DESIGN AND PROTOTYPE OF SEMI-AUTOMATIC MOVABLE

CONCRETE BLOCK MAKING MACHINE

DEBRE BERHAN UNIVERSITY

INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

Submitted in Partial Fulfillment of Requirement for the Degree of Bachelor of Science in Mechanical
Engineering

Group Members Id No

1. Tadiwos Tibebu 825/06

2. Yohannes Tegegne 753/06
3. Abdulkadir Abdela 673/06
4. Surafel Demeke 824/06
Advisor
1. Amar yimam

JUNE 2018G.C

DEBRE BERHAN, ETHIOPIA

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Declaration
I, the undersigned, declare that the thesis comprises my own work. In compliance with internationally
accepted practices, I have acknowledged and refereed all materials used in this work. I understand that
non-adherence to the principles of academic honesty and integrity, misrepresentation/ fabrication of any
idea/data/fact/source will constitute sufficient ground for disciplinary action by the University and can
also evoke penal action from the sources which have not been properly cited or acknowledged.

Name of student (s) ID No. Signature and Date

1. Tadiwos Tibebu 825/06 ________________

2. Yohannes Tegegne 753/06 ________________
3. Surafel Demeke 824/06 ________________
4. Abdulkadir Abdela 673/06 ________________

This thesis has been submitted for examination with my approval as a university advisor.

Advisor Name: Mr. Amar Yimam

Advisor’s Signature and Date: ______________________________

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 Acknowledgement
We would like to start by thanking almighty GOD for his help during this work as a part of his
generous help throughout our life.

We feel to acknowledge our gratitude and deep sense to our advisor Mr. Amar yimam(MSc) whose
valuable and kind supervision given to us throughout this thesis which shaped the present work as its
show. Also we would like to thank school of mechanical engineering instructors and laboratory
assistances for their support. Last but not least our friends are also an important inspiration for us so
with due regards, we express our appreciation’s to them.

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 ABSTRACT
The concrete block making machines is an old method of making blocks for various applications, and
over the year’s various design concepts and modifications have been attained for better functionality and
productions. However, in Ethiopia it has been observed that there is not enough block making
equipment or tools that optimized human labor, as well as the quality and quantity of production.

This project aims in achieving some of the design constrains by designing a semi-automatic movable
concrete block making. Before concept generation and selection, characteristics, types blocks was
analyzed to facilitate the next design phase. During conceptual design phase, different concepts were
proposed using concept generation methods and the best concepts were selected. From the selected
concepts, the design was developed in accordance with technical and economic criteria and general
arrangement, component shapes and materials were determined. This project involves by integrating a
hydraulic systems into the design for efficient mobility and optimizing the equipment design. A
significant increase in the production efficiency and reduction of human labor has been observed. which
also validated by prototype manufacturing and also for further enhancements. Moreover, the
components and assembly were analyzed using Solid works.

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 Table of content

Table of Contents
Acknowledgement ............................................................................................................................................................. ii
Abstract ............................................................................................................................................................................... iii
List of Tables ..................................................................................................................................................................... vi
List of Figures ................................................................................................................................................................... vii
List of Symbols, Notations And Abbreviations ....................................................................................................... viii
chapter One: Introduction ................................................................................................................................................ 1
1.1. Back ground of the study ........................................................................................................................................... 1
1.2. Statement of Problem .................................................................................................................................................. 7
1.3. Objective.......................................................................................................................................................................... 8
1.3.1. General Objective................................................................................................................................................ 8
1.3.2. Specific Objectives .............................................................................................................................................. 8
1.4. Methodology ................................................................................................................................................................... 8
1.5. Scope ................................................................................................................................................................................. 9
1.6. Limitation........................................................................................................................................................................ 9
Chapter Two: Literature Review .................................................................................................................................. 10
2.1. Background and justification of hollow block producing machine ........................................................... 10
Chapter Three: Method, Material And Design Analysis ......................................................................................... 17
3.1. Conceptual Design...................................................................................................................................................... 17
3.1.1. Establishing Functional Structure ............................................................................................................... 17
3.1.2. Concept Generation .......................................................................................................................................... 19
3.1.3. Concept selection ............................................................................................................................................... 22
3.1.4. Specification ........................................................................................................................................................ 25
3.1.5. Mechanism of block making machine ........................................................................................................ 25
3.1.6. Main components of block making machine ............................................................................................ 26
3.1.7. Power Transmission ......................................................................................................................................... 26
3.2. Material Selection ....................................................................................................................................................... 27
3.3. Detail Design ............................................................................................................................................................... 30
3.3.1. Over All Dimensional Structural Analysis................................................................................................ 30
3.3.2. Motor Selection .................................................................................................................................................. 33
3.3.3. Design of V-Belt and Pulley ........................................................................................................................... 34
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 3.3.4. Design of Worm and Worm Gear ................................................................................................................ 38
3.3.5. Design of Gear Box Housing .......................................................................................................................... 50
3.3.6. Design of Hydraulic System ........................................................................................................................... 50
3.3.7. Design of Bearing Cap ..................................................................................................................................... 59
3.3.8. Design of Frame ................................................................................................................................................. 61
3.3.9. Design of hub(coupling) .................................................................................................................................. 65
3.3.10. Design of chain drive ........................................................................................................................................ 68
3.3.11. Selection of Bearing .......................................................................................................................................... 71
Chapter Four: Manufacturing Process ......................................................................................................................... 73
Chapter Five: Cost Analysis .......................................................................................................................................... 78
Chapter Six: Result and Discussion ............................................................................................................................. 79
Chapter Seven: Conclusion and Recommendation .................................................................................................. 82
7.1. Conclusion..................................................................................................................................................................... 82
7.2. Recommendation ........................................................................................................................................................ 82
7.3. Future Work ................................................................................................................................................................ 82
Reference ........................................................................................................................................................................... 83

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List of Tables
Table 1 Literature review .......................................................................................................................... 16
Table 2 Criteria comparison table ............................................................................................................. 23
Table 3 Weight objective method ............................................................................................................. 24
Table 4 Specification ................................................................................................................................ 25
Table 5 Material selection ......................................................................................................................... 29
Table 6 Motor selection for compactor ..................................................................................................... 34
Table 7 Motor selection for traveling ....................................................................................................... 34
Table 8 Dimensions of standard V-belts according to IS: 2494 – 1974[3] .............................................. 37
Table 9 Dimensions of standard V-grooved pulleys (All dimensions in mm)[3]..................................... 38
Table 10 Selection of hydraulic pack ........................................................................................................ 52

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List of Figures
Figure 1 blocks on drying place .................................................................................................................. 6
Figure 2 blocks on manufacturing process ................................................................................................. 7
Figure 3 process of conceptual design ...................................................................................................... 17
Figure 4 over All Function Structure ........................................................................................................ 18
Figure 5 sub function structure ................................................................................................................. 18
Figure 6 schematic diagram of concept 1 ................................................................................................. 19
Figure 7 schematic diagram of concept 2 ................................................................................................. 20
Figure 8 schematic diagram of concept 3 ................................................................................................. 21
Figure 9 schematic diagram of concept 4 ................................................................................................. 21
Figure 10 power transmission ................................................................................................................... 26
Figure 12 bold structure ............................................................................................................................ 31
Figure 13 Double Acting Cylinder ........................................................................................................... 52
Figure 14 Extension and retraction stroke ................................................................................................ 54

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List of Symbols, Notations And Abbreviations
𝐹𝑒𝑥𝑡 = Extension force 𝑛𝐺 = speed of gear

𝑉𝑒𝑥𝑡 = Extension velocity 𝑇 = torque

𝐹𝑟𝑒𝑡 = Retraction force 𝜎𝑝 = principal stress

𝑉𝑟𝑒𝑡 = Retraction velocity 𝐹𝑡 = tangential force

𝑝 = Fluid pressure 𝜎 = Allowable stress

𝐹 = force 𝜎𝑝 = principal stress

𝑝 = Power 𝑑 = Diameter of the shaft

F = Force 𝑊𝑇 = Tangential tooth load

M = Mass 𝐶𝑆 = Service Factor

A = Area 𝑊𝐷 = Dynamic toot load

𝐴𝑃 = Area of piston 𝜎𝑒 = Fluxural endurance limits

𝐴𝑟 = Area of road 𝑚 = Module

𝑝 = Fluid pressure 𝐷𝐺 = Pitch diameter of the gear

Q = Pump flow Rpm = Revolution per minute

𝑖 = transmition ratio 𝑇𝑒 = Formative number of teeth width

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 chapter One: Introduction
1.1. Back ground of the study
Shelter is one of the three basic requirements of human being. Initially ancient man started living in
caves excavated below ground level on near the hill ends. thereafter, they started constructing walls
from mud, and in due course of time, the developed the techniques of burnt clay brick masonry to form
the structural part of the shelter. [1]

Concrete block is primarily used as building material in the construction of walls it is sometimes called a
concrete masonry unit. A concrete block is one of several pre cast concrete products used in
construction. Precast refers to the fact that the block is hardened before they are brought to the job site
most concrete blocks have one or more hallow cavities and their sides may be cast smooth or with the
design in use concrete blocks are stacked one at a time and held together with fresh concrete mortar to
form desired length and height of the wall. [2]

Concrete blocks are a basic commodity of the building industry. If you are looking for a great business
with a solid foundation this may be the one for you. Concrete products are used everywhere for building.
There is a constant strong demand. They are always in style unlike here today gone tomorrow products.
They are used to build large buildings. There is a market for cement blocks around the world and
particularly in North America. If you are looking for a good business, which you can start from home at
low cost, making concrete blocks and other concrete products is a great opportunity. Starting with a part
time business, using handmade molds, you can get going with as little as a few hundred dollars for
supplies and materials. You can operate out of your garage then as business grows and you need more
room you can expand to rented premises. The secret is to keep your costs as low as possible to start with.
Too many businesses fail in the first year because they spend too much money unnecessarily on tents
and equipment. Start with the necessities and add more as you grow in profitability.

Concrete products of all kinds are obviously heavy and bulky. To transport them for long distances is
costly. As a local manufacturer you can supply these products to customers in your area it so difficult to
deliver it to the customer. Your overhead cost, no rent, no staff wages mean low production cost, again
these allows you to price very competitively and still make an excellent profit.

The only things needed to start up are sheet metal and plywood to make the molds. You can obtain plans
with instructions on how to do this. To manufacture concrete blocks you will need port land cement,
gravel, sand and water. Your local building supply store can supply these items. With handmade molds
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one person can make 100 cement blocks in a days’ work. You simply fill the molds with the appropriate
concrete mix then turn the blocks out to dry. This is pretty simple. Then as your business expands you
will want to acquire a concrete block making machine which can turn out many more blocks per day
than you can with hand molds.

You can buy concrete block making machines from various sources. They are very expensive and do a
very good job. If you can afford it go ahead and buy one. It will greatly increase your productivity and
will pay for itself. You can build your own machine used auto parts and a few available and it is not a
difficult project. If you have welding skills you can do these part of the work yourself, otherwise a local
welding shop can do it for you at fairly low cost.

Making your own machine is not really difficult if you have some mechanical skills. Your home built
machine will make 800 cement blocks per day. A smaller, very simple hand operated machine can make
200 blocks per day and is quite easy to build. Operating these machines efficiently is a two-person job.
One worker runs the machine and the other takes the blocks from it and stacks them on racks to dry.
Obviously you will also need sufficient space to stack hundreds of blocks.

The desire for search of new structural materials paved the way for hollow concrete blocks due to
following advantages. [1]

a) Adequate strength and structural stability

b) Superior thermal insulation and acoustic characteristics
c) Sound control
d) Resistance to fire
e) Light weight
f) Speedy work
g) Economy

Historical Development of Concrete Block making Machine

Concrete mortar was used by the Romans as early as 200 B.C. to bind shaped stones together in the
construction of buildings. During the reign of the Roman emperor Caligula, in 37-41 A.D., small blocks
of precast concrete were used as a construction material in the region around present-day Naples, Italy.
Much of the concrete technology developed by the Romans was lost after the fall of the Roman Empire
in the fifth century. It was not until 1824 that the English stonemason Joseph Aspdin developed Portland
cement, which became one of the key components of modern concrete. [2]

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The first hollow concrete block was designed in 1890 by Harmon S. Palmer in the United States. After
10 years of experimenting, Palmer patented the design in 1900. Palmer's blocks were 8 in (20.3 cm) by
10 in (25.4 cm) by 30 in (76.2 cm), and they were so heavy they had to be lifted into place with a small
crane. By 1905, an estimated 1,500 companies were manufacturing concrete blocks in the United States.

These early blocks were usually cast by hand, and the average output was about 10 blocks per person
per hour. Today, concrete block making is a highly automated process that can produce up to 2,000
blocks per hour. [2]

Block Specification

The hollow blocks are different from other form of blocks as it requires no mortar or cement for
masonry work. This blocks interlocked with each other by means of positives and negative frogs on the
top and bottom of the blocks which disallow the horizontal movement of blocks. There is various
application of this blocks namely; load bearing wall, lintels, sills, wall corners etc. The specifications
and the characteristics of this block depend on the machine used to manufacture it. The most common
size of block is 300x150x120mm. The basic raw material is cement, fine aggregate and coarse
aggregate. Very little water is used. This is possible only with mechanized compaction and vibration and
gives the block high quality in spite of the lean mix, which uses very little cement. Weight of this block
is about 2 - 3 Kg.

Production of Block making Process

Current process of producing the hollow block is produced using a semi-mechanized stationary type
machine. The other production systems are - manual molds that require hand tamping, a mobile semi-
mechanized egg-laying machine and fully mechanized system that combines compression and manual
concrete filling in mold. The machine also compacts and consolidates the mix so that the blocks are
uniform in size and attain desired physical properties. The blocks are cured for a minimum period of 14
days, before they are ready to use. On an average 600-800 blocks can be in 8 hours by 1 skilled and 6-8
semi-skilled workers. In this project, a high quality machines in which optimize from the current
machine design is going to propose according to the feedback and the need from the hollow block
maker.

Market & Demand Aspects

Cement concrete hollow blocks are modern construction materials and as such are used in all the
constructions viz. residential, commercial and industrial building constructions. Construction industry is
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a growing a sector. The demand for this product is always high in all cities and other urban centers due
to construction of residential apartments, commercial buildings and industrial buildings. Growing public
awareness of the advantages of the product coupled with increase in the government and financial
institutions support for housing which is a basic human necessity would ensure a healthy growth in the
demand.

Types of concrete block

1. According to production
 Hollow concrete block
 Solid concrete block
2. According to its size
 100mm
 150mm
 200mm

Advantage or benefits of concrete block

 uniform shape and size

 High compressive strength
 Fire resistant
 Economical
 Negligible maintenance cost
 Speed in construction
 Due to negligible thickness it will save cement.
 Energy Efficient
 Sound Resistant
 Strong
 Durable

Raw Materials

The main component of the concrete block is

 a mixture of powdered Portland cement

 water
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  sand and
 gravel

In general, the concrete mixture used for blocks has a higher percentage of sand and a lower
percentage of gravel and water than the concrete mixtures used for general construction purposes.
This produces a very dry, stiff mixture that holds its shape when it is removed from the block mold.
A typical concrete block weighs 17.2-19.5 kg. [2]

Process of Block Making

The following steps are commonly used to manufacture concrete blocks.

1. Mixing

The sand and gravel are stored outside. As a production run starts, the required amounts of sand,
gravel, and cement are transferred by gravity or by mechanical means to a weigh batcher which
measures the proper amounts of each material. The dry materials then flow into a mixer where they are
blended together for several minutes. After the dry materials are blended, a small amount of water is
added to the mixer. If our production area is located in a climate subject to temperature extremes, the
water may first pass through a heater or chiller to regulate its temperature. Admixture chemicals and
coloring pigments may also be added at this time. The concrete is then mixed for six to eight minutes.

2. Molding

After mixing the concrete is added into molds. The molds consist of an outer mold box containing
several mold liners. The liners determine the outer shape of the block and the inner shape of the block
cavities. When the molds are full, the concrete is compacted by the weight of the upper mold head
coming down on the mold cavities. This compaction may be supplemented by air or hydraulic pressure
cylinders acting on the mold head. Most block machines also use a short burst of mechanical vibration to
further aid compaction. After completing of molding and compacting The compacted blocks are pushed
down and out of the molds onto a flat steel pallet.

3. Cubing

The next step will be placing the blocks with the help of human power or pass through a cuber for the
next production of the blocks. which aligns each block and then stacks them into a cube three blocks

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across by six blocks deep by three or four blocks high. These cubes are carried outside with a forklift
and placed in storage.

Figure 1 blocks on drying place

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Figure 2 blocks on manufacturing process
Quality Control

The manufacture of concrete blocks requires constant monitoring to produce blocks that have the
required properties. The raw materials are weighed electronically before they are placed in the mixer.
The trapped water content in the sand and gravel may be measured with ultrasonic sensors, and the
amount of water to be added to the mix is automatically adjusted to compensate. In areas with harsh
temperature extremes, the water may pass through a chiller or heater before it is used. [1]

As the blocks emerge from the block machine, their height may be checked with laser beam sensors. In
the curing kiln, the temperatures, pressures, and cycle times are all controlled and recorded
automatically to ensure that the blocks are cured properly, in order to achieve their required strength.

1.2. Statement of Problem

In most developing countries, concrete block is manufactured by using old manufacturing method.
That means, high labor force is needed for pressing the mold and for moving the manufactured concrete
block. Due to this reason the quality of the concrete may be less since some losses of ingredients that
used to make the concrete block is present during the manual work. Furthermore, high labor force is
needed for making the concrete block. Among the new technologies of concrete block making machines,
most of them are fixed or they are in the form of plant and the rest machines have very high initial cost.

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Also in our university there are many kinds of block making machines the first one is fixed and it’s very
costly. The other one it’s manually operated and movable its production time is low and use high manual
force. In this project we will try to increase the rate of production and reduce machine manufacturing
cost. Since the machine work by laying the block on the floor and the machine work automatically.
Therefore, anyone can operate it by using electrical buttons.

1.3. Objective
1.3.1. General Objective
 The main objective of this project is design of semi- automatic hydraulically operated
movable concrete block making machine.

1.3.2. Specific Objectives

 To detail design of each component.
 To reduce the production time.
 To increase production rate.
 To increase the efficacy of the machine.
 To manufacture prototype.

1.4. Methodology
In these step we have seen in what method the project will done

 Problem identification
We were first look the whole working environment and identify what major problems that face
in our country.
 Gathering row Data
To accomplish this project, it uses different data collection methods such as
a) Observation
b) direct measurement
c) Use different manual
d) Interview etc.
 Literature survey from different sources such as journals, books, websites and previously done
research paper
 Concept generation
 Concept selection

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 In these part we use weight object method to select the best concept by comparing each other
 Setting final specification
 Material selection
 Design of different components
In these part we perform different analysis like Kinematic analysis, Dynamic analysis, Stress
analysis.
 Develop solid modeling of the machine
 Manufacturing and test prototype

1.5. Scope
The scope of this project to design and manufacturing of prototype of the hollow block making
machine. It starts introducing the machine (semi-automated movable hollow block making machine) and
its product (hollow block) and the design will include the conceptual design, concept generation, detail
design, solid modeling, manufacturing the prototype if the materials are fulfilled or simulation is another
choice.

1.6. Limitation

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 Chapter Two: Literature Review
A literature review may be presented as a paper on its own, or it can be contained as an integral part of
an article, research report or dissertation. The literature search was mainly focused on semi-automatic
concrete block machine the review of publications and research work revealed the basic guidelines and
area of work need to be conducted exhaustively on a particular, where positive result is expected, in
favor of solving the critical factor which describes, compares, contrast and evaluate the major theories,
arguments, themes, methodologies, approaches and controversies in scholarly literature on a subject
manner and evaluate of the literature and explanation of what research has already been performed or
for a research area.

2.1. Background and justification of hollow block producing machine

(Wiles, Andrew. 2009)., An artificial which is called Portland cement was innovated during the
industrial revolution in England, but No construction is possible without concrete blocks. Since many
entrees concrete block making has been practiced by human beings. UN improved version of Portland
cement was produced in Great Britain though 19thcentury and held share of import to the United States
until 1871. The Construction of the first American company in Pennsylvania, The American cement
industry had organized into professional group by 1900, one of which was Portland cement association.
The obvious function of this group was to advance the use of Portland cement, which was accomplished
though workshop, advertising, catalogs and pattern books. Concrete block was highly recommended by
the association in 1905. [3]

Early production of concrete block in the 19th century was achieved by filling cast iron or wooden box
molds called “side-face machines “with a “dry mix” of concrete mixed with the minimum amount of
water for hardening. The concrete was added in layers and hand-tamped. The block was removed via the
hinged sides of the mold box and laid out to dry for seven to ten days in an upright position.

Mass production of concrete block buildings did not develop until HaBirron palmer patented a cast-iron
hollow block machine in 1900.with this invention, it was claimed that two men could produce between
eighty to one hundred blocks in a machines that rotated up 90 degrees for release of the block. Hollow
blocks were considered superior as they were lighter, insulated better and were more moisture-resistant.
Once the popularity of the concrete block as a building material was established, competing companies
began marketing their own machines. All followed palmer’s pattern of metal frame and mold box with
hand release lever for opening the sides and removing the finished product.

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The production of compacted block making machine established in 1988 in South Africa with joint free
India expertise was viewed as the CBMM (concrete block mold machine) building system replaces
conventional blocks and mortar through the use of compacted blocks, which are hollow and can be dry
stacked. The other components of the conventional building system remain unchanged since these
blocks can be made on construction site or at block yard using hollow block making machines. Today
the CBMM building system and the machines are used in over 50 countries worldwide. This block-block
can be made with local soil and cement or fly ash (brunt coal ash) and cement. Cement concrete hollow
blocks have an important place in modern building industry. They are cost effective and better
alternative to burnt clay blocks by virtue of their good durability, fire resistance, partial resistance to
sound, the viral insulation, small dead load and high speed of construction.

There are different kinds of concrete machineries existing in this world which are modern and back ward
in this project the machine needed to be modern and significantly economical as seeing different designs
most of them are costly or back ward let see some which are designed and manufactured recently.

In reviewing the pervious works there should be metrology, advantage, limitation of the machines to
compare and take idea from the previous works. To design new product, it is best to see what designs
exist before it helps for better design and more efficient work.

Reviewing the machine

The earlier recorded use of concrete was in 200 B.C where the Romans used concrete mortar to bind
shaped stones in the construction of structures. The Roman emperor Caligula, in 37-41 A.D. used small
blocks of precast-concrete as a building material. Later in the 5th century after the fall of the Roman
Empire, most of the concrete technology was lost.

In1890, Harmon S. Palmer designed the first hollow concrete-block in the United States. The design
was patented after 10 years of experimenting. Palmer’s block was so heavy making them difficult to
transport and had to be lifted by a small crane. These blocks were 8 in (20.3 cm) by 10 in (25.4 cm) by
30 in (76.2 cm). In the early 18thcentury, several companies come into existence with an estimated
1,500 companies manufacturing concrete-blocks in the United States and Europe. These blocks were
generally hand-casted, with an output of about 10 blocks per person per hour. [4] And also early
production of concrete block in the 19th century was achieved by filling cast iron or wooden box molds
called “side-face achiness “with a “dry mix” of concrete mixed with the minimum amount of water for
hardening. The concrete was added in layers and hand-tamped. The block was removed via the hinged

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sides of the mold box and laid out to dry for seven to ten days in an upright position means it is a
ubiquitous part of the built environment in most parts of the World, no construction is possible without
bricks.

There are different kinds of concrete machineries existing in this world most of them are costly or back
ward let see some which are designed and manufactured recently as follows.

Design of Innovative Conceptual Design Manual-Concrete-Block Making-Machine

A stationary type semi-automatic blocks shaping machine by plat form and mold resonance of the utility
relates to a semi-automatic small size block shape machine which have many different intellectual
different protrude in a stationary places that need a shelter for production of the material for each
concrete bricks where us the utility model consist different hand operation not only that the assist by the
motor almost for only compacting the mixed cement and sand in the mold the rest of the process
proclaimed by human labor

The rate at which structural defects or failures occur these days is alarming, and they usually come as a
result of sub-standard cement blocks used in building construction, hence, there is a need to get highly
compacted and strengthened concrete block, which can be made from cement and sand soil mixed with
some additives if needed. however most of the commercially-available block-making-machines are
imported and also expensive. Locally-made affordable block-making-machine would render useful in
lowering the cost of construction also the quality of block is determined by the reliability and the
efficiency of the brick machine, which will determine how strong the structure will be, which in turn
will eventually determine the maintenance cost of said structure since The performance evaluation of
the machine was carried out and a production of an average number of 86 blocks per hour was
recorded, with machine efficiency of 75%. The machine is effective, easy to operate, relatively cheap
with a production cost of $700 only. [5]

(Saul Sitati Namango and Daniel Arusei. 2016)., This project, therefore, was aimed to complete a
conceptual design of an innovative undemanding stationary manually-operated concrete-block-machine
that molds concrete-blocks at a fraction of a cost in comparison with power-operated options. The target
specifications were derived from the customers’ needs data collected during the local workshops’ visits
and from the secondary sources, mainly patents. Three design alternatives were developed; alternative
design #3 was chosen by the engineering design decision-weighted-matrix and by the drop and re-vote
(D&R) method. The originality of this design is essentially in the ejection system: as opposed to many

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block-making-machines available which ejects blocks instead of the mold, this machine ejects the mold
leaving the blocks on the base plate. Mild steel was a material of choice for the machine. A static
simulation study on the frame model, which was fixed at the bottom mounting and an overall normal
force of 981N or 100 Kg applied at the base plate was done using Engineering Design Software:
SolidWorks, 2013 (design and simulation tool). The study included Stress, Displacement, and Strain
analysis. Conceptual design of manual-concrete block making-machine was optimized according to
results of simulations, calculations and fundamental engineering design principles. Cost estimation
shows that this simple and economical piece of equipment could have a potential in lowering the cost of
construction. To ascertain a potential, however, the authors propose further work on prototyping and
testing to be carried out product will have some advancement.

Some of their advantage

 The machine has been developed by considering the circumstances of rural areas
 Low cost concrete block making machine for producing each block mixing with cement and sand
 A good starting point for further exploration on the same
 Cost estimation shows that this simple and economical piece of equipment could have a potential
in lowering the cost of construction

Dis advantage

The same as previous as compared previously

 Minimum 3 blocks per cycle

 It can be back ward (operate manually).
 It can consume lot of labor force.
 The selling price expensive and
 Unaffordable for the medium income society

Significant Advantages from them as compared

1. Improve the production of concrete blocks for housing and general construction.
2. Mold are changeable to make different size of blocks. Hollow block, solid bricks etc.
3. 4 motors provide big vibration force.
4. The assembling does not require much skill, and more so, faster, neater with improved
efficiency.

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 5. lighter quality control, higher efficiency, increased productivity, minimum product cost, reduced
manpower, and lesser scrap

Design modeling and simulation of block molding machine: management approach

Prof. Abdulrahim Abdulbaqi Toyin (2016)., Concrete Block Technology can be easily adapted to suit
special needs of users by modifying some design parameters such as mix proportion, water to cement
ratio and type of production system. It is an effective means of utilizing wastes generated by stone
Crushers, quarrying and stone processing units. The technology has high potential in areas where raw
materials are easily available. The reason behind this is as a result of the poor quality of material used
for the construction. The introduction of block molding machine will help to produce more solid blocks
of high quality within a short time which invariably will help reduce this problem of collapse buildings
since the virtual product The Block Molding machine was designed to operate 151.8rad/s which
compacted with the strength of 0.99N/mm2 the production rate was 500 blocks in 8 hours working day.
The machine was designed to be versatile in operation manually or to be power driven either by an
electric, petrol or diesel. Provision was made for mold sliding plates to be introduced into the mold holes
so that 6 inches’ blocks are produced when required, instead of the regular 9 inches blocks. [6]

Advantage

 The block molding machine has the added advantage that it can be operated manually or driven
either electrically or by petrol engine or diesel engine.
 The designed block molding machine is one-third the physical size of the conventional
semiautomatic block maker.

Disadvantage

 mold box is restricted to nine and six inches’ mold boxes respectively

Advantage of our block machine

 Increase in productivity (level) increased productivity

 Significant quality of brick.
 It’s portable.
 There is no damage of brick

Design, Construction and Testing of a Multipurpose Brick/Block Molding Machine

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S.O. Yakubu (2015)., Production of blocks used for wall construction have different techniques adopted
which could be in form of hollow or solid blocks produced in varying shapes laid with mortar since this
construction focused on design construction and testing of a multipurpose machine that produces high
quality blocks/bricks for low cost housing.

Regarding to great importance while designing this paper analyzed the process to consider simplicity in
the working principle but without sacrificing efficiency concrete-block-making-process and machines
are automated and can produce up to 2,215 Productions of concrete-blocks are done in various sizes and
shapes the constructed motorized compressive earth brick (CEB)/block making machine can produce on
average a total of 2,215 bricks per day and 950 blocks per day also the machine was used to produce
affordable and quality bricks and blocks not only that there is also test conduction dry density of the
produced block is often the primary measure of performance of block machine. [7]

Advantage

 It has a good quality control mechanism (such as compaction pressure control)

 There are simpler and cheaper low income brick/block producing machines.

Dis advantage

 High level skilled operator and diligence to produce good quality block/brick
 Low capacity (usually not more than 1,000 bricks per day), the absence of quality control
mechanism and high level of physical labor.

Advantage of our as compared

 It just need first day orientation only to be familiar with the machine.
 It has high capacity of production with effective efficiency.
 This machine can be modified such that it can have bigger mold and a means of feeding and
compaction of the mix in lifts, preferably automatically. This should be made simple and not
expensive.
 The machine could be automated especially the feeding and evacuation components
(mechanism). This will improve its performance and the safety of the operator.

As a summary of literature review

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 Most studies and literatures discussed the quality, efficiency, portability, size control and cheaper
and lower cost. Due to this, many researchers are done on concrete block machine but their main
concern is the currently commercially-available block-making-machine also escalating demand for
affordable simple and economical piece of equipment not only that but also properly-functioning,
affordable, durable, easy to operate the machine.

Generally, form the above researcher idea and gap

The study covered by the control system adopts the automatic control mode, and it is easy to operate.
The hollow blocks maker has the functions of man-machine interaction without any labor and time
consumption, in a matter of fact to increase the quality and efficiency of the production by evaluating
and distributes the materials compulsorily also improves the efficiency of distribution. To have better
value semi-automatic hollow bricks machine price is proper and the machine is beneficial to save the
manpower.

Authors Aim Principle Gap Year

Saul Sitati Namango Manual-Concrete- machine ejects the Realistically to predict to 2006
and Daniel Arusei Block Making- mold leaving the Improve the production of
Machine blocks on the base concrete blocks for housing
plate and general construction

S.O. Yakubu Multipurpose without sacrificing Improving the efficiency 2005

Brick/Block efficiency
Molding Machine concrete-block-
making-process

Prof. Abdulrahim block molding produce more solid To increase the time gap 2016
Abdulbaqi Toyin machine blocks of high
quality within a
short time
Table 1 Literature review

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Chapter Three: Method, Material And Design Analysis
3.1. Conceptual Design
In conceptual design it contains abstraction, establishing functional structure, searching solution based
on different method and evaluate solution variant against technical and economic criteria. At the end of
conceptual design, we will get appropriate solution of the specified problem.

Figure 3 process of conceptual design

3.1.1. Establishing Functional Structure

Over All Function

Functional structure is meaning full and compatible combination of sub function into an overall
function. The overall function showing the problem in general with inputs and output relationships.
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 Figure 4 over All Function Structure
Sub Function Structure

The overall function structure is decomposed in to sub function structure in order to search alternative
solution for each sub function.

Figure 5 sub function structure

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 3.1.2. Concept Generation
Concept 1

This system use human labor force to insert the aggregate in to the feeder plate then it is feel into the
mold the rest of the aggregate will sand to the feeder plate then create a vibration by using electrical
motor that drives the unbalance shaft by using pulley system for compacting the aggregate for better
strength. Next the pinion and the rack system pull the upper mold then using hydraulic system the upper
mold moves down ward to the mold then after some second the lower mold move upward and the block
lays on the ground finally the machine can be deriving to the next production line using electrical motor
integrated with wheel of the machine.

Figure 6 schematic diagram of concept 1

Concept 2

This system use human labor force to insert the aggregate in to the feeder plate then it is feel into the
mold the rest of the aggregate will sand to the feeder plate then create a vibration by using electrical
motor that drives the unbalance shaft by using pulley system for compacting the aggregate for better
strength. After that using hydraulic system the upper mold moves down ward to the mold then after
some second the lower mold move upward and the block lays on the ground finally the machine can be
deriving to the next production line using electrical motor integrated with wheel of the machine.

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 Figure 7 schematic diagram of concept 2
Concept 3

In this type of system, the aggregate feed to the mold by using manual power the rest of aggregate that
waste from the system is removed by manual power then create vibration from the electric motor after
that for more strength the upper mold is used for compacting the aggregate. Finally, by using labor force
the lower mold is lifted to upward direction and the block is placed in the plate that is prepared for this
purpose and removed to the place where it dry.

Concept 4

In these mechanism the aggregate is feed to the mold then then create a vibration by using electrical
motor that drives the unbalance shaft by using pulley system for compacting the aggregate for better
strength .The upper mold is pulled by human force then by moving the handle from left to right direction
to disengaged from the locked key then the mold moves down ward by gravitational force to press the
aggregate for more strength of the block then by using the handle move the lower mold in up direction.
Finally using manual power to rotate the handle when the handle it moves the chain system and this
system is directly integrated to the wheel system. Therefore, it rotates the wheel of the system to the next
production line.

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 Figure 8 schematic diagram of concept 3

Figure 9 schematic diagram of concept 4

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Gathering row data

 Question answered by the engineer;

 I want the machine is automatic and work only by one press.
 I want the machine manufacture at least four blocks per small time interval.
 I want the machine to be movable and with high strength.
 The machine to be cheap and light in weight.
 The machine that is free from environmental pollution.
 Question answered by the labor;
 I don’t want to move the block for several times.
 I don’t want to waste my energy by moving the mold to upward and downward
 Question answered by the manager;
 Increase the productivity above 1300 blocks per day
 Low manual power and machine cost
 Marketable machine
 High efficiency

Interpretation

Interpretation of the above data into engineering data this used to easily access the concept and
comparing each other

 Low labor force  Production rate

 Availability  Cost (Moderate relative to the imported
 Movable one)
 Simple  Automatic
 Light in weight  Ease of maintenance
 Performance
3.1.3. Concept selection
Weight object method (WOM)

It is an evaluation method for comparing design concept based on the overall value per design
concept. The criteria that are used to evaluate the design alternative different in their importance

Step of WOM

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 1. List of the objective or criteria
2. Rank order criteria (list of criteria)
𝑛(𝑛−1)
𝑁= 2

Where
 n – Total number of criteria
 N – total number of possible comparison pair
3. Assign relative weight to each design
4. Select the parameter design based on decision

Low labor force

Production rate
Performance

maintenance
Automation
availability
Simplicity

Movable
Light

Total
Ease
Cost

wi
Cost X 1 1 0 1 0 0 1 1 1 6 0.13

Simplicity 0 x 1 0 0 1 0 0 0 1 3 0.06

Light 0 0 X 0 0 1 0 0 0 0 1 0.02

Performance 1 1 1 X 1 0 1 1 1 0 7 0.15

Movable 0 1 1 0 x 0 0 1 0 1 4 0.08

Availability 1 0 0 1 1 X 1 0 1 0 5 0.10

Production rate 1 1 1 0 1 0 x 1 1 1 8 0.17

Automation 0 1 1 0 0 1 0 X 1 1 5 0.10

Low labor force 0 1 1 0 1 0 0 0 X 1 4 0.08

Ease maintenance 0 0 1 1 0 1 0 0 0 x 3 0.06

Table 2 Criteria comparison table

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Selecting criteria Concepts

Concept 1 Concept 2 Concept 3 Concept 4

Weightage

Weighted

Weighted

Weighted

Weighted
Rating

Rating

Rating

Rating
score

score

score

score
Cost 0.13 2 0.26 3 0.39 4 0.52 3 0.39

Simple 0.06 4 0.24 4 0.24 5 0.30 3 0.18

Light 0.02 2 0.04 3 0.06 4 0.08 3 0.06

Performance 0.15 5 0.75 3 0.45 2 0.30 3 0.45

Movable 0.08 3 0.24 3 0.24 1 0.08 3 0.24

Availability 0.10 4 0.40 3 0.30 4 0.40 3 0.30

Production rate 0.17 5 0.85 3 0.45 2 0.34 3 0.51

Automation 0.10 5 0.50 4 0.40 1 0.10 3 0.30

Low labor force 0.08 5 0.40 3 0.24 1 0.08 3 0.24

Ease of 0.06 3 0.18 3 0.18 4 0.24 3 0.18

maintenance

Score 1 3.86 2.95 2.44 2.85

Rank 1 2 4 3

Result Yes No No No

Table 3 Weight objective method

Rating

1. More verse than existing system

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 2. Worse than existing system
3. The same as the existing system
4. Better than the existing system
5. Much better than the existing system

From the above concept selection matrix, it is selected concept one is best mechanisms from the other to
develop the concrete block making machine.

3.1.4. Specification
1. Cost - with moderate cost we need to design a best block making machine
2. Dimension – height not more than 1m
3. Weight (mass of the machine) – not more than 1000kg
4. Durability- long life up to 10 years
5. Travel Speed – medium

General requirements Specification

Purchase price To be competitive in the market with suitable cost

we need to design a best block making machine.

Life time The machine has to work for about 10 year

Working area Construction area

Surface temperature Work with highest temperature

Speed Medium

Drive mechanism Electro hydraulic mechanism

Height range Not more than one meter

Weight It should be easy to move the cleaner not more

than 1000kg.

Table 4 Specification

3.1.5. Mechanism of block making machine

 The mixture of sand and cement (aggregate) is feed to the feeder and using a manual force
the aggregate will fell to the mold and the rest of aggregate will send to feeder plate.
25 | P a g e
  After creating vibration from electrical motor and connected to unbalanced shaft the
aggregate will be compacted in mold for better strength and bond of the block.
 Next the pinion and rack system will pull the upper mold in to the inside part of machine.
 After the hydraulic piston will push the upper mold down and the drag mold go up while
the pick is stationary so the block can be pushed down and drop safely at the bottom of the
machine.
 Finally, the machine can be port (derived) to another place using the wheel can be derived
by electrical motor from one direction to another place.

3.1.6. Main components of block making machine

 Hydraulic piston  Block mold
 Electrical motor  link
 Switch  Feeder plate
 Frame  Nut and bolt
 Wheel  Hydraulic motor
 Worm gear system
3.1.7. Power Transmission
Power transmission is the movement of energy from its place of generation to a location where it is
applied to performing useful work. The source of power for this machine is direct electrical energy and
hydraulic power applied to the mold. When the electrical force is applied on the machine, it directly
vibrates the mold. The power can be transmitted to the required point using mechanical components
such as belts and gears and it also used to drive the wheel to forward direction.

Figure 10 power transmission

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 3.2. Material Selection
Material selection for mold, compactor, frame, wheel and filler plate

 In selection of material for mold, frame, link, wheel and filler we should focus and select carefully
because there is a force that apply down word due to gravity and self-Wight of the machine so it
must have strength for this force and also we have some criteria in the selection of material for mold,
frame, link, wheel and filler. There are materials that used for constructing for mold, frame, link,
wheel and filler plate from this we are selecting material that are listed below
 Free cutting steel
 Steel
 Cast iron
 Wrought iron

Criteria that used to select the suitable material for the mold, frame, wheel, shaft and filler

 Cost
 Strength
 Formability and good machinability
 Resistance to corrosion
 Resistance to wear
 Availability

For the wheel there is other reason to select the material Strength and durability the material that satisfy
these properties are listed below

 Stainless steel
 mild steel

Material selection for the bolt and nut

In selection of material for the bolt and nut we should focus and select carefully because there is a
force that apply down word due to gravity and self-Wight the machine so it must have strength for this
force and also we have some criteria in the selection of material for bolt and nut. There are materials that
used for constructing bolt and nut from this we are selecting material that are listed below

 bronze
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  Steel
 Cast iron
 Stainless steel
 Nylon

Criteria that used to select the suitable material for the nut

 Cost
 Strength
 Formability and good machinability
 Resistance to corrosion
 Resistance to wear
 Availability

Material selection for the worm and worm gear

In selection of material for the bevel gear we should focus and select carefully because there is a
force that apply down word due to gravity and self-Wight the machine so it must have strength for this
force and also we have some criteria in the selection of material for the worm and worm gear.

Factors of Material Selection

In our experience, at a simplified level, there are three factors that are most important when selecting a
gear material. They are strength, durability, and cost, which includes both the cost of the material and
the cost of manufacturing. While the importance of these factors may vary from one project to another,
the key to material selection is finding the right combination of physical properties that satisfy the
requirements of the project at the lowest cost. There are materials that used for constructing worm and
worm gear and from this we are selecting material that are listed below

 Steel
 Brass
 Phosphor Bronze
 Aluminum
 Cast iron

Criteria that used to select the suitable material for the rack and pinion gear

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  Cost (material and manufacturing)
 Strength
 Durability
 Resistance to corrosion
 Resistance to wear
 Availability

S.No. Part name Selected materials Reason for selection

1 mold (drag and pick), cast iron Low Cost, high Strength, good machinability and
frame, shaft, gear box Formability, high Resistance to corrosion,
housing and filler Resistance to wear and easily available.
plate

2 Gear material(worm Phosphor bronze Low cost regarding with its properties, good
gear) formability up to moderate strength, can be
soldering and available .

3 Worm Cast iron Low Cost, high Strength, good machinability and
Formability, high Resistance to corrosion,
Resistance to wear and easily available.

4 bolt and nut Steel Low Cost, high Strength, good machinability and
Formability, high Resistance to corrosion,
Resistance to wear, easily available and
durability.

5 Wheel mild steel Strength and durability

6 Belt oak tanned leather

Table 5 Material selection

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 3.3. Detail Design
3.3.1. Over All Dimensional Structural Analysis
 Common character of block making machine
 The most common size of block is
1. Length of block 400mm
2. Height of block 200mm
3. Width of block 200mm
4. Thickness of the block 4mm
 Weight of this block is about 2 - 3 Kg

Types of concrete block

1) According to production
 Hollow concrete block
 Solid concrete block
2) According to its size
 100mm
 150mm
 200mm

Geometrical analysis of block mold structure

 The outer size of the block is equal to the inner size of the mold
 The inner size of the block is equal to the outer part of the inner mold structure

Material structure

The material that used for manufacturing the mold structure is cast iron. Cast iron have the following
properties

 Low Cost, high Strength, good machinability and Formability, high Resistance to
corrosion, Resistance to wear and easily available.

Mold analysis

Length of the block equal to 200mm

Width of the block equal to 400mm

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Height of the block equal to 200mm

Thickness of the block mold 5mm

Length of the mold = 200𝑚𝑚 + ℎ𝑗𝑔𝑛5𝑚𝑚 + 5𝑚𝑚 + 1𝑚𝑚 = 211𝑚𝑚

Width of the mold = 400𝑚𝑚 + 5𝑚𝑚 + 5𝑚𝑚 + 2𝑚𝑚 = 412𝑚𝑚

Hight of the mold = 200𝑚𝑚 + 10𝑚𝑚 = 210𝑚𝑚

For manufacturing four block we use four block molds

Length of the mold block

= 5mm + 200𝑚𝑚 + 5𝑚𝑚 + 200𝑚𝑚 + 5𝑚𝑚 + 200𝑚𝑚 + 5𝑚𝑚 + 200𝑚𝑚 + 5𝑚𝑚
+ 4𝑚𝑚 = 829𝑚𝑚

Width of the mold block = 400𝑚𝑚 + 5𝑚𝑚 + 5𝑚𝑚 + 2𝑚𝑚 = 412𝑚𝑚

Higtht of the mold block = 200𝑚𝑚 + 10𝑚𝑚 = 210𝑚

Figure 11 bold structure

 Total length of the mold is equal to 829mm
 Total width of the mold is equal to 412mm
 Thickness of the mold equal to 5mm

Mold analysis for 100mm block manufacturing process

Length of the block equal to 100mm

Width of the block equal to 400mm

Height of the block equal to 200mm

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Thickness of the block mold 5mm

Length of the mold block = 5mm ∗ 9 + 8 ∗ 100mm = 845𝑚𝑚

Width of the mold block = 400𝑚𝑚 + 5𝑚𝑚 + 5𝑚𝑚 + 2𝑚𝑚 = 412𝑚𝑚

Higtht of the mold block = 200𝑚𝑚 + 10𝑚𝑚 = 210𝑚

Mold analysis for 150 mm block manufacturing process

Length of the block equal to 150mm

Width of the block equal to 400mm

Height of the block equal to 200mm

Thickness of the block mold 5mm

Length of the mold block = 5mm ∗ 9 + 5 ∗ 150mm = 780𝑚𝑚

Width of the mold block = 400𝑚𝑚 + 5𝑚𝑚 + 5𝑚𝑚 + 2𝑚𝑚 = 412𝑚𝑚

Higtht of the mold block = 200𝑚𝑚 + 10𝑚𝑚 = 210𝑚

Feeder plate design

Dimensional analysis

Total width of the plate 259mm

Total length of the plate equal to total length of the block mold structure 829mm

The plate mounted at angle of 30° from the mold line

From the front side the length of the plate structure gain by

𝑥 = tan 30 ∗ 259𝑚𝑚 = 149.5𝑚𝑚

𝑙 = 829𝑚𝑚 − 2 ∗ 149.5 = 530𝑚𝑚

𝑡𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑑 𝑤𝑖𝑑𝑡ℎ 𝑠𝑖𝑧𝑒 = 𝑡𝑜𝑡𝑎𝑙 𝑝𝑙𝑎𝑡𝑒 𝑤𝑖𝑑𝑡ℎ + 𝑡𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑑 𝑤𝑖𝑑𝑡ℎ

𝑡𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑑 𝑤𝑖𝑑𝑡ℎ 𝑠𝑖𝑧𝑒 = 512𝑚𝑚 + 259𝑚𝑚 = 771𝑚𝑚

𝑡𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑑 𝑙𝑒𝑛𝑔𝑡ℎ 𝑠𝑖𝑧𝑒 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑚𝑜𝑙𝑑 𝑙𝑒𝑛𝑔𝑡ℎ = 845𝑚𝑚

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 𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑤𝑖𝑑𝑡ℎ 𝑠𝑖𝑧𝑒
= 𝑡𝑜𝑡𝑎𝑙 𝑝𝑙𝑎𝑡𝑒 𝑤𝑖𝑑𝑡ℎ + 𝑡𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑑 𝑤𝑖𝑑𝑡ℎ + 𝑐𝑜𝑚𝑝𝑎𝑐𝑡𝑜𝑟 𝑤𝑖𝑑𝑡ℎ + 𝑝𝑖𝑠𝑡𝑜𝑛 𝑠𝑖𝑧𝑒

𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑤𝑖𝑑𝑡ℎ 𝑠𝑖𝑧𝑒 = 420𝑚𝑚 + 259 + 400𝑚𝑚 + 420𝑚𝑚 = 1499𝑚𝑚

Over all Height of the machine

𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 ℎ𝑒𝑖𝑔ℎ𝑡 𝑠𝑖𝑧𝑒 = 300𝑚𝑚 + 150𝑚𝑚 + 100𝑚𝑚 + 150𝑚𝑚 = 700𝑚𝑚

Overall length of the machine

𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑙𝑒𝑛𝑔𝑡ℎ 𝑠𝑖𝑧𝑒 = 845𝑚𝑚 + 30𝑚𝑚 = 875𝑚𝑚

3.3.2. Motor Selection

The overall motor performance is related to the following parameters

 Acceleration capabilities
 Breakdown torque
 Efficiency
 current
 Power factor
 Service factor
 Sound level
 Speed
A good motor specification should define performance requirement and describe the
environment within which the motor operates. As the purchase, you should avoid writing design
based specification that would require modification of standard components such as the frame,
bearing, design, rotor design, or insulation.

Specification contents should include

 Motor horsepower and service factors

 Temperature rise and insulation class
 Maximum starting current
 Minimum stall time
 Power factor range
 Efficiency requirement and test standard to be used

33 | P a g e
Motor selection for vibrating the mold to compact the aggregate

Due to the power output from the motor, there is rotational motion of the pulley. The pulley drives a belt
that are used to transmit power from one shaft to another by means of pulley which rotates at the same
speed or different speed it is very important to obtain all the listed performance before making selection

 Source of input power

 Types of driven equipment
 Power to be transmitted
 Speed and size of driven shaft
 Means of center distance arrangement,
 Available lubrication type

Motor specification from European standard table by considering all the above preconditions of
selecting the motor having, the power of 2.2kw is selected.

HP KW Rpm Power factor(%) Efficiency(%) Current(A) Torque(N-

M)

3 2.2 2875 87.5 83.2 4.36 7.279

Table 6 Motor selection for compactor

Selection of DC Motor for traveling

Motor specification from standard table by considering all the above preconditions of selecting the
motor having, the power of 1.1 kw is selected.

KW Rpm

1.1 690

Table 7 Motor selection for traveling

3.3.3. Design of V-Belt and Pulley

Design of v-belt

Material property of belt

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  Material used for the belt is oak tanned leather
𝑘𝑔
 density of (𝜌) =1000 ⁄𝑚3
42.6
 coefficient of friction between belt and the pulley rim, 𝜇 = 0.54 − 152.6+𝑣 = 0.27

 the allowable tensile strength is 2 MPa may be expected to give a belt life of 15 years, over load
factor equal to 1.5

Assumption

 the central distance between pulley is 500mm

 pulley is connected by v type of belt
 the driving pulley effective diameter is 140mm
 The angle of groove on the pulley for v-belt is 36° from standard (32° to 38°)
𝑘𝑔⁄
 For the material pulley is cast iron which has mass density of (𝜌) =7200 𝑚3 from standard ,
speed ratio is 2,
To find the diameter of pulley
𝑁1 𝐷1
=
𝑁2 𝐷2

𝑁2 𝐷1 2875 𝑟. 𝑝. 𝑚 ∗ 140𝑚𝑚
𝐷2 = =
𝑁1 5750 𝑟. 𝑝. 𝑚
𝐷2 = 70𝑚𝑚

For open belt drive

𝑟2 − 𝑟1 𝐷2 −𝐷1 0.14 − 0.07

𝑠𝑖𝑛𝛼 = = = = 0.07
2𝑋 2𝑋 2 ∗ 0.5

sin−1 0.07 = 4.02

And the angle of the pulley on the pulley (pulley on the motor),

𝜃 = 180 − 2𝛼 = 180 − 4.01°

𝜃 = 175.9°

𝜃 = 175.9° ∗ 𝜋⁄180 = 3.07𝑟𝑎𝑑

35 | P a g e
We know that of the belt per meter length

mass = Area × length × density = 350 ∗ 10−6 ∗ 0.5 ∗ 1000 = 0.175𝐾𝑔

velocity of the belt

𝜋 ∗ 𝐷1 ∗ 𝑁1 (𝜋 ∗ 2875 ∗ 0.14)
𝑣= = ⁄60 = 21.07 𝑚⁄𝑠
60

Centrifugal tension,

𝑇𝐶 = 𝑚 ∗ 𝑣 2 = 0.175 ∗ 21.072 = 3.687𝑁

And maximum tension in the belt,

𝑇 = 𝜎 ∗ 𝐴 = 2 ∗ 350 = 700𝑁

Tension in the tight side of the belt

𝑇1 = 𝑇 − 𝑇𝐶 = 700 − 3.687 = 696.313𝑁

Tension on slack side

𝑇2 𝑇2
2.3 log ( ) = 𝜇 ∗ 𝜃 ∗ csc 𝛽° = 2.3 log ( ) = 0.27 ∗ 3.07 ∗ csc 18° =
𝑇1 696.313

𝑇2
log ( ) = 1.166 … … 𝑢𝑠𝑖𝑛𝑔 𝑎𝑛𝑡𝑖𝑙𝑜𝑔 𝑡𝑜 𝑓𝑖𝑛𝑑 𝑡ℎ𝑒 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑇2
696.313

𝑇2 = 47.48𝑁

Number of belts required

The power transmission per belt

(𝑇1 − 𝑇2 )𝑣 = (698.313 − 47.48) ∗ 21.07 = 13713.05𝑤 = 13.71𝑘𝑤

Therefore

𝑡𝑜𝑡𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 2.2𝑘𝑤

= = = 0.1681
𝑝𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑝𝑒𝑟 𝑏𝑒𝑙𝑡 13.085𝑘𝑤

So standing from this result, we can conclude that one belt is agreeable.

36 | P a g e
We know that the length of the belt

𝑙 = 𝜋 ∗ (𝑟1 − 𝑟2 ) + 2𝑥 + (𝑟1 − 𝑟2 )2 = 𝜋 ∗ (0.07 − 0.035) + 2 ∗ 0.5 + (0.07 − 0.035)2 = 1.1124𝑚

Subtracting 36mm for “A” type belt, we find that inside length of the belt:

= 1112.40 − 36 = 1076.4𝑚𝑚

According to IS: 2494-1974, the nearest standard inside, length of the V-belt is 1128mm.

The dimensions for standard v-grooved pulley and belt are shown in the following table,

from which we find that for ‘A’ type belt

 Minimum pitch diameter of pulley (D) =75mm

 Top width (b) =13mm
 thickness (t) =8mm
 weight per meter length in=1.06N
 13mm, thickness (t) =8mm, weight per meter length in=1.06N

Type of Power ranges in Minimum Top width Thickness (t) Weight per
belt kw pitch diameter (b)mm mm meter length in
of newton
pulley(D)mm

A 0.7-3.5 75 13 7 1.06

B 2-15 125 17 11 1.89

C 7.5-75 200 22 14 3.43

D 20-150 355 32 19 5.96

E 30-350 500 38 23

Table 8 Dimensions of standard V-belts according to IS: 2494 – 1974[8]

Type of belt w D A f E No of Groove angle (2𝛽) in

sheave degrees
grooves(n)

37 | P a g e
 A 11 12 8.7 10 15 6 32,34,38

B 14 15 10.8 12.5 19 9 32,34,38

C 19 20 14.3 17 25.5 14 34,36,38

D 27 28 19.9 24 37 14 34,36,38

E 32 33 23.4 29 44.5 20 -

3.3.4. Design of Worm and Worm Gear

Let

Table 9 Dimensions of standard V-grooved pulleys (All dimensions in mm)[8] 𝑙𝑁 =

𝑁𝑜𝑟𝑚𝑎𝑙 𝑙𝑒𝑎𝑑
λ = Lead angle

𝑋
the value of will be minimum corresponding to
𝑙𝑁

Cot3 λ = V.R. = 14 or cot λ = 2.41

λ= 22.5°

𝑋 1 1 𝑉. 𝑅
= ( + )
𝑙𝑁 2𝜋 sin λ cos λ
70 1 1 14
= ( + )
𝑙𝑁 2𝜋 sin 22.5 cos 22.5
70 1
= (2.613 + 15.15)
𝑙𝑁 2𝜋
𝑙𝑁 = 24.765𝑚𝑚

And axial lead

𝑙𝑁 24.765
𝑙= = = 26.79𝑚𝑚
cos λ cos 22.5

From Table, we can find for a velocity ratio of 14, the number of starts or threads on the worm.
𝑛 = 𝑇𝑊 = 2
Axial pitch of the threads on the worm,

38 | P a g e
 𝑙 26.79
𝑝𝑎 = = = 13.39𝑚𝑚
𝑛 2

𝑝𝑎 13.39𝑚𝑚
𝑚= = = 4.26𝑚𝑚
𝜋 𝜋

Let us take the standard value of module. 𝑚 = 6𝑚𝑚

Axial pitch of the thread on the worm

𝑝𝑎 = 𝜋𝑚 = 𝜋 × 6 = 18.849𝑚𝑚

Axial lead of the threads on the worm

𝑙 = 𝑝𝑎 × 𝑛 = 13.39𝑚𝑚 × 2 = 26.78𝑚𝑚

And normal lead of the threads on the worm,

𝑙𝑁 = 𝑙 cos λ = 26.78 cos 22.5 = 24.74𝑚𝑚

We know that the center distance

𝑙𝑁 1 𝑉. 𝑅 24.74 1 14 24.74
𝑋= ( + )= ( + )= (2.613 + 15.15) = 69.95𝑚𝑚
2𝜋 sin λ cos λ 2𝜋 sin 22.5 cos 22.5 2𝜋

𝑙𝑒𝑡 𝐷𝑊 = 𝑝𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑤𝑜𝑟𝑚

We know that

𝑙
tan λ =
𝜋𝐷𝑊

𝑙 26.78𝑚𝑚
𝐷𝑊 = = = 20.579𝑚𝑚
πtan λ 𝜋 tan 22.5

Since the velocity ratio is 14 and the worm has double threads (i.e. n = TW =2), therefore number of
teeth on the worm gear,
𝑇𝐺 = 14 × 2 = 28

From Table 31.3, we find that the face length of the worm or the length of threaded portion is

Proportions for worm gear

39 | P a g e
S. Particulars Single and double Triple and quadruple
No threaded worms
threaded worms

1. Normal pressure angle (φ) 14½° 20°

2. Pitch circle diameter for worms integral with 2.35 pc + 10 mm 2.35 pc + 10 mm

the shaft

3. Pitch circle diameter for worms bored to fit 2.4 pc + 28 mm 2.4 pc + 28 mm

over the shaft

4. Maximum bore for shaft pc + 13.5 mm pc + 13.5 mm

5. Hub diameter 1.66 pc + 25 mm 1.726 pc + 25 mm

6. Face length (LW) pc (4.5 + 0.02 TW) pc (4.5 + 0.02 TW)

7. Depth of tooth (h) 0.686 pc 0.623 pc

8. Addendum (a) 0.318 pc 0.286 pc

𝐿𝑊 = 𝑝𝑐 (4.5 + 0.02𝑇𝑊 )

𝐿𝑤 = 18.849(4.5 + 0.02 × 2) = 85.574𝑚𝑚 , 𝑝𝑎 = 𝑝𝑐

This length should be increased by 25 to 30 mm for the feed marks produced by the vibrating wheel as it
leaves the thread root. Therefore let us take
𝐿𝑊 = 100𝑚𝑚

We know that depth of tooth

ℎ = 0.686𝑝𝑐 = 0.686 ∗ 18.849 = 12.93𝑚𝑚

And addendum

𝑎 = 0.318𝑝𝑐 = 0.318 ∗ 18.849 = 5.99𝑚𝑚

Outside diameter of worm,

𝐷𝑂𝑊 = 𝐷𝑊 + 2𝑎

40 | P a g e
 𝐷𝑂𝑊 = 20.579 + 2 × 5.99 = 32.559𝑚𝑚

Design of worm gear

We know that pitch circle diameter of the worm gear,

𝐷𝐺 = 𝑚 × 𝑇𝐺 = 6 × 28 = 168𝑚𝑚

From table 31.4 proportional for worm gear we can find the following parameter

S. Particulars Single and double threads Triple and quadruple threads

No.

1. Normal pressure angle (λ) 14½° 20°

2. Outside diameter (DOG) DG + 1.0135 pc DG + 0.8903 pc

3. Throat diameter (DT) DG + 0.636 pc DG + 0.572 pc

4. Face width (b) 2.38 pc + 6.5 mm 2.15 pc + 5 mm

5. Radius of gear face (Rf) 0.882 pc + 14 mm 0.914 pc + 14 mm

6. Radius of gear rim (Rr) 2.2 pc + 14 mm 2.1 pc + 14 mm

Outside diameter(𝐷𝑂𝐺 ),throat diameter(𝐷𝑇 ),facewidth(b)

𝐷𝑂𝐺 = 𝐷𝐺 + 1.0135𝑝𝑐 = 168 + 1.0135 × 18.849 = 187.103𝑚𝑚

Throat diameter,

𝐷𝑇 = 𝐷𝐺 + 0.636𝑝𝑐 = 168 + 0.636 × 18.849 = 179.987𝑚𝑚

And face width

𝑏 = 2.38𝑝𝑐 + 6.5𝑚𝑚 = 2.38 × 18.849 + 6.5 == 51.432mm

Let us now check the designed worm gearing from the standpoint of tangential load, dynamic
Load, static load or endurance strength, wear load and heat dissipation.

Check for the tangential load

41 | P a g e
let 𝑁𝐺 = 𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟 𝑖𝑛 𝑟𝑝𝑚

Number of starts to be used on the worm for different velocity ratios

Velocity ratio (V.R.) 36 and above 12 to 36 8 to 12 6 to 12 4 to 10

Number of starts or Single Double Triple Quadruple Sextuple

threads on the worm (n = Tw)

We know that velocity ratio of the drive,

𝑁𝑊 𝑁𝑊 690
𝑉. 𝑅 = 𝑜𝑟 𝑁𝐺 = = = 49.3𝑟𝑝𝑚
𝑁𝐺 𝑉. 𝑅 14

Torque transmitted,

𝑃 × 60 1100𝑤 × 60
𝑇= = = 213.1𝑁𝑚
2𝜋𝑁𝐺 2𝜋 ∗ 49.3

And tangential load acting on the gear

2 × 𝑡𝑜𝑟𝑞𝑢𝑒 2 ∗ 213.1
𝑊𝑇 = = = 2536.5𝑁
𝐷𝐺 0.168

We know that pitch line or peripheral velocity of the worm gear,

𝜋 × 𝐷𝐺 × 𝑁𝐺 𝜋 × 0.168 × 49.3
𝑉= = = 0.4336 𝑚⁄𝑠
60 60

Velocity factor

6 6
𝐶𝑉 = = = 0.932
6 + 𝑣 6 + 0.4336

And tooth form factor for 14 1⁄2 involute teeth,

0.684 0.684
𝑌 = 0.154 + = 0.154 + = 0.1784
𝑇𝐺 28

Recommended values of lead angle and pressure angle

42 | P a g e
 Lead angle(λ) 0 – 16 16 – 25 25 – 35 35 – 45

Pressure angle(∅) 14½ 20 25 30

in degrees

Since the worm gear is generally made of phosphor bronze, therefore taking the allowable static stress
for phosphor bronze, 𝜎° = 84𝑀𝑝 𝑜𝑟 𝑁⁄𝑚𝑚2

We know that the designed tangential load

𝑊𝑇 = (𝜎° × 𝐶𝑉 )𝑏 ∙ 𝜋 ∙ 𝑚 ∙ 𝑦 = (84 ∙ 0.932) ∙ 51.432 ∙ 𝜋 ∙ 6 ∙ 0.1784

𝑊𝑇 = 13542.3𝑁

Since this is more than the tangential load acting on the gear (i.e. 3422.12𝑁), therefore the design is
safe from the standpoint of tangential load.
Check for dynamic 3+load
We know that the dynamic load,

𝑊𝑇 13542.3
𝑊𝐷 = = = 14530.4𝑁
𝐶𝑉 0.932

Since this value is more than WT =3422.12𝑁, therefore the design is safe from the standpoint of
dynamic load.
Check for static load or endurance strength
We know that the flexural endurance limit for phosphor bronze is

𝜎𝑒 = 168𝑚𝑝𝑎 𝑜𝑟 𝑁⁄𝑚𝑚2

Static load or endurance strength,

𝑊𝑆 = 𝜎𝑒 ∙ 𝑏 ∙ 𝜋 ∙ 𝑚 ∙ 𝑦 = 168 ∙ 51.432 ∙ 𝜋 ∙ 6 ∙ 0.1784

𝑊𝑆 = 29056.2𝑁

Since this is much more than𝑊𝑇 = 3422.12𝑁, therefore the design is safe from the standpoint of static
load or endurance strength.
Check for wear

43 | P a g e
Assuming the material for worm as cast iron, therefore from Table 31.5, we find that for hardened steel
worm and phosphor bronze worm gear, the value of load stress factor,
Values of load stress factor (K).

S.N Material Load stress factor

Worm Worm gear (k) 𝑁⁄𝑚𝑚2

1. Steel (B.H.N. 250) Phosphor bronze 0.415

2. Hardened steel Cast iron 0.345

3. Hardened steel Phosphor bronze 0.550

4. Hardened steel Chilled phosphor bronze 0.830

5. Hardened steel Antimony bronze 0.830

6. Cast iron Phosphor bronze 1.035

𝐾 = 1.035 𝑁⁄𝑚𝑚2

Limiting or maximum load for wear,

𝑊𝑤 = 𝐷𝐺 ∙ 𝑏 ∙ 𝑘 = 168 ∙ 51.432 ∙ 1.035 = 8942.99𝑁

Since this is more than WT = 3422.12𝑁, therefore the design is safe from the standpoint of wear.

Check for heat dissipation

First of all, let us find the efficiency of the worm gearing

We know that rubbing velocity

𝜋𝐷𝑊 ∗ 𝑁𝑊 𝜋 ∗ 0.02057 ∗ 690

𝑉𝑟 = = = 48.263 𝑚⁄𝑚𝑖𝑛
cos 𝜆 cos 22.5

Coefficient of friction,

0.275 0.275
𝜇= = = 0.1043
(𝑣𝑟 )0.25 (48.263)0.25

44 | P a g e
For the rubbing speed between 12 and 180 m/min)

And angle of friction

∅1 = tan−1 𝜇 = tan−1 0.1043 = 5.956°

We know that efficiency,

tan λ tan 22.5

ƞ= = = 0.764𝑜𝑟 76.4%
tan(λ + ∅) tan(22.5 + 5.956)

Assuming 25 per cent overload, heat generated

𝑄𝑔 = 1.25𝑃(1 − ƞ) = 1.25 ∗ 1100(1 − 0.765)

𝑄𝑔 = 352.12𝑊

We know that projected area of the worm,

𝜋𝐷𝑊 2 𝜋(20.5792 )
𝐴𝑊 = = = 332.61𝑚𝑚2
4 4

And projected area of the worm gear

𝜋(𝐷𝐺 2 ) 𝜋(1682 )
𝐴𝐺 = = = 22167.1𝑚𝑚2
4 4

Total projected area of worm and worm gear,

𝐴 = 𝐴𝑊 + 𝐴𝐺 = 332.61 + 22167.1 = 22499.7𝑚𝑚2

We know that heat dissipating capacity

𝑄𝑑 = 𝐴(𝑡2 − 𝑡1 )𝐾 = 0.022499𝑚2 (𝑡2 − 𝑡1 )378, the average value of k may be taken as 378 𝑤⁄𝑚2 .
⁄℃

𝑄𝑑 = 8.504(𝑡2 − 𝑡1 )

The heat generated must be dissipated in order to avoid over heating of the drive, therefore
equating,𝑄𝑔 = 𝑄𝑑 we have
323.12
𝑡2 − 𝑡1 = = 37.9°
8.504

45 | P a g e
Since this temperature difference ( 𝑡2 − 𝑡1 ) is within safe limits of therefore the design is safe from the
standpoint of heat.
Design of worm shaft

𝑙𝑒𝑡 𝑑𝑤 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑤𝑜𝑟𝑚 𝑠ℎ𝑎𝑓𝑡

We know that torque acting on the worm gear shaft,

1.25×1100𝑊×60
Taking 25 percent of the load ,𝑇𝐺 = = 266.33𝑁𝑚
2𝜋×49.3

Torque acting on the worm shaft,

𝑇𝐺 266.33
𝑇𝑊 = =
𝑉. 𝑅 × ƞ 14 × 0.764

𝑇𝑊 = 24.899𝑁𝑚 𝑜𝑟 24.899 ∗ 103

We know that tangential force on the worm,

𝑊𝑇 = 𝑡𝑎𝑛𝑔𝑒𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑡ℎ𝑒 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟

2 × 𝑇𝑊 2 × 24.899 ∗ 103
𝑊𝑇 = = = 2419.9𝑁
𝐷𝑊 20.579

Axial force on the worm

𝑊𝐴 = 𝑎𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑡ℎ𝑒 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟

2 × 𝑇𝐺 2 × 266.33 × 103
𝑊𝐴 = = = 3170.59𝑁
𝐷𝐺 168

And radial or separating force on the worm

𝑊𝑅 = 𝑟𝑎𝑑𝑖𝑎𝑙 𝑜𝑟 𝑠𝑒𝑝𝑎𝑟𝑒𝑡𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑡ℎ𝑒 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟

𝑊𝑅 = 𝑊𝐴 × tan ∅ = 3170.59 × tan 5.956 = 330.8𝑁

Let us take the distance between the bearings of the worm shaft (𝑋1) equal to the diameter of the worm
gear(𝐷𝐺 ).
𝑋1 = 𝐷𝐺 = 168𝑚𝑚

Bending moment due to the radial force (𝑊𝑅 ) in the vertical plane
46 | P a g e
 𝑊𝑅 ∗ 𝑋1 330.8 ∗ 168
= = = 13892.8𝑁𝑚𝑚
4 4

And bending moment due to axial force (𝑊𝐴 ) in the vertical plane

𝑊𝐴 ∗ 𝐷𝑊 3170.59 ∗ 20.579
= = = 65247.6𝑁𝑚𝑚
4 4

Total bending moment in the vertical plane

𝑀1 = 65247.6 + 13892.8 = 79140.4𝑁𝑚𝑚

We know that bending moment due to tangential force (𝑊𝑇 ) in the horizontal plane,

𝑊𝑇 ∗ 𝐷𝐺 2419.9 ∗ 168
𝑀2 = = = 101635.8𝑁𝑚𝑚
4 4

Resultant bending moment on the worm shaft,

𝑀𝑤𝑜𝑟𝑚 = √(𝑀1 )2 + (𝑀2 )2 = √79140.42 + 1016352 = 128813.96

𝑀𝑤𝑜𝑟𝑚 = 128813.96𝑁𝑚𝑚

We know that equivalent twisting moment on the worm shaft,

𝑇𝑒𝑞 = √(𝑇𝑤𝑜𝑟𝑚 )2 + (𝑀𝑤𝑜𝑟𝑚 )2 = √(24.899 ∗ 103 )2 + (128813.96)2 = 131198.3𝑁𝑚𝑚

We also know that equivalent twisting moment (𝑇𝑒𝑞 ),

𝜋 𝜋
131198.3 = ∗ 𝜏(𝑑𝑊 )3 = ∗ 50𝑑𝑤 3 = 9.82(𝑑𝑤 )3
16 16

𝑑𝑤 = 23.7 𝑠𝑎𝑦 24𝑚𝑚

Let us now check the maximum shear stress induced.

We know that the actual shear stress,

16𝑇𝑒𝑞 16 ∗ 131198.3
𝜏= = = 48.33 𝑁⁄𝑚𝑚
𝜋(𝑑𝑤 )3 𝜋(24)3

And direct compressive stress on the shaft due to the axial force,

47 | P a g e
 𝑊𝐴 3170.59
𝜎𝑐 = 𝜋 = 𝜋 = 7.01 𝑁⁄𝑚𝑚
(𝑑𝑤 )2 242
4 4

Maximum shear stress

1 1
𝜏𝑚𝑎𝑥 = √(𝜎𝑐 )2 + 4𝜏 2 += √7.012 +4 ∗ 48.332 = 48.45𝑀𝑝𝑎
2 2

Since the maximum shear stress induced is less than 50 𝑀𝑝𝑎 ,therefore the design of worm shaft is
satisfactory.
Design of worm gear shaft

Let 𝐷𝐺 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟 𝑠ℎ𝑎𝑓𝑡

We have calculated above that the axial force on the worm gear
= 3170.59𝑁
Tangential force on the worm gear
= 2419.9𝑁

And radial or separating force on the worm gear

= 330.8𝑁

We know that bending moment due to the axial force on the worm gear

𝑎𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 ∗ 𝐷𝐺 3170.59 ∗ 168𝑚𝑚

= = = 133164.78𝑁𝑚𝑚
4 4

The bending moment due to the axial force will be in the vertical plane.
Let us take the distance between the bearings of the worm gear shaft 𝑋2 𝑎𝑠 120𝑚𝑚
Bending moment due to the radial force on the worm gear

𝑟𝑎𝑑𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 ∗ 𝑋2 330.8 ∗ 120𝑚𝑚

= = = 9924𝑁𝑚𝑚
4 4

The bending moment due to the radial force will also be in the vertical plane.
Total bending moment in the vertical plane

𝑀3 = 133164.78 + 9924 = 143088.78𝑁𝑚𝑚

We know that the bending moment due to the tangential force in the horizontal plane

48 | P a g e
 𝑡𝑎𝑛𝑔𝑒𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 ∗ 𝑋2 2419.9 ∗ 120𝑚𝑚
𝑀4 = = = 72597𝑁𝑚𝑚
4 4

Resultant bending moment on the worm gear shaft,

𝑀𝑔𝑒𝑎𝑟 = √(𝑀3 )2 + (𝑀4 )2 = √(143088.78)2 + (72597)2 = 160450.9𝑁𝑚𝑚

We have already calculated that the torque acting on the worm gear shaft,
𝑇𝑔𝑒𝑎𝑟 = 266.33𝑁𝑚

Equivalent twisting moment on the worm gear shaft

2
𝑇𝑒𝑞 = √(𝑇𝑔𝑒𝑎𝑟 ) + (𝑀𝑔𝑒𝑎𝑟 )2 = √(266.33 ∗ 1000)2 + (160450.9)2 = 310927.9𝑁𝑚𝑚

We know that equivalent twisting moment (𝑇𝑒𝑞 ),

𝜋
310.927 × 103 = 50(𝑑𝐺 )3
16

𝑑𝐺 = 31.63𝑚𝑚say 32mm

Let us now check the maximum shear stress induced.

We know that actual shear stress,

16𝑇𝑒𝑞 16 ∗ 310.927 × 103

𝜏= = = 48.32𝑀𝑝𝑎
𝜋(𝑑𝐺 )3 𝜋323

And direct compressive stress on the shaft due to the axial force

𝐴𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 3170.59

𝜎𝑐 = 𝜋 = 𝜋 = 3.94𝑀𝑝𝑎
(𝑑𝐺 )2 322
4 4

Maximum shear stress,

1 1
𝜏𝑚𝑎𝑥 = √(𝜎𝑐 )2 + 4𝜏 2 = √3.942 + 4 ∗ 48.322
2 2

𝜏𝑚𝑎𝑥 = 48.36𝑀𝑝𝑎

Since the maximum shear stress induced is less than 50 𝑀𝑝𝑎, therefore the design for worm gear shaft is
satisfactory.

49 | P a g e
Peripheral velocity of worm gear
𝜋 ∗ 𝐷𝐺 ∗ 𝑁𝐺 𝜋 ∗ 0.168 ∗ 49.3
𝑣= = = 0.433 𝑚⁄𝑠
60 60
3.3.5. Design of Gear Box Housing
Gear box casing is the most critical things in the design of gear box, since it is the cover of all machine
elements which are available in the gear box. It is may be made from many materials based on the
designed mechanical properties. Most of gear box casing is made from cast irons because of it have the
following mechanical properties:

 Good strength to weight ratio

 High machinability
 High corrosion resistance
 Inherently sound absorbing
 Excellent cast ability
 The ability to absorb mechanical vibration
 Relatively abundance raw material
 Relatively cheap Due to the reason of thus mechanical properties, we have selected cast iron
casing for our gear box

Where L is the largest dimension of the housing in mm, therefore, for cast iron casting case

𝑆 = 0.01𝐿 + 6 𝑚𝑚 = 0.01(207) + 6 𝑚𝑚 = 8 𝑚𝑚

𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑤𝑒𝑙𝑙, 𝑆 = 8𝑚𝑚

𝑇𝑜𝑝 𝑐𝑜𝑣𝑒𝑟 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠: 𝑆𝑐 = 0.8(𝑆) = 0.8(8) = 6.4𝑚𝑚 ≈ 7 𝑚𝑚

𝐹𝑙𝑎𝑛𝑔𝑒 𝑐𝑜𝑣𝑒𝑟 𝑏𝑜𝑙𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐𝑏 = 1.5(𝑆) = 1.5(8 𝑚𝑚)

= 12 𝑚𝑚, 𝑡ℎ𝑒 𝑛𝑒𝑎𝑟𝑒𝑠𝑡 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑏𝑜𝑙𝑡 𝑖𝑠 𝑀12 𝑏𝑜𝑙𝑡𝑠.

The maximum total gear box size is 207𝑚𝑚 ∗ 174𝑚𝑚 ∗ 36𝑚𝑚

3.3.6. Design of Hydraulic System

Hydraulic power pack selection

Common performance specification parameter

50 | P a g e
  Flow rate
 Working pressure
 Tank volume
 Electric motor
 Fluid type

It is selecting mini power pack unit because mini power pack unit they are suitable for mobility
application. They are slightly larger than micro power pack their tank capacity range between 0.8 and
30litter and they uses a DC 0.8kw to 4.0kw motor or AC 0.75kwto 7.5kw motor.

Purposes of major hydraulic components

 Pump: - changing mechanical energy to fluid energy in the form of flow

 Tanker: - store oil, allow air to be separated and sediment the dirties in the oil by using baffle
plate
 Control valves: - allow the fluid to the desired direction

 Actuator: - by acting linier motion, changes hydraulic motion to mechanical motion

Pump selection

Before selecting of pump it is very essential to know number of consideration for a complete
hydraulic system and particular application. Some of the importance parameter are

 Flow rate requirements

 Operating speed

 Pressure rating

 Performance

 Reliability

 Maintenance

 Cost and economy

 Noise level

51 | P a g e
 S.No Description
1 Tank 6 liters
2 Gear pump
3 Electrical motor 2 hp
4 Flow rate( Q = 6 L ⁄ min)
5 Pressure 160 bar
Table 10 Selection of hydraulic pack

Cylinder Force, Velocity, Acceleration and Power

The aim is to find the stroke length of the hydraulic cylinder. For this the most important data required is
the maximum and minimum height of the material to be achieved. This date mainly gain from geometric
analysis of mold system.
Procedure for finding the stroke
From the given specification the vertical position suspended by the arm for maximum and minimum
height at point various force acting on arm at different lifting position.
The output force (F) and piston velocity (V) of double acting cylinders are not the same for extension
and retraction strokes since strokes means the distance a plunger must travel before it is stopped.

Design of Double Acting Piston

A double-acting cylinder has no spring inside to return it to its original position. It needs two hydraulic
oil supplies, one to outstroke the piston and the other to in stroke the piston. To outstroke a double-
acting cylinder we need oil to push against the piston inside the cylinder. As this happens, any oil on the
other side of the piston is forced out. This causes the double-acting cylinder to outstroke. When the
piston has fully out stroked it is said to be positive.

Double-acting cylinders are used more often in pneumatic systems than single-acting cylinders. They are
able to produce bigger forces and we can make use of the outstroke and instroke for pushing and pulling.

Figure 12 Double Acting Cylinder

52 | P a g e
To in stroke a double-acting cylinder we need to reverse this action. We supply the compressed air to the
other side of the piston. As the air pushes the piston back to its original position, any air on the other
side is again forced out. This causes the piston to in stroke and it is said to be negative.

Double-acting cylinders are used more often in pneumatic and hydraulic systems than single-acting
cylinders. They are able to produce bigger forces and we can make use of the outstroke and in stroke
for pushing and pulling.

Effective areas during extension and retraction strokes

During the extension stroke shown in Figure (a), the fluid pressure acts on the entire circular piston
area 𝑨𝒑 . During the retraction stroke, the fluid enters the rod end side and the fluid pressure acts on
the smaller annular area between rod and cylinder bore ( 𝑨𝒑 − 𝑨𝒓 ) as shown by the shaded area in
(b). Ar, is the area of the piston rod. Due to the difference in the cross sectional area, the velocity of
piston changes. Since Ap is greater than ( 𝑨𝒑 − 𝑨𝒓 ), the retraction velocity ( 𝑽𝒓𝒆𝒕 ) is greater than
the extension velocity ( 𝑽𝒆 ) for the same flow rate.

During the extension stroke, fluid pressure acts on the entire piston area while during retraction
stroke, the fluid pressure acts on the annular area ( 𝑨𝒑 − 𝑨𝒓 ),this difference in area accounts for
difference in output forces during extension and retraction strokes. Since ( 𝑨𝒓 ) is greater
than ( 𝑨𝒑 − 𝑨𝒓 ), the extension force is greater than the retraction force for the same operating
pressure.

The output force (F) and piston velocity (V) of double acting cylinders are not the same for
extension and retraction strokes.

53 | P a g e
 Figure 13 Extension and retraction stroke
Design of hydraulic cylinder one

These piston is used for moving the compactor in down ward direction the compactor is placed above
the mold in 40mm.

Cylinder specification

• Bore diameter = 80 mm

• Rod diameter =40 mm

• Stroke length= 50 mm

• Pump specification: Max. Pressure 160 ∗ 105 𝑝𝑎

• Q = 6 L ⁄ min

• Load specification

These pistons used to lift the compactor mold in to the base mold. The mass of the compactor equal to
40 kg then divided by two pistons that carry these load.

Then 𝑨𝒑 − 𝑨𝒓 , is subject to fluid pressure to 20kg then divide by the two piston that carry these load

Force = ma = 20kg ∗ 9.81 𝑚⁄𝑠 = 196.2𝑁

𝜋𝐷2 𝜋(0.08)2
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟(𝐴𝑃 ) = = = 5. .03 ∗ 10−3 𝑚2
4 4

54 | P a g e
 𝜋𝐷2 𝜋(0.04)2
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑟𝑜𝑑(𝐴𝑟 ) = = = 1.256 ∗ 10−3 𝑚2
4 4

𝐴𝑃 − 𝐴𝑟 = 5. .03 ∗ 10−3 𝑚2 − 1.256 ∗ 10−3 𝑚2 = 3.77 ∗ 10−3 𝑚2

Force and velocity during extension stroke

𝑄𝑖𝑛
𝑉𝑒𝑥𝑡 =
𝐴𝑝

𝐹𝑒𝑥𝑡 = 𝑝 ∗ 𝐴𝑝

Force and velocity during retraction stroke

𝑄𝑖𝑛
𝑉𝑟𝑒𝑡 =
𝐴𝑝 − 𝐴𝑟

𝐹𝑟𝑒𝑡 = 𝑝 ∗ (𝐴𝑝 − 𝐴𝑟 )

Power developed by hydraulic cylinder (during extension and retraction stroke)

𝑝𝑜𝑤𝑒𝑟 = 𝑓𝑜𝑟𝑐𝑒 ∗ 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 𝐹 ∗ 𝑉

Power during extension

𝑄𝑖𝑛
𝑃𝑒𝑥𝑡 = 𝐹𝑒𝑥𝑡 ∗ 𝑉𝑒𝑥𝑡 = 𝑃 ∗ 𝐴𝑃 ∗ = 𝑃 ∗ 𝑄𝑖𝑛
𝐴𝑃

Power during retraction

𝑄𝑖𝑛
𝑃𝑟𝑒𝑡 = 𝐹𝑟𝑒𝑡 ∗ 𝑉𝑟𝑒𝑡 = 𝑃 ∗ (𝐴𝑃 − 𝐴𝑟 ) ∗
(𝐴𝑃 − 𝐴𝑟 )

We can conclude that the powers during extension and retraction strokes are same

Extension force

𝐹𝐸𝑥𝑡 = 𝑝 ∗ 𝐴𝑝 = 160 ∗ 105 𝑝𝑎 ∗ 5. .03 ∗ 10−3 𝑚2 = 80.48𝐾𝑁

Extension velocity

𝑄𝑖𝑛 6𝑚3
𝑉𝑒𝑥𝑡 = = = 0.0199 𝑚⁄𝑠
𝐴𝑝 5. .03 ∗ 10−3 𝑚2 ∗ 60 ∗ 1000

Retraction force

55 | P a g e
 𝐹𝑟𝑒𝑡 = 𝑝 ∗ (𝐴𝑝 − 𝐴𝑟 ) = 160 ∗ 105 𝑝𝑎 ∗ 3.77 ∗ 10−3 𝑚2 = 60.32𝐾𝑁

Retraction velocity

𝑄𝑖𝑛 6𝑚3
𝑉𝑟𝑒𝑡 = = = 0.0265 𝑚⁄𝑠
(𝐴𝑝 − 𝐴𝑟 ) 3.77 ∗ 10−3 𝑚2 ∗ 60 ∗ 1000

Power during extension

𝑃𝑒𝑥𝑡 = 𝐹𝑒𝑥𝑡 ∗ 𝑉𝑒𝑥𝑡 = 80.48𝐾𝑁 ∗ 0.0199 = 1.6𝐾𝑊

Power during retraction

𝑃𝑟𝑒𝑡 = 𝐹𝑟𝑒𝑡 ∗ 𝑉𝑟𝑒𝑡 = 60.32𝐾𝑁 ∗ 0.0265 𝑚⁄𝑠 = 1.6𝐾𝑊

Therefore, Power during extension and power during refraction are the same.

Design of Double Acting Piston Two

The piston move vertically from up to down for moving the base mold.
Stroke length of cylinder
The critical compacter moves in vertically with the reaching maximum height of 300mm to the ground
and minimum height of 100mm from the block.
 Bore diameter = 64 mm
 Rod diameter = 35 mm
 Stroke length = 300 mm
 Pump specification: Max. Pressure = 160 ∗ 105 𝑝𝑎
 𝑄 = 6 𝐿⁄𝑚𝑖𝑛

Load specification

These pistons used to lift the base mold in upward direction . The mass of the mold equal to 60kg then
divided by two pistons that carry these load

Force = ma = 30kg ∗ 9.81 𝑚⁄𝑠 = 294.3𝑁

𝜋𝐷2 𝜋(0.064)2
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟(𝐴𝑃 ) = = = 3.22 ∗ 10−3 𝑚2
4 4

56 | P a g e
 𝜋𝐷2 𝜋(0.035)2
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑟𝑜𝑑(𝐴𝑟 ) = = = 9.621 ∗ 10−4 𝑚2
4 4

𝐴𝑃 − 𝐴𝑟 = 3.22 ∗ 10−3 𝑚2 − 9.621 ∗ 10−4 𝑚2 = 2.25 ∗ 10−3 𝑚2

Extension force

𝐹𝐸𝑥𝑡 = 𝑝 ∗ 𝐴𝑝 = 160 ∗ 105 𝑝𝑎 ∗ 3.22 ∗ 10−3 𝑚2 = 51.5𝐾𝑁

Extension velocity

𝑄𝑖𝑛 6𝑚3
𝑉𝑒𝑥𝑡 = = = 0.031 𝑚⁄𝑠
𝐴𝑝 3.22 ∗ 10−3 𝑚2 ∗ 60 ∗ 1000

Retraction force

𝐹𝑟𝑒𝑡 = 𝑝 ∗ (𝐴𝑝 − 𝐴𝑟 ) = 160 ∗ 105 𝑝𝑎 ∗ 2.25 ∗ 10−3 𝑚2 = 36.12𝐾𝑁

Retraction velocity

𝑄𝑖𝑛 6𝑚3
𝑉𝑟𝑒𝑡 = = = 0.044 𝑚⁄𝑠
(𝐴𝑝 − 𝐴𝑟 ) 2.25 ∗ 10−3 𝑚2 ∗ 60 ∗ 1000

Power during extension

𝑃𝑒𝑥𝑡 = 𝐹𝑒𝑥𝑡 ∗ 𝑉𝑒𝑥𝑡 = 51.5 ∗ 0.031 = 1.59𝐾𝑊

Power during retraction

𝑃𝑟𝑒𝑡 = 𝐹𝑟𝑒𝑡 ∗ 𝑉𝑟𝑒𝑡 = 60𝐾𝑁 ∗ 0.044 𝑚⁄𝑠 = 1.589𝐾𝑊

Therefore, Power during extension and power during refraction are the same.

Design of Double Acting Piston Three

This piston is used to enter the compactor to the machine main part.

Cylinder specification

 Bore diameter = 60 mm
 Rod diameter = 40 mm
 Stroke length = 410mm

57 | P a g e
  Pump specification: Max. Pressure = 160 ∗ 105 𝑝𝑎
 𝑄 = 6 𝐿⁄𝑚𝑖𝑛

Load specification

These pistons used to lift the compactor mold in to the forward and backward direction . The mass of the
mold equal to 40kg then divided by two pistons that carry these load

Force = ma = 60kg ∗ 9.81 𝑚⁄𝑠 = 588.6𝑁

𝜋𝐷2 𝜋(0.06)2
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟(𝐴𝑃 ) = = = 2.8275 ∗ 10−3 𝑚2
4 4

𝜋𝐷2 𝜋(0.04)2
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑟𝑜𝑑(𝐴𝑟 ) = = = 1.256 ∗ 10−3 𝑚2
4 4

𝐴𝑃 − 𝐴𝑟 = 2.8275 ∗ 10−3 𝑚2 − 1.256 ∗ 10−3 𝑚2 = 1.57 ∗ 10−3 𝑚2

Extension force

𝐹𝐸𝑥𝑡 = 𝑝 ∗ 𝐴𝑝 = 160 ∗ 105 𝑝𝑎 ∗ 2.8275 ∗ 10−3 𝑚2 = 45.24𝐾𝑁

Extension velocity

𝑄𝑖𝑛 6𝑚3
𝑉𝑒𝑥𝑡 = = = 0.035 𝑚⁄𝑠
𝐴𝑝 2.8275 ∗ 10−3 𝑚2 ∗ 60 ∗ 1000

Retraction force

𝐹𝑟𝑒𝑡 = 𝑝 ∗ (𝐴𝑝 − 𝐴𝑟 ) = 160 ∗ 105 𝑝𝑎 ∗ 1.57 ∗ 10−3 𝑚2 𝑚2 = 25.12𝐾𝑁

Retraction velocity

𝑄𝑖𝑛 6𝑚3
𝑉𝑟𝑒𝑡 = = = 0.064 𝑚⁄𝑠
(𝐴𝑝 − 𝐴𝑟 ) 1.57 ∗ 10−3 𝑚2 ∗ 60 ∗ 1000

Power during extension

𝑃𝑒𝑥𝑡 = 𝐹𝑒𝑥𝑡 ∗ 𝑉𝑒𝑥𝑡 = 58.53 ∗ 0.035 = 1.6𝐾𝑊

Power during retraction

𝑃𝑟𝑒𝑡 = 𝐹𝑟𝑒𝑡 ∗ 𝑉𝑟𝑒𝑡 = 25.12𝐾𝑁 ∗ 0.064 𝑚⁄𝑠 = 1.6𝐾𝑊

58 | P a g e
Therefore, Power during extension and power during retraction are the same.

Position analyses of piston 1,2 and 3

The role purpose of position analysis is to determine the location of all links as the driving link of the
mechanism is moved in to another position. Position analysis often involves repositioning the links of a
mechanism between two alternate arrangements but in our case the motion of the mechanism have linear
motion toward the Y- axis and x axis, move down ward only and move back ward respectively. Position
of the cylinder is constant during rest and operation. But the position of the piston rod position linearly
by magnitude same to the magnitude of the stroke.

3.3.7. Design of Bearing Cap

Cap is generally regarded as simple support beam supported by holding down and loaded at the center

A= diameter between center of holding down bolt

W= load supported at center

L= length of the bearing

T =thickness of the cap

The material used to make the bearing cap is cast iron. Cast iron have the following properties

 Ultimate tensile strength equal to 190Mpa

 Yield strength equal to 1130Mpa
 Modulus of elasticity equal to 91Gpa
 Distance between bolt center =130mm
 Width of the bearing cap(t)=30mm
 Factor of safety =3mm
 Allowable tensile stress
𝜎𝑢𝑙𝑡 190𝑀𝑝𝑎⁄
𝜎𝑎𝑙𝑙 = ⁄𝑘 = 3
𝜎𝑎𝑙𝑙 = 63.3𝑀𝑝𝑎

To calculate the maximum shear stress find the ultimate shear stress of cast iron

ultimate shear stress ≈ 0.75 ∗ 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠

59 | P a g e
 ultimate shear stress ≈ 0.75 ∗ 190𝑀𝑝𝑎

ultimate shear stress ≈ 142.5𝑀𝑝𝑎

allowable shear stress

𝜏𝑢𝑙𝑡 142.5
𝜏= = ⁄3 = 47.5𝑀𝑝𝑎
𝑘

Then find the volume of the shaft

𝑣𝑠 = 𝜋 ∗ 𝑟 2 ∗ 𝑙 = 𝜋 ∗ 0.012 ∗ 0.845

𝑣𝑠 = 2.654 ∗ 10−4 𝑚3

𝑘𝑔⁄ 𝑚
𝑤𝑠 = 𝑣𝑠 ∗ 𝜌 ∗ 𝑔 = 2.654 ∗ 10−4 𝑚3 ∗ 7870 𝑚3 ∗ 9.81 ⁄𝑠 2

𝑤𝑠 = 20.49𝑁

Mass of the other weight

= 8.5 ∗ 9.81 = 83.385𝑁

There are four bearing used to support the shaft so divide the total weight by number of bearing

20.49𝑁 + 83.385𝑁
𝑤𝑡𝑏 =
4

𝑤𝑡𝑏 = 25.9 𝑁

To find the bending stress

3 ∗ 𝑤𝑡𝑏 ∗ 𝑎 3 ∗ 25.9 ∗ 100𝑚𝑚

𝜎𝑏 = = = 0.074𝑀𝑝𝑎
2 ∗ 𝑙 ∗ 𝑡2 2 ∗ 130𝑚𝑚 ∗ 202

The bending stress of the bearing is 0.074Mpa1<63.34Mpa

Diameter of bolt

𝜋 4 𝑤
∗ 𝑑𝑐 2 ∗ 𝜎𝑡 = ∗
4 3 𝑛

For simple supported beams at the center the deflection is since there are two bolts in this

60 | P a g e
bearing support so divide w by number of bolt

𝑤 ∗ 𝑎3 𝑙 ∗ 𝑡 2 130 ∗ 202
𝛿= ,𝐼 = = = 4333.3𝑚𝑚
48 ∗ 𝐸 ∗ 𝐼 12 12

𝑤 ∗ 𝑎3 25.9 𝑁 ∗ 1003
𝛿= = = 1.33 ∗ 10−3 𝑚𝑚
48 ∗ 𝐸 ∗ 𝐼 48 ∗ 90 ∗ 103 𝑀𝑝𝑎 ∗ 4333.3𝑚𝑚

In order to design the holding down bolt the load on each of the bolt is taken as 33% higher than the
normal load on the bolt

Since the load design for a bolt should be 33% higher than the normal load

𝑤 = 25.9 + 0.33 ∗ 25.9 = 34. .447𝑁

𝜋 4𝑤 98
∗ 𝑑𝑐 2 ∗ 𝜎𝑡 = , 𝜎𝑡 = = 25.4 𝑀𝑝𝑎
4 3𝑛 4

So ,

𝜋 ∗ 𝑑𝑐 2 ∗ 24.5𝑀𝑝𝑎 4 ∗ 34.447
= = 𝑑𝑐 = 3.8𝑚𝑚 𝑠𝑎𝑦 10𝑚𝑚
4 3∗4

3.3.8. Design of Frame

Design of support frame

Material selection for the support frame

Determinate Beam

The force and moment of reactions at supports can be determined by using the 3 equilibrium equations
of statics i.e. ƩFx = 0, ƩFy = 0, ƩM = 0.

 steel

Assumption: consider the rectangular beam of width b and height h carries a concentrated load p which
is a point load on a simple supported span of length 4Lm since the shear to each point as follows figure
bellow

61 | P a g e
 1 (60∗9.81)
From the figure 𝑉𝑚𝑎𝑥 = 2 𝑝 = = 294.3 and
2

1 1 1 1
𝑀𝑚𝑎𝑥 = 𝐿( 𝑝) = 𝑝𝐿 = 𝑥 885𝑚𝑚 𝑥588.6 = 130.22 𝑥 10³𝑁/𝑚𝑚
2 2 4 2

From flexure formula

1
6𝑀 6(4 𝑝𝐿) 3𝑃𝐿 3𝑥588.6𝑥885
𝑓𝑏 = = = = = 12.20𝑁/𝑚𝑚
𝑏ℎ² 𝑏ℎ² 2𝑏ℎ² 2𝑥 40𝑥 40

3𝑃𝐿
𝑏ℎ =
2𝑓𝑏 ℎ

For shear stress formula

1
3𝑉 3( 2 𝑃)
𝑓𝑏 = = 3𝑃𝐿
2𝑏ℎ 2( )
2𝑓𝑏 ℎ

𝑓𝑏 ℎ 12.2088𝑥40
𝑓𝑣 = = = 0.275𝑁/𝑚𝑚
2𝐿 2𝑥885

Design of the column

The hoisting part of the machine needs to design a column. This is because that the sheave is put on the
beam and in turn the beam is mounted on the column. These columns carry the load, so we are going to
62 | P a g e
design this column. In the design as a considered factor of a 1-m-long with in a position of pined line
with 730mm welded-ended column of square cross section is to be made of high strength.

Assumption;

 Length of the column is 1000mm.

 The column material is high strength steel, with 𝐸 = 200𝐺𝑃𝑎, 𝜎𝑎𝑙𝑙 𝑎𝑙𝑠𝑜 100 𝑀𝑃𝑎
 Factor of safety 2.5 in computing Euler’s critical load for buckling

Since in order to determine the size of the cross section if the column is to safely support we have the
load of the compactor which is 𝑙𝑜𝑎𝑑 = 60𝑘𝑔

Using the given factor of safety, we make

Pcr = 2.5(60 kN) = 150kN

The total load of that going to carry on the column is 60 ∗ 9.81 = 588.6𝑁, since in order to determine
the size of the cross section if the column is to safely support we have the load of the compactor which
is 𝑙𝑜𝑎𝑑 = 60𝑘𝑔, but we intended to use two columns so the load is divided in to two equal parts .

588.6
𝐿 = = 294.3𝑁
2

Fig. plane of buckling

Buckling in the XY plane

The effective length of the column with respect to buckling in the plane is, 𝐿𝑒 = 0.7𝐿 the radius of
gyration 𝑟𝑍 of the cross section is obtained by

𝑏𝑎³
𝑆𝑜 𝐼𝑧 =
12

𝐴 = 𝑎𝑏 𝑠𝑖𝑛𝑐𝑒 𝐼𝑧 = 𝐴 × 𝑟𝑍²

63 | P a g e
 𝑏𝑎3
2
𝐼𝑧 12 𝑎2
𝑟𝑍 = = =
𝐴 𝑎𝑏 12

𝑎
𝑟𝑍 =
√12

The effective slenderness ratio of the column with respect to buckling in the X-Y plane is

𝐿𝑒 0.7𝐿
= 𝑎
𝑟𝑍
√12

Where 𝐿𝑒 is the effective length of the column

Buckling in the plane

The effective length of the column with respect to buckling in this plane is 𝐿𝑒 = 2𝐿, where 𝐿𝑒 is
the effective length which is when the given length is twice the actual length and the corresponding
radius of gyration is

𝐿𝑒 2𝑙
= 𝑏
𝑟𝑦
√12

𝑏
𝑟𝑦 =
√12

Most effective design

The most effective design is that for which critical stresses corresponding to the two possible modes of
buckling are equal. We note that this will be the case if the two values obtained above for the effective
slenderness ratio are equal.

We write them as follows;

0.7𝐿 2𝑙
𝑎 = 𝑏
√12 √12

since let us solve for the 𝑎⁄𝑏 ratio.

𝑆𝑜 𝑎⁄𝑏 = 0.7⁄2 = 0.35.

64 | P a g e
 𝜋2 𝐸
We know the critical load and the critical stress as 𝜎𝑐𝑟 = (𝐿⁄ since 𝐿⁄𝑟 is slender ratio so using
𝑟)²

𝑎 = 0.35𝑏, we have 𝐴 = 𝑎𝑏 = 𝑏𝑥0.35𝑏 = 0.35𝑏² and

𝑝𝑐𝑟 150
𝜎𝑐𝑟 = = 𝑎𝑥0.35𝑏² from 𝑒𝑞𝑛 (1) Making 𝐿 = 730𝑚𝑚. 𝑖𝑛 𝐸𝑞. (2), we have
𝐴

𝐿𝑒 2𝑙 2 × 2.5 × √12 17.3505

= 𝑏 = =
𝑟𝑦 𝑏 𝑏
√12

𝐿𝑒
Then substituting for E with in its and 𝜎𝑐𝑟 both we write them as
𝑟

𝜋2𝐸
𝜎𝑐𝑟 = 2
(𝐿⁄𝑟)

150 𝜋 2 (200)
=
0.35𝑏 2 17.3505 2
( 𝑏 )

so let us solve for b so

𝑏 = 15.976𝑚𝑚

Then a will be

𝑎 = 0.35 ∗ 𝑏 = 0.35𝑥15.976𝑚𝑚 = 5.5917𝑚𝑚

3.3.9. Design of hub(coupling)

Design of hub

1. Outer diameter of sleeve (𝐷)

2. Inner diameter of sleeve (𝐷𝑖 )
3. Length of sleeve (𝐿)
𝐷 = 2𝑑 + 13𝑚𝑚
𝐿 = 3.5𝑑

Inner diameter is equal to the shaft diameter (𝐷𝑖 = 𝑑)

Where 𝑑 is diameter of shaft.

Then calculate by using a shaft diameter
65 | P a g e
𝑑 = 24𝑚𝑚

𝐷 = 2𝑑 + 13𝑚𝑚 = 2 ∗ 24𝑚𝑚 + 13𝑚𝑚

𝐿 = 3.5𝑑 = 3.5 ∗ 24𝑚𝑚 = 84𝑚𝑚

We have to check the induced shear stress in hub (sleeve) let 𝜏𝑐 be the induced shear stress in hub
(sleeve) which is made of cast iron.

𝜋 (𝐷4 − 𝑑 4 )
T = × 𝜏𝑐
16 𝐷

𝑇 7279
𝜏𝑐 = 𝜋 (𝐷 4 −𝑑4 )
= 𝜋 614−214
= 0.165𝑁/𝑚𝑚²
∗ 16
×(
61
)
16 𝐷

Design of key of the hub

𝑓𝑜𝑟 𝑠ℎ𝑎𝑓𝑡 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 = 24𝑚𝑚

𝑊𝑖𝑑𝑡ℎ = 10𝑚𝑚

𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 8𝑚𝑚

𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑘𝑒𝑦 = 𝐿/2 = 84/2 = 42𝑚𝑚

Let us now check the induced shear and crushing stresses in the key. First of all, let us consider Shearing
of the key. We know that torque transmitted (T),

𝑇 = 𝑙 × 𝑤 × 𝑑/2 × 𝜏𝑆

𝜏𝑐 = 𝑇⁄
𝑙 ∗ 𝑤 ∗ 𝑑⁄2

7279𝑁/𝑚𝑚 7279
𝜏𝑆 = 24𝑚𝑚 = 𝑁/𝑚𝑚²
42𝑚𝑚 ∗ 10𝑚𝑚 ∗ 5040
2

𝜏𝑆 = 1.441𝑁/𝑚𝑚²

Now consider crushing of the key. We know that torque transmitted (T),

T = 𝑙 × 𝑡/2 × 𝑑/2 × 𝜎𝑐𝑠

66 | P a g e
 T 7279
𝜎𝑐𝑠 = = = 3.611𝑁/𝑚𝑚²
𝑙 × 𝑡/2 × 𝑑/2 42 × 8/2 × 24/2

The following table shows the proportions of standard parallel, tapered and gib head keys,

According to IS : 2292 and 2293-1974 (Reaffirmed 1992).

Proportion of standard parallel, tapered and gib head keys

Shaft diameter(mm)up to and Shaft diameter (mm)up to and Key cross section
Key cross section
including including

6 2 2 85 25 14

8 3 3 95 28 16

10 4 4 110 32 18

12 5 5 130 36 20

17 6 6 150 40 22

22 8 7 170 45 25

30 10 8 200 50 28

38 12 9 230 56 32

44 14 10 260 63 32

50 16 11 290 70 36

58 18 12 330 80 40

65 20 13 380 90 45

75 22 14 440 100 50

67 | P a g e
 3.3.10.Design of chain drive
The chains are mostly used to transmit motion and power from one shaft to another, when the
center distance between their shafts is short such as in bicycles, motor cycles, agricultural machinery,
conveyors, rolling mills, road rollers etc.

Classification of chains

The chains, on the basis of their use, are classified into the following three groups:

1. Hoisting and hauling(or crane)chains

2. Conveyor (or tractive)chains, and
3. Power transmitting(or driving)chains

Parameter that used for design chain drive

According to services classified as Extra light , Light ,Heavy ,Extra heavy ,Double extra heavy in our
machine we use light service so that the following data are associated with heavy service.

 Single chain
 Pitch(P) = 8𝑚𝑚
 Roller diameter (𝑑1 ) = 5𝑚𝑚
 Width (𝑏1 ) = 7.75𝑚𝑚
 Transverse pitch (𝑝1 ) = 5.64𝑚𝑚
 Breaking load = 4.4𝑘𝑁

Determine the velocity ratio of the chain drive

𝑁1 50
𝑉𝑅 = = =1
𝑁2 50

From table 21.5 for a velocity ratio 1

Teeth number equal to 31 with roller type chain

Number of teeth on larger sprockets

𝑁1
𝑇2 − 𝑇1 ∗ =0
𝑁2

68 | P a g e
 𝑁1
𝑇2 = 𝑇1 ∗ = 31 ∗ 1 = 31
𝑁2

Design of Power

𝑑𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = 𝑟𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 ∗ 𝑠𝑒𝑟𝑖𝑣𝑢𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟

The service factor(𝑘𝑠 ) is the product of various factor 𝑘1 , 𝑘2 𝑎𝑛𝑑 𝑘3

Load factor (𝑘1 ) for constant load =1

Lubrication factor (𝑘2 ) for drop lubrication = 1

Rated factor for 8 hours per day =1

𝑘𝑠 = 𝑘1 ∗ 𝑘2 ∗ 𝑘3 = 1 ∗ 1 ∗ 1 = 1

𝑑𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = 1 ∗ 1.4𝑘𝑤 = 1.4𝑘𝑤

Pitch circle diameter

𝑝 360°⁄ = 21.17°
𝐷= 𝛾 ,𝛾 = 17
sin ⁄2

8
𝐷= = 43.5𝑚𝑚
sin 21.17⁄2

Top diameter

𝑑𝑎𝑚𝑎𝑥 = 𝑑 + 1.25 ∗ 𝑝 − 𝑑1

𝑑𝑎𝑚𝑎𝑥 = 43.5 + 1.25 ∗ 8 − 5.0 = 48.5𝑚𝑚

1.6
𝑑𝑎𝑚𝑖𝑛 = 𝑑 + (1 − ) 𝑝 − 𝑑1
𝑇

1.6
𝑑𝑎𝑚𝑖𝑛 = 43.5 + (1 − ) 8.0 − 5.0 = 45.7𝑚𝑚
17

Tooth height

0.8
𝑘𝑚𝑎𝑥 = 0.625 ∗ 𝑝 − 0.5 ∗ 𝑑1 + ∗𝑝
𝑇

69 | P a g e
 0.8
𝑘𝑚𝑎𝑥 = 0.625 ∗ 8.0 − 0.5 ∗ 5.0 + ∗ 8.0 = 2.12𝑚𝑚
17

𝑘𝑚𝑖𝑛 = 0.5(𝑝 − 𝑑1 ) = 0.5(8.0 − 5.0) = 1.5𝑚𝑚

Chain wheel

3 3
𝑟1𝑚𝑎𝑥 = 0.505 ∗ 𝑑1 + 0.069 √𝑑1 = 0.505 ∗ 5.0 + 0.069 √5.0 = 2.64𝑚𝑚

𝑟1𝑚𝑖𝑛 = 0.505 ∗ 𝑑1 = 0.505 ∗ 5.0 = 2.525𝑚𝑚

90° 90°
𝑥𝑚𝑎𝑥 = 140° − = 140° − = 134.7°
𝑇 17

90° 90°
𝑥𝑚𝑖𝑛 = 120° − = 120° − = 114.7°
𝑇 17

𝑟2𝑚𝑖𝑛 = 0.008 ∗ 𝑑1 (𝑇 + 2) = 0.12 ∗ 5.0(17 + 2) = 11.4𝑚𝑚

𝑟2𝑚𝑎𝑥 = 0.008 ∗ 𝑑1 (𝑇 2 + 2) = 0.008 ∗ 5.0(172 + 2) = 11.64𝑚𝑚

Tooth width

Tooth width 𝐵1is narrower than width for p<12.7for single chain wheel we use 0.93*𝑏1

We know that pitch circle diameter of the smaller sprocket or pinion,

180 180
𝑑1 = 𝑝 csc( ) = 8.0 csc( ) = 79𝑚𝑚
𝑇1 31

pitch circle diameter of the larger sprocket or pinion,

180 180
𝑑1 = 𝑝 csc( ) = 8.0 csc( ) = 79𝑚𝑚
𝑇2 31

Central distance between the sprockets

𝑥 = 120𝑚𝑚

Number of chain links

𝑇1 + 𝑇2 2𝑋 𝑇1 − 𝑇2 2 𝑃
𝑘= + +( ) ∗
2 𝑃 2𝜋 𝑋

70 | P a g e
 31 + 31 2 ∗ 120
𝑘= + = 31 + 30 = 61
2 8.0

Length of The Chain

𝐿 = 𝐾 ∗ 𝑃 = 61 ∗ 8.0 = 488𝑚𝑚

3.3.11.Selection of Bearing
Bearings typically have to deal with two kinds of loading, radial and thrust Life of bearing. The life of
an individual ball (or roller) bearing may be defined as the number of revolutions (or hours at some
given constant speed) which the bearing runs before the first evidence of fatigue develops in the material
of one of the rings or any of the rolling elements.

Selection of bearing one: this bearing is the supports of the shaft one in this shaft we use four bearing
with bearing cap.

This bearing is the supports of the shaft one ; it is subjected to axial and radial load. Given parameters:
shaft diameters, d = 30 mm, rotational speed, N = 50 rpm

Bearing type: single row deep groove ball bearing

Selection of the bearing is made from catalogue of manufacturer, according to basic static and dynamic
capacities.

Selection of bearing two: this bearing is the supports of the wheel shaft; it is subjected to axial and
radial load. Given parameters: shaft diameters, d = 30 mm, rotational speed, N = 5875 rpm

Lubrication of ball bearing.

They are lubricated for the following purposes: -

 To reduce friction and wear between the sliding parts of the bearing.
 To prevent rusting or corrosion of the bearing surfaces.
 To protect the bearing surfaces from water, dirt, etc.
 To dissipate heat.
We are selecting bore diameter 30 from the following table.

71 | P a g e
Bearing No. Bore(mm) Outside Width(mm)
diameter(mm)

200 10 30 9

300 35 11

201 12 32 10

301 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

Table 11 Principal dimensions for radial ball bearings.[3]

72 | P a g e
Chapter Four: Manufacturing Process
N Part Machine Manufacturing method Operation condition Measuring and
o name fixture tool

Electrode

voltage

F .rate
RPM
1. Pulley Lathe Step 1: cut the ingot with 900 0.5  Measuring
machine grinder scale
 Scriber
Grinder Step 2: machining
 Vernal
processes take place such
caliper
as turning boring to gate
the final dimension of
these pulley is 75mm and
130mm

Step 3: make the v

section on the lath
machine

2. Frame Grinder Step 1: preparation of the 2.8 240  Measuring

components for the scale
Surface
wedeling process by  Hand vice
grinder
cutting out of larger
Arc square cross section bar
welding and round irons

Step 2: perform
appropriate welding
operations on the parts
prepared

3. Wheel Grinder Step 1: prepare the ingot  Measuring

scale
Lathe Step 2: Turning the ingot

73 | P a g e
 machine with a diameter 50 mm  Hand vice

Milling Step 3: drilling and

machine boring operations and
then tighten them on the
lower frame using pin.

4. Mold Grinder Step 1: preparation of the 2.8 240

components for the
Surface
wedeling process by
grinder
cutting out of sheet metal
Arc with thickness of 5mm.
welding
Step 2: prepare the inner
mold part that used to get
the hollow structure

Step 3: join the part that

prepared by cutting
operation and join by
using arc welding

Step 4: smooth the inner

part of the mold.

5. Feeder Surface Prepare 260*845 mm 2.8 240  Measuring

plate grinder sheet metal and then weld scale
their edge by 30°
Grinder
inclination to the mold
Arc structure, and well some
welding plates for pins

6. Compa Surface Step 1: prepare round 2.8 240  Measuring

ctor grinder iron with diameter of scale
15mm with height of  Scriber
Grinder
200mm

74 | P a g e
 Arc Step 2: prepare sheet
welding metal with 5mm
thickness and
845*410mm

Step 3: join the rod iron

with the sheet metal by
aligning with the lower
mold

Step 4: grind the welded

part for better alignment

7. Shaft 1 Grinder Step 1: Cutting the ingot 600 0.4  Verner

caliper
Center Step 2: Turning the ingot 900 0.2
 Scriber
lathe with a diameter 35mm, to
 Measuring
30 mm diameter
Milling scale
machine Step 3: Facing in axial  3 jaw
direction. Repeat this chunk
process at the other end  Alenkey
of the shaft. Length of the  Box
shaft equal to 850mm. wrench

Step 4: Cutting out key

way

8. Shaft 2 Grinder Step 1: Cutting the ingot 600 0.4  Verner

caliper
Center Step 2: Turning the ingot 900 0.2
 Scriber
lathe with a diameter 35mm, to
 Measuring
30 mm diameter
Milling scale
machine Step 3: Facing in axial  3 jaw
direction. Repeat this chunk
process at the other end  Alenkey

75 | P a g e
 of the shaft. Length of the  Box
shaft equal to 850mm. wrench

Step 4: Cutting out key

way

11 Roller Lathe Step 1: cut the ingot with 900 0.4  Measuring
. machine grinder and the turn the scale
ingot  Scriber
Grinder
 Vernal
Step 2: make the
caliper
grooved circular section.

12 Key Grinding Milling operations on 800 0.4  Measuring

. machine milling machines or tool
shaping operations on  Scriber
Vertical
shaper machines  Varner
milling
caliper
machine

13 Key Milling Slotting operations on 800 0.4 Varner caliper

. way machine milling machines

Material that is directly buy from the market are listed below

Material Specification

Vibration Motor 3HP,2.2KW,2875rpm,4.36A

Travel Motor 1.5HP,1.1KW,690rpm,3.15A

Hydraulic mini pack Full pack ( Tank 8 liters, gear pump, electric motor 2HP,flow rate 8l/m,
(pump, reservoir, pump pressure 160bar )also known as hydraulic mini pack
electric motor and
seals)

Hose

76 | P a g e
Directional control
valve

Piston one Stroke=50mm, bore diameter = 80mm, rod diameter = 40mm

Piston two Stroke = 300mm, bore diameter = 64mm, rod diameter = 35mm

Piston three Stroke = 410mm, bore diameter = 60mm, rod diameter = 40mm

V belt length 1128mm, thickness 8mm, top width 13mm

Chain No strand 31

Sprocket Teeth no 17

Bearing cap Width 30mm,thickness 20mm , Distance between bolt center =130mm

Bearing Internal diameter=30mm

Outer diameter= 40mm

Internal diameter=30mm

Outer diameter=40mm

Hub Diameter =61mm, length=84mm

Worm gear m=6mm,picth circle diameter 168mm material ( Phosphor bronze)

Worm shaft Diameter 24mm

77 | P a g e
Chapter Five: Cost Analysis

78 | P a g e
Chapter Six: Result and Discussion
From the part design we have gate the following result the results are presented with partition the first
class the mechanical design the second one is the hydraulic system and lastly the selection parts are
listed in tabular form.

1. Mechanical design result

Parts Parameters and assumption Result

Pulley effective diameter of pulley 𝐷1 = 140𝑚𝑚

𝐷2 = 70𝑚𝑚

Worm gear Heat dissipation, wear, coefficient m=6mm,picth circle diameter

of friction, module ,efficiency, 168mm material, central distance
bending and twisting moment 69.95mm,addendum5.99mm

Worm shaft bending and twisting moment 𝑑𝑤 = 24𝑚𝑚

Warm gear shaft Tangential force, bending and 𝑑𝐺 = 32mm

twisting moment

Gear box housing The maximum total gear box size is

207𝑚𝑚 ∗ 174𝑚𝑚 ∗ 36𝑚𝑚,

𝑆 = 8𝑚𝑚

𝑆𝑐 = 7𝑚𝑚

Bearing cap Shear stress, tensile stress No of bolt equal to 2

𝑑𝑐 = 10𝑚𝑚

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 Hub 𝑑 = 24𝑚𝑚

𝐿 = 84𝑚𝑚

Shaft Shaft one diameter

Shaft two diameter

Sprocket pitch circle diameter (𝑑1 ) = 79𝑚𝑚

2. Hydraulic system design result

Parts Parameters and assumption Result

Pump selection Pressure rating, Performance, Tank 6 liters, gear pump,2hp, Flow
Reliability, Maintenance ,Cost rate( Q = 6 L ⁄ min), Pressure 160
and economy and Noise level bar

Piston one Stroke=50mm, bore diameter =

80mm, rod diameter = 40mm

Piston two Stroke = 300mm, bore diameter =

64mm, rod diameter = 35mm

Piston three Stroke = 410mm, bore diameter =

60mm, rod diameter = 40mm

3. Selection parts result

Parts Parameters and assumption Result

Selection of Acceleration capabilities, Compactor motor

motors Breakdown torque, Efficiency, 3HP,2.2KW,2875rpm,7.279N-M
current, Power factor, Service and 4.36A
factor, Sound level ,Speed
Travel motor dc motor

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 1.1kw,690rpm

V belt V type and central distance Length =1128mm from the

standard

Chain Number of link(K) 61

Length of chain (L) 488mm

4. Outcome result of the design

Outcome result of the machine

Production time Production rate per hour Production rate per 8 hour

40-50 Second 288 Blocks 2300 Blocks

5. Outcome result of the previous machine

Outcome result of the previous machine

Production time Production rate per Production rate per 8 Factor that affect
hour hour production rate

72 second 200 blocks 1200-1300 blocks Human working

capacity

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Chapter Seven: Conclusion and Recommendation
7.1. Conclusion
In reflecting on this project all objectives were successfully met. The design product engineered that
help a user to maximize the production of the hollow blocks in the moderate cost. Whereby the current
product doesn’t have a simple hollow making machine that having an automatic working systems
features. A major objective of the new design of hollow block making machine was to be able to ensure
that the block productivity increase compare to the current machine design. Therefore, the decided
design must be reflecting the main goal and incorporated it together with the components design
objective. Time management was a very crucial portion of the project because a lot of work had to be
done in a short period of time.

7.2. Recommendation

7.3. Future Work

For the next phase, this machine can be upgraded to more user kindly by adding the features semi-
automatic concrete machine is improve to fully automatic block making machine these improve a better
working condition for the labor that operate the machine, improve the feeding mechanism to higher
automation system and also output of the block increased to eight and blocks per a time.

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Reference
1. Mr.M K Maroliya IOSR journal of engineering (IOSRJEN) volume 2, issue10, pp05-08
2. https://www.madehow.com/volume-3/concrete-block
3. Wiles, Andrew. 2009. St John and St Mary Magdalene, Goldthorpe: The conservation of an early
concrete building. Transactions (Association for Studies in the Conservation of Historic
Buildings)32: 40–50
4. Koski & John, 1992
5. Saul Sitati Namango and Daniel Arusei School of Engineering ISSN 2222-1727 (Paper) ISSN
2222-2871 (Online) Vol.7, No.7, 2016
6. Prof. Abdulrahim Abdulbaqi Toyin and Engr.Samuel I.Ukwuaba, FNSE, FNIMeche Department
of Mechanical Engineering Petroleum Training Institute International Journal of Engineering
Science and Innovative Technology (IJESIT) Volume 5, Issue 3, May 2016
7. S.O. Yakubu, M.B. Umar American Journal of Engineering Research (AJER) e-ISSN: 2320-
0847 p-ISSN: 2320-0936 Volume-04, Issue-02, pp-33-43
8. [3] R.S. Khurmi & J.K. Gupta. A Text of Machine Design, Eurasia publishing house (pvt.) ltd Ram
Nagar, New Delhi-110 055 2005 [p1005-1007, p1030-1045]

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