ABSTRACT

In India, pottery industry is run by many people in villages, even in cities for some extent. Its a
tedious job to make pots by hands, so these people invented two machines. One of them is clay
granular making machine while another one is a simple press, powered by various mechanisms.
Clay granular making machine is used to produce small granules out of terracotta clay billets. That
billets are inserted in that machine and directly granules come out.
Now, the problem they are facing is, as per the usage from high to low, the nails used in the grinding
wheel of the machine are worn out in either 1 day to a week respectively.
So, our aim is to somehow extend that nail life at least by two-fold.
For that, we have tried different angles for nails in our setup to note any changes in yield rate, so
if there is a significant increase in yield rate for any angle in compare to original 90-degree angle,
then we can propose that angle for nails in actual machine.
Another approach that we implemented due to time shortage is cost analysis of various quality of
nails and their respective life in probabilistic way. It is based on Break-Even concept. We know
the price of individual nails of different variety. By calculations, we get a range of minimum
required service life, which in case if achieved, gives a no profit no loss situation and also found
for reduced cost up to 50%.

Key words: Clay, Granules, Wear, Pottery, Nails, Lifecycle

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TABLE OF CONTENTS

Page No.
ACKNOWLEDGEMENT III

ABSTRACT IV

TABLE OF CONTENT V

LIST OF IMAGES VI

LIST OF FIGURES VII

LIST OF TABLES VIII

CHAPTER 1 INTRODUCTION 1

CHAPTER 2 REVIEW OF LITERATURE 2

CHAPTER 3 DIFFERENT APPROACHES 4

TO IMPROVE LIFE OF NAIL

3.1 First Approach: Angle Variation 4
3.2 Second Approach: Nail Material Hardening 6
3.3 Third Approach: Alternative Material 6

CHAPTER 4 COST ANALYSIS 7

CHAPTER 5 CONCLUSION 8

REFERENCES 9

II
LIST OF IMAGES

Page No.
Image 1.1 Clay Granule Making Machine 1

Image 3.1 Spectrographic Report 6

III
LIST OF FIGURES

Page No.
Fig. 3.1 Detail Drawing of 45 Rotor 5

Fig. 3.2 Detail Drawing of 60 Rotor 5

IV
LIST OF TABLES

Page No.
Table 4.1 Cost Analysis Calculation 7

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 CONTENT

CHAPTER 1

INTRODUCTION

This project, Lifecycle Enhancement of Clay Granular Making Machine, is in continuation with
the previous one. In the previous semester, we did experimental analysis of wear out of nail. But
those were partially correct. Flows in that are as follow:
Linear instead of circular trajectory due to limitation of set-up
o Depth of nail penetration in clay will differ in both the cases
o Angle of impact will be different
Was not able to maintain constant velocity though we managed to maintain constant dead
load acting on it
Actual wear out of nail could not be determined with the taken experimental set up

So, to actually decide the orientation, we need to actually put into implementation without which
one cannot yield exact result. From this our project continued.

Image 1.1

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 CHAPTER 2

REVIEW OF THE LITERATURE

Abrasive wear: Abrasive wear may be described as damage to a surface by harder material. There
are two general situations when this type of wear occurs.
I. One of the surfaces is harder than the other rubbing surface
II. Hard surface is a third body, generally a small particle of abrasive, caught between the two
surfaces and sufficiently harder than one or both of them
Our case is similar to the first one. In the abrasive wear process, asperities of the harder surface
press into the softer surface, with plastic flow of softer surface occurring around the asperities from
the harder surface. When a tangential motion is imposed, the harder surface removes the softer
material by combined effects of micro ploughing, micro cutting and microcracking.
Rabinowitz derived an expression for abrasive wear by assuming that the asperities of the harder
surface are conical. The wear volume per unit sliding distance is given by
=/=(/){tan}
This expression relates wear volume per unit sliding distance to the asperity slope (tan bar, which
is the weighted average of tan values of individual cones) of the penetrating abrasive particle and
hardness of the abraded material.
Another model was proposed by Zum Gahr (1982) who considered the detailed processes of micro
ploughing, micro cutting and microcracking in the abrasive wear of ductile materials.

fab = model factor (1 for micro cutting)

K1 = relation of normal and shear stress = friction angle at abrasive material interface
K2 = texture factor (1 for FCC metals) = cone angle of asperity
c = shear stress for dislocation movement

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We could conclude a few things from that.
The basic problem is wear out of nails. This phenomenon is nothing but the abrasive wear process.
The abrasive wear process depends on three angles. Angle of attack, cone angle and friction angle.

Parameters affecting Material Removal rate:

Angle of attack of nails with clay slabs
Speed of Grinding wheel
Radius of Grinding wheel
Pushing force of worker

From above parameters, in our experiment, we have taken only one parameter in
consideration while keeping all other parameters as constant.

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 CHAPTER 3

DIFFERENT APPROACHES TO
IMPROVE LIFE OF NAIL

3.1 First Approach: Angle Variation

To get the exact result of wear out of nail, we decided to make rotor drums containing nails at
different angle. We chose 45 degree and 60 degree angles from the reference of our last project, as
these angles were most promising to start with.

Now, when it came to put into application, we needed to fabricate them first. Gujarat Matikam
Kalakari & Rural Technology Institute, the institution from which we had taken our project
promised to help us in our project and took sincere interest in it.

We visited its head office situated at Gandhinagar several times and met the main authority, who
was our advisor in this project. We explained him work we did in our last project and convinced
him to carry out practical experiment for our project. He consented to fabricate the drum once we
are done with design and also for its implementation. So, we prepared model of drum having
multiple holes at 45 and 60 angle across the periphery of the drums, which are shown in the
following page.

But when we approached him a week after our last meeting, he told that the higher authority has
been changed and he cannot help us anymore. So, we had to drop our Experimental approach of
changing orientation of nail in drum.

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Fig. 3.1

Fig. 3.2

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3.2 Second Approach: Nail Material Hardening

We decided hardening of nail can be another option to increase life of nail and decrease its wear.
For that we first did spectrographic test on the nail that they were using for cutting clay slabs to get
clay in powder form.
In the report, it came that the nail has significantly low carbon content, so it cannot be hardened.

Image 3.1

3.3 Third Approach: Alternative Material

It may be possible to increase life of nail by changing its material. If we chose harder material and
if it has improved life, then it can also work as an alternative solution to the current problem. For
that we prepared calculation data sheet.

Basic Idea of Cost Analysis:

If we are changing the material of nail, then it is becoming costlier. So, we can calculate how much
improvement in life will suffice the need and overall decrease in cost. For that we have done
comparative cost analysis for nails having different material and costs.

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 CHAPTER 4

COST ANALYSIS
Break Even
Yearly
Nail Actual life
Usage Total
Price/Kg Hours
(Ton)
55
10 2 110000 20% Cost Cut (Cost=88000)
(Original)
Required Expected Required Expected
Proposed Proposed
Life Hrs. Usage Ton Life Hrs. Usage Ton
60 10.91 1.83 60 13.64 1.47
75 13.64 1.47 75 17.05 1.17
82 14.91 1.34 82 18.64 1.07
92 16.73 1.20 92 20.91 0.96
100 18.18 1.10 100 22.73 0.88
115 20.91 0.96 115 26.14 0.77

25% Cost Cut (Cost=82500) 30% Cost Cut (Cost=77000)

Required Expected Required Expected
Proposed Proposed
Life Hrs. Usage Ton Life Hrs. Usage Ton
60 14.55 1.38 60 15.58 1.28
75 18.18 1.10 75 19.48 1.03
82 19.88 1.01 82 21.30 0.94
92 22.30 0.90 92 23.90 0.84
100 24.24 0.83 100 25.97 0.77
115 27.88 0.72 115 29.87 0.67

40% Cost Cut (Cost=66000) 50% Cost Cut (Cost=55000)

Required Expected Required Expected
Proposed Proposed
Life Hrs. Usage Ton Life Hrs. Usage Ton
60 18.18 1.10 60 21.82 0.92
75 22.73 0.88 75 27.27 0.73
82 24.85 0.80 82 29.82 0.67
92 27.88 0.72 92 33.45 0.60
100 30.30 0.66 100 36.36 0.55
115 34.85 0.57 115 41.82 0.48

Table 4.1
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 CONCLUSION
From first approach, we found out that without fabricating as well as actually implementing the
proposed rotors, there is no other way that one may find out the results. Even Computational
Simulation wont work with necessary accuracy, as the material in consideration is a complete
anisotropic clay. We could have carried out experiments if there wasnt any hurdle from the
authority side.
Then, in second approach, we found out that the nails currently being used are having carbon
content much less than the required level for hardening process. So, we cant even go with
hardening process to reduce wear of the nails subjected.
In the final approach, as the rates of nails as well as their wear resistivity arent readily found, and
also theres no attempt in past to find out the lives of different type of nails with different materials,
subjected to application in Clay Granular Machine or some similar application, we took relative
approach. First, we found out, with increase in price, how much increment in life is necessary that
the cost before and the cost after are found to be equal. After that, we also calculated necessary life
of nails in hours necessary to cut the costs of purchase of nails by 20, 25, 30, 40 & 50%.
This calculation sheet is direct resource to calculate final costs once experiments are carried out.