TITLE OF SEMINAR/PROJECT REPORT

DESIGN AND DEVELOPMENT OF PAN-MIXTURE FOR MIXING AND

CRUSHING OF FLY-ASH,CEMENT,SAND AND WATER.

Submitted by
DARSHIN MAKVANA(080160119032)
HAMIR BAMBHANIYA(080160119001)
BALDEV VAGHASIA(080160119124)
NITESH KUCHA(080160119027)

In fulfillment for the award of the degree
Of BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING


GOVERNMENT ENGINEERING COLLEGE-MODASA
Gujarat Technological University, Ahmedabad
April, 2012
GOVERNMENT ENGINEERING COLLEGE- MODASA
MECHANICAL ENGINEERING 2011-012

CERTIFICATE


Date:25/04/2012

This is to certify that the dissertation entitled DESIGN AND
DEVELOPMENT OF PAN-MIXTURE FOR MIXING AND CRUSHING
OF FLY-ASH,CEMENT,SAND AND WATER has been carried out by
MAKVANA DARSHIN ASHOKBHAI under my guidance in fulfillment of
the degree of Bachelor of Engineering in MECHANICAL(7th Semester) of
Gujarat Technological University, Ahmadabad during the academic year
2011-12.


Guides: INTERNAL GUIDE EXTERNAL GUIDE
Prof. K.D. PANCHAL Mr. J.M. UPADHYAY



Head of the Department
Prof. N.K. PANCHAL

ABSTRACT

DESIGN AND DEVELOPMENT OF PAN MIXTURE FOR MIXING
AND CRUSHING OF FLY ASH, CEMENT, SAND AND WATER.

The main function of Pan Mixture is to mixing and crushing of fly ash,
cement, sand and water.

Pan mixture is mostly used to make material fly ash bricks.

Any Design work of pan mixture done by industry is not proper, so
humble effort to improve the design work of pan mixture throughout this
project work.


This design process will be done by some assumption and mathematical
relation.

By proper designing the performance of pan mixture will be improve.

LIST OF TABLES



TABLE NO. TABLE DISCRIPTION PAGE NO.
TABLE:1 Following data about sand specific gravity 8
TABLE:2 Particle size limits of sand 8
TABLE:3 Approximate composition 9
TABLE:4 bearing of 60 series 25
TABLE. 5 Proportion of stan`parallel , tapered & gib head keys: 34
TABLE 6. selection of bolt 34

LIST OF FIGURES


FIGURE NO. FIGURE DESCRIPTION PAGE NO.

FIG.1 BASIC DIAGRAM OF PAN 12
FIG.2 MATERIAL FILL IN WHOLE PAN 12
FIG.3 CASE 2 OF DESIGN OF PAN 13
FIG.4 CASE 1 OF DESIGN OF PAN 14
FIG.5 FINAL DIMENTION OF PAN 15
FIG.6 FREE BODY DIAGRAM OF ROLLER ARM 20
FIG.7 FREE BODY DIAGRAM OF ROLLER 21
FIG.8 FRONT VIEW ROLLER FREE BODY 23
FIG.9 TENSION AT ROLLER ARM ( SIDE VIEW) 24
FIG.10 SHOVEL 27
FIG.11 ARRANGEMENT OF SHOVEL. 28
FIG.12 FLANGE COUPLING Courtesy of 32
MECHANICAL HAND BOOK
FIG.13 TOP & FRONT VIEW OF PAN MIXTURE COURTESY
OF NEPTUNE PVT LTD.
FIG.14 3-D VIEW OF PAN-MIXTURE COURTESY OF
FORTUNE PVT.LTD. 37

LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE

Symbol Abbreviations
Name

M Mass
L Length
Mass density
F Force
T Torque
V
c
Volume of cement
V
s
Volume of sand
V
f
Volume of fly ash

V Total volum

ut
Ultimate shear stress

ut
Ultimate bending stress
W Weight

c
Crushing strength

s
Shear strength
M Bending moment
Z Section of modulus
Angular velocity
P Power
N Revolution per minute
P.C.D Pitch circle diameter

b
Bearing stress
D Diameter

TABLE OF CONTENTS

CHAPTER:1 INTODUCTION TO PROJECT WORK
1.1 introduction
1.2 process study of mixing and crushing.
1.3 determination of process parameters.

CHAPTER:2 BRIEF HISTORY OF WORK

CHPTER:3 Literature Survey
3.1 rotamixer forced action rotary
mixer, hd stainless steel pan
3.2 replacement rotamixer stainless
steel pan
3.3 electronic mixer timer, for
regulating mix duration

3.4 rmp55 rotamixers

CHAPTER:4 PROJECT WORK

4.1general study of pan mixture
4.2property of cement
4.3calculation of volume of shell:
4.4 design of pan
4.5 functional desing of pan mixture
4.6 design of roller

4.7 functional design of shovel

4.8 design of shaft:
4.9design of coupling
4.10 design of plate for whole machine
4.11 hydralic gate system design


CHAPTER NO:5 CONCLUSION

CHAPTER NO:1
INTRODUCTION TO PROJECT WORK
1.1 INTRODUCTION

The IDP consists of following two steps.

Design of components.
Development of existing parts.

Design of components like,

Main Vertical shaft (critical component).
Roller weight & size.
Scrappers.
Shovel and shovel arm.
Shell.
Bearing housing.
Rubber bush coupling.


Development of existing parts like,

Setting of shovel angle arrangement.
Numbers of scrappers & rollers to crushing and mixing.

Solution of this problem is carried out by following steps.

1.2Process study of mixing and crushing.
- As per given data by industry material ratio to be mixed and crushed:

Fly ash: 60%,
Cement: 30%,
Sand: 10%,
Required quality of water to make slurry.
1

-From the ratio of material volume of each material will be finding out from
V=
m


M=mass of material

=Density of material

-By adding sub volume of each material total volume of material will be find out.
-By giving some allowance in height top holding plate & in radius for bearing
housing shell drum height and radius can be computed.



1.3Determination of process parameters.

- As per information from free body diagram of roller, shovel for ,scrapper total load
can be found out.
- From this load torque on shaft can be found.
- For specific mixing time specific r.p.m of shovel& roller are required which can be
studied from process study of mixing.
- According to this study &torque electric motor is selected.
-To reduce high r.p.m of motor into small required specific type of gear box is
selected.
- From the gear box & motor the total height of mixture is determined .

1.3.1 Basic free body diagram for pan-mixture.
-FBD is best way to study the machinery completely.
-Draw the load diagram of roller& shovel as per process study.
-Free body diagram of critical component also drawn to design the machine.
-Analyze the forces from these load diagrams.

1.3.2Select the material for safe limit.

-In pan mixture some components have to bear, wear &corrosion.
-So, for that component like,
Roller drum
Roller arm
Shovel plate
Shovel arm
Select the special type of material.

1.3.3Find the dimensions of rollers.

Roller size.

-From civil engineering handbook crushing strength of sand will be determine.
-Crushing strength of cement & fly ash is negligible.
- Determine the weight of roller from the crushing strength of sand.
-Find the dimension of roller as per density of roller material.

1.3.4Find the dimension of shovel.

Shovel size.

-Calculate the shear force of mixture from the property of material as per mixing
requirement.
-Calculate the shear force of fly ash, cement, sand & water by some formula.
-Determine the dimension of four shovel & one scrapper from the shear force of
mixture for safe limit.


Capacity of pan mixture is 1000 kg.
Design the outer shell of pan mixture and the base of this machine.
Select the gear box as per requirement which is used to transmit the power from
motor to main rotating shaft.
Finally determine the total height of machine from gear box.

CHAPTER NO:2
BRIEF HISTORY OF WORK


In past bricks were made by mixing fly ash, sand, cement and water by hand. It was very
tedious work and mixing process required lot of time. Another disadvantages of hand mixing
is that the sand should be crushed in crushing machine.

But due to development in infrastructure sector it required drastically demand of bricks so the
designer felt to do automation in bricks and ceramics industry. So from that point pan mixture
machine was invented.

Now , a many types of design and working model available in market according to need of
ceramics industry.

There are ,
Vertical pan,
Horizontal pan,
Inclined pan mixing machines are available.
Also automated and manually operated machines are available.

CHAPTER NO:3
Literature Survey

Refine Ltd 2004 Telephone: 01202 632270 Fax: 01202 632432 14 Email:
sales@refina.co.uk Website: www.refina.co.uk


3.1ROTAMIXER FORCED ACTION ROTARY MIXER, HD stainless
steel pan

Stock no Description Power Weight Drum Size Capacity ex VAT
705500 RMP55 1.5kw 80kg 55 ltr 46cm 75kg 995.00

3.2REPLACEMENT ROTAMIXER STAINLESS STEEL PAN

Stock no Description Size Depth ex VAT
323205 mixing pan, 55 ltr 46cm 47cm 189.00


3.3ELECTRONIC MIXER TIMER, for regulating mix duration

Stock no Description ex VAT
802010 electronic timer 189.00
TECHNICAL & APPLICATIONS
3.4RMP55 ROTAMIXERS

Robust forced action mixers
Twin paddles for thorough mix action
No unmixed pockets

Radial & axial mix, turns & lifts material

Paddles are adjustable
Suitable for up to 8mm aggregate
55 liter stainless steel rust free pan
Easy clean & low maintenance

RMP55 ROTAMIXERS are robust forced action mixers that are designed to mix all
those materials that cant be successfully mixed in a conventional free-fall cement mixer The
mixer uses the same frame as the heavy duty RM65 with a 55 ltr stainless steel pan It is
driven by a 1.5kw, 110 volt high torque motor and sealed gear box; 240 and 415 volt motors
are also available The rotating pan produces a centrifugal mix and the technically designed
paddles generate a radial and axial action; the paddles mix right up to the tub sides The
RMP55 is the ideal mixer for up to 2 bags of repair mortar and grout, epoxy, screed, flooring
latex and self levelers, cements, adhesives and coatings P12 L shaped paddle + P22 rotary
paddle The RMP55 is also available with a 2.2kw motor option and larger gearbox - add
1952 bag, 45 liter capacity output up to 800kg/hr 1.5kw, 110 volt, 22 amps.

RMP55
55 liter stainless steel pan

CHAPTER NO:4
Project work

4.1General study of pan mixture

Pan mixture is used to mixing and crushing of fly ash, cement , sand and water.
Main components for mixing of materials are four shovels.
Main component for crushing is two roller.
One scrapper is used to clear the wall of shell.

4.1.1Materials which mixed in pan mixture are:

Fly ash -60%
Cement -30%
Sand -10%


4.1.2Property of sand:

Specific gravity :2.65 to 2.95
Crushing strength:650kg/cm
2


The specific gravity G
s
of a soil without any Qualification is taken to be
average value for the soil grain in numerical values are given in a discuss where it
may be clear the specific gravity is reffered , the magnitude of the value may indicate
the correct usages since the specific gravity of the soil grains will always be larger
than the bulk specific.

If one is considering only the soil grains, one G
s
as


G
s
=

mutcuI
ywatcr at 4

G
s
=specific gravity,
motcriol
=
Density of material,
Ywatei= Density of water.

TABLE:1 Following data about sand specific gravity

Type of sand G
s

Sand 2.65-2.67
Silty sand 2.67-2.70

Bulk density of sand =
wcght o] sund
oIumc o] sund

TABLE:2Particle size limits of sand
Type Range (mm)
Fine gravel 6-2
Corse sand 2-0.6
Medium sand 0.6-0.2
Fine sand 0.2-0.06

Specific gravity of sand: 2.65
Bulk density :1200kg/m
3

4.1.3 Shear strength :

The shear strength of a soil may be defined as the maximum
resistance of the sand to shearing stress under any given condition .

Coulombs law and in its simplest form
T=c+tan
T=shear stress
=total compressive stress
c=apparent cohesive stress
=angle of shearing resistance

4.2property of cement
TABLE:3 approximate composition
Silica 20to25%
Aluminum oxide 4to8%
Calcium oxide 60to65%
Ferrous oxide 2to4%
Magnesium oxide 1to3%

4.2.1compression strength of cement:
the dry mixture of cement &sand is added water is given by following
formula.
P=
pn
4
+3.5

P=% of water by weight of dry material

P
n
=%of water required for making cement paste of normal
consistency.

Compressive strength of Portland cement should not less Then
After 3days=115kg/cm
2

After 7days=175 kg/cm
2
Density of cement: 1290kg/m
3

4.2.2Property of fly ash

Density of fly ash: 2100kg/m
3


4.3calculation of volume of shell:
here,
fly ash-60%
cement-30%
sand-10%

volume of fly ash:
V
f
=
m
p

m=mass of fly ash
p=density of fly ash
V
f
=
600
2100

=0.2857m
3

volume of cement:
V
c
=m/ p
=300/1290
=0.2325m
3

volume of sand:
V
s
=m/ p
=100/1200
=0.0833m
3

Total volume of materials = (0.2857+0.2325+0.0833)10
5

=6.013710
5
cm
3

4.4 DESIGN OF PAN
V=r
2
h
Where,
r=radius of drum
h=height of drum
h=500mm (assume)
r
2
=0.6015h
=0.60150.5
R =1.0968 m
Now take height 100cm
V= r
2
h
6.013710
5
=3.14r
2
100
r
2
= 6.01310
5
/1003.14
= 43.76cm

Take r = 45.00 cm (radius of pan)

Show a figure of pan





H=1000 mm


D=900 mm
FIG.1 BASIC DIAGRAM OF PAN
Now,
All density are taken as minimum value so, any type of material which has any
density can be included in a cylinder of h=1000 mm , r=450 mm.
As per above assumption material fill in cylinder are as below:




H=1000 mm




D=900 mm

FIG.2 MATERIAL FILL IN WHOLE PAN

As shown in fig. condition is not actually not reliable because for crushing of sand the roller
have to roll on the material and in this condition roller is not perfectly roll on material.
So, we can apply two type of condition:
1. either increase radius of pan
2. either increase height of pan.

If increase the height of pan then contact between base of pan and roller is not done
perfectly.

This condition shown in figure below:



Main shaft

roller


H=1000mm

D=900 mm

FIG.3 CASE 2 OF DESIGN OF PAN

As shown in fig. this condition is not sufficient.

So, we chose the second option increase radius of pan and reduce height of material filling.
For this condition some advantage also:
1.Increase the contact of roller with base.
2. Reduce the H.P of drive motor.
3. Improve the crushing quality.

This condition also shown in fig.






1000 mm


R 150 mm

FIG.4 CASE 1 OF DESIGN OF PAN

So, it seems very advantageous to increase radius of pan for perfect crushing of sand &
mixing the materials.

Suppose ,we fill material at height of h=150 mm
Than, V
old
=V
new

R
1
2
H
1
= R
2
2
H
2

45
2
100 = R
2
2
15
R
2
=

113.6 cm
Take, R
2
= 1140 mm
So, D
2
=2280 mm
Now, it is also high fill up & we have to take a roller with three times diameter of material fill
up height.
Diameter of roller =3* height of fill up
= 3*15
= 45
It can be seen that roller diameter is higher than the weight of roller also high. So, we have to
reduce material fill-up area.
So, take
H = 100 mm
Than V
old
= V
new
*114
2
*15 = *R
2
*10
R= 1390.62 mm
Take, R=1400 mm
Now final fig. of pan fill up and diameter of pan view



D=2800mm


H=1000mm
H=100mm
FIG.5 FINAL DIMENTION OF PAN

Here extra 900mm height can be eliminated as per requirement and as shown in
fig final diameter of pan is 2800mm.

4.5 FUNCTIONAL DESING OF PAN MIXTURE
Now force require ton crush sand particles in to fine sand particle:

F=L(d
1
-d
2
)
c

Here ,
L=length of roller,
d
1
=diameter of input sand particles,
d
2
=diameter of output sand particles,

c
=crushing strength.
L=500mm,
d
1
=6 mm,
d
2
=1mm,

c
=3.5 Mpa
F=500(6-1)3.5
F= 8750 N

Torque acting at shaft
T =F
1
r
1
+F
2
r
2
F
1
,F
2
=force acting by roller 1&2
r
1,
r
2
=radius of roller 1&2
=87501.05+87500.55
=14000 Nm
T = 14 KNm
Now , Extra 5% torque is taken for shovel friction with material.

So ,Torque at shaft
T`=1.05T
= 1.0514
T`=14.7kNm

4.5.1 TIME CYCLE

Generally the process cycle of pan-mixture batch is varied from 4-6
minutes per batch .For neglecting the centrifugal force acting on the material it
is recommended that peripherical velocity of roller& shovel should not exceed
2M/s.(from mechanical system design. (R.B.PATIL)
So, angular speed of roller = 2m/s
=
2N
60

N=
60o
2

N=19 R.P.M
Now, power required to do the main function of pan mixture is given below,
P=Torque angular speed
P= 14
2N
60

= 142
P=28 KW


4.5.2 GEAR BOX

Now, generally available electric motor are at 1400 r.p.m. so, it is require to reduction
from 1400 to 19 r.p.m. there are power loss in the reduction of gear box hence taking
extra 90% efficiency of gear box so 10% extra power of motor is required.

P=10% extra of 28kw

P=30.8kw

Generally 30.8kw rated motor is not available in market. So, it is require to take 31kw
motor with 1440 t.p.m.

So, motor configuration :
P=31kw
N=1440r.p.m
Now , gear box configuration:

G=N
1
/N
2


=speed of elect. Motor/speed of roller

= 1440/19

G = 75.78:1
Take G=76:1


4.6 DESIGN OF ROLLER:

4.6.1FUNCTION OF ROLLER:

Roller is used for crushing of sand particles in form of powder of small
fine particles.
For that function we have required minimum 2 roller.


Take clearance of 600 mm on both side of main shaft
Now force require ton crush sand particles in to fine sand particle:
F=L(d
1
-d
2
)
c

Here ,
L=length of roller,
d
1
=diameter of input sand particles,

d
2
=diameter of output sand particles,

c
=crushing strength.
L=500mm,
d
1
=6 mm,
d
2
=1mm,

c
=3.5 Mpa
F=500(6-1)3.5
F= 8750 N
So, mass of roller :
=3.5 Mpa
F= 8750 N
So, mass of roller :

M=
P
g


=
8750
9.81


M = 891.94kg
=892 kg

= 6800kg/m
3
(for C.I)
so, volume of roller:

V=
m

=
892
6800

V= 0.13117m
3

Now roller length L=500mm

V = r
2
L
0.13117 = 3.14 r
2
0.5
R= 289.05 mm
R = 290 mm (radius of roller)
But holding purpose of roller it is required to hole in roller center so extra radius distance
should be provide to roller.
So, Take
R =300 mm
4.6.2 DESIGN OF ROLLER ARM:

Roller arm connect top plate with roller . it is squre in cross section .
Free body diagram of roller arm is shown below:
Arm -1 800mm 300mm Arm -2

700mm
700mm
1000mm
FIG.6 FREE BODY DIAGRAM OF ROLLER ARM

But pure tension on arm it is modified as below:

700mm L
L

300mm

So, length of arm
L=7uu
2
+Suu
2

L= 361.57 mm

Free body diagram of roller with arm:

T





mg
FIG.7 FREE BODY DIAGRAM OF ROLLER

Tan =
700
300


= 66.8
0

now from fig.

Tsin= Mg

T=
mg
sn0


=
8929.81
sn66.8


T= 9520.38N

Now ,


t
=
]occ
ucu



t
=
1
A


A=
9520.38
ct


wb=
9520.38
ct


here select cast iron rod of grade FG150 , for square cross-section area

W=b

b
2
=
9520.38
150


b=7.96 mm

taking b=10 mm


4.6.3 DESIGN OF ROLLER SHAFT:


Free body diagram of roller shaft:
T/2 T/2










FIG.8 Front view roller free body

T






Fig.9 tension at roller arm ( Side view)

So, max banding moment of roller shaft,
M
max
= T/2L
= (9520.38500)/2

M
max
= 2380095 Nmm

So, taken circular shaft,


b
=
Mmux
z


M
max
= S2
b
d
3

Now taking shaft material FG400(C.I)

b
= 400 N/mm
2

so,
2380095= = S2400 d
3

d = 39.28mm
d= 40 mm

for fitting purpose inner diameter of roller:
d= 41 mm
now two bearings fitted at two ends of roller ,
TABLE:4 BEARING OF 60 SERIES
Bearing
no
Bore(mm) Outside
dia(mm)
Width Static
c
0
(kN)
Dynamic
C(kN)
Grease
lubrication
Oil
lubrication
6005 25 47 12 6.55 11.2 15000 18000
6006 30 55 13 8.3 13.3 12000 15000
6007 35 62 14 10.2 15.9 10000 13000
6008 40 68 15 11.6 16.8 9500 12000

From manufacturers catalogs selecting bearing . so, we can select
ball bearing from axial & radial load .

Series : 6008
Bore : 40 mm
Outer dia. : 68 mm
Width: 15 mm
Static c
0
= 11.60 kN
Dynamic c =16.80 kN
Grease lubrication = 9500 r.p.m
Oil lubrication = 12000 r.p.m
4.7 Functional design of shovel.

Number of shovels
n = 4

So , width of shovel =
L-uIIowuncc
n

=
140-30
4

=27.5 cm





h
27.5
275mm




h w




Now, equation of projectile motion,
R =
sIn20
2g

So , taking = 45 for maximum mixing of material at given velocity of shovel.
Now, sin0 =
h
w

But, h = height of filling material + allowance
h = 10cm + 1cm
= 11cm

sin4S =
11
w


w =
11
sIn45

W = 15.5 16 cm

250mm

160mm


FIG.10 shovel

Arrangement of shovel.

FIG.11 Arrangement of shovel.

Angle between two shovels =
360
4

= 90
Angle between two rollers =
360
2

= 180


4.8 DESIGN OF SHAFT:

Shaft is a critical component of pan mixture. If it fail working of all machine is stop.
Material of shaft is mild steel, for cost benefits and higher working life. Here shaft is
designed on basis of twisting moment and bending moment. Bending moment is due to
unbalanced force of rollers.
Here ,

T=14kNm
N=19r.p.m
Now , the unbalanced force acting on shaft is calculated below:



m
2

2
r
2
m
1

2
r
1
shaft




so, unbalanced force
F= m
1

2
r
1
- m
2

2
r
2

=(89221.05)-(89220.55)
F= 1784 N
So, bending moment
M=FL
M=17841
M=1784Nm
Now, according to max. shear stress theory
T
e
= H
2
+I
2

=14uuu
2
+1784
2

T
e
= 14113.2 Nm
But T
e
=/16d
3

Here mild steel of 45 C8 type
So,

ut
=500Mpa

ut
=700Mpa
taking factor of safety = 6
so,
t
=
c
ut
P.S


= 700/6
,
t
=116.67 N/mm
2
And
=
:
ut
P.S

= 500/6
= 83.34 N/mm
2

now according to shear stress theory ,
T
e
=/16d
3

Where,
d=diameter of shaft
14113.21000 =/1683.34d
3

d= 95.2 mm
now equivalent bending moment
M
e
=1/2(M+H
2
+I
2
)
=1/2(M+T
e
)
=1/2(1784+14113.2)
M
e
=7948.6
According to max tensile stress theory
M
e
=/32
t
d
3

7948.6= /32166.67 d
3

d= 91.37 mm

but, taking higher value

d= 95.2 mm
taking value
d=96 mm
L=130 mm

4.9 DESIGN OF COUPLING
Coupling is used to connect housing shaft to gear box shaft.

Main function of coupling is to provide engagement & disengagement of power drive
from machine.

In this case flange coupling is used.

Specification of coupling is obtain by design.

d = diameter of shaft
= inner diameter of hub

D = outer diameter of hub
= 2d

Length of hub, L = 1.5d

=1.595
L = 142.5mm

Pitch circle diameter of bolts,

D
1
= 2d
= 295
= 190mm

FIG.12 FLANGE COUPLING Courtesy of MECHANICAL HAND BOOK

Outer diameter of flange
D
2
= D
1
+ ( D
1
D )
= 4d
= 4 95
= 380 mm

Thickness of flange,

t
f
= 0.5d
= 0.5 95
= 47.5 mm

Selecting material 45C8

ut
= 700 MPa

ut
= 500MPa

Taking, F.S. = 6

t
=
ut
/ F.S

t
= 166.67 MPa

=
ut
/F.S

= 83.34 MPa

design of hub.

T = n /16
c
(

4
- d
4

c
= 450 MPa

c
<
ut

Design of key.

Material of key 45C8

Length of key,
L = Length of hub
L = 142.5 mm

From the standard table of IS: 2292 and IS: 2293 at 197

TABLE. 5 Proportion of standard parallel , tapered & gib head keys:

Shaft dia. Upto &
including(mm)
Width(mm) Thicknees(mm)
50 16 10
58 18 11
65 20 12
75 22 14
85 25 14
95 28 16
110 32 18
130 36 20
150 40 22

Width = 28 mm

Thickness = 16 mm


Design for bolts.
TABLE 6. SELECTION OF BOLT
Shaft
dia(mm)
35to55 56to150 151to230 231to390 Above390
No.of bolts 4 6 8 10 12

According to IS: 36523 number of bolts required at 95 mm diameter shaft is 6.

n = 6

load on each bolt = /4 J
1
2

b


torque transmitted by bolt,

T = /4 J
1
2

b
n D
1
/2

For maximum safety we should take steel material,

b
= 30 MPa

d
1
= 10 mm.

4.10 Design of plate for whole machine

From, Hertz contact stress theory it is reccomanded that plate should following specification,
Material: stainless steel
Poisson ratio of S.S.:0.27
Poisson ratio of C.I. :0.22
Ys moduls for S.S. : 193GPa
Ys module for C.I. : 170 GPa
And force of upper plate F=8750 N
So, from that data we can find thickness of plate T=10 mm
And side plate thickness=8 mm.


In hertz contect stress theory two components are come in contact
Here in this case two cylindarical surface are come in contact
1. Roller
2. Base plate (take its radius infinite.).

So,
Contact stress,

ch
=
2]
nbI

Where, b=contact space
F=force
L=width of roller.

b=_
4]
nI
|
(1-1)2
L1
, +
(1-2)2
L2
,
1
1
, +
1
2
,
]_
1
2
,

= _
47-8750
3.14-500

|
(1-0.27)2
193
, +
(1-0.22)2
170
,
(1300)
]_
1/2


=8.3 mm
Take 10mm. thickness of plate.

4.11 HYDROLIC GATE SYSTEM DESIGN:

Here empting time of material from pan is 2 minute. In this gatting system hydraulic system
are used so one master cylinder are used . for controlling the motion of gate open & close
there are limit swich are used.
Gate are finally open after completing mixture of material in pan. In 2 minute cycle
1 minute for opening gate.
1 minute for closing gate.





MASTER
CYLINDER
HYDRALIC CYLINDER
GATE
GATE
fulcrum point
end of gate
5
0
2
0
400
P
O

As shown in fig.
Po= distance traveled by point on gate.
=1/3* circumference of gate circle.
= 1/3**400
=418.66 mm

Now speed of point p
=distance/time
=418.67/60
==6.97 mm/sec.


Now from fig.
12.
P1P2
=
0
P0


P1P2=
418.8-400
50

P1P2=52.35MM.
So required stroke for second piston =52.32mm
Take 53mm.
p`
p
p2
Q1
Q
Q2
O

Now bore of piston is 30mm

Then volume displacement per minute v=/4*d2 *L
=/4*30
2
*53
= 37444.5mm
3
/mm
So, drive motor has to supply above volume of fluid to the second cylinder.
If bore of second cylinder is20mm
So, volume displacement by one revolution
V
2
=/4*20
2
*20
=6280mm
3
So number of stroke frist cylinder require
=v
1
/v
2

=37444.5/6280
=6 (approch).

4.11 FINAL VIEW OF PAN MIXTURE

FIG.13Top & front view of pan mixture Courtesy of NEPTUNE PVT LTD.

FIG.14 3-D view of pan-mixture courtesy of fortune pvt.ltd.

CHAPTER NO:5
Conclusion

5.1 Advantages of design & development of pan mixture.

Prevent the failure of machine
To reduce production cost.
To improve mixing performance.
To improve crushing efficiency.
To produce mixing material in laser time.
To settle the shovel & roller.
To reduce power required of motor.

In any machinery the failure of machine occur due to critical component failure. This
can be prevented by proper designing of critical component (in our case vertical
shaft).

Select suitable size of rollers so, selecting the roller not over size or under size.

Appendices

value of poisson ratio for materials
Sr. no. Material Poissons ratio
1 Steel 0.25 to 0.33
2 Cast iron 0.23 to 0.27
3 Brass 0.32 to 0.42



Values of modulus of rigidity for materials.
Sr.no. Material Modulus of rigidity (GPa)
1 Steel 80 to 100
2 Cast iron 40 to 50
3 Brass 30 to 50


Strength of material as per IS codes.
Sr.no. IS designation Strength in MPa
1 FG400 400
2 FG150 150
3 45C8 700






REFERENCES

1. Mechanical system design by S.P. PATIL

2.Machine design vol.1&2 by R.B. PATIL

3.Machine design by R.S KHURMI& J.K GUPTA

4. Mechanical hand book by SADHU SINH
5.Catelog of NEPTUNE INDUSTRY PVT. LTD
6.Property of soil by M.J. SMITH

SPECIMEN
DESIGN AND DEVELOPMENT OF PAN-MIXTURE FOR MIXING AND
CRUSHING OF FLY-ASH,CEMENT,SAND AND WATER.
A PROJECT REPORT
Submitted by
DARSHIN MAKVANA(080160119032)
HAMIR BAMBHANIYA(080160119001)
BALDEV VAGHASIA(080160119124)
NITESH KUCHA(080160119027)

In fulfillment for the award of the degree
of
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING


GOVERNMENT ENGINEERING COLLEGE-MODASA
Gujarat Technological University, Ahmedabad
April, 2012