CONCRETE MIXER MACHINE DESIGN AND

FABRICATION

 PREPARED BY : ZEMED BIHONEGN

 PREPARED TO : JIMALE ROGORA GENERAL METAL WORK

AND GENERAL MACHINE MANUFACTURING PLC.

 DATE: 2023, DIRE DAWA

OUT LINE

1. Introduction
2. Material selection
3. Design calculation
4. Manufacturing process selection
5. Manufacturing process
6. Cost estimation
7. Conclusion
8. Recommendation
 2. MATERIAL SELECTION

Sub topic out line

2.1 Shaft material selection
2.2 Pulley material selection
2.3 Frame material selection
2.4 Fastener material selection
2.5 Bearing material selection
2,6 Barrel material selection
2.7 Blade material selection

2.1. Shaft material selection

To select the proper shaft material we calculate the estimation of needed

shaft diameter. This estimation can be done by applying some known
concept.
By using the assumption of “shaft in bending and torsion only” we can
develop the initial estimated diameter formula. The formula that we
found on Robert L.MOTT machine design book is:

D = √ (T(π∗∗16)
3

τ)

Then now we can calculate “T” and “τ "

T = F*l and its value 3654
According to Robert L.MOTT machine design book fig 12-10 torsion and
yield strength in torsion of material have the max ratio value of 1.0. so
now we take the average of the ratio value of 0.5. now the formula
become
τ
Sy = o.5 …… τ = Sy*0.5
Sy found from material property table.

estimated shaft diameters are: based on engineering assumption

D1 = > 35 mm
D2 = > 45 mm

We cheek the first 5 materials

Su Sy D.RESULT
1006 H.R 300 170 60
C.D 330 280 51
1010 H.R 320 180 59
C.D 370 300 49.8
1015 H.R 340 190 58
C.D 390 320 48.8
1018 H.D 400 220 55
C.D 440 370 46.5
1020 H.R 380 210 56
C.D 470 390 45.7
1030 H.R 470 260 52
C.D 520 440 43.9
Source: spread sheet

Based on the above table we can select several material thous colored
with green for our shaft material

2.2. PULLEY MATERIAL

the most preferred material is cast iron. This is chosen due to the following properties.
Tensile strength – about 483 Mpa.
Compressive strength – almost high as high as that of mild steel.
Resistance to deformation.

2.3. Frame Material Selection

To select frame material we consider material type which the material

made of and the shape of the material (round,angel, rhs, shs..etc).
The mother material that frame steel made off is usually mailed steel.
No Maaterial Availability Cost Srengt Functinaly Total
. shape h recommende
d
1 H.R.B 5 5 4 5 19
2 R.H.S 4 5 4 4 17
3 Angle 4 3 5 4 16
iron

Based on the above table our frame material is H.R.B.

2.4. Fastener Material Selection

3. DESIGN CALCULATION

3.1. Design approche

 Speed ratio or sheave ratio = N1/N2 = 7/1 =7/1

 N1 = motor speed = `900rpm
  N2= shaft speed = 127rpm
 d = motor pulley = 50.8 mm
 D= shaft pulley = 360 mm

 Required Power calculation

Pnom = T.v
3.14 ∗0.36 ∗ 127
V = (pi*D2*n2)/ 60 = 60
= 2.39 N/m
T = Fmix X length of shaft from pulley center to Fmix
Length = 0.085m
Fmix(mixing force) = (Mconcrete + Mbarrel ) * gravity
Mconcrete = densityconcrete * volumebarrel = 2461 * 0.170 = 418.37kg
Mbarrel = 50kg
Fmix = (418.37 + 50) * 9.81 = 4594.7097N
T = 4594.7097 X 0.085 = 390.55N.m
P = 390.55 * 2.39 = 934.46watt
 P = 1.2476hp = 2hp recommended = 1500watt

 Design power
Pdes = power factor * Pnom
Power factor = DC shun wound, normal service 8 – 10 hours daily = 1.2
 Pdes = 1.2 * 2 = 2.4 = 1800watt

 Motor specification
Hp = 2hp
N = 900rpm

 Belt design of concrete mixer

 Belt length (Lp)
L = 2C + 1.57(D – d) + ¿ ¿
Nominal. C: D < C < 3(D + d) = 13.7795`` < C < 49.6``, so let C = 20``
Lp = 2(20) + 1.57(13.7795`` + 2.7559``) + ¿ ¿
Lp= 67.485`` = 1,714.119mm = 1.7m ≈ 2m
 So from table 5 our v belt no. is 3VX670

 Center distance ( C)
b+ √ b2 −32( D − d)
C=
16
b= 4L – 6.28(D + d) = 2( 67.485) – 6.28 (13.7795 + 2.7559) =
b = 269.94 – 103.8423
b= 166.097688
166.097688+ √(166.097688)2 −32(13.7795 −2.7559)
C= = 6892.7 – 352.7552
16
C= 166.097688 + 165.03238094 = 331.129261 / 16 = 20.69 = 21`` = 504.7mm

 Tension force calculation

 Belt tension from belt tension ratio

2.3𝑙𝑜𝑔(T1/T2) =µ x α
µ = friction factor = 0.47
α = 179.377 x (π / 180) = 3.13 rad
2.3log(T1/T2) = 0.47 x 3.13 = 1.47/2.3 = 0.6396
log(T1/T2) = 0.6396 = e0.6396 = 1.89574
T1/T2 = 1.89574
T1 = T2 x 1.8954…………….(1)
Belt tension from belt power
P = (𝑇1 − 𝑇2) 𝑉
P = 1800
V= 2.39m/s
T1 – T2 = P/V = 1800 /2.39 = 753.14
T1 – T2 = 753.14 ……………… (2)
Substitute equ (1) into equ.(2)
T2(1.8954 – 1) = 753.14
T2 = 753.14 / 0.8954
T2 = 841.12 N
Now solve for T1 from equ (2)
T1 = 753.14 + 841.12
T1 = 1594.26 N
Tight side tension = 1594.26 N and Slack side tension = 841.12
Effective pull = T1 –T2 = 1594.26 – 841.12 = 753.14 N

 Number of belt calculation

 Standard transmission = base HP rating + speed ratio adder

Base HP = 0.86
Speed ratio adder = 0.16
Standard transmission = 0.86 + 0.16 = 1.02

 Contact angle
−1 D−d
Small = 180 - 2sin ( ) = 179.377
2C
−1 D−d
Larg = 180 + 2sin ( ) = 210.4SS
2C
  Number of belt
Pdes
No.belt = = 2.4/ (1.02 * 1.0* 1.01) = 2.329
S . T ∗ coeff . contact ∗ coeff . belt lengtℎ
= 3 belts needed
Coeff.arc of contact = 1.0
Coeff. Belt length = `1.01
 Belt specification = 3VX cross section(A-section), 67``
length, 3 belts

Shaft design

input 1229.66
power 2 1.639549 2
513.676
Torque 3
2.39384
velocity 6
Fmix 6043.25
L.paddel 0.085
Pi 3.14153

"A tie bar is made of a material having an ultimate tensile strength of 231 mPa, and must carry
a load of 255 kN. What is the diameter of the bar if a factor of safety of 7 is required? I know
that the formula to find factor of safety is ultimate stress/allowable stress. So I'm thinking I
need to find the allowable stress in order to find the final answer. So here is what I have
attempted, but I feel that I'm way off: A = 3.1416(d^2)/4 = .25*pi*d^2 255 kN*1000 =
255*10^3 N 231 mPa*100 000 = 231*10^6 n/m^2 231*10^6 N/m2= 255*10^3
N/.25*pi*d^2 .25*pi*d^2 = 255*10^3 N/231*10*6 N/m^2 d^2 = 255*10^3
N/.25*3.1416*231*10^6 N/m^2 d^2 = 255 000 N/1.8143*10^8 N/m^2 d^2 = 1.4055*10^-
3m^2 = 1.39m

Reference: https://www.physicsforums.com/threads/stress-problem-finding-the-diameter-of-
a-tie-bar.774316/