Академический Документы
Профессиональный Документы
Культура Документы
E.Vijaya Kumar
Assistant Professor, Department of Mechanical Engineering, Siddhartha Institute of Technology & Sciences, Ghatkesar, Hyderabad, INDIA
ABSTRACT
The paper deals with the Design and analysis of shaft and rotor assembly for hammer mill crusher of capacity 0.1
(100kg/hr) tones per hour transmitting 20 B.H.P and a speed of 750 rpm. The design is based on the standard design procedure.
In the present work by using the standard design procedure, diameter of rotor shaft of hammer mill crusher has been designed. The
design should be safe when the values obtained from the present design procedure were compared with the values and results
obtained from the analysis using Ansys package.
When the shaft is rotated at rated speed (rpm) and the loads applied to the shaft it should not bend during rotation. When
the shaft is rotated under free conditions, deflections will be created due to the critical speed of the shaft.
To compare this deflection shaft was designed such that the natural frequency and speed is under limits. In this project the shaft and
rotor assembly of hammer mill crusher was modeled using Pro-e modeling package and the FEM model of the shaft was developed
using Ansys package. Meshing of the shaft model was done and the loads, stresses that were applied for the shaft to be checked out
that the design should be safe one.
22
Material used for Shafts:
Recycling glass
The material used for shafts should have the
Feed industry
following properties:
Stone crushing
1. It should have high strength
Size reduction of waste materials
2. It should have good machinability.
Electronics recycling
3. It should have low notch sensitivity.
Ceramics
4. It should have good heat treatment
Pulverization of sea shells
property.
Minerals
5. It should have high wear resistant
Wood particles for fuel wood
property.
Limestone
Depending on the requirement, the shafts can be
made of plain carbon steel or alloy steel.
III. DESIGN OF SHAFT Designing of Shafts:
A shaft is a rotating machine element, The shafts may be designed on the basis of
which is used to transmit power from one place 1) Strength and 2) rigidity and stiffness
to another. The power is delivered to the shaft by In designing shafts on the basis of strength, the
some tangential force and the resultant torque (or following cases may be considered:
twisting moment) set up within the shaft permits 1) Shafts subjected to twisting moment or
the power to be transferred to various machine torque only.
linked up to the shaft. 2) Shafts subjected to bending moment
The following stresses are induced in the only.
shafts: 3) Shafts subjected to combined twisting
1. Shear stresses due to the transmission of and bending moment
torque (i.e. due to torsional load). 4) Shafts subjected to axial loads in
2. Bending stresses (tensile or addition to combined torsion &
compressive) due to the forces acting bending loads
upon machine element like gears,
pulleys etc. Shafts subjected to twisting moment or
3. Stresses due to combined torsional and torque only:
bending loads. When the shaft is subjected to twisting
moment (or torque) only, then the diameter of
the shaft may be obtained by using the torsion
IV. CLASSIFICATION OF equation. We know that
SHAFTS
Shafts involved in power transmission may be
Where,
classified as T=Twisting moment acting on the shaft,
1) Transmission shafts are used to transmit J=Polar moment of inertia of the shaft
power between source and the machines using about the axis of rotation,
the power. They include line shafts, jackshafts F s =Torsional shear stress, and
and counter shafts. r=Distance from neutral axis to the outer
i) Line shaft is a long continuous most fiber
shaft, which receives power from =d/2 where
the source and distribute to We know for round solid shaft, polar moment of
different machines. inertia,
ii) Jackshaft is directly connected to
the source of power and from
which other shafts are driven.
iii) Counter shafts receive power from The equation may be written as
line shaft and transmit to a T/πd4= 2f s /32d
machine. T = f s πd3/ 16
Twisting moment (T) may be obtain by the
2) Machine Shafts are incorporated within the
following relation:
machine, such as crank shaft
23
In S.I units, power transmitted (in watts) by the 1) Guest’s Theory: According to maximum
shaft, shear stress theory the maximum shear stress due
to combined load is
Let
P=2πNT/60 or
f s = Shear stress induced to
T=(P х 60)/2πN
twisting moment
Where,
f b = bending stress (tensile or
T=Twisting moment in N-m
compressive) induced to Bending moment
N=Speed of the shaft in RPM
According to Maximum shear stress theory, the
In M.K.S units, horse power transmitted by the
maximum shear stress in the shaft
shaft,
P=2πNT/4500
f s ( max) =√[( f b )2 + 4(f s )2]
T=P х 4500/2πN
Where,
Substituting the values of f b & f s as per above
T=Twisting moment in N-m and
equations
N=Speed of the shaft in rpm
πd3 х f s = 16 х √ (M2+T2)
Shafts subjected to bending moment only: f s =√ (32M/ πd3)2+4(16T/ πd3)
When the shaft is subjected to a bending moment
only, then the maximum stress (tensile or 3) Rankine’s Theory: According to
maximum normal stress theory, the
compressive) is given by the bending equation.
We know that maximum normal stress in the shaft
24
Given Data: We know
T= (π/16) х f s х d³ = 11
9549= π /16 х 650 х d³ Selected diameter of shaft =122.7mm ≈
125mm
d=4.21 cm (or) 42.1mm
V. DESIGN OF BEARINGS
Bending Moment:
25
two orthogonal directions within a specified axial direction only. The outer surface of the
angular limit based on the bearing geometry. inner ring and the inner surface of the outer ring
Typically these bearings support a rotating shaft are collectively considered the raceway and they
in the [bore] of the inner ring that must move not slide against each other, either with a lubricant or
only rotationally, but also at an angle. a maintenance-free based liner. Some spherical
Construction of spherical bearings can be bearings incorporate a rolling element such as a
hydrostatic or strictly mechanical. A spherical race of ball bearings, allowing lower friction.
bearing by itself can consist of an outer ring and The design of this bearing permits radial load
an inner ring and a locking feature that makes the and heavy thrust load in either direction.
inner ring captive within the outer ring in the
26
Fig Rotor Assembly with Bearings
2D Beam Analysis:
3D Shaft Analysis:
27
Fig Deformed Shape
28
Fig. Von Mises Stress
Now we can see the stresses in shaft. 10.As per analysis of shaft and rotor
Maximum stress developed in shaft is 36.15 assembly done in Ansys, deflection values
N/mm2 which is far less than the yield strength of the shaft and rotor assembly are 0.008637
of the material, which is 45 N/mm2. So that shaft and 0.006404.
will not fail under these conditions
REFERENCES
IX. CONCLUSIONS
1. Scham Tickoo, “Pro-Engineer-
As per drawings and information provided 2001”, 2nd edition.
by Bevcon, 3D models are developed in Pro-e 2. J.N.Reddy, “An Introduction
and the shaft of crusher is analyzed in Ansys to Finite Element Method”, 3rd
package. edition.
1. Based on calculations and analysis 3. R.K.Allan,“Rolling Bearing “,
reports the safe diameter is selected as 3rd edition
125mm, which is safe.
4. S.S.Rao, “Mechanical
2. Factor safety for selected diameter is
Vibrations’’, 4th edition.
11. This factor of safety chosen for
crusher to address sudden impact and 5. Richard G.Budynas Jata,
shock loads created by the material. “Advanced Strength and
3. Deflection of shaft as per theoretical Applied Stress Analysis”, 2nd
edition
calculations is 0.009mm. .
4. Deflection of shaft in Ansys analysis is 6. V.B. Bhandari, “Introduction
0.007mm (load applied on shaft only). to Machine Design”.
5. Deflection of total rotor assembly in 7. Robert L.Norton, “Machine
Ansys is 0.006mm. Design”, 2nd edition.
6. Selected bearing for this application 8. Hall, Holowenko Laughlin,
based on shaft diameter 125mm is “Theory and Problem of
heavy-duty spherical roller bearings on Machine Design”, Schanm’s
adapter sleeve. series.
7. 3D models developed in pro-e 9. PERRY, r.h., and d.w.Green,
& analyzed reports have been “Perrys Chemical Engineers”
submitted to Bevcon for their handbook, “7th ed.
consideration in their designs 10. F.D.Bond, “Crushing
8. We suggested to consider this analysis Calculations”.
report to reduce the bearing diameter 11. Pennsylvania, “Crushing
metal for optimizing the rotor design Technologies”.
of the hammer mill crusher. 12. P.C.Hayes, “Construction of Hammer
9. Bearing life for selected bearings is 450 Mill Crusher”.
Millions of revolutions.
29
30