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ABSTRACT
A vibration exciter is a machine which produces mechanical vibratory motion to provide forced
vibration to a specimen on which modal analysis and testing is to be performed. This article
presents the design & construction of a mechanical vibration exciter which ha s a cam and follower
mechanism used to generate uniaxial vibrations. The exciter is designed to produce displacement
through a given range of frequencies. The construction of working device and its important parts
and the results obtained from FFT analyser are described here.
Key words: Mechanical, Vibration.
Cite this Article: Aditya Pawar, Sumit Vajre, Shubham Patil, Ashish Badade and Kamlesh Sasane,
Design and Fabrication of Mechanical Vibration Exciter. International Journal of Mechanical
Engineering and Technology, 7(6), 2016, pp. 5875.
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1. INTRODUCTION
A vibration exciter is a force generator that provides vibration, shock, or modal excitation source for
testing and analysis produces mechanical vibratory motion to test object. The exciters are designed to
produce a given range of harmonic or time dependent excitation force and displacement through a given
range of frequencies. These machines can be mechanical, electro-hydraulic or electro-dynamic in nature.
Vibration exciters are used for development, simulation, production, studying the effects of vibration, and
simulate the shock or vibration conditions found in aerospace, construction, agricultural, automobile, etc.
[1]
After invention of vehicles, advancement in each section has been in full force in improving the
performance of the vehicle like vibration isolation, ride comfort, stability and efficiency. Ride comfort
problems mainly arise from vibrations of the vehicle body, which may be induced by a variety of sources,
including surface irregularities, aerodynamic forces, vibrations of the engine and driveline, and imbalances
of the tire against assembly. Usually, surface irregularities excite the vibration of the vehicle body.
Vibration exciter acts as an input to the designed models of vehicle and those models can be analyzed by
different ways to improve vibration behavior of vehicle. [2,3]
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Design and Fabrication of Mechanical Vibration Exciter
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Aditya Pawar, Sumit Vajre, Shubham Patil, Ashish Badade and Kamlesh Sasane
CHAPTER 2
2. DESIGN AND DEVELOPMENT
The previous chapter gave an introduction to the concept of the project and literature review help in
deciding the components to be used and parameters that can affect the results of the project.
This chapter will include the discussion regarding the layout of the project and design considerations
based on calculations. The experimental layout, components and their functions are explained in figure 2.1.
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Design and Fabrication of Mechanical Vibration Exciter
2.3.1. Shaft
The design power for shaft is taken as 2kW considering factor of safety. The motor speed is taken to be
1000rpm.
Data:
Let =2 , = 1000
The Eq. (1) will give the torque acting on the shaft
= /( ) = 19.1 (1)
1. V.F.D
= 0,
+ " = 1000
#$ = 0
" = 500
= 500
2. V.B.M.D
$) = $* = 80000
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Aditya Pawar, Sumit Vajre, Shubham Patil, Ashish Badade and Kamlesh Sasane
The Eq. (2) will give the equivalent moment acting on the shaft
$, = .(2$/ ) + (2
( ) (2)
$, = 164.5 109
The Eq. (3) will be used to find out the diameter of shaft
12
= 3 6 = 81 /
*
(3)
45
7 = 22
Let, 7 = 30
Thus, the diameter of shaft is 30 mm.
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Design and Fabrication of Mechanical Vibration Exciter
Figure 2.3 shows the forces acting on cam and the symbols used for various dimensions of the cam and
the follower.
R
G; = = 0.63 /F
Q
2P
R ;
E@ = S = 79.38 /F
O 2
E; Q = 79.38 /F
= ; = 10
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Aditya Pawar, Sumit Vajre, Shubham Patil, Ashish Badade and Kamlesh Sasane
; Q = ; = 400
The Eq. (6) will give radius
adius of curvature of cam surface
surfa
6
Z [ Z Z
V@W X>YY Xf
X h
) = U [
iZ
j = 53.7 (6)
(@W X>)Z X ( )Z ](@
] W X>) Z
\
Thus, the induced stress value is less than the design value of contact stress.
stress.
Follower body:
The follower body dimensions are based on the dimensions of the roller, which has diameter of 20 mm
and width of 20 mm.
7 = 46
Thread: $46 2
Design of Roller pin:
The roller pin is designed to withstand the double shear failure.
= 45 /
The Eq. (8) will give the value for diameter of roller pin
*W Z
; Q = 2 c d
e = 400 (8)
7C = 3
Let, 7C = 8
Thus, the safe value of roller pin is 8 mm.
Figures 2.4 & 2.5 shows the cam and follower models
models prepared on Autodesk Inventor as per the design
calculations & its behaviour shown in Figure 2.6
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Design and Fabrication of Mechanical Vibration Exciter
Displac
ement,
Velocit
y,
Acceler
ation
Angular Displacement
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Aditya Pawar, Sumit Vajre, Shubham Patil, Ashish Badade and Kamlesh Sasane
R
G; = = 0.35 /F
Q
2P
R ;
Em = S = 24.5 /F
O 2
E; Q = 24.5 /F
= ; = 10
; Q = ; = 400
The Eq. (11) will give the value of radius of curvature of cam
6
Z [ Z Z
V@W X>Y Xf h
) = U [
iZ
j = 62.31 (11)
(@W X>)Z X ( )Z ](@W X>) Z
\
The Eq. (12) will give the value of contact stresses between cam and follower
_` a a
() ) = 189.8^ ( + @ ) = 218.14 / l 1130 /
- @
(12)
k
Thus, the induced stress value is less than the design value of contact stress.
Follower body: -
The follower body dimensions are based on the dimensions of the roller, which has diameter of 20 mm
and width of 20 mm.
7 = 46
Thread: $46 2
Design of Roller pin:
The roller pin is designed to withstand the double shear failure.
= 45 /
The Eq. (13) will give the value of diameter of roller pin
*W Z
; Q = 2 c e = 400
d
(13)
7C = 3
Let, 7C = 8
Thus, the safe value of roller pin is 8 mm
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Design and Fabrication of Mechanical Vibration Exciter
Figures 2.7 & 2.8 shows the cam and follower models prepared on Autodesk Inventor as per the design
calculations & its behaviour shown in Figure 2.9
Fig
Figure 2.7 Inventor Model of Snail Drop Cam
Displac
ement,
Velocit
y,
Accele
ration
Angular Displacement
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Aditya Pawar, Sumit Vajre, Shubham Patil, Ashish Badade and Kamlesh Sasane
2.3.4. Spring
The spring design is based on fatigue loading.
; Q = 400 , ; Q = 10 ,o= 6
Material: ASTM A228
p = 79.3 p E, qr, = 1800 / ,
= 504 /
The Eq. (14) will give the value of Wahl stress factor
d)]a
s = fd)]dh = 1.2525 (14)
The Eq. (15) will give the value of wire diameter of the spring
t_)
= s ( *Z) (15)
7 = 4
u = 24
Hence, the wire diameter is 4 mm and the coil diameter is 24 mm
The Eq. (16) will give the value of number of coil
_viw y*
= xviw
= 40 / = t ) 6z (16)
(Eo{|G}) ~ = 7
({{E)~` = ~ + 2 = 9
Thus, the total number of turns is 9.
The Eq. (16) will give the value of solid length of spring
= (~ + 2)7 = 36 (17)
The Eq. (18) will give the value of free length of spring
" = + ; Q + (~` 1) 1 = 54 (18)
The Eq. (19) will give the value of pitch of spring
Lf = pn+2d (19)
p = 6.6 mm
Thus the value of pitch is 6.6mm.
2.3.5. Key
The key will be subjected to shear and crushing stresses. So it is designed to withstand these stresses.
7 = 30
The Eq. (20) will give the value of width of key
* 9
= =
d d
(20)
= 7.5
The width of key is 7.5 mm.
The Eq. (21) will give the value of height of key
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Design and Fabrication of Mechanical Vibration Exciter
= =5
9
(21)
The height of key is 5 mm.
= 30
The Eq. (22) will give the value of force acting on key
d.a 6
= = = 3184
a
(22)
= 45 /
)@ = 135 /
The Eq. (23) will give the actual value of shear stress
_
() = s
= 14.15 / (23)
The Eq. (24) will give the actual value of crushing stress
_
()@ ) = = 21.23 /
H
(24)
Thus, the actual crushing stress is less than the permissible value of crushing stress.
Thus, the dimensions of the keys that are found out are safe.
The design of shaft, cams, follower, key and springs is done and their calculated stress values are
within the specified limit, so these parts can be taken for manufacturing; hence in next chapter a complete
part list can be discussed.
CHAPTER 3
3. FABRICATION OF VIBRATION EXCITER
3.1. Fabrication of Vibration Exciter
In this chapter, different components of vibration exciter are described in terms of their dimensions given
in Table 3.1. The shaft was fabricated on lathe machine. The cams were made on VNC machine. The IGES
files of the cams were opened in Master Cam software to get the co-ordinates for VNC machining. The
follower was made using lathe and VNC machine. Internal threading in plate was done by tapping. Deep
groove ball bearings and springs were directly purchased from the market. The fabricated parts of vibration
exciter such as shaft, SHM cam, Jerk cam and follower are shown in diagram 3.1, 3.2, 3.3, 3.4 and 3.5
respectively.
Sr. Quantity
Component Dimensions Material
No.
Diameter: 30 mm EN 19 1
1. Shaft
Length: 700 mm
Base circle radius: 40mm EN 24 2
2. SHM Cams Maximum rise: 10mm
Width: 20 mm
Base circle radius: 40mm EN 24 2
3. Drop Cams
Maximum rise: 10mm
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Aditya Pawar, Sumit Vajre, Shubham Patil, Ashish Badade and Kamlesh Sasane
Width: 20 mm
Roller radius: 20 mm MS 4
Roller width: 20 mm
4. Follower Roller pin diameter: 8mm
Body diameter: 42 mm
Body length: 150 mm
Height: 5 mm MS 4
5. Key Width: 7.5 mm
Length: 20 mm
ID: 30 mm 2
6. Deep groove ball bearing OD: 62mm
Width: 16mm
Length: 600 mm MS 1
7. Plate Width: 600 mm
Thickness: 6 mm
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Design and Fabrication of Mechanical Vibration Exciter
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threaded follower reinforcement is attached with four equidistant threaded holes. .A complete assembly is
shown in Figure 3.6.
CHAPTER 4
4. RESULT AND ANALYSIS OF VIBRATION EXCITER
4.1. Results
The mechanism used to operate one type of input at one time in vibration exciter having two different type
of cam profile on same shaft is represented in fig. 4.1 and 4.2 as SHM input and jerk input. Its been shown
in both the figures, two types of cams consider type A and type B. Where type A has jerk type motion and
those cams are mounted on the shaft at the outer ends, where as type B has SHM type motion and those
cams are mounted on the shaft at the central portion. The output is measured by using FFT analyzer i.e.
output/amplitude in frequency domain. For Jerk motion and SHM motion, output is shown in Figure 4.3
and 4.4 respectively.
Follower
Drop
cam
SHM
cam
Figure 4.1 Schematic Diagram for Jerk Motion.
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Design and Fabrication of Mechanical Vibration Exciter
Follower
Drop
cam
SHM
cam
Figure 4.2 Schematic Diagram for SHM Motion.
Jerk Motion
2.5
2
Diplacement (cm)
1.5
1
0.5
0
-0.5
-1
-1.5
-2
0 0.5 1 1.5 2
Time (sec)
SHM Motion
15
Diplacement (cm)
10
5
0
-5
-10
-15
Time (sec)
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For SHM type input with 1cm amplitude, a peak of 1.14 cm is observed in upward direction and 1.28
cm is observed in downward direction as shown in figure 4.4.
4.2. Analysis
The graphs obtained by FFT analyzer with the help of accelerometer are slightly out of range due to
following reasons-
Insufficient damping as the setup is not fixed to the ground.
Required contact stresses between follower roller and cams cannot be measured.
Friction between roller and roller pin is causing slight slipping of the roller initially.
Based on results obtained, the conclusion of the project is discussed in next chapter.
CHAPTER 5
5. CONCLUSION
In chapter 4, the results obtained from the FFT analyzer are discussed. The time vs amplitude graph shows
that both the types of output waveformsSHM and sudden jerk, are achieved with the cam and follower
mechanism. The exciter can be used for rpm value of the motor up to 1000 rpm. The variation in the
amplitude indicates that the damping provided by external weights is insufficient. By fixing the frame to
the ground or by using vibration dampening pads, sufficient damping can be provided, which will give
better accuracy. Use of ball bearing as roller in the roller follower will reduce the friction between the
roller and cams and also reduce the stress on the roller pin. This will increase the life of both the roller and
the cams.
REFERENCE
[1] http://www.globalspec.com/learnmore/sensors_transducers_detectors/acceleration_vibration_sensing/sh
akers_vibration_shock_testing.
[2] D. Dorugade, (2012), Suspension modeling, analysis and optimization of SUV using Matlab,
ME Dissertation Report.
[3] Wong J. Y, (2001), Theory of Ground Vehicles, 3-ed. John Wiley & Sons.558 p.
[4] S. H. Sawant, Mrunalinee V. Belwalkar, Manorama A. Kamble, Pushpa B.Khot & Dipali D. Patil,
Vibrational Analysis Of Quarter Car Vehicle Dynamic System Subjected To Harmonic Excitation
By Road Surface, Mechanical Engineering Department, Dr. J. J.Magdum College of Engineering,
Jaysingpur.
[5] Brian Wallace, Brandon Dawe, Design of a Vibration Exciter Device, Mechanical Engineering Senior
Design Project, Honors Theses, Paper 1913, Western Michigan University.
[6] Nitinkumar Anekar, V.V. Ruiwale, Shrikant Nimbalkar, Pramod Rao, Design and Testing of
Unbalanced Mass Mechanical Vibration Exciter, IJRET, pISSN:2321-7308.
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Design and Fabrication of Mechanical Vibration Exciter
[9] R.S. Khurmi& J.K. Gupta, A Text Book of Machine Design. Pg 509-557,820-884.
[10] PSG, Design Data Book, p4.13, p.7.21, p7.22, p7.100, p7.110, p7.113-p7.116.
[11] Ameya R. Salunke and Prof. Nishant S. Kulkarni, Analysis of Friction Induced Vibration during
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3 ), 2016, pp. 2 85 298 .
[12] Prof. Dr. Zena K. Kadhim and Hadi O. Mery . Free Convection From Optimum Sinusoidal Surface
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