Academic Project

on
“Design and Manufacturing of Automatic
Two Wheel Drive Forklift for Material
Handling”
Sanket Suresh Desai Roll No.: A47
Siddhant Santosh Malvade Roll No.: C13
Sanket Chandrakant Kurade Roll No.: B67
Aditya Kamalakant Morajkar Roll No.: C24
Project Guide
Prof. G.S. Sawadadkar
JSPM, Narhe Technical Campus
Department of Mechanical Engineering
2019-20
Abstract
• Introduction of Project
Forklift can be defined as tool capable of lifting hundreds of
kilograms. Mechanical forklift is an improved and advance technology that
helps brought about revolution in the mechanical industries, today all heavy
engineering company uses it.

• Importance of Project
The forklifts are generally used for moving heavy good and supply
from one place to another quickly and with less effort.

• Problem Statement
Factories, industries and storages need forklifts and cranes for
storages and moving large goods. Also there are a number of goods
weighting around 80-100 kg that are comparatively lighter but cannot be
moved easily by human factor.
SOLUTION

• To overcome this problem, we here propose two

wheel drive forklift to lift and transport such
medium weight goods across factories and
industrial warehouses
• Advantages
The two wheel drive is a fast efficient and low
power consumption vehicle that does not require
much space to move around.
Methodology
• Visit to the industry
• Identification of problem
• Idea of project
• Collection of data
• Literature survey
• Design of CAD model
• Material selection
• Fabrication work
• Testing’s
• Conclusion
• Submission of project
Current Model
Advancement

• In this project, our work is to reduce the human

effort, our aim is to manufacture the automatic
forklift by using ardiuno control unit.

• Design of lead screw, Design and analysis of forks,

estimation of capacity of motors based on loads.
CATIA MODEL
Collection of Data
• Requirement of industry: Handling of Equipment's
efficiently
 Load lifting up to 100kg
To carry load and shift at particular place
Components required
Material specification
Components
• Motor (DC)
• Lead screw
• Wheels
• Frame
• Lifting mechanism
• Controlling unit
Fig. Lead Screw Fig. DC Motor
 MODEL CALCULATION

lifting mechanism
1) We considering the weight of object is 100 kg .
=Weight of object + weight of panel +weight vertical Structure
=100+100+100
=300 kg
Mass carrying (m) = 300 Kg
Length of screw = 1220 mm
Factor of safety (FS) = 3

Total Load (W) = Mass (m) × Acceleration due to gravity (g)

= 300×9.81
= 2943 N
 Material = (mild steel)
• Material Properties,
• 𝑆𝑦𝑡 =400 Mpa
• E=200Gpa

Permissible compressive stress (𝜎𝑐 )-

𝑆𝑦𝑡
• 𝜎𝑐 =
𝑓𝑜𝑠
400
=
3
𝑁
=133.33 ( 2)
𝑚𝑚
Core diameter of screw (𝑑𝑐 )
𝑊
𝜎𝐶 = 𝜋
×(𝑑𝑐 )2
4
133.33= 2943/( π/4×(dc)2
𝑑𝑐 = 5.3 mm
Basic dimensions for square threads in mm
There are additional stresses due to torsional and bending moments. The diameter should be
increased to account for these stresses. As a square threaded screw with 22 mm nominal diameter
and 5 mm pitch is selected.
We know, d= 22 mm, p= 5 mm
Core diameter of screw (𝑑𝑐 )
𝑑𝑐 = (d– p)
= 22 – 5
= 17 mm

Mean diameter of screw (dm)

dm = d – 0.5p
= 22 – 0.5(5)
= 19.5 mm

It is assumed that the screw has single start

threads. l = p = 5 mm

Helix angle (α)

1
tan α = πd
m
5
= α
π(19.5)
= 4.666º
Friction angle (∅)
The possible value of the coefficient of friction between screw and nut is 0.35
tan∅ = μ
= 0.35
∅ = 19.29º
Since ∅ > α the screw is self- locking.

Torque required to lift & lower the load

(Wdm)
Mt = 2 ×tan(∅±α)

For Lifting –

(2943× 19.5)
Mt =2×tan 19.29 + 4.666

Mt = 12749.10 Nmm
 For lowering –

(2943× 19.5)
Mt = × tan(19.29 − 4.666)
2

Mt= 7487.1286 Nmm

1. Check for shear & compressive stress failure

1. τ = (16 Mt)/ π (𝑑𝑐 3)
= (16(10613.43)/(π(17)3)
= 13.21 N/mm2

2. σc= W/[π/4×𝑑𝑐 2]
= 2943/(π/4×(17)2 )
= 12.665 N/mm2
Checking for buckling failure
Moment of Inertia (I) –
I = π/64 ×𝑑𝑐 4
= π/64 × (17)4
= 4099.82 mm4
Cross sectional area (A) –
A = π/4 × 𝑑𝑐 2
= π/4 × (17)2
= 226.98 mm2

Radius of gyration (K)

K = √(I/A)
= √(4099.82/226.98)
= 4.249 mm
Slenderness ratio (l/K) –
l/K = 1220/4.249
= 287.12

Critical slenderness ratio

End fixity coefficient (n) = 0.25
Syt/2 = (nπ2 E)/(l/K)2
400/2 = (0.25π2×210×(10)3/(l/K)2
l/K = 50.89

Critical load on buckling (Pcr) –

Pcr = Syt A[1- Syt/4nπE (l/K)2 ]

Pcr = 400 × 226.98 [1- 400/(4 ×0.25 × π2×210 ×103 ) (50.89)2 ]
Pcr = 45413.15 N
Factor of safety for buckling Failure –
FS = Pcr/W
= 45413.15/2450
= 15.43

So the design is safe against buckling failure

 CONCLUSION

The development of Mechanical forklift assures the ergonomically comfort to the

operator or worker and to reduces time required for manual lifting and handling. It
lifts the maximum load of 200 Kg. This increases efficiency of productivity & it
provide safety of operator while handling of the material.
References
• Design of pedal operated wheel drive forklift by Aditya Vaidya, Krunal Rotliwala,
Mahesh Prajapati, Nikunj Patel, Rahul Rajpurohit Mechanical Engineering
Department, International Journal of Design and Manufacturing Technology
(IJDMT) Volume 9, Issue 1, Jan-April, pp. 17–22, Article ID: IJDMT_09_01_003
• The study of Efficiency and Effectiveness of Warehouse Management in the
context of Supply Chain Management, Ms. Sneha Vishnu More Assistant
Professor, Karmaveer Bhaurao Patil College, Vashi, Navi Mumbai-400705,
International Journal of Engineering Technology, Management and Applied
Sciences, August 2016, Volume 4, Issue 8, ISSN 2349-4476
• 3 wheel drive forklift for industrial warehouse, rajat.rajendra wade, digvijay k
take, mahesh s deshmukh, pranaw a raut, Student, Department of Mechanical
Engineering 1,2,3,4 Jawaharlal Darda Institute of Engineering & Technology,
Yavatmal, Maharashtra, International Research Journal of Engineering and
Technology (IRJET) , Volume: 05 Issue: 02 | Feb-2018
• Design and Development of Mechanical Forklift, Lobo Allwyn , Khebude Karan ,
Adsul Ganesh , Bhosale Prathamesh , Khade Omkar , Naik Abhijeet ,Student,
Sanjeevan Engineering & Technology Institute, Panhala, MH, India 6 Professor,
Dept. of Mechanical Engineering, Sanjeevan Engineering & Technology Institute,
Panhala, International Research Journal of Engineering and Technology (IRJET),
Volume: 05 Issue: 03 | Mar-2018
• Optimization of Material Handling Trolley using Finite Element Analysis,
Ramkumar, Krishnaraju, Assistant Professor, Mechanical Engineering, Mahendra
Engineering College, Namakkal, IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 13,
Issue 6 Ver. V (Nov. - Dec. 2016), PP 137-148