April 2016, Volume 3, Issue 4 JETIR (ISSN-2349-5162)

Design, Analysis and Development of a Studs

Grinding Machine
1
EJEHSON PHILIP SULE, 2KENNETH .O.ENEBE, 3ASHA SATURDAY, 4UGWU HYGINUS SUNDAY
1,3,4
Scientific Equipment Development Institute SEDI, BOX 3205, Enugu, Enugu State, Nigeria
2
Agricultural Machinery and Equipment Development Institute (AMEDI), Mbutu, Aboh Mbaise, Imo State. Nigeria

Abstract-Nigerian grains like millet, sorghum, maize, cowpeas, guinea-corn and soya beans grinded into flour by mills
which could be time consuming, energy sapping, monotonous and virtually environmental pollution usually associated
with the operation of conventional mills A Stud grinding machine has been designed, fabricated and tested. The tests and
analysis were carried out by using vertical throw electromagnetic sieve to determine particle size distribution on the
grinded roasted soya beans by the stud grinder to show its efficiency of specific size of 50 to 80 .at an optimum
speed of 2880RPM powered by a single phase 2hp 1440RPM electric motor . This would diversify storage options for the
grains, deepen and widen the available food choices for all Nigerians and enhance food security and rural development.

Index Terms: design and development, Nigerian grains, stud grinder, particle size distribution efficiency.

1. INTRODUCTION
Grinding and milling may be interchangeable when referring to particle size reduction. Hammer mills for fine pulverizing and
disintegration are operated at considerable high speeds. The rotor shaft may be vertical or horizontal, generally horizontal; Perry
and Don, [1998]. The shaft carries hammers, sometimes called beaters. The hammers may be T-shaped element, bars, or rings
fixed or pivoted to the shaft or to disks fixed to the shaft. The grinding action results from impact and attrition between lumps or
particles of the material being ground, the housing and the grinding elements. It also consists of a heavy perforated screen
(Henderson and Perry, 1982) which can be changed. Though it is a versatile machine and its hammer wear does not reduce its
efficiency, yet the power requirement is high and it does not produce uniform grind. Common types available in the industry
include the Imp Pulveriser, the Mikro Pulveriser, the Fitz Mill, etc. Another class of size reduction machines is the Ringroller
mills. They are equipped with rollers that operate against grinding rings; Perry and Don, [1998]. Pressure is applied with heavy
springs or by centrifugal force of the rollers against the ring. Either the ring or the rollers may be stationary. The grinding ring
may be in a vertical or a horizontal position. Ring-roller mills also are referred to as ring roll mills or roller mills or medium-
speed mills.
Another category available is the Attrition Mills. The disc attrition which is sometimes called the Burr mill consists of a set of two
hard surfaced circular plates pressed together and rotating with relative motion , Onwualu, A.P., C.O. Akubuo and I.E. Ahaneku
,[2006]. Stones are replaced by steel disks mounting interchange metal or abrasive grinding plates rotating at higher speeds, thus
permitting a much broader range of application. They are used in the grinding of tough organic materials, such as wood pulp and
corn grits (Perry and Don, 1998). Grinding takes place between the plates, which may operate in the vertical or horizontal plane.
The material is fed between the plates and is reduced by crushing and shear. Though the power requirement is low, operating
empty may cause excessive burr wear and a lot of heat is generated during shearing action.
These are good designs with their respective limitations besides the bulkingness of the machines, environmental pollution with
the dust of the products. Stud grinder is portable, manufactured with light locally sourced materials while considering the fact that
it is made for grinding consumables.

2. PROBLEM STATEMENT
Bulkingness of a machine will rise the cost of its production and will in turn affect the selling price, this is a source of
discouragement on the side of the user or the producer besides its performance or efficiency. Production and quick output turn out
have to be considered with the time saving and energy conservation ability of a mechanical product; hence the design and
fabrication of a stud grinder for grinding of bone dried or roasted grains.

3 SCOPE OF STUDY
This study show case the design and analysis of a stud grinder with all equations involving the design synthesized and detailed to
be use for the fabrication in SEDI Enugu.

4. AIMS AND OBJECTIVES

Design and development of a stud grinder is aim at :
1. Saving time and conserving energy for grinding bone dried grains in mills.
2. Minimizing spills that would result to pollution.
3. Developing a portable machine where weight reduction is considered.
4. Establishing a choice for using stud grinder when grinding bone dried or roasted grains than mills.
5. Creating a source of revenue for local fabricators since the materials were locally sourced and enhancing the use and
consumption of local products.

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5. MACHINE DESCRIPTION
The stud grinding machine is comprise of three main units- power transmission unit, grinding unit, and delivery unit besides
the frame . Power transmission unit includes v-belt ,v-pulley with power shaft and machine shaft. Grinding unit is the
rotating disc with studs mounted, and the cylindrical grinding chamber. Deliverying unit is the hopper ,perforated sieve,and
chute. The frame is to give rigidity and support to all other components parts of the machine like the skeleton to the human
body. The grinding operation is by continous impact of the solid particle of materials to be grinded with the studs and wall of
the grinding chamber.

Fig1 VIEW OF THE STUD GRINDING MACHINE SHOWING COMPONENTS

Fig 2.VIEW OF THE MACHINE SHOWING STUDS IN THE DRUM

6. DESIGN
6.1 DESIGN CONSIDERATION
Design is the transformation of concepts and ideas into useful machinery (Bernard et al., 1999).
The following factors were considered in the design and development of a stud grinding machine.
i. Material selection.
ii. Corrosion.
iii. Size of electric motor or power requirement.
iv. Size of machine shaft.
v. Hygiene.

a. MATERIAL SELECTION
All materials are locally sourced on the basis of the local content initiative in Nigeria. The pulley is aluminum made ,the machine
shaft is stainless steel together with the disc, the studs ,cylindrical grinding chamber, hopper chute and the perforated sieve. The
frame is mild steel with the bushon for the aluminum pulleys. Since different materials are involved, hence different metal
joining processes and alloy electrodes will be used with stainless steel and mild steel.
b. CORROSSION AND HYGIENE

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Corrosion is prevalent in engineering materials especially the mild steels. The machine is designed for processing consumables
hence in making choice of materials corrosion must be considered to avoid food poisoning and contamination. Thus ,the choice
for stainless steel material which are also very available in local markets.

6.2 GRINDING PROCESS ANALYSIS

The stud grinding machine grinds by impact method. The disc and the stud have impellers ability to hit and deform or break the
particles continually among the member studs or with the hard wall of the grinding chamber. Each stud is in a particular radius
RA from the axis of rotation (0).Thus, the have different impacts since their radii R A are different and under the different angular
speed as their individual radius RA is a function of their relative position to the axis of rotation ,this follows the principles of
placing two masses at different position relative to the axis of rotation. Assuming the impelling studs to posses equal masses m
but different radii RA.
Tangential linear velocity of the particle, Vt
(1)
The acceleration of the Particle, aT
(2)
the centripetal force Cf is determined as
(3)
Where m =mass of particle
Therefore,
RA (4)
Collision between the particles and particles and the studs is perfectly elastic.

7. ELECTRIC MOTOR SELECTION

Considering the load to be carried by the motor on full load condition at starting torque of the motor
Weight of the studs and shaft assembly
Weight of machine pulley
Weight of materials to be grinded WM
The Torque Load F

( ) (5)
Where ,
g=acceleration due to gravity =9.81m/s2
Considering a safty factor( sf) of 1.5
Maximum load =sf x applied load
Thus ,Ultimate load Fult
(6)

Torque developed by the electric motor TM

= RM (7)
Where
RM =radius of motor pulley

Power of the motor PM

( ) (8)

8. DESIGN FOR PULLEY

The machine pulley diameter was selected using the equation for speed ratio determines the sizes of the pulleys. A speed ratio of
machine to electric motor is chosen to be

(9)
(10)
where,
Nm = Rotational speed of electric motor = 1440 rpm
Dm = Measure diameter of motor’s pulley = 0.15
DC = Measure diameter of machine’s pulley
Nc = Rotational speed of machine (rpm)

9. DESIGN FOR BELT

Selection of belt type is based on the power transmitted (3.7 kw) and according to the Indian
standards (IS: 2494-1974), belt type A was selected from Khurmi and Gupta (2004) developed equation for calculation of
length, L:

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( ) ( )
(11)
where,
L = Length of belt (in)
D1 = Smaller sheave diameter = Dm
D2 = Larger sheave diameter = Dr
x = Centre distance of pulleys

10. DESIGN FOR SHAFT:

A shaft is the rotating machine element which transmits power from one place to another (Khurmi and Gupta, 2004). The shaft of
the cassava flour machine which is rotating the beaters and fan will be subjected to twisting moment only. For a shaft subjected to
twisting moment only, the diameter of the shaft was obtained by using the torsion only
(12)
where,
T = Twisting moment (Nm)
= Torsional shear stress (N/m2) = 42 MPa (Khurmi and
Gupta, 2008).
d = Diameter of shaft (m)
from the equation T can also be calculated as
( )R (13)
where;
T1 = Tight side tension (N)
T2 = Slack side tension (N)
R = Radius of machine pulley (m)
The tight side tension was gotten as:

(14)
Tm = Maximum tension in belt (N)
Tc = Centrifugal tension (applicable for belt running at high speed).
Tm = Maximum stress x cross-sectional area of belt
(15)

11. DETERMINATION OF BELTS CROSS-SECTIONAL AREA, a:

The cross-sectional area of the belt was calculated by considering area of a trapezium with
top width, a= 13 mm; thickness, h = 8 mm and by calculation, the bottom width ,b ,was got
as 8 mm. Source (Khurmi and Gupta, 2008)

Fig 3. Cross section of the belt showing its trapezoidal orientation

( )
(16)

(17)
Maximum allowable stress of belt, = 2.8 MPa (2.8N/mm2)The centrifugal tension, Tc was determined using
(18)
where m = mass of belt per unit length. It was calculated using:
(19)
Where, = density of belt material (Rubber) (m3/s) = 1140kg/m3(Khurmi and Gupta, 2004)
V = linear speed of belt given as:

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(20)
V-belt drive, the tension ratio is given by
⁄
= (21)
where, :
= Coefficient of friction between belt and pulley
= Angle of wrap (radian)
= Groove angle = 34º (Khurmi and Gupta, 2004))
* ( )+ (22)

12.KEY AND KEY WAY DESIGN

The assembly between alluminium pulley and the mild steel shaft involves two engineering materials.Wear should be avoided as
it is imminent if they are used together,hence, flanged bushons are force fitted and bolted to the pulleys.The thickness of the
bushons are sush that the key way can be created.A square sunk key is considered.
W=t=d/4=7.5mm (23)
Where;
w=width of the key
t=thickness of the key
d=diameter of the shaft=30mm
As standard,a shaft of 30mm diameter has 8mm thickness and 10mm width,
[R.S Khurmi &J.K Gupta,table 13.1,pp.472]
The depth of the key way =h=t/2=4mm (24)
The force acting [F]on the key is given as a function of the torque [T] and diameter [d]of the shaft.
F = 2T/d =633.3N (25)
12.1 EFFECT OF KEY WAYS ON SHAFT
The experiment conducted by H.F.Moore, showed that key way on shaft reduces the load carrying capacity as regards the
tensional strength of the shaft.

13.BEARING SELECTION
Design consideration:
(1) Rating life of bearing
(2) Inner diameter of bearing
Bearing selection is important for reduction of friction or grinding .noise pollution and efficiency or performance of the machine.
The relations stated below are guide to determine the life of a bearing and the choice of selection for the inner diameter. It is
determined by the size of shaft. A rolling bearing is selected for the under listed reasons:
i. They give warning sign on event of failure
ii. They can be preloaded when desirable to reduce deflections in the bearing
iii. They can be pre packed with grease to provide maintenance free installation
iv. They have an advantage of having starting torque to be high because of loads for short periods

14.DETERMINATION OF LIFE OF A BEARING

The approximate life of a bearing is given by:
( ) million revolution (26)
Lb = life of a bearing
c* = specific dynamic capacity of a bearing
Pe = equivalent load
(27)
This is the equivalent load for radial and angular contact bearing of conventional types except filling slot bearing under
combined constant radial and thrust load.
X = radial factor
Fa = thrust load N
Fr = radial
V* = rotational factor
The X and γ are obtained in the table 11.3 on ref no 10 for dynamic loaded bearing.
For single load bearing,
When wt/wr ≥ θ
Xo = 1, Yo = 0
The maximum reaction load on the bearing at A
Assuming a factor of 2 for V – belt taking into account of both dynamics as it affects the belt vibration and additional force to
maintain proper tension in the belt.
(28)
Mg = Impeller weight = 25N

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Fa = 25N
V=1
Fa/VFr = 25/1857.64 = 0.013
Wt/WR = fa/FR 0.013
Hence deep groove ball bearing is selected because this value is found in table 27.4 pp1008[Gupta/Khurmi)The diameter of shaft
is 30mm. The bearing bore will be less than However 30mm for clearance. Assume a clearance of 5mm for a bore of 25mm, the
bearing number 205 having 25mm bore,5mmclearance,52mm outside diameter,width 15mm is chosen using thetable 27.1
pp1000 [Gupta/Khurmi).The dynamic load capacity C,is selected from table 27.6 pp1013[Gupta/Khurmi)

15. POWER TRANSMITTED BY BELT, Pb

The power transmitted per belt was calculated using
( ) (29)

16. NUMBER OF BELTS REQUIRED, n

The number of belts required to transmit power from electric motor was calculated using

(30)

17. CONCLUSION
The stud grinding machine was designed and developed to investigates the performance and efficiency of the machine on bone
dried grains or roasted grains. Focusing on the design are basic factors that can lead to dynamic imbalance, hence it was ensured
that the shaft was turned with good running centers on the lathe and same was maintained using a four jaw chuck for the pulleys.
This is made possible with good marking ,the assembly become necessary for alignment of the components. The shaft and the
bearing must be aligned to have a common axis of rotation this helps to solve problem of dynamic imbalance that will cause
vibration. Tension on the belt and pulleys alignment should be monitored as this could lead to a great deal of heat generation that
will burn the belt at some certain speed. It is therefor necessary to build an alternative machine that will be energy ,power and
time saving in grinding dried or roasted grains than the stone grinder

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[8] Khurmi, R and Gupta, J. (2008), “A Textbook of Machine Design”. Eurasia Publishing House (PVT) Ltd, New Delhi,
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[9] Norton, R. (2006), “Design of Machinery: An Introduction to the Synthesis and Analysis of Mechanisms and Machines”.
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