Design of Hand Operated Forklift for Mill 2015

Acknowledgements
First Thanks to our God to help our successful completion of our project .Second we are grateful
and we would like to express our sincere gratitude to our advisor TESFAYE.K for providing
their guidance, assistance and encouragement throughout the duration of the project. Third to all
our friends and classmates, thanks for the comments and suggestions given which is crucial for
the successful completion of this project. Special thanks to our lovely parents for their support,
love, and sacrifice throughout our life. We would like to appreciate their devotion, support and
faith in our ability to attain our goals.
By:- Hailu Gebru, Halid Yesuf and Babusew Bikis
ITR/502/03, ITR/1134/03, ITR/178/03
BSc, Mechanical Engineering
Kombolcha Institute of Technology,2015

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 Design of Hand Operated Forklift for Mill 2015

Abstract
This project focuses in design and analysis of the part of manually operated forklift. to achieve
this project objective. This lift machine body structure and pulley system need to concern some
other criteria such as strength, safety and ergonomic design. This project flow machine design
procedure (i.e., material selection, geometric analysis design each components and assembly of
machine).Before develop the lift machine (using wire rope and pulley), it must compare with
other product (forklift) in market. It is because to study the customer need and to create a new
design with new feature.

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 Design of Hand Operated Forklift for Mill 2015

Table of Content
Content Page

Acknowledgements .....................................................................................................i
Abstract ..................................................................................................................... ii
List of table ................................................................................................................v
List of Figure............................................................................................................ vi
CHAPTER ONE ........................................................................................................1
1. INTRODUCTION .................................................................................................1
1.1 Background of Hand Operated Forklift ..................................................................... 1
1.2 Problem statement and justification ........................................................................... 2
1.3 Objectives of the project ............................................................................................ 2
1.3.1 General objective the project .......................................................................................... 2
1.3.2 Specific objective of the project ..................................................................................... 2
1.4 Significant of the project ............................................................................................ 2
1.5 scope of Project .......................................................................................................... 2
1.6 Methodology .............................................................................................................. 2
1.7 Organization of the Thesis ...................................................................................... 3
CHAPTER TWO .......................................................................................................4
2. LITERATUR REVIEW .........................................................................................4
CHAPTER THREE ...................................................................................................8
3. Design Analysis .....................................................................................................8
3.1 Material selection ....................................................................................................... 8
3.2 Geometrical analysis .................................................................................................. 9
3.3 Force analysis ........................................................................................................... 11
3.4 Design of each components of hand operated forklift machines ............................. 17
3.4.1 Design of shaft .............................................................................................................. 17
3. 4. 2 Design of wire rope .................................................................................................... 19
3.4.3 Fork Design .................................................................................................................. 24

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 Design of Hand Operated Forklift for Mill 2015
3.4.4 Design of fork holder .................................................................................................. 28
3.4.5. Design of screw ........................................................................................................... 31
3.4.6. Design of nut ............................................................................................................... 34
3.4.7. Design of handle .......................................................................................................... 37
3.4.8 Design of Chain Drives ................................................................................................ 39
3.4.9. Frame design................................................................................................................ 42
3.4.12. Selection of bearing ................................................................................................... 48
3.4.12. Design of Wheel ........................................................................................................ 49
3.5. Manufacturing process ............................................................................................ 52
3.6. Assembling procedure ............................................................................................. 53
3.7 Cost analysis& machine weight ............................................................................... 53
3.7.1 Cost of current existing system .................................................................................. 53
3.8.3.Weight of machine........................................................................................................ 54
CHAPTER FOUR ....................................................................................................55
4. Conclusion& Recommendation ...........................................................................55
4.1 Conclusion................................................................................................................ 55
4.2 Recommendation...................................................................................................... 56
Reference .................................................................................................................57
3D , Part and Assembly Drawing ............................................................................58

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 Design of Hand Operated Forklift for Mill 2015

List of table
List of table page

Table .3.1: Mechanical properties of steels used for shafts…………………………………….. 17

Table.3.2: Standard designation of ropes and their applications. ………………………….….. 20
Table 3.3: Factor of safety for wire ropes …………………………………………………….... 20
Table.3.4: Diameter of wire and area of wire rope …………………………………………...... 20
Table 3.5: Steel wire suspension ropes for lifts, elevators and hoists…………………………... 21
Table 3.6: Sheave diameters (D) for wire ropes ……………………………………………… 22
Table.3.7: Dimension of square thread ……………………………………………………...... 32
Table .3: 8Number of teeth on the smaller sprocket …………………………………………... 39
Table 3.9: power rating (in Kw) of simple roller chain ……………………………………....... 40
Table.3.10: Characteristics of roller chains according to IS: 2403 — 1991................................ 41
Table.3.11: for standard dimensions for radial ball bearing Ball bearing …………………….. .48
Table3.12: cost analysis………………………………………………………………………………….. 54
Table 3.13: weight of a machine ………………………………………………………………. 54

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 Design of Hand Operated Forklift for Mill 2015

List of Figure
Figure Page
Figure .2.1: A US airman operating a Hyster forklift …………………………………..……4

Figure.2.2: the process of lifting in mill house ……………………………………..………..7

Figure 3.1: Geometric analysis …………………………………………………….……….....9
Figure3. 2: fork with fork holder ………………………………………………….………….11
Figure3.3: free body diagram rope with pulley ……………………………….………………13
Figure 3.4: free body diagram frame ………………………………………………………....15
Figure 3.5.bending moment diagram for shaft ……………………………………………….18
Figure 3.6: pulley for winding rope .……………………………………………………...…..22
Figure3.7: wire rope sheave rim …………………………………………………………………….…23

Figure 3.8: fork ………………………………………………………………………………..25

Figure3.9: dimension of fork …………………………………………………..……………26
Figure 3.10: free body diagram for fork ……………………………………………………....27
Figure.3.12: fork holder ……………………………………………………………………………… 28

Figure 3.13: shaft for fork holder …………………………………………………………….29

Figure.3.14: bending moment diagram for shaft for fork holder…………………………......30
Figure.3.15: roller ……………………………………………………………………………………..32

Figure 3.16: force on power screw…………………………………………………………….33

Figure 3.17: nut………………………………………………….………………………….....35
Figure 3.18: handle …………….………………………………………………..…………….37
Figure.3.19: for vertical frame………………………………………………….……………...42
Figure 3.20: The bending moment diagram for upper frame………………….………….…...44
Figure 3.21: bending moment diagram for lower base……………………….………………..46
Figure .3.22: fillet weld………………………………………………………………………...47
Figure.3.23.roller bearing………………………………………………………………………49

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 Design of Hand Operated Forklift for Mill 2015

CHAPTER ONE
1. INTRODUCTION
A forklift has two metal forks on the front used to lift heavy weight. The forklift operator drives
the forklift forward until the forks lift over the surface. The forks, also known as blades or tines,
are usually made out of steel and can lift up to a few kilograms.
A forklift is a powerful tool that allows one person to precisely lift and place large heavy loads
with little effort .Using a tool such as a forklift. Instead of lifting and carrying items by hand can
reduce the risk that you will suffer a back injury. Hand operated lifts offer effortless lifting and
lowering capabilities. Sturdy push handless and rugged wheels or rollers provide easy mobility
and maneuverability. Some models feature upper level rollers to allow stacker to be positioned
on its back. Aluminum construction is corrosion resistant and the lifter .If you are serious about
reducing emissions, and your product doesn't weigh too much, then this human-powered forklift
may be a good.
It is important for forklift operators to follow all safety precautions when using a forklift. Drivers
should be careful not to exceed the forklift’s weight capacity. Forklift operators also need to be
able to handle forklifts. The driver must be aware of the forklift’s ever-changing center of gravity
and avoid making any quick sharp turns or going too fast .the center of gravity is a point in an
object around which all the weight is evenly distributed. This point is often different than the
physical center of the object. This is because the weight distribution is not always even.

1.1 Background of Hand Operated Forklift

In 1929, Hyster Company is already built. This company is one of the earlier company that make
The lift machine with the original machine were steel and lumber carries. The middle nineteenth
century through the early twentieth century saw the developments that led to today's modern
forklifts. The forerunners of the modern forklift were manually powered hoists that were used to
lift load. The first actual lift machine was built is in 1935 based on a reversed tractor Chassis.
The range was broadened again with the ―Kerry krane‖. It used during world war 2 by American.
The modern lift machine was developed in the 1920
Before year in milling house the workers use their labor to lift heavy weight. This is difficult to
lift heavy weigh because of human labor supply small force due to this fork lift very important to
lift heavy weight by using small labor force. By reading literature review it used to take the
proper design compare with the previews fork lift design.

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 Design of Hand Operated Forklift for Mill 2015
1.2 Problem statement and justification
In most milling house heavy weight especially maize, teff and different serial sometimes
weighing up to 100 Kg are lift on the stair by human labor, this is difficult to lift by human
labor. Especially our mother and sister are damage their flank, to solve this problem we are
initiated to design hand operated forklifts. It is used to mount between machineries.

1.3 Objectives of the project

1.3.1 General objective the project
 The main objective of the project is to design hand operated fork lift for mill.
1.3.2 Specific objective of the project
 Design each components of the machine
 To design manually hand operated forklift which is used to lift maximum load of
100kg and lifting height up to 2.2m
 To prepare the complete specification of the main components including estimated
cost.
 Prototype manufacture & assembly drawing

1.4 Significant of the project

It can also perform easily within small force .Our mother and sisters also work easily without
Offer. After the design of this project mill house use these forklift for loading and unloading
purpose. It hazardous &no need of other manpower

1.5 scope of Project

The general scope of this project is to design every component of a machine such as pulley,
shafts, screw, ropes, fork and handle and detail manufacturing drawing for each part. It also
needs some knowledge and skill to finish the project.

1.6 Methodology
The hand operated fork lift helps to lift heavy load so that in order to design we must consider
the following. :
 . Literature review:-In this portion we read about our topic, title and sub title ,this is
used increasing our knowledge about our thesis title. Also we discus in each literature
then we take the advantage &limitation of preview work and its working principle &over
all view of forklift and the method of that used to load and unloading of weight in the
milling house
 Design Analysis:-Includes material selection, geometrical analysis force analysis&
component design. In addition to that preparing its prototype.

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 Design of Hand Operated Forklift for Mill 2015
 Selection of Material:- design in the martial selection discuss about the material
properties &cost of the material &its manufacturing process.
 Geometric & Force Analysis:- In geometric analysis we put overall dimension that
come from direct measurement or different assumption. In the force analysis calculate all
forces that excreted on all components of machine
 Design of each Component:- component design include the strength analysis & each
detail dimension.
 Draw assembly &Part drawing:-In this portion drawing each components of the
machine &finally assemble drawing .This make the project more pure& easy to
manufacture& finally preparing prototype.

1.7 Organization of the Thesis

The first chapter of the thesis deals with different aspects of the research. It discusses
outlined introduction, main objective and specific objective, project limitation and scope
of project.. The second chapter deals with the basic concepts of literature review and
previous research works carried in the field and gave the necessary background to
proceed throughout the fork lift machinery. In the third chapter concern geometrical
analysis, detail design and part drawing. And bending moment diagram, shear force
diagram and load type expressed. Chapter four covers all the numerical results,
discussion of results, obtained in the thesis, gives a conclusion to the thesis, its
contribution and possible future research directions.

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 Design of Hand Operated Forklift for Mill 2015

CHAPTER TWO
2. LITERATUR REVIEW
A forklift truck (also called a lift truck, a fork truck, or a forklift) is a powered industrial truck
used to lift and move materials short distances. The forklift was developed in the early 20th
century by various companies including the transmission manufacturing company Clark and the
hoist company Yale & Towne Manufacturing. Following World War II the use and development
of the forklift truck has greatly expanded worldwide. Forklifts have become an indispensable
piece of equipment in manufacturing and warehousing operations. In 2013 alone the top 20
manufacturers worldwide posted sales of $30.4 billion with 944,405 machines sold and the U.S.
forklift market was nearly $33 billion. The cost of a new forklift can vary between $15,000 to in
excess of $150,000, dependent on the model and in particular the capacity of the forklift. The
most common forklifts are typically gas powered and have a capacity of between 2 and 2.5 tones.
The cost of these varies from around $18,500, for some of the less well known Chinese
manufactured forklifts, up to around $20,000, for the German forklifts from well established
manufacturers; it is important to take into account fuel and maintenance costs when calculating
the total cost of ownership

Forklift truck

Fig.2.1A US airman operating a Hyster forklift[9]

Powered industrial trucks’ is a common term referring to forklifts, container-handling trucks,

reach-trucks, turret trucks and the like. Since their forklifts have been an integral ingredient for
materials handling across a multitude of industries. Global injury/fatality data identifies forklifts
as a prominent occupational hazard that has occurred as a by-product of automation and bulk
material handling. With the introduction of forklifts came a shift in plight of materials handling

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 Design of Hand Operated Forklift for Mill 2015
towards adopting a bulk oriented approach. This derived jointly from the need to improve
productivity and to reduce the instance of workplace manual handling injuries. As a result, a
niche` market was created for specific plant and equipment to cater for such demand, but also
unfortunately released a new ream of hazards to the workplace.
A lack of consideration of the interface between pedestrian workers and forklifts in the workplace has
resulted in forklifts comprising many of the more serious injuries and fatalities in the workplace. These
effects have been felt throughout industries ranging from manufacturing to retail environments, and
require an array of engineering and administrative interventions to combat the exposed risks. These
interventions should extend from the current hygiene and ergonomic focus and look towards integrating
automated logistics planning, with on-board intelligent vehicle technology.
The design features of forklifts is in many ways is at the heart of many forklift related accidents.
The intersection between the shifting centre of gravity and the narrow track of the forklift,
combined with the requirement to handle loads at height can have detrimental effects on the
vehicle’s stability. Much of the problem lies is in the success of the operator maintaining the
forklifts centre of gravity within the triangle formed by the three suspension points. ―If the centre
of gravity goes out of this area by lifting a load that is too heavy, or by carrying a load too high
and tilted forward, the forklift will tip over‖. (AMIC, 1999)
Our forklift is a powerful tool that allows one person to precisely lift and place large heavy loads
with little effort .Using a tool such as a forklift. Instead of lifting and carrying items by hand can
reduce the risk that you will suffer a back injury.
Forklifts are either powered by gasoline, propane, or electricity. Electric forklifts rely on
batteries to operate. Gasoline or propane forklifts are sometimes stronger or faster than electric
forklifts but they are more difficult to maintain, and fuel can be costly but hand operated fork lift
is the simplest and less costly. Hand operated forklifts are a smart choice if your business needs a
light or medium duty to mount different milling thing at a low price. Their cost-effective and
simple design makes them excellent options for small businesses that need to move heavy weight
at short distance.
Lifting Process in Mill House:- In most mill house the lifting process is difficult. Most of time
this action performed by human force.

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Fig.2.2 .the process of lifting in mill house

Hand Operated Forklift Compare to Other Forklift Machine

Each hand operated fork lift are different but it is has same similarities in function as well as the
materials in which the forklift are lifted. They have their own operating system capacity,
efficiency, operating time, performance, the working space and others, so we can compare each
fork lift.
Based on performance
The performance of lifting which works with compression as a better performance to compare
other system, because when we apply force by using the handle much amount of load will be
lifted, due to multiplying our force by pulley. The performance of hand operated forklift which
will work against gravitational force due to the presence of unlimited force applied on the
system. But hand operated forklift has better control of balance.
Based on capacity
It is difficult to compare each hand operated forklift machine due to the various forms of design.
But the capacity of hand operated forklift which works centrifugal forces is limited.

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 Design of Hand Operated Forklift for Mill 2015
Based on operating system.
The operating systems of hand operated forklift works by applying force first by handle&
multiply the force by pulley then the fork rise upward until required height.
Based on operating system
The operating system of hand operated fork lift which is compare with other works with easy due
to the simplest movement of the handle that is in one direction move up and down with a fixed
angle where as the other systems works by revolving the handle until the lifting material lifted
maximum height.
Based on the cost:
The cost of each hand operated forklift depends on the material types to be constructed. But
when we see generally the cost of hand operated forklift low. but it is not much differ in the
lifting.
Based on operating time:
The operating time of hand operated forklift is very low to compare the other system. Because
the operation is performed with a short period of time by moving the handle..
Design modification
Our design modified from forklift, which work with compression system as shown as we seen at
the previous it has much more disadvantage but we try to solve the problem on it so our design
would be. Comfort for working for milling house, less costly, does not take power working
simply manually, does not need professional worker any one can work by this machine.
The operating system completely change in to a simpler system that is the fork moves up and
down by using a fixed handle arm with available condition due to this the operator enables to do
much work with it relative to the previous design as we can say , we takes more productivity.
The fork and its load do not affect for bending due to special force on its that is equal distribution
of forces (balanced load) applied by moving the handle arm due to the presence of sliding guide
on the two supported (vertical) frame.
New modification:-
The most mill house there is no new design of forklift for lifting heavy load but we saw other
design of forklift such forklift truck ,different hydraulically worked forklift from those previous
modified forklift machine cannot work independently power source, required much space so we
should modify again. The above problems removed by the new modified manual operated
forklift machine.

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 Design of Hand Operated Forklift for Mill 2015

CHAPTER THREE
3. Design Analysis

3.1 Material selection

Shaft:- The material used for shaft is steel(45C8) which have the following mechanical The
material used for shaft should have the following properties:
properties that ultimate tensile (650) M Pa strength ,yielding strength(350)MPa

 It should have high strength

 It should have good machine ability
 It should have low notch sensitivity factor
 It should have good heat treatment properties
 It should have high resistance properties

NUT:- As we know there always a relative motion between screw and nut, which cause a
friction. The friction causes wear if some material is used for screw & nut it will wears both
components. So one out of two has to be softer than other so as to ease of replacement. The size
& shape of screw is costlier than nut, so generally we use softer material for nut than screw.
Phosphor bronze is ideal material for nut which is a copper alloy having 0.2%phospher which
increases tensile strength.
The material used for Nut should have the following properties

 Good corrosion resistance.

 Low coefficient of friction
 Higher tensile strength than copper brass

Handle:-the material we select for handle is the plain carbon steel30C8 ( S y =400N/mm2)
because the plain carbon steel has the following properties.

 It has high strength

 It has high wear resistance
 It has good mach ability

Screw :- The material used for screw is mild steel. It have the following properties

 It should have high strength

 Good machinabilty
 Low notch sensitivity facto
 Good heat treatment property
 High wear resistance property

The material that used to the other components are same as the above.

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 Design of Hand Operated Forklift for Mill 2015
3.2 Geometrical analysis

Fig 3.1 Geometric analysis

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Geometric analysis is the way of analyzing the dimensions of the member of the parts by
standing from the designer’s service of the product, standards, and assumptions. All dimension in
mm.
For hand operated forklift for mill the following assumptions are taken
H max =maximum lifting height =2.2m = 2200mm
H min = minimum lifting height of fork from the ground = 250mm
Direct measurement of sack
Length of sack=0.8m=800mm width of the sack =0.5m=550mm
Assumption L2 =80mm, a = 100mm b =80mm h1 =1m where b=The width of forklift leg
Then the length of the fork (Lf) is depend on the width of sack
Lf = width of sack +clearance=550mm+50mm=600mm
Also assuming that the width of the fork =3/4 length of the sack
=3/ 4(800mm)=600mm
The length of the fork is equal to L1.
L1 =Lf = 600mm
L3 = is depend on length of the handle and also same clearance between the handle
&the vertical frame
L3=Maximum handle length +working space =150mm+70mm=220mm
Then the total length of the fork lift will be LT= L1+L2+L3 + 2d where, d= The distance b/n the
center of wheel to the end of the base which is equals to 50
LT = 600+220+80 +2 × 50=1000mm=1m
The total height of the machine. HT=H Max +a=2.2m +0.1m =2.3m
The total width of the fork lift machine WT=Wf+2b=600+2(80)=760mm
Then calculate the angle between the vertical frame &the rope or tension

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 Design of Hand Operated Forklift for Mill 2015

H=HT – h1=2.3-1=1.3

b= 100mm+200m-50=250mm
𝐨𝐩𝐩 𝐛
tan (𝜽) = =
𝐚𝐝𝐣 𝐡

𝟐𝟓𝟎
= = 0.1923
𝟏𝟑𝟎𝟎

𝜽 = tan-1(0.1923) =10.88

3.3 Force analysis

 Force analysis on fork &fork support

Fig .3.2 free body diagram of Fork

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 Design of Hand Operated Forklift for Mill 2015
MA=W×300

=1KN×300mm

=300KNmm

Fork supporter:- it is moveable by means of rope & pulley the force analysis will be:-

.
F1
MA
F Ay 200
.A
. 50

F2

∑MA = 0

150×F1 +50×F2= 0
300KN
F1= = 1.5kN
200mm

∑FX = 0

F1+F2 = 0 F1=F2

∑F y=0 T-F Ay weight of fork &fork supporter= Wf

Assume that the weight of fork &supporter 100N

T =FAy+ wf

=1KN+0.1KN

=1.1KN

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 Design of Hand Operated Forklift for Mill 2015
Force analysis on rope &pulley

B C TB TC

P P P P

P P P

TA

Fig.3.3. free body diagram rope with pulley

Calculate the tension P that exert at pulley at pulley A. T from the above
analysis TA=T=1.1KN

∑Fy=0 P +P+P-TA =3p =TA

P =T/3= 0.367KN =367N

TB =2P=2(367N)=734N

TC =2P=2(367N)=734N

 Force analysis on shaft

P=367N

RA 300 300 RB

∑FY=0 RA+ RB –P=0

∑MA=0 P×300N-RB×600=0

Substitute the value of p in to equation

367 ×300- RB×600=0

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 Design of Hand Operated Forklift for Mill 2015
RB =183.5N

RA = P-RB

= 367N-183.5N

= 183.5N

Force analysis of frame:-has three parts the upper, vertical frame & base. All three parts are
welded .then calculate the applied load first on the upper frame.

TB+TC

A B

RA RB

From pulley analysis TB +TC are applied by the pulley then, TB=TC=734N

1468N

A B

RA 600 RB

∑Fy=0 1468N-FA –FB =0

RA +RB =1468N……………………………..Eq 1

Bending moment at A ∑MA =0 RB×600-1468×300=0

RB=734N

Substitute the value of RB on equation 1 to get RA

RA = 1468N- 734N

= 734N

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Then, calculate force on vertical frame:-The force F1 can be calculate in the above calculation
(i.e. fork holder force analysis),to calculate the force use F1/2 because the force f1 applied in to
two vertical frame ,also the distance between D&C are consider in the fork during maximum
lifting height.

Fig. 3.4.free body diagram frame

∑FX =0
RD-F1/2 =0 Where F1= 1.5KN from fork holder force analysis

RD= F1/2 =1.5KN/2=750N

∑Fy=0 , RA/2-RD =0 where RA= The load exerted by the upper frame

= 734N but we calculate in the single vertical frame the load

can be divided in to two

RD= RA/2=734 / 2=367N

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 Design of Hand Operated Forklift for Mill 2015
Force analysis on Base (lower frame)

FV is The force exerted by the vertical frame, in one side two vertical fame transmit load to the
base FV1and FV2.

FV1=RD= FV2=367N

∑F y=0 RF+RR-FA-RB= 0 Where ,RB Is the force exerted by the shaft or the reaction
force on the shaft, from force analysis of shaft RB=183.5N

RF+RR=FV1+FV2+RB=367N+367N+183.5N

RF+RR= 917 .5N ………………….eq1

From the geometric analysis L1=600,L2=80 L3 =220

∑MF=0 RR×900-RB×900-FV1×600 – FV2× 680= 0

RR×900=183.5N×900+367N×600+367N×600

RR= 705.46N

Then substituting the value of RR in to equation 1

RF+RR= 917.5N

RF = 917.5N-705.46N

= 212.04N

Therefore the applied force on the front &rear wheel are 212.04N and 705.46N respectively.

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3.4 Design of each components of hand operated forklift machines

3.4.1 Design of shaft

A shaft is a rotating machine element which is used to transmit power from one place to another.
Moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft. In order to transfer the power from one shaft to another, the various members
such as pulleys, gears etc, are mounted on it. These members along with the forces exerted upon
them causes the shaft to bending .In other words, we may say that a shaft is used for the
transmission of torque and bending moment. The various members are mounted on the shaft by
means of keys o spines. The material used for ordinary shafts is carbon steel of grades 40 C 8, 45
C 8, 50 C 4 &50 C12.The mechanical properties of these grades of carbon steel are given in the
following table. (2)

Indian standard designation Ultimate tensile strength ,MPa Yield strength, MPa
40 C 8 560 – 670 320
45 C 8 610 – 700 350
50 C 4 640 - 760 370
50 C12 700 Min. 390

Table .3.1 Mechanical properties of steels used for shafts [2]

 The material used for shaft is steel(45C8) which have the following mechanical
properties that ultimate tensile (610-700)MPa strength ,yielding strength(350)MPa
because it have high strength good mach inability low notch sensitivity factor ,have good
heat treatment properties &high wear resistance properties.

367N

300 mm 300 mm

RA RB
From force analysis RA = 183.5N, RB=183.5

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Let find its shear force and bending moment diagram.
At section AC:-

X1 V
M1
183.5N

∑Fy=0 V=183.5N
∑MA=0 (183.5N)X1=0 M1@0.3=0.3× 183.5N=55.05N

Section CB 367N

V2 M2

183.5N X2

V=367N-183.5N=183.5N
∑M2=0 183.5x2 -367(x2 – 0.3)=0
-183.5x2 +110.1 =0 , x2=0.6m
M2@x2 =06 = 0

Fig .3.5.bending moment diagram for shaft

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Maximum bending moment is 110Nm&Torque is radius time force
T= r× F = 200mm× 50N=10000Nmm
T et= ((𝑀𝑏)2 + 𝑇 2 ) where:- d =diameter of shaft

𝝅×𝒅𝟑 𝝉
= ((110100)2 + 100002 ) τ:-= shear stress of the shaft
𝟏𝟔
τ = 42Mpa
d=25mm Therefore the diameter of the shaft is equal to 25mm.

3. 4. 2 Design of wire rope

When a large amount of power is to be transmitted over long distances from one pulley to
another (i.e. when the pulleys are up to 150 meters apart), then wire ropes are used. The wire
ropes are widely used in elevators, mine hoists, cranes, conveyors, hauling devices and
suspension bridges. The wire ropes run on grooved pulleys but they rest on the bottom of the
grooves and are not wedged between the sides of the grooves. The wire ropes are made from
cold drawn wires in order to have increase in strength and durability. It may be noted that the
strength of the wire rope increases as its size decreases. The various materials used for wire
ropes in order of increasing strength are wrought iron, cast steel, extra strong cast steel, plough
steel and alloy steel. For certain purposes, the wire ropes may also be made of copper, bronze,

Advantages of Wire Ropes

The wire ropes have the following advantages as compared to fiber ropes.
1. These are lighter in weight, 2. These offer silent operation,
3. These can withstand shock loads, 4. These are more reliable,
5. These are more durable, 6. They do not fail suddenly,
7. The efficiency is high, and 8. The cost is low
The following procedure may be followed while designing a wire rope.
1) Selection of a suitable type of rope from a table displaying the standard designation of
ropes and their application

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Standard designation Application

6 × 7 rope It is a standard coarse laid rope used as haulage
rope in mines,
Tramways, power transmission.
6 × 19 rope It is a standard hoisting rope used for hoisting
purposes in mines,
quarries, cranes, dredges, elevators, tramways,
well drilling
6 × 37 rope It is an extra flexible hoisting rope used in steel
mill ladles,
Cranes, high speed elevators.
8 × 19 rope It is also an extra flexible hoisting rope.

Table.3.2.Standard designation of ropes and their applications [2]

2. Find the design load by assuming a factor of safety 2 to 2.5 times the factor of safety n
obtained from table of wire rope applications
Application of wire rope Factor of safety
Up to 150 m 8
300 – 600 m 7
600 – 900 m 6
over 900 m 5
Miscellaneous hoists 5

Table 3.3. Factor of safety for wire ropes [2]

3. Find the diameter of wire rope (d) by equating the tensile strength of the rope selected to the
design load.
4. Find the diameter of the wire (dw) and area of the rope (A) from the table below

Type of wire 6× 8 6 × 19 6 × 37 8 × 19
rope
Wire 0.106 d 0.063 d .045 d 0.050 d
diameter(dw)
Area of wire 0.38 d2 0.38 d2 0.38 d2 0.35 d2
rope(A)

Table.3.4. Diameter of wire and area of wire rope [2]

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5. Find the various stresses (or loads) encountered by the rope such as direct and bending stresses
as well as stresses the effective stresses (or loads) during normal working, during starting and
stopping, and during acceleration of the load.
6. Now find the actual factor of safety and compare with the factor of safety obtained in step 2. If
the actual factor of safety is within permissible limits, then the design is safe.
Analysis of Wire Rope Design
1. Since the intended application was for the making of elevators, rope type selected was a 6X19
kind, i.e. 6 strands, each strand consisting of 19 ropes. The strands are wound around a flexible
core made of asbestos. The wires are made from cold drawn alloy steel for high strength and
durability

Type of rope Nominal Average Ultimate tensile strength (N)

diameter weight Tensile strength of wire
(mm) weight (N/m) 1100–1250 1250–1400
(MP a) (MP a)

6 × 19 6, 8,10,12,14, 0.0383 d2 385 d2 435 d2

16, 19,22, 25

8 × 19 8,10,12,14,16 0.034 d2 355 d2 445 d2

18, 20, 22, 25

Table 3.5 Steel wire suspension ropes for lifts, elevators and hoists [2]

2. Design load is determined by first extracting from the table a suitable factor of safety of n = 8
and multiplying it with 2
N = n * 2 = 8 * 2 = 16
Hence, the design load on the wire will equal the heaviest possible weight to be supported by the
wire times the new factor of safety:
W = N * W = 16* 1 KN = 16 KN Where W = weight of load
3. Rope diameter was determined by using the equation relating wire tensile strength to rope
diameter specific to 6X19 type from the table above:
By selecting rope grade of 1,400Mpa wire, the diameter of the rope is found as:
4350d2= 16000 N
d= 6 mm from the table above the nominal diameter is 6
4. From table (step 4) the wire diameter and the area of rope are given respectively as:
Where, dw = wire diameter; A = cross-sectional area of the rope; d = rope diameter
Therefore,
d w= 0.0383d = 0.0383 * 8mm = 0.228mm
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A = 0.38d2= 0.38 * (6)2 = 13.68mm2

Sheave or Pulley Selection

For the 6X19 type rope selected, the application being for elevator, the sheave diameter is given

Type of wire Recommended sheave diameter (D) Uses

Minimum sheave Preferred sheave
diameter diameter

6×7 42d 72d Mines, haulage

tramways
6 × 19 30 d 45d Hoisting rope.
6 × 19 20d 30d Derricks, dredges,
elevators, tramways,
well drill

Table3.6. Sheave diameters (D) for wire ropes [2]

D=20d D = 120mm r = 0.53d= 4.24mm

Fig 3.6.pulley for winding rope

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Fig .3.7.wire rope sheave rim [2]

r1 = 1.1d = 8.8 mm
a = 2.7d = 21.6 mm
b = 2.1d = 16.8 mm
c = 0.4d = 3.2 mm
h = 1.6d= 12.8 mm
l = 0.75d = 6 mm

5. Stresses on the rope:

A. Direct stress due to axial load lifted and weight of the rope itself:

𝛿 d = (WL + W r) / A
Where
σ d= direct tensile stress induced on rope;
WL= Carried load rope = weight of the rope
A = cross-sectional area of the rope

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B. Weight of the rope is obtained using the relation from table (step 3 analyses) as:
W r =0.0383d2× L =0.083 × 36L=2.988LN/ m
Length =2m
W r = 2.988N/m×2m=6N
Er ×dw
𝛿b = D
Where
Er = Modulus of elasticity of the wire rope,=84kN/mm2
d w = Diameter of the wire,
D = Diameter of the sheave or drum, and
A = Net cross-sectional area of the rope

Er ×dw 84× 103× 0.228

δb = = =106.4N/mm2
D 180mm
and the equivalent bending load on the rope,
W b = σ b × A = 106.4N/mm2 × 13.68mm2 = 1455.55 N
We know that the impact load during starting (when there is no slackness in the rope),
W st = 2 (W + w) = 2(1000 + 6) = 2012 N
C. We know that the effective load on the rope during normal working (i.e. during uniform
Lifting or lowering of the load) = W + w +W b =1000 + 6 + 1455.55=2461.55N
Actual factor of safety during normal working
D. Effective load on the rope during starting
W st + Wb=2012+1455.55=3467.55N
Actual factor of safety during starting

16000
=5
3467 .55

 Since the actual factor of safety as calculated above are safe, therefore a wire rope of
diameter 6 mm and 6 × 19 type is satisfactory [2]

3.4.3 Fork Design

Material selection: from standard table A-20 of shigely’s steel selected for fork.

Processing=hot rolled (HR)

Tensile strength=300MPa
Yield strength=100MPa
Brunel hardness=86 Source: 1986 SAE Handbook, p. 2.15. [7]

For more loading condition and lifting tolerance, the safety factor should be𝑛 = 5.

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δy= Sy=100MPa, n=5

δall = δy / n

=100/5

=20Mpa

Fig .3.8 .fork

Cross-sectional area A= w * t=0.1t

Where, w=fork width

t=fork thickness at the end (where maximum load is applied)

The maximum load (F max)= m max*g=1000kg × 9.81m/s2

Where, m max= maximum load

g =gravity or acceleration

Then, F max/2 is the load at each fork, because the fork acts on support reaction for the load.

F max

But when I consider the system, the mass of the load isn’t concentrated and balanced. It can
center at one end of the body. Therefore to lift this type of mass concentrated body, it should be
both end have the ability to lift the mass with balance. F max Should be applied at each fork.

F max =1KN

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F max F max 1KN
δ all= ,A= = =0.0008m2
2A 2 δ all 2×20×106

Then, A=W× t , t =A/ w =0.0008m2/0.08m = 0.01m

This is because for more lifting performance and initial height the fork should have tapered to the
thickness of almost zero and the bend at the end of the horizontal flat surface should have an
angle of 𝟗𝟎°to the vertical support holder part of the fork, that is upper flat horizontal surface of
the fork is 𝟗𝟎° with that of the vertical part of the for

Fig.3.9. dimension of Fork

𝜃 t1 t =10

50

150

𝜃 5
tan =
2 150

𝜃
= tan−1 (0.033333)
2

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𝜃
= 1.9°
2

𝜃 = 3.8°

The calculate the thickness of the fork at end, t2

𝜃 𝑡2
tan =
2 50

t2
0.0333 =
50

t2 =2mm

t=10mm therefore it can lift perfectly with good durability and strength.

Bending moment diagram for fork

Fig 3.10.free body diagram for fork

The maximum bending moment is at the fixed point A.

M max =1000N× 300mm=300000Nmm

1000N

Mb

M=300000Nmm
Fig 3.11 .bending moment diagram for fork

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3.4.4 Design of fork holder
Material selection: from standard table A-20 of shigely’s steel selected for fork holder.
Tensile strength=300MPa
Yield strength=100MPa

Fig .3.12.fork holder

Depend on the fork width with the clearance h=650mm. assume, b=30mm,t=3mm
From the force analysis F1=F2=1.5KN AND MA=300KNmm
The maximum bending moment is at point A.
M ma x =1.5kN∗150mm
=225kNmm=225Nm
3 b1h13
bh
I xx = 12 – where, b1=b-2t h1= h-2t
12
b1 = 30-10=20mm
h1 = 650-10=640mm
30∗650 3 − 20∗640 3
I xx = =0.249∗10-3m4
12
M max ∗y 225Nm ∗0.325m 293.675N
δ b= = = =0.293Mpa
𝐈xx 𝟎.249∗ 10 −3 m 4 10 3
δ b≪ δ b max (300Mpa) therefore our design is safe‼

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Design of shaft for fork holder
The fork holder have two shaft that shafts are fixed on the fork holder in the above calculation
the force exerted on the shaft holder in one side is equal to 1.5kN.
P1 +P2= 1.5N
P1=P2=750N

Fig .3.13.shaft for fork holder

∑F y =0 P1 + P2 =F1 +F2
F1 +F2 =1.5kN

∑ MA =0 , F2∗ 700-P2 ∗ 675-P1 ∗ 25=0

P2 ∗ 675+P1 ∗ 25 750∗700
F2 = = =750N
700 700

c 650 D

A B
700
MA =MB=0

V1 Mc V1 = F1=750N

F1
M max=18750Nmm

𝛿 b =M max

MC=F1∗x= F1∗25 = 750N∗25= 18750

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P1
25 x MD

F1
MD = P1(x -25)- F1∗x = 750(700 -25) - 750∗700

= -18750N

Fig.3.14.bending moment diagram for shaft for fork holder

M max=18750N
M max ∗y
δ b= y=d/2 Iyy = 𝜋d3/64 [2]
𝐈yy

take the factor of 3 δ b/f.s =116.66N/mm2

18750 Nmm ∗32
116.66N/mm2 =
d2

18750 Nmm ∗32

D= = 19mm
116.66N/mm 2

M max ∗y 18750 ∗32

δ b= = =116.94≡ 117N/mm2
𝐈yy 𝛑∗𝟏𝟗𝟑

Therefore δ b ≪ δ b(max)(360Mpa) therefore the design is in safe limit . f.s= 300/117 =2.56

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Roller:-The roller is mounted to the shaft that shaft is fixed to the fork holder .the roller is used
to transport the fork up& down ward by the means of rolling .The roller has two parts in our
condition rings &bearing, the purpose of ring is to increase the life of the bearing.
Assumption
d= bearing outer diameter +clearance
Let the thickness t=3mm
From above calculation shaft diameter equals to 19 mm, then the bearing diameter equals to
20mm.
From table 3.10 outer diameter of bearing equals to 52mm, also width equals to 14mm.
Roller diameter = d+ t
=52+2+4
=58mm

Fig .15.roller

3.4.5. Design of screw

A screw thread is formed by cutting a continuous helical groove on a cylindrical surface. a screw
made by cutting a single helical groove on the cylinder is known as single threaded (or single-
start) screw and if a second thread is cut in the space between the grooves of the first, a double
Threaded (or double-start) screw is formed similarly, triple and quadruple (i.e. multiple start)
threads may be formed. The helical grooves may be cut either right hand or left hand.
a screwed joint is mainly composed of two elements i.e. a bolt and nut. the screwed joints are
widely used where the machine parts are required to be readily connected or disconnected
without damage to the machine or the fastening. This may be for the purpose of holding or
adjustment in assembly or service inspection, repair, or replacement or it may be for the
manufacturing or assembly reasons
the material we select for screw is mild steel which has the property δ t =100MPa & τ = 50MPa

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Table3.7. Dimension of square threads [2]

The applied force on the screw is F=µN Where

N= the weight of the sack, N=1KN
µ= Coefficient of between the puller and the fork
µ is 0.16 to 0.4(for dry lubrication sliding friction)

The load on the screw,

F = 0.4(1KN) = 400N
F = 𝜋/4 ∗dc2∗δt
400 = 𝜋/4 ∗dc2 ∗100∗ 106
4× 400N
dc2 = = dc= 7.25 say 9 mm
𝜋×100 N/ mm
Since the screw also subjected to tensional shear stress, therefore to account for this , let us
adopt.
dc =14mm
Nominal or outer diameter of the screw do= dc + p = 14mm +6mm =20mm
Mean diameter d=do – p/2 = 20-6/2 =17mm
Then calculate the applied load on the leaver (i. e, p L) and efficient

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p
F

L
PL
Fig 3.16.force on power screw

Applied torque =p L× L

Effective torque =p L×r

p=F tan (𝛼+ ∅) to push the load of the thread [ 8]

Where, F=Horizontal load on the screw

P L= Force applied on the screw

P = net force applied

R = mean radius of screw

P = pitch of the screw

α = angle of the tread

∅ = angle of friction between the fixed nut p & the screw

µ=0.15 then tan (∅ )=0.15 ∅=tan-10.15=8.5o

tan (∅) =p/ 2𝝅r =6/ 2𝝅 (8.5mm)=0.1123= α=6.4o

p=400N × tan (6.4o+8.5o) =106.43N

P2L=P1 r Assume that L = 50mm

𝟏𝟎𝟔.𝟒𝟑𝐍∗𝟖.𝟓𝐦𝐦
p2 = = 18N
𝟓𝟎 𝐦𝐦

Work out put=F× P Work input=p2×2 𝝅 ×L

𝐅𝐫𝐭𝐚𝐧(𝛂) 𝟒𝟎𝟎×𝟔
η= = = 45 %
𝐏𝟐∗𝐋 𝟏𝟖𝐍×𝟓𝟎𝐦𝐦×𝟐 × 𝝅

Shear stress in the screw due to torque

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τ =16T/ 𝜋 dc3 T =P×d/2 where T=torque required to rotate the screw
=106.43×8.5 d =nominal diameter
d c = 14mm
16×904.66Nmm 14474 .48
τ= = = 1.679N/mm2
𝜋 (14mm)3 𝜋 (14mm )3

We know that direct tensile stress in the screw

δ t = F/ 𝜋 (dc)2
400N
= (𝜋 /4)(14mm )2 = 2.6mpa

Maximum principal (tensile) stress.

δ t(max) = δ t/2 +1/2 δt 2 + 4τ2

= 2.6mpa/2+1/2 (2.62 + 4(1.764)2)

= 3.135Mpa

Maximum shear stress τ max=1/2 δ t 2 + 4τ2

=1/2 (2.62 + 4 ∗ 1.6742 ) =1.835Mpa

Therefore the maximum stress is within safe limit therefore the design of square threaded screw
is satisfactory

3.4.6. Design of nut

The material of the nut is Phosphor Bronze.

Phosphorus increases strength and ductility of casting.

Properties of Phosphor Bronze;

Yield stress in tension, σ yt = 126MPa

Yield stress in compression, σ yc = 112MPa

Yield stress in shear, τy = 105MPa [8]

Let n = Number of threads in contact with the screw (i.e. square threaded rod).
Assuming that the load F is distributed uniformly over the cross-sectional area of the nut,
therefore bearing pressure between the threads ( pb )

The bearing pressure is-

p b = 10MPa Factor of safety = 2

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F = π/4 (do2- dc2)* p b×n ……. n= number of thread
4∗400N
n= = 0.25
π(20 2 −14 2 )∗10

but the minimum number of thread in contact must be 4,

The height of the nut will be

h = p*n

= 6*4 = 24mm

The width of the nut (b) is taken as 1.5do.

1.5×20mm=30mm

The nut threads are subjected to crushing &shear, to cheek whether crushing is expected or not.
4×F 400×4
δc = = = 0.625Mpa
π (DO 2_ DC 2 )n π (20 2 −14 2 ) ×4

δc << δCy(112Mpa)

From the above result, crushing is not expected because crushing stress much smaller than the
bronze yield stress at compression.

Checking stress strength of nut

F = τ π don t

t=6/2 = 6/2 = 3

𝜏 = F/π do n t fig.3.17.nut

= 400/π*17*6*8

= 2.65MPa < τall = 52.5MPa

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Therefore the nut is quite safe!

Puller

The Puller in our in our design used to push the load to the horizontal direction by means of
screw ,the nut mounted in the puller at the center .the material of puller is steel fe E 250
(Syt=250N/mm2) the force acting on the puller is distributed .factor of safety equal to four

b= 50mm f. s =4

From screw design F=400N

∑Fy=0 W∗ x =w=F/ x =400/600mm=666.7N/mm

The bending moment at section y-y

0<x<300 ∑Fy=w∗x- v=0

V=w∗x

V max =w∗x max =666.7(300mm/1000)

Mb=w∗x∗x=wx2 where ,0<x<300 at x=0 Mb=0

At x=300mm Mb =666.7N/m∗0.32m2=60Nm=6000Nmm
hb 3 h50 3
I= = = 10416.67 h mm2
12 12

250N/mm 2
δ t =S yt / f.s= =62.5N/mm
4

Mb∗y 60000 Nmm ∗150mm 432N/ mm

δb= = =
I 10416 .67 h mm 2 h

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432N/ mm
h = 62.5N/mm2 =7mm

δb≪ δb(max)(250Mpa) therefore the design is in safe limit‼

3.4.7. Design of handle

The handle is subjected to bending moment. The force exerted by workers on the handle
is given and as will have selected the material from material selection. Plain carbon steel of
Grade30 C8 (Syt =400N/MM2)is selected. Since the material have the following properties:-

 Preventing from bending of material or has higher strength.

 It protects corrosion
 It absorbs sheet loads
 It cheap in cost

Material –plain carbon steel Grade30C8 =400N/mm2

Fig .3.18.handle

When the workers are at work, there is inconvenience and the resultant force is less than twice
the individual force. A coefficient of 0.9 is assuming in this case to account for reduction in force
to inconvenience. Therefore, total hands force exerted on the handle by workers (p) is given by,

P = (0.9× 1 × F)

The diameter of handle (d) is obtained from bending considerations. It is assumed that the effort
(p) applied on the handle acts at 2/3 rd it length.

The force exerted by the workers on the handle is given by:- F=145N

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P exerted = 0.9× 1 × 145𝑁

=130.5N

Therefore maximum bending moment (M):

M = P× 2/3 × 𝑙

= 130.5𝑁 × 2/3 × 300𝑚𝑚

= 26100N mm
𝜋
Section of modulus Z = × 𝐷h
32

𝜋
Resisting of moment =𝛿 b× 𝑍= δ× 32 × 𝐷h

Therefore equating the resisting moment :- then we find handle diameter

𝜋
δb × × (Dh)3 =2/3× p × L
32

3 2×𝑝×𝐿×32
Dh= Where L – length of the handle
𝜋𝛿𝑏

δ b :-is permissible bending stress for material of handle

Syt =400N/ mm2

D h - diameter of the handle [2]

3
32×29580Nmm
Dh = 3
80N/mm 2 ×π

3
Dh = 3766.242573𝑚𝑚3

Dh = 15.558𝑚𝑚

= 16mm

A chain drive is consists an endless chain wrapped around the two sprockets. Chain can be
The diameter of handle is 16mm

Locking mechanism

Locking mechanism is advice that is used to operate to lock or unlock. Atypical locking is a
small pieces of metal consisting of two parts of the blade which slides in the way of the lock.

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When the shaft is rotate in clockwise direction the locking mechanism is used to not return to
back. The blade is fixed on the shaft &the pine is mounted to frame.

3.4.8 Design of Chain Drives

Defined as a series links of links connected by pines or joints .the sprocket is the toothed wheel
with special profile for the teeth. The chains are mostly used to transmit motion and power from
one to another, when the centre distance between their shafts is short such as in bicycles, motor
cycles, agricultural machinery, conveyors, rolling mills, road rollers etc.
Type of chains is Roller Chains. Many manufacturers offer high-strength, extra clearance,
Sintered metal bushing, sealed-joint, and corrosion-resistant chains for Special applications or
adverse environments. And material types are steel. First of all, determine the velocity ratio of
the chain drive. The velocity ratio is 3.
Select the minimum number of teeth on the smaller sprocket or pinion from Table

Types of Number of teeth at velocity ratio

Chain 1 2 3 4 5 6
Roller 31 27 25 23 21 17
Silent 40 35 31 27 23 19

Table 3.8. Number of teeth on the smaller sprocket [2]

Note: The numbers of teeth on the small sprocket a chain drive a small number of teeth tend to
make the drive noisy a large number of teeth makes chain pitch small which is favorable for
keeping the drive silent and reducing force centrifugal and friction force.
We select the silent chain medium speed by the principle of the following diagram
Number of Sprocket Teeth

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Small sprocket usually is the driver. The minimum number of teeth on the small sprocket is
limited by the effect of chordal action (speed variation).lower speed with tolerate chordal action
higher speeds. The minimum recommended number of teeth on the small sprocket is

Slow speed 12 teeth

Medium speed 17 teeth

High speed 25 teeth

The smallest teeth number is 19. next Find the number of teeth on the larger sprocket.

T2=T1*N1/N2
T2=17*(31/25) =21.08 =22
Where the T2 is the largest teeth number. We know that the design power
= Rated power × Service factor (K S )
The service factor (KS) is the product of various factors K1, K2 and K3. The values of these
factors are taken as follows:
Load factor (K1) for variable load with heavy shock = 1.5
Lubrication factor (K2) for drop lubrication =1
Rating factor (K3) for 16 hours per day = 1.25
∴ Service factor, KS = K1.K2.K3 = 1.5 × 1 × 1.25 = 1.875
And design power = 0.25 × 1.875 = 0.468 kW from the standard
Choose the type of chain, number of strands for the design power and r. p.m. of the smaller
Sprocket from Table 3.8

Table 3.9. power rating (in Kw) of simple roller chain[2]

Note down the parameters of the chain, such as pitch, roller diameter, minimum width of

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Roller etc. from Table the code number is 06B

Table.3.10.Characteristics of roller chains according to IS: 2403 — 1991[2].

Find pitch circle diameters and pitch line velocity of the smaller sprocket. The pitch
9.525mmRoller diameter, d = 6.35 mm
Minimum width of roller, w = 5.72 mm
Breaking load, WB = 8.9 k N = 8.9 × 103 N
We know that pitch circle diameter of the smaller sprocket or pinion,
d1= p*cosec (180/T1)
= 9.525cosec (180/17)
= 51.84mm
And pitch circle diameter of the larger sprocket or gear
d2 = p*cosec (180/T2)
= 9.525*cosec (180/22 = 66.93mm
Pitch line velocity of the smaller sprocket,
π∗d1∗N1
V1 =
60
= 0.27 m/s
Rated power
Load on the chain, W=
Pitch line velocity

= 250W/0.27
= 0.925kN
The minimum centre distance between the smaller and larger sprockets should be 30 to 50 times
the pitch. Let us take it as 30 times the pitch.

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X2 = (10002+3502)
350 X = 1060mm=1.06m

1000 x

In order to accommodate initial sag in the chain, the value of centre distance is reduced by 2 to 5
mm.Correct centre distance.
X=1060- 4 = 1056mm
We know that the number of chain links
𝑇𝐼+𝑇2 2𝑥 𝑇2−𝑇1 2
K= + +( ) p/x
2 𝑝 2𝜋

=242mm
Length of the chain is L = k*p
= 242*9.525 = 2305.mm = 2.305m

3.4.9. Frame design

We select mild steel used for designing frame of forklift. The mild steel has the following
properties. Maximum tensile stress (σ) = 360MPa

Maximum shear stress (τ) = 242.24Mpa

3.4.9.1 Vertical frame

Fig.3.19. for vertical frame

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Maximum bending moment at the fixed point is equal to
M max = 750N × 1900mm= 1425Nm
t ∗b 3 t ∗80 3 t ∗0.08 3
IXX= = =
12 12 12
y= b/2 =80mm/2=0.04m
M max ∗y 1425 ∗0.04∗12 1335437 .5
δ b= = =
Ixx t(0.08)3 𝑡
syt
δb = =360Mpa/3=120×106Nm
𝑛
1335437 .5
t= =10.5mm
120𝑀𝑝𝑎

10.5mm ∗(80mm )3
I XX = = 448000mm
12
M max ∗y 1425000𝑁𝑚𝑚 ∗ 40mm
δ b= = =120Mpa
Ixx 448000 mm 4
δb≪δmax (350Mpa) therefore our design is safe‼

3.4.9.2 Upper frame

From the force analysis, RA, RB&T will be
RA=734N ,RB=734N T=1468N
Bending moment at
Section AB:-
V M1
X1
∑F y =0 V1=734N
∑MA=0 V1x1 = 734N ∗ 0.3 = 220.2Nm
At section BC
1468N
C V2
M2
RA X2 =600mm

∑F y = 0, RA+V2-1468=0 V2 =734N
M2 =RA∗x2-1468(x2-0.3) , x2 =0.6m
M2 = - 220.2Nm

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Then maximum bending moment

M max=220200 N mm, let b =70mm, h=8mm
hb 3 8∗70 3
I yy= = =228666.67mm4
12 12

Mmax ∗𝑦 220.2Nm ∗70/2

δ b= = =33 .93Mpa , y=h/2
Ixx 228666 .67
δ b≪ δmax (350Mpa),there fore the design will be under safe limit

Fig .3.20 .The bending moment diagram for upper frame

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3.4.9.3 lower frame ( base)

From force analysis Fv1=Fv2 =367N, RB=183.5 ,RF=212.04, RR=705.46

L1=600, L2=80, L3=220
Bending moment analysis at
Section FD
V1 Mb
RF X

∑F y=0 RF – V1=0 V1 = 212.04N

Mb = R f ∗ x 0 ≤ 𝑋 ≤600
Mb =212.04𝑁 ×600mm = 127224Nmm =127.224Nm

Section EG
FV1
V2 Mb
RF 600 X

∑F y=0 RF –FV1-V2=0
V=212.04 - 367=0 V= -154.96
Then the direction of v is up ward
Mb = R F × X – FV1(X-600) at x= 680
=212.04×680 – 367(680-600) = 114827.2=114.827Nm

Section GR
FV1 FV2
600 80 v2 Mb
RF x1

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∑F y=0 RF –FV1 –FV2 - V2=0
V=212.04 – 367-367 =0 V= -521.96
Then the direction of v is up ward
Mb = R F × X 1– FV1(X1-600) – FV2(X1-680) 0 ≤ X1 ≤900
Mb = 212.04 × 900– FV1(900-600) – FV2(900-680)
=0 367N 367 N 705.46 N

183.5N
212.04N
127.224Nm
114.827Nm

0
Fig 3.21 bending moment diagram for lower base
M max = 126153.5Nmm
= 126.15Nm y
M max ×y/2
𝛿b = , y=b/2
Ixx
t tt t h
y
b h=30mm
b= 80 mm
I yy = t/6(b3+ht2 – 2t3) [2]
Let the thickness of the base t=3mm
= 3/6(803+30(30)3-2(3)3)
=1/2(512000+810-54) =256378mm4
M max ∗y/2 127224Nmm∗ 40mm
𝛿b = = = 19.85N/mm2
Ixx 256378 mm 4
𝛿 b≪ 𝛿 b(max) =350N/ mm2 then we use the of the frame for base ,t= 3mm

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3.4.9.4 Design of welding
Welding can be define as a process of joining metallic part by heating to a suitable temperature
with or without the application of pressure .A welded joint is a permanent joint which is obtained
by the fusion of the edges of the two parts to be joined together, with or without the application
of pressure and a filler material. The heat required for the fusion of the material may be obtained
by burning of gas (in case of gas welding) or by an electric arc (in case of electric arc welding).
The latter method is extensively used because of greater speed of welding. Welding is
extensively used in fabrication as an alternative method for casting or forging and as a
replacement for bolted and riveted joints. It is also used as a repair medium e.g. to reunite metal
at a crack, to build up a small part that has broken off such as gear tooth or to repair a worn
surface such as a bearing surface .
If a permissible shear stress in the weld is limited to 75Mpa
Welding design for vertical frame with base
p=F1/2 =750N…… From Force analysis of frame
τ max =75Mpa =75 N/mm2
L=80mm Where L=Weld length Which is equal to the width of vertical frame.
e =1900mm
S= size of the weld
t=throat thickness
The joint is subjected to direct shear stress and the bending stress ,we know that the throat area,
A for rectangular flat weld,
A=t (2t) =0.707s (2×80) =0.707(160)s
=113.12smm2
Direct shear stress ,τ = p/A=750N/ 113.12 ×s= 6.63 / S N/ mm2
We know the bending moment
M=p×e =750N×1900=1425000 =1.425× 106Nmm
We find section modules z=tL2/ 3 from table
=802t/3=3333.33t
1.425× 10 6 Nmm
Therefore bending stress δ b =M/Z = = 604.67 / s N/ mm2
3333 .33(0.707s)
Therefore maximum shear stress (τ max)
τ max =1/2 𝛿𝑏 2 + 4𝜏 2 = 1/2 (604.67/𝑠)2+ 4(6.63/𝑠)2 [ 2]
75N/mm2 = 302.346N/mm/s
302.346 N/mm
S=
75N/mm 2
= 4 mm

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Fig .3.22. fillet weld

3.4.12. Selection of bearing

Bearing must be selected based on its load carrying capacity, life expectancy and reliability , the
requirement of the situation and the characteristics of different types of bearing .for low &
medium radial lodes, A ball bearing are used ,whereas for heavy loads &large shaft diameters
roller bearing are selected. After analysis the different types of bearing we have decide to select
ball bearing.

Bearing NO. Bore(mm) Outside diameter Width(mm)

200 10 30 9
300 35 11
201 12 32 10
302 37 12
202 15 35 11
302 42 13
203 17 40 12
303 47 14
403 62 17

204 20 47 14
304 52 14
404 72 19
205 25 52 15
305 62 17
405 80 21
Table .3.11.for standard dimensions for radial ball bearing Ball bearing [2]

The bearings should be well lubricated in during operation in order to:-

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 To reduce friction and wear
 To prevent rusting or corrosion
 To dissipate the heat

Fig .3.25.roller bearing

3.4.12. Design of Wheel

A wheel:- is a circular component that is intended to rotate on an axial bearing. The wheel is one
of the main components of the &which is one of the six simple machines which allow heavy
objects to be moved easily facilitating movement or transportation while supporting a load, or
performing labor in machines. Wheels are also used for other purposes, such as a ship's wheel,
steering wheel, potter's wheel and flywheel. Common examples are found in transport
applications. A wheel greatly reduces friction by facilitating motion by rolling . In order for
wheels to rotate, a moment needs to be applied to the wheel about its axis, either by way of
gravity, or by the application of another external force or torque.As stated in the design
parameter section the wheel needs to be adjustable for different direction, So that in mill house
there is enough space to a just the forklift to side to side &forth and back direction . the
minimum lifting of the lifting machine is 250 then the diameter of the wheel can be calculated as
follows.

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Fig 3.26.wheel

d= H m-(H f + c1+c2+c3+t) where :-

H m= minimum lifting height

H f = base height

c1 = clearance b/n the fork &the base during minimum lifting.

c2 = clearance b/n the base & the wheel supporter

c3 = clearance b/n the wheel supported & the wheel

t = thickness of the wheel supported

Assumption:- c1=10mm

c2 =3mm

c3=3mm

From the above calculation the base height H f = 30mm

d=250-(10+3+3+4) =200mm Therefore, the diameter of the wheel will be 200mm the
width of the wheel will be equal to 40m

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Results:-
The following are basic results:-

 The load that apply on the handle during statics

T =FR × r………………… (1)
T=FH∗L……………………. (2) Where
Fr =load that exert by trope
FH =load exerted by human
r = radius of the shaft
L = length of the handle
The equating two equation we get
FR × r = FH∗L from force analysis
367𝑁
FR= 𝐶𝑂𝑆 12.8° =376N
From the above design of shaft & handle l
L=200mm& r =12.5mm
376N∗12.5mm
FH = = 23.5N
200mm
 The number of revolution of shaft to move the load upward maximum lifting
height(L)=2m
From the rotation =𝜋(d+d1/2)
= 𝜋(0.025+0.003) where d=the diameter of the shaft
= 0.088mm d1= the diameter of the wire rope
Then calculate the revolution of shaft 2m length of the wire rope
1 revolution= 0.088m
? = 2m
2m∗1 rev
=23 rev
0.088m

Therefore the r evolution of the shaft is equal to 23rev.

 The required force to rotate the power screw is equals to 18N.

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3.5. Manufacturing process
Primary shaping processes:-
The processes used for the preliminary shaping of the machine component are known as primary
shaping processes. The common operations used for this process are casting, forging, extruding,
rolling, drawing, bending, shearing, spinning, powder metal forming, squeezing, etc
Machining processes. The processes used for giving final shape to the machine component,
The following are the various manufacturing processes used in Mechanical engineer.
according to planned dimensions are known as machining processes. The common operations
used for this process are turning, planning, shaping, drilling, boring, reaming, sawing, broaching,
milling, grinding, hobbling, etc.
Surface finishing processes. The processes used to provide a good surface finish for the
machine component are known as surface finishing processes. The common operations used for
this process are polishing, buffing, honing, lapping, abrasive belt grinding, barrel tumbling,
electroplating, super finishing ,sheradizing, etc.
Joining processes. The processes used for joining machine components are known as joining
processes. The common operations used for this process are welding, riveting, soldering, brazing
, screw fastening, pressing, sintering, etc.
Processes effecting change in properties. These processes are used to impart certain specific
Properties to the machine components so as to make them suitable for particular operations or
uses. Such processes are heat treatment, hot-working, cold-working and shot peening.
Manufacturing process wire rope:- The wires are first given special heat treatment and then
cold drawn in order to have high strength and durability of the rope. The wire ropes are made
from cold drawn wires in order to have increase in strength and durability. It may be noted that
the strength of the wire rope increases as its size decreases.
Manufacturing process of pulley:-pulley can be manufactured by sand & molded casting.
Manufacturing process shaft:- the manufacturing process of the shaft can be manufactured by:
 Hot rolling
 Finished to size by cold drawing .
 Cutting the row material
 Turning first grinding
 Turning the second grinding
 Profile – spherical
 Heat treatment
 Cylindrical grinding
 Finally inspection
Manufacturing process of screw
Machining:-The machine method works for small screws or screws with unique designs. A
device called a mechanical coil feeds straightened wire into a mechanism called a cold head
machine, which cuts a piece of wire to a certain length This part of the process also performs the
screw heads on screw blanks. Screws blanks go into a die, called a head-slotting machine; the

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machinery fastens the blanks into channels positioned around the perimeter of a wheel on the
head-slotting machine. As the wheel revolves, a circular cutting device slots the screws.
Thread Rolling:-Manufacturers use one of three thread rolling techniques for cutting blanks
screws. A vibrating hopper feeds screw blanks into thread cutting dies. The hopper directs the
screw blanks down a channel into dies. The channel positions the screw blanks so that the blanks
feed into the dies properly. One method rolls the blank screw between a stationary and
reciprocating die.

Working principle of Manually Operated Forklift

The manual operated fork lift works by the principle of load and effort. One end of the rope is
fixed on the fork holder &the other ends fixed to the shaft. The handle is directly assembled to
the shaft. That is when we rotating handle clockwise direction the shaft will be rotating. In this
time rope turned on the shaft again also the fork rises by rolling mechanism on the frame. Then
the load rise required height.

3.6. Assembling procedure

1. First weld the vertical frame in the horizontal frame.
2. Weld the fork in the fork holder frame in the fork holder again also assemble the roller in the
shaft that shaft is fixed to the fork holder.
3. Insert the fork with fork holder between two vertical frames.
4. Join the two pulleys in the upper frame, the other one fixed the fork holder.
5. The wire rope mounted on the pulley& one end to fixe of the wire rope is fixed to the fork
holder &the other end of the wire rope is fixed to the shaft.
6. Insert the ball bearing in the frame also inserts the ball bearing in the shaft position again also
locking mechanism fixed in the frame.
7. Finally joining the upper frame to the vertical also fixed the wheel.

3.7 Cost analysis& machine weight

3.7.1 Cost of current existing system

 Cost of labor is calculated as:-
 Payment for a single employee per a day is 35 birr
 Available working day is calculated as:- Days in a year 365
 Working days per a week 7 days
 Working hours per a day 9 hours
So the annual available time is 365*9 = 3285 hours
But throughout the year there are days like:-

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 Annual sick and mortality leave = 30 days= 270 hours
So the total available working time per a year is calculated as:-
Total available time = annul available time-(public holiday + annul sick)
= 3285- 270 =3015 hours
 2 workers by half month or in 15 days get salary 525 birr means 2 workers
1050 in 15 Day.
 Then the available working day is =3265 hours/9 hour = 365days.
 So the total payment for a single employee is = 365*35 =12775 birr per
year
 The total payment for the 2 employees is= 12775*2= 25550 birr per year
3.7.2.Cost Estimation
NO Material Quantity Cost (in birr)
1 Shaft 1 300
2 Pulley 3 200
3 Handle 1 150
4 Frame 1 1500
5 Wire rope 7m 200
6 Roller chain - 300
7 Fork 2 300
8 Screw 1 300
9 Bucket 1 100
10 Bearing 4 250
11 Wheel 4 150
12 Lock mechanism 1 30
13 Fork holder 1 400
Total 4180
Table.3.12.Cost Estimation

3.8.3.Weight of machine
Material Volume(v) Density(kg/m3) Mass(kg)
Fork holder(steel) Steel 1.5∗10-3 5850 9
−4
Fork(steel) Steel 5.1∗ 10 5850 3
Vertical frame Mild steel 4(1.6∗ 10−3 ) 5850 37.44
−4
Horizontal Mild steel 2(6.24∗ 10 ) 5850 7.3
frame(base)
Upper frame Mild steel 2(2.85∗ 10−4 ) 5850 3.34
Shaft Carbon Steel 3(3.73∗ 10−4) 5850 6.54
Other - 5
Total weight 71. 62
Table 3.13.weight of a machine

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CHAPTER FOUR
4. Conclusion& Recommendation

4.1 Conclusion
The project is about the design procedure of a selected problem i.e. manual forklift for mill
house. we decided to design manual forklift, because A forklift is a powerful tool that allows one
person to precisely lift and place large heavy loads with little effort. Instead of lifting and
carrying items by hand can reduce the risk that you will suffer a back bone injury of our
mothers& sister. A gain also to save both labor and time .After manufactured it can be functional
in milling house, The design project is designed by following normal design procedures.
Problem statement→geometric analysis→force analysis→material selection and stress
analysis→part drawing and assembly drawing.

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4.2 Recommendation
We recommended that hand operated fork lift for mill house you use properly. That is use
this fork lift for mill house necessarily

 Check the fork lift machine near to the stair ,but not touch to the belt
 Operator of forklift rotate the handle by medium speed s
 When the forklift is in the operation the machine make it is sure that in normal
position if not in normal position damage will be cause
 Keep the machine in dry place to keep the machine from rest.

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Reference
1. David RH Jones &Michael F Ashby. An introduction to material microstructures processing
and design (3rd Edition)
2. R.S.KHURMI & J.K.GUPTA. A TEXT OF MACHINE DESIGN, Eurasia publishing house
(pvt) ltd RAM NAGAR, NEW DELH
3. Ir .Fiche Meresa. Teaching material for mechanical vibration .
4. Joseph E.shigly & Charles R.mischke Standard hand book of machine design (2nd
Editio]
6. Micelle p.Groover. Fundamentals of modern manufacturing,(3rg Edition) United states of
America
7. Shigley’s Mechanical Engineering Design, Eighth Edition
8. Machine Element 2nd Edition Bahardor.
9.http://www.altanitcomutal.com/losscontrol/vlce/forklift/stability.htm

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3D , Part and Assembly Drawing

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