CALCULATIONS

USERS REQUIREMENT IN OUR PROJECT 1. 2. 3. 4. 5. 6. 7. Low coat raw material Low cost of maintenance Safety Easy to operate Low environmental pollution Durability Quality product

MAIN COMPONENT 1. 2. 3. 4. 5. 6. 7. Piston crank mechanism Slider mechanism Gear and pinions Shaft Belt drive Pully Bearing

Main power supply AC current Slider mechanism

40 cm A c d B

Both Rod c,d length =40 cm Rod moving distance =40 cm Time taken for arrive last end =10 sec So the actual rod speed =4 cms-1

Next step consider the feeding section Feeding piston should move within the rod moving distance between 10.04cm 20.08cm So the feeding time =5.02 sec From above data the feeding piston speed = =7.96cms-1 Here the feeding piston moving distance is 20 cm Then calculate the crank speed

4cms-1

40cm

20cm

Slider rod moving actual distance during one cycling =80 cm After one cycle, the crank rod get the angular distance = 2 So the time taken for whole cyclic motion =10s

So the crank angular speed =

=0.314rads-1 rads-1

Crank speed = 0.314 Speed ratio = 2 Speed ratio =

=G

Number of teeth in pinion

=T

Gear

Pinion

G= 2=

Wp =0.628rads-1

gear

Motor pinion 0.628rads

-1

Gear ratio= 2= Rg= 30cm

T1

From above datas T1

G=2 Teeth number of wheel =30

Wt=FmCvy Wt FmCvy

Gear Torque= Wt PcD/2 = Wt 30 10-2 Nm Power = Wt3010-2 = Wt3010-20.314 W = Wt0.30.314 W Calculate the power transmitted Weight of each slider =10kg So force acting on the crank rod = 100N In this case the slider moving through 40cm distance Moving distance = 40 cm So work done during half cycle of rod =4010010-2 w Minimum 4 w required to lift the one slider From above datas, we assume 8.5 is the maximum power transmitted

substitute on above equation Power 8.5W Wt Strength= FmCvy Pinion y= 0.154 -0.912/T /* number of teeth (T=15)*/ = 0.0932 Wheel y=0.154- 0.912/30 = 0.1236 = Wt0.30.314 W = Wt0.30.314 W =90.23N

Pinion material

Material Tensile Strength Yield strength Density

AISI 6051 Normalized 939.8 MPa 615.7 MPa 7.850 gcm-3

Wheel material Material Tensile Strength Yield strength Density pinion ; y= 939.8 106 0.0932 = 87. 5894 106 wheel ; y = 891.5 1060.1236 = 110.1894 106 AISI 3140 Normalized 891.5 MPa 599.8 MPa 7.850 gcm-3

F=6m Calculate the V V=3150.628/2 /* Wp=0.628, Wa=0.314*/ = 14.13 Calculate the strength of the pinion Strength =6m2 y{3/(3+v)} ( /3)0.0932 =6(0.003)2 {3/(3+14.13)} ( 87.58106/3)0.0932 = 8.673 106 0.0932 = 80.83 pa

Calculate the strength of the gear

Calculate the V V=3150.628/2 = 14.13 Strength =6m2 y{3/(3+v)} ( /3)0.1236 =6(0.003)2 {3/(3+14.3)} ( 110.18106/3)0.1236

Strength =134.86 pa

80.83< 134.86 pa So strength of pinion < strength of wheel

shaft selection Main shaft connect with gear and bevel gear

Gear A

Pinion B

Gear B

Shaft

Bevel Gear C

Calculate Torque on the shaft

T=

= =
=13.53N

Calculate the force

F= F= 90.2 N

Vertical force = F = 90.20.3639 =32.82 N

Horizontal force = Wt= 90.23 N

90.23N H1 32.82N

V1

H2 Gear A V2

Bevel gear sets

G = gear ratio Calculate the bevel gear teeth

G= =

Ng= 0.157 rads-1

2=

Tg= 60 teeth

Here Dg=diameter of bevel gear Dp= diameter of pinion Tg= number of teeth in bevel gear Tp= number of teeth in pinion Wt=(Cv)6my{(L-b)/L}

Cv= {6/(6+v)}

L=(

( )

( )

( )

Stress of the pinion

Y1p= 0.124 -

/////TEP= 30
Y1p= 0.124 -

= 0.1011
Allowable stress of the gear = 55Mpa Allowable stress of the pinion= 110.18Mpa

Calculate the Cv V= = =

=4.71m =4-710.003 =0.014 ms-1

Cv= 6/(6.014) =0.997

L=(

( )

( )

( )

=m33.54

b= L/3 =33.54/3 =11.18m

Strength of the pinion Strength = (110.18106)(0.997)(11.18m)()(m)(0.101)(0.66)

{L-b/L} = 0.66 =257.19m2106 =257.19(0.003)2106 =2314.71 pa

Wheel Cv Cv= {6/(6+v)}

Calculate the v V= =

= m300.157
=4.710.003 ms-1 =0.014 ms-1

The amount of the Cv Cv= 6/(6.014) =0.997 Strength of the gear wheel Strength =(105106)(0.997)(11.18m)()(m)(0.112)(0.66) =2445.54 Pa Torque on the pinion Tp = = Calculate the Wt Wt= = 90.23N

Axial force on piston shaft WRH =Wt

=90.23 0.3640.3161 =10.38N

Radial force acting on the pinion shaft WRV= 90.23 0.3640.9487 =31.15N

WRV

WRH Pinion shaft

H1

90.23N 31.15N -32.82N V1 -10.38N

-H2

V2

Apply Newton low

Vertical V1+ V2= 90.23 +31.15

Horizontal

H1 +H2 = 10.23 + 32 .82 + 43.23

Take moment V17010-2 =31.152010-2 +90.235010-2 V1 =73.35N H170 = 10.3820 +32.8250 H1 = 26.40N

V2= 121.38 -73.35 = 48.03N

H2= 43.2 -26.40 = 16.8N

R1

R2 A

Calculate the R1 R1=

R1=

R1=77.95N

Calculate the R2 R2= R2= R2=50.88

Mp=77.950.2 Maximum torque = 90.233010-2

=

27.06N

Shear stress of AL alloy = 30 Mp 30.3510-6 d= 3.11 cm bearing which used in shaft bore of the ball bearing = 3.22 cm expected life time = 0.31460601036510

=6.56 (million revelation )

L=
6.56=

Dynamic load rating of bearing (C) =145.92 N

6.56=

Pr = XFr +
=

Y. Fr

77.96

So calculate the ca value C = 145.92 N Bearing number =6800

B A Wb=1.25 Wa= 0.157 Speed of the largest pulley = 0.157 Speed of the smaller pulley = 1.25 diameter of the largest pulley = 600 mm diameter of the smaller pulley = 75 mm speed ratio = 8 using table , assume largest pulley diameter = 560 mm

= 0.95 = 123 degree K = 0.83

Less than 10-16 hours per day And heavy duty So select type 01 Service factor Ks = 1.3 Power transmitted by belt = 100 W Design power = Nd = Nt . Ks

=130 W Sin= = 0.47

= 31.54 degree = 0.55 rad L = (-2)d/2 + (+2)D/2 + 2c cos =216.15 cm KL=1.05 No= 0.91 + 0.17 = 1.08 Number of belts = n = n =0.106 we are using one belt (T1 + T2)/2 = initial tension of belt = 2500 N (T1 - T2) . d/2 . Wb = 100 W

(T1 + T2) = 3000 N (T1 - T2) = 2133 N T1 =2566.5 N T2 = 433.5 N Along the direction AB = (T1 + T2) cos = 2639.29 N Perpendicular direction of AB = (T1 - T2) sin = 1014.04 N H1

31.15N V1 2639.29 N H2 10.38N

1014.04 N

V2

Apply Newton low Horizontal

V1+ V2= 2639.29 +31.15 N =2670.44 N

vertical

H1 +H2 = 10.38 + 1014.04 =1024.42 N

Take moment V17010-2 =31.155010-2 +2639.29 2010-2 V1 =776.33 N H170 = 10.3850 +1014.04 20 H1 = 297.14 N V2= 2670.44 -776.33 = 1894.11 N

H2= 1024.42 -297.14 = 727.28 N

R1

R2 A

Calculate the R1 R1= R1=

R1=830.18N

Calculate the R2 R2= R2= R2=2028.93 N

Mp=2028.93 0.2 = 405.78 Nm Power transmitted in pinion shaft = 7.3 W Maximum torque = 774.86010-2
=

46.49 Nm

Shear stress of AL alloy = 30 Mpa 518.1510-6 d= 8.03 cm bearing which used in shaft bore of the ball bearing = 8.03 cm expected life time = 0.1576060836510

=16.5 (million revelation )

L=
16.5=

Dynamic load rating of bearing (C) =5165.2

16.5=

Pr = XFr +
=

Y. Fr

2028.93 N

X= 1.0 Y= 0.0

So calculate the ca value C = 5165.2 N Bearing number =16002

Prime mover selection

Required maximum torque = 2 Nm Required maximum velocity = 1440 rpm = 150.8 rads-1 Required minimum velocity = 0.025 rads-1 Power requirement = 100W = 0.13hp Selected modal motor = KJ3000LHC PSC

trimming section

Rotating velocity of gutter = 1720 rpm

Required velocity of prime mover = 1440 rpm Power requirement = 100W = 0.13hp Selected modal motor = KJ3000LHC PSC