PMCM DP

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE
JIMMA UNIVERSITY JIMMA INSTITUATE OF TECHNOLOGY DEPARTMENT OF MECHANICAL ENGINEERING
SUBMITTED TO ABIYOU SOLOMON SUBMITION DATE 25-MAY-2012
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AKNOWLEDGEMENT
First and above all we would like to express our deep acknowledgement to our instructor Mr. Abiyou Solomon (MSc) for his continuous assistance and advice consultancy. Next, we also express our heartfelt acknowledgement to Mr. Solomon Mulugeta a member of JU research office for his unlimited support and advice. Last but not the list we also acknowledge our group member to their great effort and tolerance.
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ABSTRACT
The main purpose of this work is to design pedal meat chopping machine. The work includes design of different machine elements such as design of shaft, gear, keys, screw, and selection of bearing, design of fasteners, tables, forked plate, blades and design of chain drives. This machine is made to be manually input power, in order to be used to the community where electric power is insufficient. This is also aimed at reducing electric power consumption. According to the website http://www.gizmag.com an average human can produce 400W power for two hours and 200W for about 8 hours which is enough to cut a meat.
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TABLE OF CONTENTENT
Contents
AKNOWLEDGEMENT ........................................................................................................................ ii ABSTRACT........................................................................................................................................ iii LIST OF FIGURES .............................................................................................................................. vi LIST OF TABLES ................................................................................................................................ vi SPECIFICATION ................................................................................................................................. 1 CHAPTER 1 INTRODUCTION ............................................................................................................. 2 CHAPTER 2 PROBLEM FORMULATION ............................................................................................. 3 2.1 POBLEM STATEMENT OF THE PROJECT ................................................................................. 3 2.2 GOALS AND OBJECIVES OF THE WORK .................................................................................. 3 2.3 SCOPE OF THE WORK ............................................................................................................. 4 CHAPTER 3 LITERATURE REVIEW ..................................................................................................... 5 3.1 BACKGROUND INFORMATION ............................................................................................... 5 CHAPTER 4 PRODUCUCTION DESIGN .............................................................................................. 6 CHAPTER 5 DESIGN OF COMPONENT .............................................................................................. 7 5.1 INTRODUCTION ...................................................................................................................... 7 5.2 DESIGN OF SHAFT .................................................................................................................. 8 5.3 GEAR DESIGN ....................................................................................................................... 36 5.3.1 Introduction .................................................................................................................. 36 5.4 DESIGN OF CHAIN DRIVE...................................................................................................... 41 5.4.1 Roller Chain ................................................................................................................... 41 5.5 Key design ............................................................................................................................ 43 5.6 SELECTION OF SCREW .......................................................................................................... 44 5.6.1 Bolted joints .................................................................................................................. 44 5.6.2 Design for bolts and nuts .............................................................................................. 45 5.7 Selection of Bearing ............................................................................................................. 45 5.7.1 Ball bearing ................................................................................................................... 45
5.7.2 Types of ball bearing ..................................................................................................... 46 5.7.4 Material selection ......................................................................................................... 47 5.7.5 Types of bearing lubrication ......................................................................................... 47 5.7.6 Calculation of bearings.................................................................................................. 47 5.9 DESIGN OF TABLE ................................................................................................................. 48 5.10 DESIGN OF PLATE ............................................................................................................... 48 5.11 DESIGN OF BLADE .............................................................................................................. 49 CHPTER 6 ASSEMBLY AND PARTS OF DRAWING ........................................................................... 50 CONCLUSION.................................................................................................................................. 54 RECOMMENDATION ...................................................................................................................... 54 BIBLOGRAPHY ................................................................................................................................ 55
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LIST OF FIGURES
LIST OF TABLES
SPECIFICATION
Specification is important and essential characters tics which states limits that are to be specified. Specification includes parameters which have to be specified us not calculated directly -The following parameters are specified in our design work. - Diameter of the sprocket - Number of teeth on the two sprockets - Diameter of the blade etc. In order to make it easy, we have listed all specification in the following table.
Input power Means of driving Blade diameter Length of shaft-1(blade on it) Length of shaft-2 Number of teeth of smaller sprocket Number of teeth of larger sprocket Speed of smaller sprocket Speed of larger sprocket Table dimension Table height Plate dimension Size of output meat
200W Manually by pedal 200 mm 450 mm 350 mm 21 49 140 60 500 mm X 800 mm 750mm 306 mm X 500 mm 20 mm X 20 mm
CHAPTER 1 INTRODUCTION
As described above the objective the objective of this course s to make students to design their own machine element. Based on what they have learned in a class. Based on this objective we have chosen to design Pedal meat chopping machine. The reason why we choose to design this machine is that in our locality there is no such type of machine. People usually chop meat manually by hand. Which is takes a long time to chop even a single kilogram of meat. We mainly focus on chopping of meat but not to mince it, since there is a machine which is used to mince a meat and usually people need a small amount of minced meat than chopped meat. So we are trying to solve this problem and to show our effort by designing such type of machine which able to solve the community problem as large.
CHAPTER 2 PROBLEM FORMULATION

2.1 POBLEM STATEMENT OF THE PROJECT
The reason why we want to do this pedal meat chopping machine is that in our community people usually chop by hand which is very tiresome and take much time to chop even a small K.G. of meat. Especially in the institutions where large number of people live like universities, military camp and jails is many K.G. of meat is chopped by hand. And it would be good evidence that in our university meat is chopped by hand and this is vary tiresome to cafeteria workers. So this problem initiates us to design this machine. - Overload of the kitchen workers. - over size of meat cutting due to the extreme amount of meat, which leads variable distribution of wet for the students and discomfort at the time of meal. - need to extra kitchen workers for meat cutting at the time of holydays.
2.2 GOALS AND OBJECIVES OF THE WORK

Objective The objective of this design project is mainly aimed at: Enable students to change the knowledge they grasp in the class to real work problem. Initiating students to formulate their own problem and come up with good idea of creativity. Observing their environment or community problem and give response to the observed problem. Broadness our knowledge on design of machine elements and procedures GOALS Based upon the objectives of machine design project our goal is mainly on: Observing our community problem end give response to it Investing our best effort to broaden our knowledge which has a sound benefit in our feature profession.
2.3 SCOPE OF THE WORK

This pedal meat chopping machine is not designed to mince a meat rather to chop a meat into small pieces specifically in size of 2cm by 2cm or 2cm by any length of the meat feed into the blades. The machine may also use to chop vegetables such as cabbage, carrot, potato and tomato etc. if we accidentally feed a bone into the blade the machine cannot cut the bone, but it can cut a cartilage. A small bone feed may cause a wear to the blades.
CHAPTER 3 LITERATURE REVIEW

3.1 BACKGROUND INFORMATION
Principle of Meat Processing Technology Meat processing technology comprises the steps and procedure in the manufacture of processed meat products. Which includes various different types and local/regional variation are food of animal origin which contribute valuable animal protein to human diets. Meat processing involves a wide range of physical and chemical treatment method, normally combining variety of methods In our case we focus on physical meat treatments method i.e cutting /chopping/comminuting or size reduction. Equipment used in meat processing In modern meat processing, most of the processing stapes can be mechanized. In fact, modern meat processing would not be possible without the utilization of specialized equipment. Such equipment is available for small scale, medium sized or large scale operations. The major items of meat processing equipment needed to fabricate the most commonly known meat products are listed. As an example, Bowl cutter (Bowl Chopper) Bowl cutter is commonly used meat chopping equipment designed to produce small or very small (finely comminuted) lean meat and particles. Number, shape, arrangement and speed of knives are the main factor determining performance of the cutter. The two main component of processed meat products are animal muscle meat and animal fat. Apart from pure muscle tissue, muscle meat also contains some connective tissue and inter & intra muscle fat which determine the quality of muscle meat. Animal fats are of firmer or softer texture of fats depending on their location in the animal body.
CHAPTER 4 PRODUCUCTION DESIGN

This pedal meat chopping machine is operated manually. One person is being seated in front of the machine and operate by his leg using the pedal, when the pedal is rotate the shaft connected to the chain will be rotate and also the blades are rotate. Product design is the determination and specification of the parts of a product and their interrelationship so that they become a unified whole. The design must satisfy a broad array of requirements in a condition of balanced effectiveness. A product is designed to perform a particular function or set of functions effectively and reliably, to be economically manufacturable, to be profitably salable, to suit the purposes and the attitudes of the consumer, and to be durable, safe, and economical to operate. For instance, the design must take into consideration the particular manufacturing facilities, available materials, know-how, and economic resources of the manufacturer. The product may need to be packaged; usually it will also need to be shipped so that it should be light in weight and sturdy of construction. The product should appear significant, effective, compatible with the culture, and appear to be worth more than the price
CHAPTER 5 DESIGN OF COMPONENT

5.1 INTRODUCTION
In order to make the machine fully functional, the components of the machine element have to be designed carefully. In our pedal meat chopping machine there are a number of component designs and selection. The components are separately designed and (some elements of the machine as selected) to make a single assembly of machine so that the machine is operational. The following machine elements are designed - Design of shaft (shaft 1 & shaft 2 ) - Design of chain drive - Design of gear (gear 1 & gear 2) - Design of sprocket (smaller & larger) - Design of blades (13) - Design of forked plate - Design of tables The following machine elements are selected per size of our machine element - Selection of bearing - Selection of screw - Selection of the size of the table - Selection of materials to be used for components
5.2 DESIGN OF SHAFT

Shaft is a rotating machine element which transmits power from one point to another point. It is one of the most common and basic machine elements which are used in a variety of ways in mechanical equipment. It is used with power transmission elements like gears, pulleys, flywheels, cranks, etc. These shafts are designed to transmit produced torque and to support the rotating elements like gears and pulleys. These elements produce bending moment in addition to torque. A shaft must be strong enough to sustain static and dynamic loading.
Types of shaft
Shafts are classified as follows according to their industrial application: Line Shaft: It is a shaft which transmits power to several machine elements. Spindle: Stub Shaft: Counter shaft: A spindle is a short revolution shaft. A shaft that is integral with an engine, motor or prime mover. A short shaft that connects a prime mover to a line shaft of a machine.
(i)
Transmission shaft:
These shafts transmit power between the source and the machine and absorbing power. Counter shafts and line shafts are transmission shaft.
(ii)
Machine shafts:
These shafts form an integral part of the machine itself. Example: Crank shaft, stub shaft.
Shaft material selection

The material selection commonly used for shaft is cold drawn, low carbon steel with carbon content 0.1 to 0.35 percent. When greater strength is required, as in high-speed machinery, an alloy steel such as nickel, nickel chromium or chrome vanadium steel are used. When resistance to corrosion is desired, some copper alloys are used. Below table lists some commonly used for shaft and their mechanical properties.
Material
Ultimate tensile Strength, N/mm2
Yield strength, N/mm2
Plain carbon steels C 07 320 - 400 200 C 10 340 - 420 210 C15 370 - 490 240 C20 440 - 520 260 C25 460 - 550 280 C30 500 - 600 300 C40 580 - 680 330 C45 600 - 750 380 C50 660 - 780 380 40 Ni 3 750 - 1050 600 30 Ni4 Crl 1000 - 1150 600 40 Cr 3 Mol V20 1350 1120 40 Crl 700 - 850 540 Table commonly used for shaft and their mechanical properties.
Shaft design calculation

Gear Sprocket Bearing Bearing
50 mm
250 mm
50 mm
Torque transmitted by the shaft Mt =
= 13.64Nm=13640 N.mm
Where: Mt - Torsional moment P - Power
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N - Revolution speed W - Load Assuming that the torque on the gear is same as that of the shaft, the tangential force acting vertically upward on the gear:-
Ft =
=161.42 N
Normal load on the gear WD =
=171.78 N
When the gear is driven by downward tangential force Vertical component:
WVD = WG x cos
=171.78 x cos 200 =161.42 N
Horizontal component:
WHD =WG x sin

= 171.78 x sin 200 =58.75 N Total vertical component on the shaft at D WV + WD (left) =161.42 N + 2k.g x 10 m/s2 =181.42 N Let T1 and T2 are tension on the right side and back side of the chain respectively on sprocket 2 at B
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Since the torque on the gear is the same with shaft value (i.e. 13640 N.mm) Mt = (T1 T2) x RD 13640= (T1 T2) x 84.5 mm = T1 (1-T2/T1) x 84.5mm Let we assume tension ratio T1/T2 = 2 Then 13640=T1 (1-1/2) x 84.5 mm 13640=45.25T1 T1=322.84 N T1/T2=2 T2=161.42 N Therefore total vertical load acting downward on the shaft at B T 1+T2+WB (LEFT) And neglecting weight of the sprocket T1+T2=322.84+161.42 =484.26 N Since the sprocket 2 is mounted at 450 inclination the total tension is resolved into X and Y component.
Tt = 484.26
45 45
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FX = Tt cos = 484.26 cos 450 =342.42 N
F Y = Tt sin =484.26 sin 450 = 342.42 N
Bending moment diagram

RAV
RAH TY B
TX
RBV RBH
Wt Wr
50
mm
250
mm
50
mm
FBD Horizontal force

TH A B RAH RBH Wr
C
50 mm
250 mm
50 mm
FH =0 RAH + RBH TH + WV= 0 RAH + RBH = TH + WV RAH + RBH = 342.2 161.41 RAH + RBH =180.78 N ------------------------------------ 1 M at A= 0 TH x 50 RBH x 300-WV x 350=0
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342.2 x 50 RBH x 300 161.42 x 350 =0 17110 RBH x 300 56497=0 RBH x 300 = - 39387 RBH = -131.29 N (downward) ---------------------------- 2 Now inserting 2 into 1 we get RAH + RBH =180.78 N RAH =180.78 (-131.29) = 312.07 N
Bending moment on horizontal
MB at section 1
A RAH
X
=RAH x X =312.07 x X At X=50 , 15603.5 N.mm
MB at section 2
TH A B RAH
X (X-50)
50 mm
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=312.07x 342.2(x-50) =312.07x 342.2x + 17110 =-30.13x + 17110 At X=50, 15603.5 N.mm At X=300, 8071 N.mm MB at section 3
TH A B RAH
C
x 250 mm
RBH
50 mm
(X-300)
=-30.13x + 17110 131.29(x-300) = -30.13x 131.29x + 17110 + 39387 =-161.42x + 56497 At x=300, 8071 N.mm At x= 350, 0
Vertical load FBD

TV A B RAV RBV Wt
C
50 mm
250 mm
50 mm
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F=0
RAV + RBV TV+ WV=0 RAV + RBV=342.2 + 58.75 RAV + RBV=283.45 N -------------------------- 3
M at A= 0 =TH x 50 RBV x 300 WV x 350 =342.2 x 50 - RBV x 300 58.75 x 350 =17110 20562.5 - RBV x 300 RBV =-11.508 N----------------------------------------------4 4 into 3 Then, RAV + (-11.508 N) =283.45 N RAV =294.9 N Bending moment on vertical axis
A RAV
x
MB at section 1 =RAV x X =294.9 x 50
=14747.9 N-mm
MB at section 2
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TV A B RAV
X (X-50)
50 mm
=294.6x 342.2 (x-50) =294.6x 342.2x + 17110 =-47.24x + 17110 At X=50, 14747.9 At X=300, 2937.4 MB at section 2
TV A B RAV RBV
C
50 mm
250 mm
(X-300)
=-47.24x + 17110 11.508(x-300) =-58.75x + 3452.5 + 17110 =-58.75x + 20562.5 At x=300, 2937.4 At x=350, 0 Resultant force MH
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Maximum bending at V=2937.4 Maximum bending at horizontal H=8071 R= = =8588.9 N-mm The resultant bending moment is MB max = 8588.9 N-mm Resultant maximum bending moment = = =21469.6 N-mm
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Gear Sprocket Bearing Bearing
B 50 mm 250 mm
15603.5 N-mm
C 50 mm
8071 N-mm
14747.9 N-mm
Horizontal Banding Moment

2937 N-mm
Vertical Banding Moment

21469.5 N-mm 8588.7 N-mm
Resultant Banding Moment
The shaft material is made from C45 and from standard of PSGDB; the ultimate load is in the range of 600-750 we take the average of the range. i.e 675 N/mm2 and allowable load is y =380 N/mm2 Factor of safety (n) =
= 675/380 = 1.78
Since the machine is not heavy duty machine take s.f n=2 The factor of safety is 2. This factor was chosen by considering Variations in material properties The effect of size of the shaft The type of loading
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The effect of machining or forming The effect of heat treatment The effect of shear on function The effect of operating environment The specific operating requirements and the concern for human safety
According to maximum shear stress theory y = n is stands for safety factor
N/mm2
= 190 N/mm2 Allowable shear stress = = = 95 N/mm2
Equivalent bending moment
Mte = [(Mt kt )2 + ( Mb kb )2
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Nature of loading Stationary shaft Stationary applied load Suddenly applied load Revolving shaft Suddenly applied load Minor shock load Heavy shock load
Kb
Kt
1 1.5-2.0
1 1.5-2.0
1.5 1.5-2.0 2.0-3.0
1 1-1.5 1.5-3.0
Kt and Kb values are 1 because the shafts of natural load is stationary applied load = =45436.06 N-mm Since our shaft material solid and subjected to pure torsional moment M te the shaft diameter can be found from the torsional strength equation given by Shear strength =16Mt /d3 =16Mt /d3 95=
d3 = =2435.83
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d = =13.45 say 15 mm Checking for tensile strength = = =20.58 N/mm2
Force analysis on blade
P=T =rF F= where P= power F= force r= radius of the blade = angular velocity
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Given that r=200/2 mm =100mm = = = 14.67 rad/s
Therefore F=
= 0.14 N
Torsional moment P= Mt = = = 13640 N-mm
Where Mt = torsional moment P= power N = revolution Force analysis for shaft 1 The shaft is made from C45, from PSGDB y =380 N/mm2 According to maximum shear stress theory y = n is stands for safety factor
N/mm2
= 190 N/mm2 Allowable shear stress
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= 95 N/mm2
Force on shaft
C D E F G H I
J K L M N O
WV
68 mm 50 mm
WH
68 mm
266 mm 22 mm
RAH
RAV
RBH RBV
We have force from blade force analysis, F= 0.14 N Horizontal force
WH
400 mm 50 mm
RAH
RBH
FH =0 RAH + RBH WH= 0 RAH + RBH = WH RAH + RBH = 85.74 N --------------------- ------- 5
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Moment at point
M at A = 0 0= RBH x 400 85.75 x 450 RBH = 6 into 5 RAH + RBH = 85.74 N RAH +96.46 =85.74 RAH = -10.66 (downward) = 96.46 N ------------------- 6
Bending moment Section 1
RAH
=RAH x X =-10.66 x X At x = 400, -4264 N-mm Section 2
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RAH
(x-400)
RBH
=-10.66 x X + 96.46(x-400) =85.8 x 38610 At x= 400, -4264 N-mm At x= 450, 0 Vertical force FV = 0 =- RAV + FC + FD + FE + FF + FG + FH + FI +FJ + FK + FL + FM +FN + FO -RBV RAV + RBV = (13 x 0.14 N) +161.24 RAV + RBV = 163.18 N --------------------------------------- 7
M at A = 0 = 0.14(68+90+112+134+156+178+200+222+244+266+288+310+332) +161.42 x 450 RVB x 400 = 337.28 + 72639 - RVB x 400 RVB = 364.04 N ------------------------------------------ 8 7 into 8 RAV + RBV = 163.18 N
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RAV + 364.04 = 163.18 RAV = - 200.8 N (downward)
Bending moment Section 1
RAV
=-200.8 x At x=68, -13657.8
Section 2
68 mm
RAV
=-200.8 x 0.14(x-68) =-200.936x +9.248 At x= 68, 13657.8 N-mm At x=90, -18074.9 N-mm Section 3
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C D
68 mm
22 mm
RAV
=-200.936x + 9.248 0.14(x-90) =-201.072x + 21.488 At x=90, -18074.9 N-mm At x=112, -22498.5 N-mm
Section 4
C D E
68 mm
22
mm
RAV
x
= -201.072 x + 21.488 0.14(x-112) = -201.208x 36.72 At x=112, -22498.9 N-mm At x=134, -26925.152 N-mm
Section 5
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C D E F
68 mm
22
mm
RAV
x
=-201.208x + 36.72 0.14(x-134) =-201.344x + 54.944 At x=134, -26925.152 N-mm At x=156, -31354.72 N-mm
Section 6
C D E F G
68 mm
22
mm
RAV
=-201.344x + 54.94 0.14(x-156) = -201.48x + 76.156 At x=156, -31354.72 N-mm At x=178, -35787.284 N-mm Section 7
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C D E F G H
68 mm
22
mm
RAV
x
=-201.48x +76.156 0.14(x-178) =-201.616x + 100.364 At x= 178, -35787.28 N-mm At x= 200, -40222.83 N-mm
Section 8
C D E F G H I
68 mm
22
mm
RAV
=-201.616x + 100.364 0.14(x-200) =-201.752x + 127.564 At x= 200, -40222.8 N-mm At x= 222, -44661.38 N-mm
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Section 9
C D E F G H I
68 mm
22
mm
RAV
x
=-201.752x + 127.564 0.14(x-22) =-201.868x + 157.756 At x= 222, -44661.38 N-mm At x= 244, -49102.9 N-mm
Section 10
C D E F G H I J K
68 mm
22
mm
RAV
=-201.868x +157.756 -0.14(x-2446) =-202.024 x +190.94 At x= 266, 49102.9 N-mm At x= 288, -57994.96 N-mm Section 11
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C D E F G H I
J K L
68 mm
22 mm
RAV
=-202.024x +190.94 0.14(x-268) =-202.16x + 227.116 At x= 266, -49102.9 N-mm At x=288, -57994.96 N-mm
Section 12
C D E F G H I J K L M
68 mm
22 mm
RAV
=-202.16x +227.116 0.14(x-288) =-202.296x +266.284 At x=288, -57994.96 N-mm At x=310, -2445.476 N-mm Section 13
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C D E F G H I
J K L M N
68 mm
22
mm
RAV
= -202.296x + 266.284 0.14(x-310) = - 202.432 x + 308.45 At x= 310, -62445.48 N-mm At x=332, -66398.984 N-mm
Section 14
C D E F G H I
J K L M N O
68 mm
22 mm
RAV
= -202.432x + 308.45 0.14(x-332) = -202.568x + 358.596 At x= 322, -66898.98 N-mm At x=400, -80675.8 N-mm
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Section 15
C D E F G H I
J K L M N O
68 mm
22
mm
RAV
RBV
=-202.568x + 358.596 + 364.0382(x-400) =161.4702x 145256.684 At x= 400, -80675.8 N-mm At x= 450, 0
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C D E F G H I J K L M N O
WV
68 mm 50 mm
WH
68 mm
266 mm 22 mm
RAH
RAV
RBH RBV
Horizontal Bandin Moment

-4264 N-mm
-13687.8 N-mm
-18074.9 N-mm -26925.1 N-mm -22498 N-mm -35787.2 N-mm -44661 N-mm -31354.7 N-mm -40222 N-mm -53547.4 N-mm -49102.9 N-mm 62445.4 N-mm 57994.9 N-mm 66898.9 N-mm -80675.8 N-mm 80788.4 N-mm
Vertical Banding Moment
Resultant Bandin Moment

Resultant bending moment:= = =80788.4 N-mm, Maximum bending moment Equivalent bending moment
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Met = (Mtkt )2 + ( Mbkb )2]
Kt and Kb values are 1 because the shafts of natural load is gradually Met = =81931.77 N-mm Since our shaft material solid and subjected to pure torsional moment M te the shaft diameter can be found from the torsional strength equation given by Shear strength =16Mt /d3 =16Mt /d3 95=
d3 = =43350.94 d = =13.37 say 14 mm Checking for ultimate tensile strength = = =25 N/mm2 Since the tensile strength is less than the ultimate tensile strength our design is safe.
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5.3 GEAR DESIGN

5.3.1 Introduction
Spur gears are used to transmit rotary motion between parallel shafts. They are Cylindrical, and the teeth are straight and parallel to the axis of rotation. The pinion is the smaller of two mating gears; the larger is called the gear or the wheel. The circular pitch p is the distance, measured on the pitch circle, from a point on one tooth to a corresponding point on an adjacent tooth. Thus the circular pitch is equal to the sum of the tooth thickness and the width of space.
TERMS USED IN SPUR GEAR The following terms, which will be mostly used in this chapter, should be clearly understood at this stage. 1. Pitch circle. It is an imaginary circle which by pure rolling action, would give the same motion as the actual gear. 2. Pitch circle diameter. It is the diameter of the pitch circle. The size of the gear is usually specified by the pitch circle diameter. It is also called as pitch diameter. 3. Pitch point. It is a common point of contact between two pitch circles. 4. Pitch surface. It is the surface of the rolling discs which the meshing gears have replaced at the pitch circle 5. Pressure angle or angle of obliquity. It is the angle between the common normal to two gear teeth at the point of contact and the common tangent at the pitch
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point. It is usually denoted by . The standard pressure angles are 14 1 /2 and 20. 6. Addendum. It is the radial distance of a tooth from the pitch circle to the top of the tooth. 7. Dedendum. It is the radial distance of a tooth from the pitch circle to the bottom of the tooth. 8. Addendum circle. It is the circle drawn through the top of the teeth and is concentric with the pitch circle. 9. Dedendum circle. It is the circle drawn through the bottom of the teeth. It is also called root circle. Note: Root circle diameter = Pitch circle diameter cos , where is the pressure angle. 10. Circular pitch. It is the distance measured on the circumference of the pitch circle from a point of one tooth to the corresponding point on the next tooth. It is usually denoted by pc. Mathematically, D= diameter of the pitch circle, and T= number of teeth on the wall A little consideration will show that the two gears will mesh together correctly, if the two wheels have the same circular pitch. Note: If D1 and D2 are the diameters of the two meshing gears having the teeth T1 and T2 respectively; then for them to mesh correctly, Circular pitch, Where
pc =D/T
pc =
or D1/D2 = T1/T2
Given that
d=169 mm, N=143 m= =169/43 = 3.9 say 4 Where: - m module, mm d Pitch diameter, mm
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N Number of teeth Circular pitch: P= = = =12.34 = 0.254
Diametral pitch: - Pd =
Spur Gear 5.3.2 Force analysis of spur gear Before beginning the force analysis of gear trains let us agree on the notation to be used. Beginning with the numeral 1 for the frame of the machine, we shall designate the input gear as gear 2, and then number the gears successively 3, 4, etc. Next, there may be several shaft involved and usually one or two gears are mounted on each shaft as well as other elements. We shall designate the shafts, using lowercase letters of the alphabet, a, b, c, etc.
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40
The free body diagram of the pinion has been redrawn and the forces have been resolved into tangential and radial components. We now define Wt =Ft 32 =161.42 KN As the transmitted load this tangential load is really the useful component, because the radial component Fr32 serves no useful purpose. It does not transmit power. The applied torque and the transmitted load are seen to be related by the equation. T= Wt = x 161.42
= 13,639 Nmm The power H transmitted through a rotating gear can be obtained from H= where Wt transmitted load H Power in kW Next we designate the pitch line velocity by V, V= dn/12 mm where V - pitch-line velocity, ft/min 1ft = 304.8
d - Gear diameter, in n - Gear speed, rev/min

And V= Then H= = 6194.17 ft/min = 31m/s = H= = 0.15 kW
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5.4 DESIGN OF CHAIN DRIVE

5.4.1 Roller Chain
Roller chain is an assembly of alternating roller links and pin links in which the pins pivot inside the bushings, and the rollers, or bushings, engage the sprocket teeth to positively transmit power
Roller Chain
Length of chain
GIVEN VALUES RATED POWER= 200W N1=140 N2=60 We know that the velocity of chain drive, V.R =
= 2.33 say 2.5
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Number of teeth for smaller is T1=21 & larger sprocket is T2= 49 Design power = Rated power x service factor The factor Ks=K1 .K2 .K3 = 1.5 x 1 x 1.25=1.875 And the design power= 200 x 1.875=375W According to ISO: 2403-1991 the pitch for chain number 10B is p=15.875 and the roller diameter d=10.16mm, breaking load (WB) =22.2Kn minimum roller width w =9.65mm We know that pitch circle diameter for the smaller sprocket is d1 = p cosec (
) = 15.875 cosec ( ) =107mm=0.107m
And pitch circle diameter for largest sprocket d2 = p cosec (
) =15.875 cosec ( ) = 248mm=0.248m
Pitch line velocity of the smaller sprocket,
v1 =
= 0.78m/s
And there for the load on the chain: W=
= 255 N
The minimum center distance between the smaller and larger sprockets should be 30 to 50 times of the pitch. Therefore we take 30 times of the pitch Center distance x= 30 15.875 =476.25 mm
In order to accommodate initial sag in the chain, the value of center distance is reduced by 2 to 5 mm. Therefore Correct center distance
X=476.25 4= 472 mm
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We know that the number of chain links K, K=
+ +
+( +(
)2 )2
=35+59.46+0.67 =95.1=95 And length of the chain, L
L=K x p= 95 x 15.875= 1508 mm=1.508 m
5.5 Key design

Keys are used to enable the transmission of torque from the shaft to the shaft supported element. d=D- 0.028L where d diameter at small end, mm D Diameter at large end, mm L Length, mm Matrix dimensions for some standard rectangular key application according to the shaft diameter.
SUNK KEY
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In order to find the dimensions of this rectangular key Given that Mt = 1364 N-mm =190 N/mm2
c = 380 N/mm2
d= 15 mm
For the given shaft diameter from standard table of keys Width of the key b= 6mm
Thickness of the key t=6mm Height of the key Length of the key h= 4 mm L=1.5 d = 25.5 mm
Now checking for shear strength of the key
Mt = x L x b x d/2
=
= 1.18 N/mm2
Which is less than the allowable strength, hence the dimensions are in safe limit
Checking for crushing
Mt = c x L x h/2 x d/2 c = = 3.56 N/mm2
Which is less than the allowable strength, hence the dimensions are in safe limit
5.6 SELECTION OF SCREW

5.6.1 Bolted joints
A screw fastening is composed of two elements as illustrated by a bolt and a nut. Frequently one of the parts to be connected is so constructed that it becomes one of the elements of the fastening. In fact both of the parts to be connected may serve as the
45
element of the fastening as in case of a handle with thread turned on one end to engage in a tapped whole maneuver. In study of threads and their representation on drawing, It is necessary to define a few important terms as shown below
Crest Roof
Thrade Thickness angle P Flank
dc dp
5.6.2 Design for bolts and nuts

The square bolts and nuts shall be designated as illustrated according to our need, as per ISO 2585-1968 the square bolt may also be used with hexagon nuts. From the table of designation system for square bolts and nuts, we found that for stress area is designated as M27, pitch P, 3.
5.7 Selection of Bearing

5.7.1 Ball bearing
Ball bearings are used in greater quality than any other types of rolling bearing. Ball bearings are used in many kinds of machine and devices with rotating point. The following characteristics make ball bearing more desirable than hydrodynamic bearings in many situations: 12345Law starting and good operating friction The ability to support combined radial and thrust load Less sensitivity to interruption in lubrication No-self exited instability and Good low temperature starting
46
Within reasonable limits changes in load, speed and operating temperature have, but little effect on the satisfactory performance of ball bearing. 123456Finite fatigue life subjected to wide fluctuation Larger space required in radial direction Low damping capacity High noise level More severe alignment requirement High cost
5.7.2 Types of ball bearing

Most type of ball bearing originates from three basic design single row radial, single row angular contact and the double row angular contact.
Single row radial, non-filling slot

The most widely used ball bearing and is employed in any modified form. It is also known as Conrad type or deep groove type. It is symmetrical unit capable of taking combined radial and thrust loads in which the thrust component is relatively high but is not intended for pure thrust loading. However, because this type is not self-aligning accurate alignment between shaft and housing bore is required.
Single row radial, filling slot

This type is designed primarily to any radial loads. Bearing of this type is assembled as many balls as can be introduced by eccentric displacement of as in non-filling slot type and then several more balls are inserted.
Single row angular contact

Designed for combined radial and thrust where the thrust component may be large and axial deflections must be confined with very close limit.
Double row bearing

This are in effort angular two single raw angular contact bearing built as a unit with the internal fit between balls and fixed at the time of bearing assembly.
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5.7.4 Material selection

Cast iron can be used only in the case of light loads and law speeds, (usual values: Pbp up to 100 N-cm2 and V up to 3 m/sec). it is susceptible to end pressure and seizure, and must be will lubricated , service temperature.
5.7.5 Types of bearing lubrication

Basically in any bearing ideal is never to allow any metal to metal contact between the bearing and the shaft but instead to maintain between them by introducing and the shaft but instead to maintain a separation between them by introducing and sustaining an oil film in between the parts. The oil is pressed in this narrow region. This generates oil pressure sufficient to physically separate the surfaces against the load on the bearing. This type of lubrication is called hydrodynamic lubrication and is governed by the laws of viscosity.
5.7.6 Calculation of bearings

For the determination of the size of bearings, the diameter is first calculated on the basis of the bearing forces involved and then it is checked against the bending stress produced the load to be carried by the bearing is given by:F (N) = (dl) Pb Where d= diameter of the bearing (cm) l= width of the bearing (cm) Pb= specific bearing pressure produced (N/cm2) The expansion (dl) represents the projected area of the loaded journal and for safe working P must be or equal to the allowable bearing pressure, P bp. The value of Pbp depend on the service condition, circumstance velocity of the shaft duration , design and material combination of journal and bearing type of lubrication and cooling guiding values of this allowable pressure in some of the cases commonly encountered in service.
48
Since the material of bearing is cast iron, the allowable pressure of bearing Pb is 20 to 80 N/cm2 Width of the bearing is 1 and circumstantial velocity V(m/s) is 3.5 to 1. For the given shaft diameter of 15 mm F (N) = (1.5cm x 1) (80 N/cm2) = 120N/cm =12N
5.9 DESIGN OF TABLE

The table is the main structure that carries the whole mass of the machine. Due to the fact that this machine is operated by manually by pedal, the table may develop the vibration and shock. To overcome this vibration, the table has to be somewhat heavy and strong. So, that we use 40 mm x 40 mm and 4 mm thick rectangular hollow tube.
5.10 DESIGN OF PLATE

For our design we need to have a forked plate. This plate is used to move the meat to be chopped to the blade of the machine. The plate is made from forked in order
49
to give a small gap between two consecutive forks so that the blade is rotated between them for asy chopping of the meat.
5.11 DESIGN OF BLADE

Blades are the main parts of machine element in our meat chopping machine. These blades are circular in shape and 200 mm in diameter and 1.5 mm thick. As these are the main parts which chop the meat, have to be protected from corrosion and rest so that they are made from stainless steel material. These blades are mounted horizontally in rows on the table. Since they are mounted on a single shaft they rotate simultaneously at its tip and sharpened for easy chopping meat. It has a spacing ring at the center.
50
CHPTER 6 ASSEMBLY AND PARTS OF DRAWING
X2
51
52
ASSEMBLED PARTS OF DRAWING
53
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CONCLUSION
From the observation and from what we have faced during the course of this design project, we give the following conclusions. While we are doing this project we have get a good knowledge and many information which broaden our knowledge and also gives us experience. The project work also gives us information and some procedure of design of machine element such as chain drive, shaft and etc. & selection of some components like bearing & screw. This work also enables us to strengthen our habit of working together which is the most important experience and we may develop that uses us in our future profession. The spirit of cooperation & working together with collogues. Due to the fact that the learning process in our campus is community based, we have tried to solve the community problem especially that of our campus.
RECOMMENDATION
It was our wish to finish the project early. But due to shortage of some facilities such as computer hinders our progress, so we recommend that the department have to do something to solve this problem. Its known that design project gives great opportunity to student to design their own machine component and assembly, so we believe that it should get a great attention, as it have to be.
55
BIBLOGRAPHY
BOOK Mechanical Engineering design, Joseph E. Shigley & Charles R. Mischke, sixth edition Standard Handbook of Machine design by Joseph Shigley, second edition, 1996 A text book of machine design by R.S Khurmi & J.K Gupta Theory of Machine by R.S Khurmi & J.K Gupta Handbook of Mechanical Design, GITW M. Maltra, Lv Prassad, second edition Mechanical Design Handbook, Harold A. Rothbart, second edition Machinery Handbook, Eric Oberg Franklin D. Jones Halbrook L. Horten & Henry H. Rafeal, 27th New York, 2004 Machine Design by Abdul Mubin, 4th edition, New Delhi, 2005 Mechanical engineers Handbook Material and Mechanical Design, Book 1, 3rd edition New Jersey, 2006 Design of Machine Elements by G.K Vijayraghavan & S. Vishnu Priyan, 4th Edition, Muscat Oman, June 2009 SITES www.google.com www.fao.org www.slideshare.net www.gizmag.com www.catarina.udlap.mx
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MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

JIMMA UNIVERSITY JIMMA INSTITUATE OF TECHNOLOGY DEPARTMENT OF MECHANICAL ENGINEERING

SUBMITTED TO ABIYOU SOLOMON SUBMITION DATE 25-MAY-2012

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

CHAPTER 2 PROBLEM FORMULATION

2.2 GOALS AND OBJECIVES OF THE WORK

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

2.3 SCOPE OF THE WORK

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

CHAPTER 3 LITERATURE REVIEW

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

CHAPTER 4 PRODUCUCTION DESIGN

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

CHAPTER 5 DESIGN OF COMPONENT

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

5.2 DESIGN OF SHAFT

Shaft material selection

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

Ultimate tensile Strength, N/mm2

Yield strength, N/mm2

Shaft design calculation

Torque transmitted by the shaft Mt =

Where: Mt - Torsional moment P - Power

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

Normal load on the gear WD =

When the gear is driven by downward tangential force Vertical component:

WHD =WG x sin

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

FX = Tt cos = 484.26 cos 450 =342.42 N

F Y = Tt sin =484.26 sin 450 = 342.42 N

Bending moment diagram

FBD Horizontal force

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

Vertical load FBD

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

Bending moment diagram

Horizontal Banding Moment

Vertical Banding Moment

Resultant Banding Moment

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

According to maximum shear stress theory y = n is stands for safety factor

= 190 N/mm2 Allowable shear stress = = = 95 N/mm2

Equivalent bending moment

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

1.5 1.5-2.0 2.0-3.0

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

d = =13.45 say 15 mm Checking for tensile strength = = =20.58 N/mm2

Force analysis on blade

MACHINE DESIGN PROJECT: PEDAL MEAT CHOPPING MACHINE

Given that r=200/2 mm =100mm = = = 14.67 rad/s