10/13/2022

Project Report
Machine Design
ME-311

Submitted By Received By
Name: Muhammad Abdullah Name: Muhammad Rizwan
Reg #: 938-FET/BSME/F20

Signature: ___________________

Name: Syed Ali Ibrahim

Reg #: 917-FET/BSME/F20

Date: ____________________ Date: _______________________

Machine Design-II Complex Engineering Problem

Contents
Abstract........................................................................................................................................................ 1
Introduction ................................................................................................................................................. 3
Problem Statement...................................................................................................................................... 3
Objectives..................................................................................................................................................... 3
Literature review ........................................................................................................................................ 3
Significance of project ................................................................................................................................ 3
Working & Calculation .............................................................................................................................. 4
Power Selection for Motor ...................................................................................................................... 4
Determination of Actual Motor Torque .................................................................................................. 4
The chain/belt drive ................................................................................................................................. 5
The Actual Speed of the Roller ................................................................................................................ 5
Tangential Driving Force (FT) ................................................................................................................... 5
Power Transmitted by Chain/belt ........................................................................................................... 6
Shaft Design .............................................................................................................................................. 6
Allowable Shear Stress ............................................................................................................................. 7
Torque twisting moment by a solid shaft................................................................................................ 7
Design Analysis of Crusher ....................................................................................................................... 7
Torque Transmitted to the Crusher ......................................................................................................... 8
Permissible Angle of Twist for Crusher.................................................................................................... 8
Axial Deflection of Crusher ...................................................................................................................... 9
Advantages................................................................................................................................................... 9
Disadvantages .............................................................................................................................................. 9
Result.......................................................................................................................................................... 10
References .................................................................................................................................................. 10

Abstract

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Machine Design-II Complex Engineering Problem

In this report we are going to analysis on the transmission system of Sugarcane plant in Ansys &
Solid work and solving its calculations.

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Machine Design-II Complex Engineering Problem

Introduction
The sugarcane plant is the common name of a species of herb belonging to the grass family.
There are three major categories of sugarcane found in Pakistan. Extracting the juice from
sugarcane through the use of a traditional way could damage the gum of the teeth and putting the
human teeth in distress and require much energy as a major problem. The quantity of the
extracted juice produce from the traditional way will not be sufficient enough. The design of a
sugarcane extracting machine, which is made of two stainless steel roller crushers, will be able to
extract enough sufficient juice without putting pressure on the machine. The main objective of
the project is to design power transmission system and construction of sugarcane juice
extracting machine, extraction of juice from sugarcane, separation of juice from the sugarcane
and the bagasse.

Problem Statement
We have a sugar cane plant on which we will analysis on the transmission system of Sugarcane
plant in Ansys & Solid work and solving its calculations.

Objectives
Analyzing the power transmission in software and solving the its calculations

Literature review
The development of sugarcane machines has been started hundreds of years back in many
countries. The Trapiche is a traditional wooden roller used by people of Pakistan to extract
sugarcane juice, the trapiche is a Spanish word “sugarcane crusher”. It is varying in size which is
made up of wood. It has two rollers that are vertically placed and held by a wooden frame. A
sugar cane juice extractor machine is a machine used to extract the juice from sugar cane. These
juice extractor machines were built to help human extract the juice from sugar cane through
crushing and rolling process. A conventional machine is a simple machine consists of several
gears, rollers, and lever attached on a cast-iron chassis body. Most conventional machines are
made up of cast iron material which is strong and durable. These machines were made by a
simple mechanism of rolling and crushing (Kulkarni, 2005).

Significance of project
Significance of the project is to know about the power transmission system that how the gears
transmit the power and also, we can improve the power by different types of gears diameter
The transmission is responsible for converting both speed and momentum into power that then
gets the entire blades of helicopter moving faster and its main aim is to make the engine as
efficient as possible by reducing the amount of fuel consumption whilst getting the best amount
of power.

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Machine Design-II Complex Engineering Problem

Working & Calculation

We will analysis on the following factors
➢ Power Selection for Motor
➢ Determination of Actual Motor Torque
➢ The chain/belt drive
➢ The Actual Speed of the Roller
➢ Tangential Driving Force (FT)
➢ Power Transmitted by Chain/belt
➢ Shaft Design
➢ Allowable Shear Stress
➢ Torque twisting moment by a solid shaft
➢ Design Analysis of Crusher
➢ Torque Transmitted to the Crusher
➢ Permissible Angle of Twist for Crusher
➢ Axial Deflection of Crusher

Power Selection for Motor

We have 3hp motor which has 1450rpm so,
The required power for the electric motor was calculated using equation
P=T×ω
Where:
➢ T is the torque in (N/m)
➢ P is the transmitted power in watt
➢ ω is the angular speed
putting the values in the above formula we will get,
P = (14.7 × 151.86) ➔P = 2237 KWatt

Determination of Actual Motor Torque

The actual motor torque (Tm) was obtained using equation
𝑴𝒐𝒕𝒐𝒓 𝑷𝒐𝒘𝒆𝒓
Tm = 𝑨𝒏𝒈𝒖𝒍𝒂𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚

Where:
Motor Power is 2237 KWatt
Angular velocity is 151.86

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Machine Design-II Complex Engineering Problem

putting the values in the above equation we get,

𝟐𝟐𝟑𝟕
Tm = 𝟏𝟓𝟏.𝟖𝟔 ➔ Tm = 14.7Nm

The Actual Motor Torque was 14.7 Nm

The chain/belt drive

The required chain drive was calculated using equation
𝑻𝒓𝒂𝒏𝒔𝒎𝒊𝒕𝒕𝒆𝒅 𝑷𝒐𝒘𝒆𝒓 ×𝑺𝒆𝒗𝒊𝒄𝒆 𝑷𝒐𝒘𝒆𝒓
Design power for a strand = 𝑵𝒐.𝒐𝒇 𝒕𝒉𝒆 𝒔𝒕𝒓𝒂𝒏𝒅

Where:
Transmitted Power is 2237 kW
Service Power is 1.3
No. of the stand = 1
Putting the values in the above formula we get,
𝟐𝟐𝟑𝟕 ×𝟏.𝟑
Design power for a strand = ➔ 2908.1KW
𝟏

The Actual Speed of the Roller

The actual speed of the rollers was obtained using equation
𝑵
η2 = η1 (𝑵𝟏 )
𝟐

Where:
n1 is the speed of driver which is 28.4 rpm
n2 is the speed of the roller
N1 is the speed of rotation of smaller sprocket in rpm, which is 28.4 rpm
N2 is the speed of rotation of larger sprocket in rpm,
which is 75.3 rpm
putting the values in the above formula we get,
➔ n2 = 10.7rpm

Tangential Driving Force (FT)

The required tangential driving force was calculated using equation
𝑷𝒐𝒘𝒆𝒓 𝑻𝒓𝒂𝒏𝒔𝒎𝒊𝒕𝒕𝒆𝒅
FT = 𝑺𝒑𝒆𝒆𝒅 𝒐𝒇 𝒕𝒉𝒆 𝒃𝒆𝒍𝒕

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Machine Design-II Complex Engineering Problem

Where:
FT is the tangential driving force
P is the power transmitted in watt, which is 2237 Watt
V is the speed of chain, which is 0.45 m/s
Putting the values in the formula we will get,
𝟐𝟐𝟑𝟕
FT = ➔ FT = 4.97N
𝟎.𝟒𝟓

Power Transmitted by Chain/belt

The power transmitted by the chain basis on breaking load was calculated from equation
𝑾𝑩 ×𝑽
Sf = 𝒏 × 𝑲𝒔

Where:
WB is the braking load in newton, which is 8971 N
V is the velocity of the chain in m/s, which is 0.45 m/s
n is the factor of safety which is 30.7
Ks is the Service factor K1 x K2 x K3
K1 is the load factor, which is 1.25, K2 is the lubrication factor, which is 1.5, K3 is the rating
factor, which is 1
Sf is the power transmitted by a chain
Putting the values in the formula we will get
𝟖𝟗𝟕𝟏 × 𝟎.𝟒𝟓
Sf = 𝟑𝟎.𝟕 × 𝟏.𝟖𝟕𝟓 ➔ Sf =70.1Watt

Shaft Design
Torque T transmitted by the shaft is calculated from equation
𝑷 × 𝟔𝟎
𝑻 =
𝟐𝝅𝑵
Where:
T is the torque in (N/m)
p is the transmitted power in watt, which is 2237 Watt
N is the Speed of Shaft in rpm, which is 1450 rpm
Putting the values in the formula we will get,
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Machine Design-II Complex Engineering Problem

𝟐𝟐𝟑𝟕 × 𝟔𝟎
𝑻 = ➔ 14.7N/m
𝟐𝝅∗𝟏𝟒𝟓𝟎

Allowable Shear Stress

The required allowable shear stress was calculated using equation
Ԏ𝐮
𝛕 =
𝑭𝒔
Where:
τ is the stress
Ԏu is the Ultimate Shear Stress for Steel is 360 MPa
Fs is the Factor of Safety is 8
Putting the values in the formula we will get,
𝟑𝟔𝟎
𝛕 = ➔ 45N/mm
𝟖

Torque twisting moment by a solid shaft

The required torque twisting moment by the solid shaft was calculated using equation
𝝅
Te = 𝟏𝟔 × τ × d3

Where:
τ is the Shear Stress, which is 45 N
Te is the Twist moment
d is the diameter of the shaft
Putting the value in the formula we will get,
𝝅
14.7*103 = 𝟏𝟔 × 45 × d3 ➔ d = 12mm

Design Analysis of Crusher

The required design analysis of the crusher was obtained from equation
Fc = Mf * Sf
Where:
Fc is the crushing of the design
Mf is the Mass of Roller, which is 220 N
Sf is the factor of safety, which is 1.7
Putting the values in the formula we will get,
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Machine Design-II Complex Engineering Problem

Fc = 220 * 1.7 ➔ Fc = 374 N

Torque Transmitted to the Crusher

The torque transmitted to the crusher was calculated from equation
T=r×F
Where:
T is the torque
F is the Force, which is 374 N
r is the radius of crusher which is 0.068

Putting the values in the formula we will get,

T = 0.068 × 374 ➔ T = 25.4Nm

Permissible Angle of Twist for Crusher

The required Permissible Angle of Twist for Crusher was calculated from equation
𝟓𝟖𝟒 𝑴𝒕 𝑳
θ= 𝑮 𝒅𝟒

where:
θ is the angle of twist
L is the length of the roller, which is 0.265 m
G is the modulus of rigidity for steel, which is 80 x 109 Nm2
P is the power transmitted which is 2.2371 kW
N is the speed of the shaft, which is 1450 rpm
d is the diameter which is 0.134 m
Mt is the moment of twist of the crusher,
Mt = (P * 9550)/N ➔ which is 14734 Nm
Putting the values in the formula we will get,
𝟓𝟖𝟒 𝒙 𝟏𝟒𝟕𝟑𝟒 𝒙𝟎.𝟐𝟔𝟓
θ= ➔ θ = 0.088o
𝟖𝟎 𝒙 𝟏𝟎𝟗 𝟎.𝟏𝟑𝟒𝟒

Hence the Permissible Angle of Twist for Crusher is 0.088°

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Axial Deflection of Crusher

The axial deflection of the crusher was calculated from equation
𝑭𝑳
ðL = 𝑨𝑬

Where:
ðL is the axial deflection
A is the area of crusher = 0.014m2
L is the length of the roller, which is 0.265 m
E is the modulus of elasticity, which is 200 x 103 N/mm2
D is the diameter of the roller, which is 0.134 m
F is the Force of the crusher
Putting the values in the formula we will get,
𝟑𝟕𝟒∗𝟎.𝟐𝟔𝟓
ðL = ➔ ðL = 3.50*10-4m
𝟎.𝟎𝟏𝟒∗𝟐𝟎𝟎𝟎𝟎𝟎

Advantages
1. The instantaneous transmission ratio is constant, and the working stability is high.
2. The non-circular gear is adopted, and the instantaneous transmission ratio can be
designed according to the required change rule.
3. Wide range of transmission ratio variation, suitable for decelerating or increasing speed
transmission.
4. The peripheral speed range of gear is large.
5. The transmission power range is large, and the bearing capacity is high.
6. The transmission efficiency is high, especially the cylindrical gear pair with high
precision.
7. Compact structure, such as the use of planetary transmission, small tooth difference
transmission, or harmonic gear transmission, can make the components smaller and
become coaxial transmission,

Disadvantages
The main disadvantage of this project is given below
1. Vibration, impact and noise during operation, and generate dynamic load
2. No overload protection.
3. When the precision of gear cutting is required to be high or with special tooth shape, high
precision machine tools, special cutters and measuring instruments are needed to ensure
that the manufacturing process is complex, and the cost is high
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Result
From the design analysis of the sugarcane juice extracting machine, the machine will require an
electric motor of 3 hp with speed of 1450 rpm that would be connected to a reduction gear motor
that will reduce the motor speed from 1450 rpm to 28.4 rpm of the crushing rollers, with an
actual speed of the rollers 10.5 rpm and the crusher having the permissible angle of twist of
0.0088° and the torque transmitted to the crusher 25.432 N, having an axial deflection of the
crusher 3.540 x 105m. The sugarcane juice extractor performs optimally with an efficiency of
about 84 % when using an electric motor of 3HP and a reduction gear to reduce the speed of the
electric motor that will reduce the roller speed to about 28.81 rpm. The machine was tested using
a sample of sugarcane weighing 22.5 kg, and the mass of juice extracted was 4.1 kg, while the
extraction took about 22min and the sugarcane juice extracting machine having an efficiency of
extraction of 83.7%, It can be seen that the efficiency of the machine was as high as expected.
The effective extraction of the juice is done by sets of rollers; this is because since that the
double sets of the roller are used in the arrangement which will effectively extract the juice in
two-pass. This ensures higher efficiency and a capacity of 61.36 kg/hr. The extracting machine
with a capacity of 61.36 kg/hr was developed.

References
Khurmi R.S and Gupta J.K (2010): A Textbook of Machine Design. Eurasia Publishing House (P) Ltd., 7361,
Ram Nagar, New Delhi -110 055

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