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DUMAGUETE CITY
PRESENTED TO
IN PARTIAL FULFILLMENT
OF THE REQUIREMENTS
IN
BY
CONTENTS:
INTRODUCTION3
REVIEW OF RELATED LITERATURE..4
Other Crusher Types.4
Single Roll Crusher4
Jaw Crusher..5
Brad-multi Roll Crusher.5
Clinker Crusher6
DRAWING..7
Isometric View (a)7
Isometric View (b)8
Top View.9
Front View10
Side View..10
DESIGN CONSIDERATION.11
DESIGN CALCULATION11
Solving for Radius of the Rolls 11
Solving for Feedrate12
Solving for the Crusher Power12
Solving for the Force Required.....13
Solving for Torque13
Design Horsepower to drive mechanism including losses14
Transmitted Power on V-belt.14
DRIVING SYSTEM DESIGN.14
V-belt Design..14
Solving for Design Hp.14
Solving for the Diameter of the Drive and Driven Sheave.15
Solving for Center Distance15
Solving for V-belt Length.15
Solving for V-belt Speed..16
Solving for kd(small diameter factor).16
Solving for Rated Hp. 16
Solving for Adjusted Hp16
Solving for the Number of Belts17
Solving for the Tension.17
Computing the Arc of Contact.18
Power Transmitted on V-belt..18
Solving for Thickness of Sheave.18
Computing the weight of the Motor Sheave..19
Computing the weight of the Driven Sheave..19
SHAFT DESIGN..19
Shaft 1 19
Computing the Angle of Wrap.20
Solving for Forces on Belt at Section A.20
Forces at Section A due to Weight of the Sheave, W2..21
MACHINE DESIGN 2 1
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 2
2012 [DOUBLE ROLL CRUSHER DESIGN]
INTRODUCTION
Double roll crushers consist of two adjacent rolls placed parallel to each other and
rotated in opposite directions. These are typically used in situations in which fines are to be
minimized. They are widely employed on friable materials such as coal, lime, limestone,
petroleum coke, and chemicals.
As the two rolls rotate toward each other, the material is pulled down into the crushing
zone where it is grabbed and compressed by the rolls.
Product size is determined by the size of the gap between the rolls, and this gap can be
changed to vary product size or to compensate for wear.
Since both rolls rotate at the same speed, there is no relative motion between the two
roll surfaces, and crushing is primarily accomplished by compression.
MACHINE DESIGN 2 3
2012 [DOUBLE ROLL CRUSHER DESIGN]
Sized material falls directly out through the discharge end of the crusher which is
completely open.
There are no screen bars, and consequently there is no recrushing of the sized materials,
a factor that helps to reduce power demand while minimizing product fines.
The clearance between the breaker plate and the roll determines the product size. This
clearance is adjustable from outside the machine by a shim arrangement. Adding or removing
shims causes the plate to pivot about its top hinge, moving it into or away from the roll.
For protection against uncrushable debris, the breaker plate assembly is secured with an
automatic release device. As pressure from the uncrushable is exerted against the plate, the
device allows the entire breaker plate assembly to move away from the roll instantly. The
uncrushable drops clear of the machine by gravity, and the breaker plate assembly immediately
returns to its normal crushing position.
MACHINE DESIGN 2 4
2012 [DOUBLE ROLL CRUSHER DESIGN]
Jaw Crusher
For crushing of
hard, abrasive materials,
Jaw Crushers are often
preferred, since this type of
machine will crush virtually
any mineral.
While one jaw is fixed, the other jaw pivots about a top hinge. This moving jaw is shaped
to move firmly and squarely against the material, at 250 to 400 strokes per minute. There is no
rubbing or grinding, only compression, which produces a generally cubical product with
minimum fines.
The moving jaw is so balanced that fully 95% of the drive motor power is used for
crushing, while only 5% of the power is needed to move the jaw itself. As a result of this high
mechanical efficiency, smaller motors may be used, keeping power costs down.
Behind the stationary jaw are shims, used to compensate for plate wear and to adjust
the closed side setting. For protection from uncrushables, there is also an automatic drive
disengagement feature that acts instantaneously on the moveable jaw assembly.
The Brad-Multi-Roll
Crusher was introduced to
produce material with output
smaller than 1/4" (6mm) while
producing a minimum of extreme
fines.
MACHINE DESIGN 2 5
2012 [DOUBLE ROLL CRUSHER DESIGN]
This machine is capable of handling moist materials when operated in open circuit.
Drying is usually recommended when closed-circuit operation is needed to meet a specific
gradation curve.
The Brad-Multi-Roll Crusher is well suited to abrasive materials. To compensate for any
reduction in charge level resulting from wear, additional charge can simply be added. This
greatly simplifies maintenance, and provides a machine with exceptionally high availability.
For some closed-circuit applications, integral screening can be accomplished. The great
compactness of this design means that a smaller building is required, while minimizing the need
for peripheral equipment. Optional sound housings can be provided to control noise emissions.
When compared with other machines that require air classification to achieve specified
product sizes, users of the Brad-Multi-Roll Crusher will enjoy significant and continuing savings
in power costs.
Clinker Crusher
MACHINE DESIGN 2 6
2012 [DOUBLE ROLL CRUSHER DESIGN]
DRAWING:
MACHINE DESIGN 2 7
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 8
2012 [DOUBLE ROLL CRUSHER DESIGN]
Top View
MACHINE DESIGN 2 9
2012 [DOUBLE ROLL CRUSHER DESIGN]
Front View
Side View
MACHINE DESIGN 2 10
2012 [DOUBLE ROLL CRUSHER DESIGN]
DESIGN CONSIDERATION:
Roll Crusher Type: Double Roll Crusher
Further specifications and design considerations were made along the design process.
DESIGN CALCULATION:
Solving for Radius of the Rolls: (assuming all surfaces are smooth and particle to be
crushed is spherical)
To solve for the radius of the rolls, it is convenient to assume that the particle to be
crushed is spherical and roll surfaces are smooth. The figure below shows a spherical particle
about to enter the crushing zone of a roll crusher. The nip angle is defined as the angle that is
tangent to the roll surfaces at the points of contact between the rolls and the particle. Usually
the nip angle is between 20 and 30 but in some large roll crushers it is up to 40.
Where:
D/2
R
R= radius of the roll
L= distance between rolls, 1 in.
d= diameter of the feed, 2 3/8 in.
= Nip angle, 20
L
( )
R= 6.067001948 in.
D= 12.1340039
MACHINE DESIGN 2 11
2012 [DOUBLE ROLL CRUSHER DESIGN]
For the roll diameter, the calculated diameter is not available in the market so I use D = 15
available at http://www.gundlachcrushers.com/crushers/roll-crushers-coal-salts-lime-
minerals.cfm with a chisel tooth profile.
Where:
Q= crusher capacity
D= diameter of roll, m (15 in= 0.381 m)
W= width of the roll, m (50 in = 1.27 m)
= roll speed, 130 rpm
L= distance between rolls, m (1 in = 0.0381 m)
B = bulk density of feed material, t/m3 (.833 t/m3)
Q= (60)(0.381)(1.27)(130)(0.0381)(.833)
Q= 376.3077383 t/h
MACHINE DESIGN 2 12
2012 [DOUBLE ROLL CRUSHER DESIGN]
Where:
Nsf = 1.4+0.2 (Table 17.7 by Faires, p. 460)
Design Hp = 26.80965147 Hp
Where:
P1 and C1 = Power and Capacity for the crusher to be design
P2 and C2 = Power and Capacity for a commercial crusher
P1 = 15.76356142 hp
T=
Where:
P= 15.76356142 hp
N= 130 rpm
T= x
T= 636.8615984 lb-ft
F= x
MACHINE DESIGN 2 13
2012 [DOUBLE ROLL CRUSHER DESIGN]
F = 1018.978557 lb
V-Belt Design
Design Consideration:
Motor type: squirrel cage motor
Type of service: continuous (16 hr/day) service
V-belt material: Leather belt
From: http://www.engineeringtoolbox.com/electrical-motors-hp-torque-rpm-d_1503.html,
Power versus torque and motor velocity in electric motors Table.
Where:
Nsf = 1.4+0.2 (Table 17.7 by Faires, p. 460)
(From figure 17.14 Belt Selection from Horsepower and Speed by Faires, p.457, I choose
section D)
MACHINE DESIGN 2 14
2012 [DOUBLE ROLL CRUSHER DESIGN]
Where:
N1= Motor speed, 500 rpm
N2= Crusher speed, 130 rpm
D2= diameter of the driven sheave
D1= diameter of the drive sheave
From: Table 17.3, Standard V-belt Lengths; Horsepower Constants (Faires, p. 458)
I choose D2=48 in. and D1= 13 in. which is nearest to 130 rpm.
C= 43.5 in.
Note: The center distance is made adjustable so that the belts can be mounted into the grooves
without harmful stretching and so that initial tension can be maintained (Faires, p. 457).
L=157.3580798 in.
MACHINE DESIGN 2 15
2012 [DOUBLE ROLL CRUSHER DESIGN]
From table 17.3, Standard V-belt length (by Faires p. 458) at section D, select D158 with pitch
length equal to 161.3 in.
Vm = 1701.696021 ft/min
Kd= 1.14
* ( ) +
Where :
Vm= belt speed, 1701.696021 ft/min
Kd = 1.14
Rated hp constants:
a= 18.788
c= 137.7
e= 0.0848
* ( ) +
Rated Hp = 9.505200567 Hp
MACHINE DESIGN 2 16
2012 [DOUBLE ROLL CRUSHER DESIGN]
Where:
Kl= Length correction factor, 0.92 from table 17.6 Length Correction Factors by Faires, (p.459)
k= arc of contact factor
By interpolation,
0.70 0.89
0.729166666 K
0.80 0.87
K = 0.884166668
Therefore,
Use 4 D158 leather V-belts with pitch length equal to 161.3 in. from section D, b x t = 1 in., 3/4
in., figure 17.14, Belt Section from Horsepower and Speed by Faires, p. 457.
F2
F1 / F2 = ef Eq. 1
MACHINE DESIGN 2 17
2012 [DOUBLE ROLL CRUSHER DESIGN]
Where:
From eq.1
F1 / F2 = ef
F1 = e(.25) (2.395222057) F2
F1 = 1.819943605 F2 Eq.2
Where:
Hp= transmitted Hp, 16.59322255 hp
F1 =total tension on the tight side, lb
F 2= total tension on the slack side, lb
m = belt speed, 28.36153368 ft/sec
(F1-F2)= 550(16.59322255)/28.36153368
(F1-F2)= 321.7827023 Eq. 3
F2 = 392.4449198 lbs.
F1 = 1.819943605 (392.4449198)
F1 = 714.2276221 lbs.
MACHINE DESIGN 2 18
2012 [DOUBLE ROLL CRUSHER DESIGN]
= (1 )x 4
T = 5 in.
Where:
W1 = (/4)(13)2(5)(0.256)
Where:
W2 = (/4)(48)2(5)(0.256)
W2 = 2316.233432 lbs
SHAFT DESIGN
Shaft 1
Design Consideration:
Material Used: AISI C1117 Normalized Carbon Steel
Tensile strength: 63,700 psi
Yield strength: 35,000 psi
From Table AT 8 Typical Properties of Steel (Faires, p.578)
Shaft diameter: 4 in
MACHINE DESIGN 2 19
2012 [DOUBLE ROLL CRUSHER DESIGN]
Fx1
F1
Fy1
Fr
Fy2
Ft
F2
Fx2
Components of shaft 1
Where:
D = diameter of big sheave, 48 in
D = diameter of small sheave, 13 in
C = centre distance, 48in
Therefore,
= cos-1
= 68.61805742
F2 = 392.4449198 lbs.
MACHINE DESIGN 2 20
2012 [DOUBLE ROLL CRUSHER DESIGN]
where:
= density of the roll, 0.283244983 lb/in3 (Material Science and Engineering 4th Edition,
V. Raghavan, p.396)
v= roll volume
v= (/4)(D-d)2w
where:
D= diameter of the roll, 15 in.
d= shaft diameter, 4 in.
w= roll width, 50 in.
v= (/4)(15-4)2(50)
v= 4751.658889 in3
therefore,
MACHINE DESIGN 2 21
2012 [DOUBLE ROLL CRUSHER DESIGN]
w = (4751.658889) (.283244983)
w = 1345.883541 lbs.
where:
= compressive strength of coal, 500 psi, (Table 8.2, Handbook of Coal Analysis by J.G. Speight)
A= area of the coal to be crushed
19/16
w
3/4
1 1/2
X = ( )
X = 0.920682491
W = 2(0.920682491)
W = 1.841364983
Therefore:
A = (1.841364983)(50)(0.6)
A = 55.24094949 in2
Fr = 500 x 55.24094949
FVC = w - Ft
FVC = 1345.883541- 1018.978557
FVC = 326.904984 lbs (downward)
FHC = Fr = 27620.47475 lbs
MACHINE DESIGN 2 22
2012 [DOUBLE ROLL CRUSHER DESIGN]
Rvb Rvd
MB = 0
72 Rvd = 8 (2433.550037) - 36(326.904984)
Y=0
6.53809968 lb/in
A B C
D E
MACHINE DESIGN 2 23
2012 [DOUBLE ROLL CRUSHER DESIGN]
Shear Diagram
433.846941 lbs
106.941957 lbs
2433.550037 lbs
Moment Diagram
1176.386495 in-lb
14696.08395 in-lb
19468.4003 in-lb
FHA FHC
MB = 0
MACHINE DESIGN 2 24
2012 [DOUBLE ROLL CRUSHER DESIGN]
Y = 0
552.409495 lb/in
A B C D E 0
Shear Diagram
13695.73596 lbs
1030.512805 lbs
X = 24.79326224 in
13924.7388 lbs
Moment Diagram
328678.1846 in-lb
8244.10244 in-lb
MACHINE DESIGN 2 25
2012 [DOUBLE ROLL CRUSHER DESIGN]
Resultant moment
MB =
MB = 21141.99223 in-lb
Mc =
MC = 159575.3565 in-lb
MD=
MD= 153176.6461 in-lb
MF=
MF= 328678.1846 in-lb
Load
Section Resultant
Vertical Horizontal
A 2433.550037 lbs 1030.512805 lbs 2642.749028 lbs
B 2867.396978 lbs 12665.22315 lbs 12985.75538 lbs
C 326.904984 lbs 27620.47475 lbs 27622.40924 lbs
D 106.9419566 lbs 13924.7388lbs 13925.14945 lbs
Moment
Section Resultant
Vertical Horizontal
B 13468.4003 in-lb 8244.10244 in-lb 21141.99223 in-lb
C 14696.08395 in-lb 158897.198 in-lb 159575.3565 in-lb
D 1176.38695 in-lb 153172.1287 in-lb 153176.6461 in -lb
F 0 328678.1846 in-lb 328678.1846 in -lb
MACHINE DESIGN 2 26
2012 [DOUBLE ROLL CRUSHER DESIGN]
Fr = 13925.14945 lbs.
When a rolling bearing turns while receiving a load, a lot of stress is repeatedly placed on the
small contact surface of the bearing rings and rolling elements, and the bearing must maintain
high precision while rotating. That means bearing materials must satisfy the following demands.
Must be hard.
Rolling fatigue life must be long.
Wear must be slight.
Must be shock-resistant.
Dimensions must not vary largely with the passing of time.
Must be economical and easy to machine.
Design Consideration:
Material Used for the bearing: High Carbon Chrome Bearing Steel
The expected life of operation for the bearings is 10 years for 16 hrs/day operation.
Shaft diameter may be reduced to accommodate the bearing.
Where:
Fc = catalog rating of bearing, lb (Table 9-7 & 9-8)
Ka= application factor taking into account the amount of shock (Table 9-4), 1.0
for uniform and steady load
Kl = , life factor
Kl = = 1.800822669
MACHINE DESIGN 2 27
2012 [DOUBLE ROLL CRUSHER DESIGN]
Ko= oscillation factor, 1.0 for constant rotational speeds of the races
Ks = , speed factor
Kr = rotational factor, 1.0 for bearing with fixed outer races and rotating inner
races
Ks = = 0.646994673
Therefore,
FC = (1.0 x 1.800822669 ) x 1.0 x 1.0 x 0.646994673 x 1.0 x 13925.14945
FC = 16224.50736 lbs
From Table 9-7 Typical radial capacity Fc of ball bearings (Doughtie and Vallance, p.212).
I select SAE 419 Two-row angular type ball bearing with radial capacity (Fc) of 20300 lbs and
shaft diameter be reduced to 3.7402 in.
From Table 8 outside diameter is equal to 9.8425 in and width 2.1654 in.
Material used: AISI C1117, Normalized Carbon Steel, same as the material used in shafting
Su = 63,700 psi
Sy = 35,000 psi
MACHINE DESIGN 2 28
2012 [DOUBLE ROLL CRUSHER DESIGN]
Shearing Stress, Ss
Ss=
Where:
Sy = yield stress, 35,000 psi
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one
direction, gradual mild shock (Faires, p.20)
Therefore,
Ss = = 5833.3333333 psi
Compressive Stress, Sc
Sc=
Where:
Sy = yield stress, 35,000 psi
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one
direction, gradual mild shock (Faires, p.20)
Therefore,
Sc = = 11,666.66667 psi
Hp =
Where:
Hp = transmitted power, 16.59322255 hp
T = maximum torque
N = rpm of the shaft, 135.4166667 rpm
Therefore,
T=
T=
MACHINE DESIGN 2 29
2012 [DOUBLE ROLL CRUSHER DESIGN]
F = 4129.610638 lbs.
Sc=
11,666.66667 =
L = 1.132693203 in.
Ss =
5833.3333333 =
L = 0.809066574 in.
Design Condition:
Material Used: AISI C1117, Normalized Carbon Steel
Sy : 35,000 psi
Su : 63,700 psi
Fs = 3.0, from Table 1.1 Factors of Safety, based on yield strength of steel, ductile metals (Faires,
p.20)
MACHINE DESIGN 2 30
2012 [DOUBLE ROLL CRUSHER DESIGN]
To compute for the size of bolt I will use the resultant force that will cause shearing (F =
27622.40924 lbs) divided by the number of bolts.
Where:
Sy = yield stress, 35,000 psi
Fs= factor of safety, 3.0
Ss=
Where:
F = maximum shear force, 27622.40924 lbs
A= cross sectional area of the bolt
Therefore,
=
( )
=
( )
d= 1.227714667 in.
From Table 6-1 Unified & American National threads, coarse, fine, and extra-fine series
(Doughtie and Vallance, p.130) I select 1 in-11 UNC bolt with Ar = 0.969 in2 and minor diameter
of 1.0747 in. The bolt being screwed into the post is the threaded part.
Shaft 2
Design Consideration:
MACHINE DESIGN 2 31
2012 [DOUBLE ROLL CRUSHER DESIGN]
36" 36"
Fr
w = 1345.883541 lbs
Fr = 27620.47475 lbs
Total Load
FvB = 1345.883541 lbs
FHB = 27620.47475 lbs
36" 36"
RvC
RVA
MACHINE DESIGN 2 32
2012 [DOUBLE ROLL CRUSHER DESIGN]
26.91767082 lbs
A B C D
Shear Diagram
672.417705 lbs
X= 25 in
672.417705 lbs
Moment Diagram
15801.81607 in-lb
36" 36"
RHA RHC
MACHINE DESIGN 2 33
2012 [DOUBLE ROLL CRUSHER DESIGN]
Shear Diagram
13810.23738 lbs
X = 25 in
13810.23738 lbs
Moment Diagram
324540.5784 in-lb
151912.6112 in-lb
151912.6112 in-lb
Resultant Moment
ME =
ME = 324925.0439 in-lb
MB = MC =
MB = MC = 152092.574 in-lb
maximum moment occurs at section E.
Data for the Loading at Shaft 2
Load
Section Resultant
Vertical Horizontal
A 672.417705 lbs 13810.23738 lbs 13826.59763 lbs
B 1345.883541 lbs 27620.47475 lbs 27653.24625 lbs
C 672.417705 lbs 13810.23738 lbs 13826.59763 lbs
MACHINE DESIGN 2 34
2012 [DOUBLE ROLL CRUSHER DESIGN]
Moment
Section Resultant
Vertical Horizontal
E 15801.81607 in-lb 324540.578 in-lb 324925.0439 in-lb
B or C 7396.594755 in-lb 151912.6112 152092.574 in-lb
Fr = 13826.59763 lbs.
When a rolling bearing turns while receiving a load, a lot of stress is repeatedly placed on the
small contact surface of the bearing rings and rolling elements, and the bearing must maintain
high precision while rotating. That means bearing materials must satisfy the following demands.
Must be hard.
Rolling fatigue life must be long.
Wear must be slight.
Must be shock-resistant.
Dimensions must not vary largely with the passing of time.
Must be economical and easy to machine.
Design Consideration:
Material Used for the bearing: High Carbon Chrome Bearing Steel
The expected life of operation for the bearings is 10 years for 16 hrs/day operation.
Shaft diameter may be reduced to accommodate the bearing.
Where:
Fc = catalog rating of bearing, lb (Table 9-7 & 9-8)
Ka= application factor taking into account the amount of shock (Table 9-4), 1.0
for uniform and steady load
Kl = , life factor
MACHINE DESIGN 2 35
2012 [DOUBLE ROLL CRUSHER DESIGN]
Ks = , speed factor
Na = rotational speed, 135.4166667 rpm
Nc = catalog rated rotational speed, 500 rpm
Kr = rotational factor, 1.0 for bearing with fixed outer races and rotating
inner races
Ks = = 0.646994673
Therefore,
FC = (1.0 x 1.800822669 ) x 1.0 x 1.0 x 0.646994673 x 1.0 x 13826.59763
FC =16109.71837 lbs
From Table 9-7 Typical radial capacity Fc of ball bearings (Doughtie and Vallance, p.212).
I select SAE 419 Two-row angular type ball bearing with radial capacity (Fc) of 20300 lbs and
shaft diameter be reduced to 3.7402 in.
From Table 8 outside diameter is equal to 9.8425 in and width 2.1654 in.
MACHINE DESIGN 2 36
2012 [DOUBLE ROLL CRUSHER DESIGN]
SPRING DESIGN
Design Consideration:
Number of Spring: 8
Load = 27620.47475 / 8
Load = 3452.559344 lbs
From Table 9 Century Spring Catalog, I use 4053 spring with wire diameter, Dw = 1.00 in with
maximum suggested load = 4200 lbs
Free Length = 10 in
Dm = 3 in
Deflection = .4 in
K= +
K= +
MACHINE DESIGN 2 37
2012 [DOUBLE ROLL CRUSHER DESIGN]
K= 1.58
Ss = k
Ss = 1.58
Ss = 38.67346463 ksi
Design stress
Ssd = 0.324 Su
Where:
Su = 140/ Dw0.19
Ssd = 40.2084/10.19
Nc =
( )
Nc =
MACHINE DESIGN 2 38
2012 [DOUBLE ROLL CRUSHER DESIGN]
k= 8631.39836 lb/in
Fc = 17262.79672 lbs
Where:
Q = 70
X= 0.19
Ss =
Ss = 70 ksi.
P = 1.33333333 in
= 11.98081357
MACHINE DESIGN 2 39
2012 [DOUBLE ROLL CRUSHER DESIGN]
Spring Mounting
MACHINE DESIGN 2 40
2012 [DOUBLE ROLL CRUSHER DESIGN]
3 4
D=1.5 in
8 in
19 in
69 in
r
Fr
Fd Fm
1 58 in 2
69 in
1.5 in
T1 = T2
T3 = T4 = (1.5/70.5) F1
MACHINE DESIGN 2 41
2012 [DOUBLE ROLL CRUSHER DESIGN]
Mo = 0
T1 = 182.6323599 lbs
Max = ( )
Where:
x = TA/ Ar
y = 0
= Fr / n Ar
Max =
N = number of bolts
Ar = stress area
Fs = 3.0, from Table 1.1 Factors of Safety, based on yield strength of steel, ductile metals (Faires,
p.20)
Solving for Fm
r=
r = 45.06939094 in
Fm = 108.6088745 lbs
Fm Components:
tan = 29/34.5
MACHINE DESIGN 2 42
2012 [DOUBLE ROLL CRUSHER DESIGN]
= 40.46222749
Solving for Fr
Fr =
Fr = 1104.090756 lbs
= ( )
5833.3333333 = +
Ar = 0.263546125 in2
From Table 6-1 Unified & American National threads, coarse, fine, and extra-fine series
(Doughtie and lVallance, p.130) I select in-10 UNC bolt with Ar = 0.334 in2 and minor diameter
of 0.6273 in.
MACHINE DESIGN 2 43
2012 [DOUBLE ROLL CRUSHER DESIGN]
DESIGN SUMMARY
Elements Specifications Loadings
Motor 20 Hp
500 rpm
V-belt C = 48 in HpTransmitted = 16.59322255
L = 161.3 in
Vm = 1701.696021 ft/min
N = 4 leather belts
b x t = 1 x in
Sheave of V-belt D1 = 13 in W1 = 169.8973307 lbs
D2 = 48 in W2 = 2316.233432 lbs
T = 5 in
C = 48 in
N1 = 500 rpm
N2 = 135.4166667 rpm
Shaft 1 AISI C117 Normalized Carbon @ section F,
Steel Mmax = 328678.1846 in-lb
D = 4 in T = 7722.784855 in-lb
L = 80 in
Bearing on Shaft 1 High Carbon Chrome Bearing Fr = 13925.14945 lbs
Steel
Ha = 58400 hrs.
SAE 419 Two-row Angular
Type Ball Bearing
Bore = 3.7402 in
Key at Shaft 1 AISI C117 Normalized Carbon T = 7722.784855 in-lb
Steel F = 4129.610638 lbs
b = 7/8 in
t = 5/8 in
L= 1.132693203 in
Bolt on Bearing @ Shaft 1 AISI C117 Normalized Carbon F = 27622.40924 lbs
Steel
Ar = 0.969 in2
N= 4 bolts
1 in-11 UNC bolt
MACHINE DESIGN 2 44
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 45
2012 [DOUBLE ROLL CRUSHER DESIGN]
LIST OF REFERENCES
Books :
Faires, V.M. (1969). Design of Machine Elements (4thed.). New York: MacMillan Company.
Spotts, M.F. (1991). Design of Machine Elements (6thed.). Singapore: Simon & Schuster (Asia) Pte
Ltd.
Internet:
Engineering Tool Box, electrical motors - Hp, torque and rpm. Retrieved July 5,2012 from
http://www.engineeringtoolbox.com/electrical-motors-hp-torque-rpm-d_1503.html
BL Precision Bearings Radial Ball Bearings Catalog. Retrieve September 12, 2012 from
http://www.qbcbearings.com/BuyRFQ/ThrustB_Bearing_B_CSBW.htm
MACHINE DESIGN 2 46
2012 [DOUBLE ROLL CRUSHER DESIGN]
APPENDIX:
Torque
1 0.75 18 1.5 2.1 32 2.6 3.6 63 5.3 7.1 126 10.5 14.2
1.5 1.1 27 2.3 3.1 47 3.9 5.3 95 7.9 10.7 189 15.8 21.4
2 1.5 37 3.0 4.1 63 5.3 7.1 126 10.5 14.2 252 21.0 28.5
3 2.2 55 4.6 6.2 95 7.9 10.7 189 15.8 21.4 378 31.5 42.7
MACHINE DESIGN 2 47
2012 [DOUBLE ROLL CRUSHER DESIGN]
40 30 731 61 83 1260 105 142 2521 210 285 5042 420 570
50 37 913 76 103 1576 131 178 3151 263 356 6302 525 712
60 45 1096 91 124 1891 158 214 3781 315 427 7563 630 855
70 52 1279 107 145 2206 184 249 4412 368 499 8823 735 997
80 60 1461 122 165 2521 210 285 5042 420 570 10084 840 1140
90 67 1644 137 186 2836 236 321 5672 473 641 11344 945 1282
100 75 1827 152 207 3151 263 356 6302 525 712 12605 1050 1425
125 93 2283 190 258 3939 328 445 7878 657 891 15756 1313 1781
150 112 2740 228 310 4727 394 534 9454 788 1069 18907 1576 2137
175 131 3197 266 361 5515 460 623 11029 919 1247 22058 1838 2494
200 149 3654 304 413 6302 525 712 12605 1050 1425 25210 2101 2850
225 168 4110 343 465 7090 591 801 14180 1182 1603 28361 2363 3206
250 187 4567 381 516 7878 657 891 15756 1313 1781 31512 2626 3562
275 205 5024 419 568 8666 722 980 17332 1444 1959 34663 2889 3918
300 224 5480 457 620 9454 788 1069 18907 1576 2137 37814 3151 4275
350 261 6394 533 723 11029 919 1247 22058 1838 2494 44117 3676 4987
400 298 7307 609 826 12605 1050 1425 25210 2101 2850 50419 4202 5699
MACHINE DESIGN 2 48
2012 [DOUBLE ROLL CRUSHER DESIGN]
450 336 8221 685 929 14180 1182 1603 28361 2363 3206 56722 4727 6412
550 410 10047 837 1136 17332 1444 1959 34663 2889 3918 69326 5777 7837
600 448 10961 913 1239 18907 1576 2137 37814 3151 4275 75629 6302 8549
Table 1 Power versus torque and motor velocity in electric motors
MACHINE DESIGN 2 49
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 50
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 51
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 53
2012 [DOUBLE ROLL CRUSHER DESIGN]
Table 9-4 Typical Values of application factor for roller and ball bearings
MACHINE DESIGN 2 54
2012 [DOUBLE ROLL CRUSHER DESIGN]
Table 9-2 SAE and International Standard dimensions for ball and Roller Bearings
MACHINE DESIGN 2 55
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 56
2012 [DOUBLE ROLL CRUSHER DESIGN]
Table 9-4 Typical Values of Application factor for roller and ball bearings
MACHINE DESIGN 2 57
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 58
2012 [DOUBLE ROLL CRUSHER DESIGN]
Table 6-1 Uniform and American National Threads, coarse, fine and extra-fine.
MACHINE DESIGN 2 59
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 60
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 61
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 62
2012 [DOUBLE ROLL CRUSHER DESIGN]
MACHINE DESIGN 2 63