Design & Modeling of Mechanisms Used For Chalk Manufacturing in Semi Automated Chalk Making Machine

IPASJ International Journal of Mechanical Engineering (IIJME)
A Publisher for Research Motivation........
Volume 3, Issue 6, June 2015
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: [email protected]
ISSN 2321-6441
Design & modeling of mechanisms used for

chalk manufacturing in semi automated chalk
making machine
1
Mrs. G.Udayasree , Mr. V.Ratnakiran2
PG student at VNR VJIET, Bachupally, Hyderabad
Assistant Professor at VNR VJIET, Bachupally, Hyderabad
ABSTRACT
To step forward in the field of automation the concept of Design & modeling of mechanisms used in chalk manufacturing in a
Semi Automated chalk making machine is proposed. The Mechanisms used in chalk manufacturing in a Semi Automated
chalk making machine is designed to overcome the limitations of existing manual chalk making machine by enhancing the
productivity & machine utilization time. The existing chalk making machine has the limitations like less machine utilization
time, decreased productivity, increased setup time, increased human effort. After implementing the designed mechanisms the
Semi automated chalk making machine is expected to have the advantages like improved productivity, Low cost, Less area
occupied by the machine when compared with the existing machine, Reduced setup times, less scope for manual errors etc. The
paper provides a scope for fully automating the machine by automating few mechanisms. The mechanisms designed in this
paper helps in developing new machines in future. In order to design the mechanisms used in chalk manufacturing in a Semi
automated chalk making machine designing criteria of all the parts & existing different models are studied. Modeling
&assembly of parts is done using CATIA work bench.
Key words: low cost, improved productivity, reduced setup time, reduced manual errors.
1. INTRODUCTION
To step forward in the field of automation the concept of Design, modeling & analysis of Mechanisms used for semi
automated chalk making machine is proposed. Using the advantages of existing mechanisms & to improve the
productivity of chalk making machines a new model is developed. The mechanisms of this model are the combinations
of different existing mechanisms like with worth quick return mechanism, Geneva indexing mechanism, rack & pinion
mechanism, piston crank mechanism, etc. Chalk manufacturing is a small scale business. The manual chalk making
process involves 10 to 12 steps to manufacture the chalks like, adjusting the machine, lubricating the mould, mixing
the raw material, pouring the raw material, spreading the raw material, removing the excess material, drying,
punching, packing etc. Few of these steps are automated in the new model to decrease the setup time, to decrease the
manufacturing time, to reduce the manual effort, to decrease the cost of manufacturing, to minimize the wastage, to
minimize the manual errors & to improve the productivity. Design of mechanisms is done by studying the existing
models, chalk mould is designed to get chalk with standard dimensions, and modeling is done in CATIA.
2. MECHANISMS USED TO DEVELOP THE MODEL

2.1Geneva indexing mechanism: Geneva indexing mechanism is a gear mechanism that translates a
continuous rotation into an intermittent rotary motion. In this paper the Geneva mechanism is used to drive the
conveyor belt &pistons of lubricant tank &raw material tank.
2.2Rack &pinion mechanism: Rack &pinion mechanism is used to convert rotator motion to linear motion &vise
versa. In this paper we use rack & pinion mechanism to convert reciprocating motion to rotary motion.
2.3Slider crank mechanism: slider crank mechanism is used to convert rotator motion of crank to sliding motion of
piston. In this paper we use slider crank mechanism to drive the pistons in the tanks.
2.4With worth quick return mechanism: with worth quick return mechanism is used to convert rotary motion to
reciprocating motion. Unlike slider crank mechanism this mechanism has different rate of forward stroke & return
stroke. This mechanism helps to bring down the piston slowly & taking back quickly.
3. DESIGN OF MECHNAISMS &PARTS USED TO DEVELOP SEMI AUTOMATED

CHALK MAKING MACHINE:
3.1 GENEVA INDEXING MECHANISM:
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Geneva indexing mechanism is designed with 6 slots

Angle of rotation of wheel during indexing =360/n s =360/6 =60
If n= rotational speed of drive
Cycle time (Tc) =1/n =1/ (1/4) =4mins.
Available service time (Ts) = (180+)/360n =2.66mins
Indexing time (Tr) =180-/360n =1.33mins
3.2 DESIGN OF MOULD
The mould id designed to get 56 chalks with a diameter of 100 & length of 75mm. gap between the chalk homes is
2mm.there is a rack with a plate at the bottom to avoid raw material falling on the conveyor belt. Height of rack is
6mm.height of mould is 81mm (75mm +6mm).The mould is designed with dimensions 90 x110 x81mm.
3.3 DESIGN OF CONVEYOR BELT
Conveyor belt is designed for 18moulds of dimensions 90 x110 mm with a gap of 50mm between the moulds. Length of
conveyor belt is 2880mm & width of 120mm.
3.4 DESIGN OF RAW MATERIAL TANK
Raw material tank is designed to fill 3moulds. So volume of raw material tank is sum of volume occupied by raw
material & volume occupies by the piston.
Volume of one mould=329867.2286mm3
Volume of 3moulds=989601.6859mm3
Volume of piston=334560mm3
Volume of raw material tank =1324161.686mm3
Dimensions of tank= 90mm *110mm * 160mm
3.5 DESIGN OF SLIDER CRANK MECHANISM FOR RAW MATERIAL TANK
Height of tank occupied by raw material=120mm
Tank is designed for 3 moulds. So the piston moves a distance of 40mm for filling each mould.
Since the total distance moved by piston is 120mm, the diameter of crank is 120mm.
3.6 DESIGN OF LUBRICANT TANK
Volume of one mould is 329867.2286mm3.
Let 5 % of mould volume is occupied by raw material. So volume occupied by raw material = 16498.361mm3
To discharge the required percentage of lubricant the piston should move a distance of 13.12mm in a cylindrical tank of
diameter 20mm for one mould.
For 3moulds the piston should move a distance of 40mm.
Height of piston is 40mm.
So height of lubricant tank is 80mm.
However there is a rectangular tank of dimensions of mold is attached to the cylindrical tank for proper lubrication of
mould.
3.7 DESIGN OF SLIDER CRANK MECHANISM FOR LUBRICANT TANK
Since the distance moved by the piston is 40mm. diameter of crank is 40mm
3.8 DESIGN OF WITH WORTH QUICK RETURN MECHANISM
The quick return mechanism is designed with forward stroke of 12mins & the return stroke of 3mins.i.e it takes 4mins
to fill the mould.
The greater & smaller sectors of its wheel are 288&72 respectively.
3.9 DESIGN OF RACK &PINION MECHANISM
The rack is designed for a radius of 15mm & pinion is designed for a length of 282.85mm
FIGURE 1: 3D MODEL OF MACHINE MODELLED IN CATIA
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ISSN 2321-6441
4. RAW MATERIAL REQUIRED

Plaster of Paris, water, kerosene, coconut oil or vegetable oil, and Ultramarine blue. Plaster of Paris when mixed with
water forms a quick hardening paste used for chalk manufacturing. Plaster of Paris is the raw material for school chalk
manufacturing. Coconut oil or vegetable oil mixed with water acts as lubricant to avoid sticking of plaster of Paris to
the mould. Ultramarine blue is a coloring agent to get blue colour to the chalk.
5. WORKING OF SEMI AUTOMATED CHALK MAKING MACHINE

The semi automated chalk making machine consist of a conveyor system. The conveyor system has a powered pulley &
an idler pulley which supports the conveyor belt. The pulley is connected to the Geneva indexing mechanism which has
a cycle time of 4mins, indexing time of 1.6mins &service time of 2.33mins. As a result the conveyor will have a
synchronous mechanism where the belt moves for 1.6mins& stops for 2.33mins for each cycle. The system consists of
two tanks lubricant tank & raw material tank. The mould first gets lubricated &then gets filled by the raw material.
There will be some setup time given to the mould to lubricate properly. The lubricant tank consists of cooking oil or
coconut oil mixed with kerosene. The lubricant tank has small holes from which the lubricant flows. The lubricant tank
consist of a piston which moves for 1.6mins & stops for 2.33mins. Similarly the raw material tank consists of plaster of
pairs. The raw material tank has small holes from which the material flows. The piston will move for 1.6mins& stops
for 2.33mins. The mould gets filled here & goes for drying. The drying can be electrical drying or can be dried in the
sun. Piston assembly of both the lubricant tank & raw material tank has an added advantage of moving down slowly
while filling the mould & moving back fast after emptying the tank. This is achieved by joining the slider crank
mechanism to Geneva mechanism, Geneva to rack & pinion mechanism &rack & pinion to the quick return
mechanism.
The resulted assembly works as follows.
1. The gear of quick return mechanism is connected by a motor. The rotational motion of gear is transferred as the
linear motion of cam. But the cam moves slow in the forward direction & moves fast in the back ward direction.
This helps in moving the piston slowly in the forward direction & fast in the backward direction.
2. The cam of quick return mechanism serves as rack for rack & pinion mechanism. The rack is attached to a gear
which serves as a pinion. The pinion is joined to one end of the shaft. The rack & pinion mechanism converts
linear motion to rotational motion.
3. The shaft transfers power to Geneva drive wheel. The drive wheel is attached to the driven wheel. Geneva
mechanism is a indexing mechanism which helps the piton to move & stop for equal intervals of time. I.e. the
piston moves when mould is under the tank & stops when it is moving.
4. The shaft from Geneva driven wheel is attached to slider crank mechanism. In slider crank mechanism the rotator
motion of crank is converted to the linear motion of piston.
5. Because of this assembly the piston moves slowly while moving down & moves fast when moving up. This
mechanism helps in decreasing the set up time of machine. Hence increases the productivity.
6. ADVANTAGES
Decreased setup time, Decreased cost of manufacturing, decreased human effort, Decreased wastage of raw material,
Decreased manual errors, Decreased lead time, Low cost of machines, Less area occupied by the machine, Increased
productivity, Easy to operate the machine.
7. LIMITATIONS
There are chances of leakage. In accuracy or misplace of any part disturbs entire system, Failure of any part stops the
production, Initial cost of equipment is high, the parts of machine should be manufactured with high accuracy &
precision, Requires a skilled operator.
8. FUTURE SCOPE
There is a scope for complete automation of the machine by automating the following things.
1. Pouring of raw material in to the tank.
2. Pouring of lubricant in to tank.
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ISSN 2321-6441
3. Placing of moulds on the conveyor.

4. With drawl of mould from the conveyor.
5. Punching & removal of chalks from the mould.
6. Packing.
7. Storage & retrieval system.
The resulted mechanism achieved by the combination of different mechanisms like with worth quick return
mechanism, Geneva mechanism, Rack & pinion mechanism & slider crank mechanism has advantage of indexing the
piston such that it moves down wards slowly & stops for equal interval of time & moves up fast. This decreases the lead
time of machine. This mechanism can be used to develop new machines.
9. RESULT
Design, modeling& analysis of mechanisms used for semi automated machine are done. Using the existing mechanisms
& combining the existing mechanisms new mechanisms are developed. The mechanism developed by combining
different mechanisms can be used to develop new machines. The semi automated chalk making machine has advantage
of Decreased setup time, decreased cost of manufacturing, decreased human effort, decreased wastage of raw material,
decreased manual errors, decreased lead time, Low cost of machines, Less area occupied by the machine, Increased
productivity, Easy to operate the machine etc
10. CONCLUSION
The mechanisms used in this model helps in semi automating the chalk making machine. It also provides a scope to
fully automate the machine in the future. The mechanisms used in this model can be used for developing new
machines. Replacing or redesign of few parts may improve the productivity. The present model is developed to increase
the production, reduce the lead time, minimize the errors etc. Designing is done by studying the existing models.
Modeling is done in CATIA. The dynamic analysis is performed in ANSYS workbench to study the behavior of
machine under working conditions. Simulation of model is done to explain the working of the model.
REFERENCES
[1]. J.E.johnson, Geneva wheel geometry July 2011.
[2]. Home Business Manuals.
[3]. Chetan Detroja Aum enterprises Rajkot.School chalk making process & operation manual. Video, September
2011.
[4]. practical study of conveyor &its mechanism in Vega Industries Pvt Ltd, pashyamailaram industrial area.
AUTHOR
G.Udayasree received her B.Tech with distinction in Mechanical engineering in the year 2013 from
PRRM Engineering College Shabad .Presently she is pursuing her M.Tech in CAD/CAM from VNR
VJIET Bachupally.
V.Ratna kiran is an Assistant professor in the department of Mechanical engineering at VNRVJIET

Bachupally Hyderabad. He received his M.tech in CIM from REC, Warangal. He has 9 years of
teaching &2years of industrial experience.
Page 25

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 3, Issue 6, June 2015

Web Site: http://www.ipasj.org/IIJME/IIJME.htm