SUNK KEY
44
In order to find the dimensions of this rectangular key Given that Mt = 1364 N-mm =190 N/mm2
c = 380 N/mm2
d= 15 mm
For the given shaft diameter from standard table of keys Width of the key b= 6mm
Thickness of the key t=6mm Height of the key Length of the key h= 4 mm L=1.5 d = 25.5 mm
Mt = x L x b x d/2
=
= 1.18 N/mm2
Which is less than the allowable strength, hence the dimensions are in safe limit
Which is less than the allowable strength, hence the dimensions are in safe limit
45
element of the fastening as in case of a handle with thread turned on one end to engage in a tapped whole maneuver. In study of threads and their representation on drawing, It is necessary to define a few important terms as shown below
Crest Roof
dc dp
46
Within reasonable limits changes in load, speed and operating temperature have, but little effect on the satisfactory performance of ball bearing. 123456Finite fatigue life subjected to wide fluctuation Larger space required in radial direction Low damping capacity High noise level More severe alignment requirement High cost
47
48
Since the material of bearing is cast iron, the allowable pressure of bearing Pb is 20 to 80 N/cm2 Width of the bearing is 1 and circumstantial velocity V(m/s) is 3.5 to 1. For the given shaft diameter of 15 mm F (N) = (1.5cm x 1) (80 N/cm2) = 120N/cm =12N
49
to give a small gap between two consecutive forks so that the blade is rotated between them for asy chopping of the meat.
50
X2
51
52
53
54
CONCLUSION
From the observation and from what we have faced during the course of this design project, we give the following conclusions. While we are doing this project we have get a good knowledge and many information which broaden our knowledge and also gives us experience. The project work also gives us information and some procedure of design of machine element such as chain drive, shaft and etc. & selection of some components like bearing & screw. This work also enables us to strengthen our habit of working together which is the most important experience and we may develop that uses us in our future profession. The spirit of cooperation & working together with collogues. Due to the fact that the learning process in our campus is community based, we have tried to solve the community problem especially that of our campus.
RECOMMENDATION
It was our wish to finish the project early. But due to shortage of some facilities such as computer hinders our progress, so we recommend that the department have to do something to solve this problem. Its known that design project gives great opportunity to student to design their own machine component and assembly, so we believe that it should get a great attention, as it have to be.
55
BIBLOGRAPHY
BOOK Mechanical Engineering design, Joseph E. Shigley & Charles R. Mischke, sixth edition Standard Handbook of Machine design by Joseph Shigley, second edition, 1996 A text book of machine design by R.S Khurmi & J.K Gupta Theory of Machine by R.S Khurmi & J.K Gupta Handbook of Mechanical Design, GITW M. Maltra, Lv Prassad, second edition Mechanical Design Handbook, Harold A. Rothbart, second edition Machinery Handbook, Eric Oberg Franklin D. Jones Halbrook L. Horten & Henry H. Rafeal, 27th New York, 2004 Machine Design by Abdul Mubin, 4th edition, New Delhi, 2005 Mechanical engineers Handbook Material and Mechanical Design, Book 1, 3rd edition New Jersey, 2006 Design of Machine Elements by G.K Vijayraghavan & S. Vishnu Priyan, 4th Edition, Muscat Oman, June 2009 SITES www.google.com www.fao.org www.slideshare.net www.gizmag.com www.catarina.udlap.mx
56
57
58