CHAPTER FOUR

DETAIL DESIGN
4.1. PARAMETERS OF MATERIAL SELECTION
When creating a honey extractor machine, we consider the following factors. We considered a number of key
factors. Here are some of the most crucial variables to think about when designing the machine. [10]
Cost: - When designing the equipment, cost has always been a primary issue. The ideal machine design is
one that allows for the production of a finished product with all of the primary functions and the greatest
possible quality at the lowest feasible cost.
High output and efficiency: - While earlier machines were fairly heavy and required a lot of power,
our machine utilizes less power with the force applied to the handle and delivers a high output in terms of
the number of frames integrated in the machine.
Strength: - The machine parts or the machine itself should be robust enough to withstand all of the forces
it is designed to withstand over its lifetime so that it is neither destroyed nor permanently deformed.
Stiffness or rigidity: - The machine should be stiff enough that it does not deform when subjected to the
applied forces for which it was built.
Wear resistance: - The removal of material from a metallic surface is known as wear. If more material is
removed, the material component will get weaker and eventually break. To preserve the material from wear,
increasing its hardness is crucial.
Lubrication: - Lubrication between the two mating surfaces of the machine's components aids in minimizing
friction and wear of the two surfaces.
Operational safety: - Hazardous generating items from the machine should be removed for the safety of
the machine operator, and the design should be maintained for safety.
Ease and simplicity of disassemble: -the disassemble of the machine also should be easy for
replacement of the part.
Easy of assemble: the elements of the machine should be assembled very easily.
Light weight and minimum dimension: - The machine elements and machine itself should be sturdy, stiff,
and wear resistant, with the smallest possible weight and dimensions.
Reliability: - The possibility that a product, system, or service will perform its intended function satisfactorily
for a certain amount of time or in a specific environment without failure is characterized as reliability.
Durability: - Durability is defined as a material's capacity to stay usable in its environment throughout its
useful life without being damaged or requiring unexpected repair.
Design Specification
Table 4.1 design specification

No

1 Human applied force a minimum 260N

2 Length of a main vertical shaft 670mm

3 Length of bevel gear shaft 130mm

4 Length of frame holder 480mm

5 Length of round bar 480mm

6 Length of hollow rectangular bar 600.001mm

4.2 Material Selection

When we are selecting materials for our honey extractor machine, make sure that each component
fulfills the defined goal at the lowest possible cost. When choosing material, we kept the following
aspects in mind. [11][14]

 Availability of materials
 Suitable for the working condition
 Cost of the material

4.2.1 Pulley design, belt selection and specification

The belts are used to transmit power from one shaft to another by a means of pulleys which
rotate at the same speed or at different speed. The amount of power transmitted depends up on
the following factors [16]
1. The velocity of the belt.
2. The tension under which the belt is placed on the pulleys.
3. The arc of contact between the belt and the smaller pulley.
4. The conditions under which the belt is used
It may be noted that
a) The shafts should be properly in line to insure uniform tension across the belt section.
b) The pulleys should not be too close together, in order that the arc of contact on the smaller
pulley may be as large as possible.
c) The pulleys should not be so far apart as to cause the belt to weigh heavily on the shaft, thus
increasing the friction the load on the bearings.
d) A long belt tends to swing from side to side, causing the belt to run out of the pulleys which
in turn develops crooked spots in the belt.
e) The tight side of the belt should be at the bottom, so that whenever sag is present on the loose
side will increase the arc of contact at the pulleys.
f) In order to obtain good results with flat belts, the maximum distance between the shafts should
not exceed 10 meters and the minimum should not be less than 3.5mm the diameter of the larger
pulley.

4.2.2 Selection of a Belt Drive

Following are the various important factors upon which the selection of a belt drive depends [16]
1. Speed of the driving and driven shafts,
2. Speed reduction ratio,
3. Power to be transmitted,
4. Centre distance between the shafts,
5. Positive drive requirements,
6. Shafts layout,
7. Space available, and
8. Service conditions

Types of belts
Though there are many types of belts used these days, yet the following are important from the
subject point of view [13]:
1. Flat belt: The flat belt is mostly used in the factories and workshops, where a moderate
amount of power is to be transmitted, from one pulley to another when the two pulleys are not
more than 8 meters apart.

2. V belt: The v belt is mostly used in the factories and workshops, where a great amount of
power is to be transmitted, from one pulley to another, when the two pulleys are very near to
each other.

3. Circular belt or rope: The circular belt or rope is mostly used in the factories and
workshops, where a great amount time power is to be transmitted, from one pulley to another,
when the two pulleys are more than 8 meters a part.
Selection of belt for Honey extraction machine are V belt, because it is mostly used in the
agricultural machineries, where a great amount of power is to be transmitted, from one
pulley to another, when the two pulleys are very near to each other.

Advantages of V belt [13]

 The V-belt drive gives compactness due to the small distance between centers of pulleys.
 It provides longer life, 3 to 5 years.
 It can be easily installed and removed.
 The operation of the belt and pulley is quiet.
 The belts have the ability to cushion the shock when machines are started.
 Since the V-belts are made endless and there is no joint trouble, therefore the drive is
smooth.

[Link] V Belt material

Rubber belt: The rubber belts are made of layers of fabric impregnated with rubber composition
and have a thin layer of rubber on the faces. These belts are very flexible but are quickly
destroyed if allowed to come into contact with heat, oil or grease. One of the principle
advantages of these belts is that they may be easily made endless. These belts are found suitable
for saw mills, paper mills where they are exposed to moisture.[13]

4.2.2.2Density of v Belt Materials

The density of various v belt materials is given in the following table
Table 4.2 Density of v belt material (Source: Gupta and Khurmi, 2005)
Materials of belt Mass density in kg / m3

Leather 1000

Rubber 1140
 Single woven belt 1170

Double woven belt 1250

4.2.3 Selection of pulley for v belt

Figure 4.1: Pulley arrangement

Following are the various types of pulleys for v belts [13]:

 Cast iron pulleys
 Steel pulleys
 Wooden pulleys
 Paper pulleys
 Fast and loose pulleys.
From the above types of pulley cast iron pulleys are selected for V belt; because of their low cost
and low weight. The rim is held in place by web from the central boss or by arms or spokes. The
arms may be straight or curved.

Types of belt drives

The belt drives are usually classified into the following three groups.

1. Light drives: These are transmitting small powers at belt speeds up to about 10 m/s as in
agricultural machines and machine tools.

2. Medium drives: These are transmitting medium powers at belt speeds over 10m/s but up
to 22m/s, as in machine tools.
3. Heavy drives: These are transmitting large powers at belt speeds up to 22m/s as in
compressors and generators.
Table 4.3: Types of belt drives (Source: Gupta and Khurmi, 2005)
Types of belt drives Belt speeds ( m ⁄s)
Light device ≤ 10
Medium device 10-20
Heavy device 20 ≤

4.2.2.3Types of v belts and pulleys

According to Indian standards (IS: 2494 – 1974), the v belts are made in five types i.e. A, B, C,
D and E. The dimensions for standard for v belts. The pulleys for v belts are cast iron to reduce
weight [6].
Table 4.4: Dimensions of standard v belts according to IS: 2494 – 1974
(Source: Gupta and Khurmi, 2005)
Type of belt Power ranges Minimum Top width (b) Thickness Weight per
in Kw pitch (mm) (mm) unit length in
diameter of newton (N)
pulley (D)
(mm)
A 0.7 – 3.5 75 15 8 1.06
B 2-15 125 17 11 1.89
C 7.5-75 200 22 14 3.43
D 20-150 355 32 19 5.96
E 30-350 500 38 23 ……..

From the above standard table, we select of v belt type A, @ transmitted motor power 1.5 Kw.
Belt width: 13 mm
Belt thickness: 8 mm
Minimum pitch diameter of pulley: 80 mm
Maximum pitch diameter of pulley: 𝐷p = dp × Vr = 80× 1.5 = 120 mm ………. (Take Vr = 1.5)

4.2.3Motor selection and specification

An electric motor is a device for converting electrical power into mechanical power. An electric
motor will try to deliver the required power even at the risk of self-destruction. Motor selection
for honey extraction machine is induction single phase motor.
The induction motor is the motor most commonly used in agriculture. The speed of rotation of an
induction motor is fairly constant, but it does vary somewhat with loading. As the motor is
loaded, it slows down slightly. And the motor can rotate in both directions because it is single
phase. T2he single-phase induction motor is most commonly used for extraction applications.
Because it has long lifespan, high power and low starting torque .
Table 4.5: Common single-phase induction motor sizes used for agricultural applications; At AC
supply 220 – 240 V, 60 Hz operation, Foot MTG; (source: BS 5000 Part 11 / IS 996 for
performance)

So select 1.5 KW from the above standard table single phase induction motor serial number 7,
which have the following specification:
Motor power: 2 hp
Motor power: 1.5 Kw
Motor speed: 1450 rpm
Weight: 8 Kg Frame: 100s
Enclosure Type: TEFC (Totally Enclosed, Fan Cooled)
Capacity type: CSCR
Efficiency: 75.5 % = 0.755
Motor torque (T) p = 2𝜋𝑁𝑇/ 60 …………………… [1]
60 × P 60 ×1500
T= = =9.88 Nm=9880 Nmm
2 πN 2 π ×1450
Number of poles (n)
 2 ×3450
N=
n
2 ×3450 2 ×3450
n= = =5 poles
N 1450

4.3Centrifugal Force
Centrifugal force is an outward force apparent only in rotating reference frame. In rotating
reference frame all objects appear to be under the influence of a readily [from the axis of
rotation] out ward force that is proportional to their mass, the distance from the axis of rotation
of the frame, and the square of the angular velocity of the frame [14]
2
F C =M × ω r……………………………………….[eq. 2]

Where m= mass of the object in our machine [mass of wood frame +mass of honey]
We measure the wood frame dimensions that are available for modern hives to be used shows in
fig as follows.

Figure 4.2; modern hive wood frame

The thickness of wood =15mm and the diameter of wire which is used inside the wood frame is
0.04mm. Then we are calculating the volume of each side wood
Total wire used =4
2 2
πd 0.04
Area of wire = =π =0.00126mm2
4 4
Volume of wire =A×L= 0.00126×169= 0.213m3
Total volume =4×0.213 =0.85m3
The volume of each side wood is
V1 =478×25×15 =1792500mm3 =0.17925m3
V2= 194mm×25mm×15mm =72750mm3 =0.07275m3
V3=362mm×25mm×15mm =135750mm3 =0.13575m3
V4=169mm×25mm×15mm =63375mm3
The total volume of the wood frame is equivalent to

VT =V1+V2+V3+V4 wire
VT= 0.17925+0.07275+0.13575+0.0633=0.45mm3
Mass of wood is calculated as the following using the material density center wood
M= ρ V=0.57× 103kg/m3×0.45m3=0.256kg

Our machine contains 4 frames

Mt=4×0.256kg=1.026kg [total mass of wood]
Mass of wire =density of wire ×volume of wire
0.00893kg/m3 ×8.5×10-7 m3 =7×10-9 ×4 frame
= 2.8×10-8 kg
Mass of total=mass of wood+ mass of wire+ mass of honey
1.0256kg+0.000000028kg+6kg = 7.0256kg
Centrifugal force [Fc] =m ω2 r
Fc=6.001kg× [12.56]2×0.254=164N

Design of Bevel Gear

Bevel gear is used to change the motion at somewhat angle. We need meter gear to change
motion at 90 angles without varying speed. The position of this bevel gear is located at the end
shaft of driven applied force of human force extracted 260N and rotated a handle by 60rpm,
center of rotation[R]=80mm.

4.3.1. Input parameter

π D2 N 2
Velocity of input shaft v= = 0.251 m/s………………….. [eq. 3]
60
Power transmitted P = F × V = 65.26w = (2 × p)
Velocity ratio (G) = 1 since constant speed meter gear.
Angle between shafts θs = 90° because meter gear
Pitch angle θp = 45°
Number of teeth on the wheel T = 18 mm (minimum number of teeth for smooth operation)
Modules m = 2mm

Material Selection
The cast iron is widely used for the manufacture of gears due to its good wearing properties, excellent
machinability and ease of producing complicated shapes by casting method. The cast iron gears with cut
teeth may be employed, where smooth action is not important. So we select cast iron highest grade having
mechanical property [6].
Allowable static stress σo = 105MPa
Young’s Modules E = 196GPa
Requirement Dimension of both gear and pinion
Checking the strength of the gear

Terms used in bevel gear

 Figure 4.3; terms used in gear

Geometric Analysis
Since we don’t need any increase or decrease in speed so gear and pinion has the dimension.
Proportion of bevel gear.
Table 4.6 : Proportional Values of Bevel Gear [5]
No Parameter General Dimension
formula
1 Addendum, a a=1m 2mm
2 Duodenum, d d = 1.2 m 2.4mm
3 Clearance c c = 0.2 m 0.4mm
4 Working h=2m 4mm
depth h
5 Thickness of t = 1.5708 m 2.1416mm
tooth

Pitch diameter Dp = m × T = 32mm

The outside cone diameter Do
Do = Dp + 2a cos θp = 80mm
The inside cone diameter Dd
 Dd = Dp − 2d cos θp = 45mm
The circular pitch pc = πm = 6.28mm

Strength Analysis
The strength of a bevel gear tooth is obtained in modified form of the Lewis equation for the
tangential tooth load is given as follows [6]:
L−b
WT = (σ0 × Cv) b. π. m. y’ ( )……………………………… [eq. 4]
L
Where wT = Tangential load,
WT = p/v = 0.248 kN
σo = Allowable static stress
Cv = Velocity factor,
C V = 3/( 3 + v ) = 0.5 , for teeth cut by form cutters,

v = 3 m⁄s Peripheral speed in m /s,

b = Face width, [9m___13m] is the required weather satisfied (L /b ≤ 3 ) or not.
m = Module,
y’= Tooth form factor (or Lewis factor) for the equivalent number of Teeth,
0.912
=0.154- for 20° full depth involute system
T
= 0.1033
L = Slant height of pitch cone (or cone distance)

√
L¿ (
Dp 2
2
¿ )+¿ ¿25.45mm

By rearranging the above equation, we gained

∴ b = 17.65mm Say 18mm L / b = 1.44 ≤ 3
So, the design is satisfactory.

Checking Gear for Wear

Ratio factor Q
2 ×G
Q= …………………………………. [eq. 5]
G+ 1
Using formula, the load-stress factor K
2
(σ es ) 1
k= sinφ ¿ + E ]………………………….[eq. 6]
1.4 G

Where σes = 630 MPa Surface endurance limit in MPa or N/mm2

Ep = EG = 196GPa Young’s modulus for the material of the gear in N/mm2
φ = 20 ° Pressure angle
, So, k = 0.99MPa The maximum or limiting load for wear, Ww
Ww = Dp. b. Q. K
Ww = 570.24 N

Since the maximum wear load is much more than the tangential load on the tooth, therefore the
Design is satisfactory from the standpoint of wear.

4.4 Design of Shaft

4.4.1Material Selection for Shafts
Shafts is a rotating machine element which is used to transmitted power from one place to
another, the material we choose to use for shafts in our project design should have the
following properties[2]
 Low notch sensitivity
 Have good heat treatment property
 High wear resistance
 Good machine ability
Table 4.7: material selection of shafts [9th edition shigley mechanical
engineering design]

Material type Part name Sty Sut Density

Plain carbon Large gear shaft 370mpa 360mpa 7850kg/m3
(steel[50c4]
Plain carbon Pinion gear shaft 2240mpa 7850kg/m3
(steel[4142]
Plain carbon Main vertical 320mpa 560mpa 7850kg/m3
(steel[40c8] shaft

4.4.2Shaft Design due to Strength

The shaft is always subjected to fatigue load hence they are must be calculated
fatigue strength under combined bending and torsion loading. The bending moment
variation along the length of shaft is established after fixing some structural feature
like distance between supporting bearings applied force on it. Using maximum
shear stress theory [Guest hypothesis] .

From the above table we select plain carbon steal (50c4) and sut =360mpa ,syt
=370mpa ρ=7850 kg/m 3

2 πNT
P=
60

60∗1500
T= =9.88Nm =9880Nmm
2 πN

sut 320
τ= = =¿53.3N/mm 2
2∗fs 2∗3

π 3
T= τd
16

3 16 T
d= =53.3*9880/ πτ =42.4 mm=44mm
τπ

d=44mm
By considering the transmitted torque on straight shaft that is subjected to combined bending and torsion.
We should be calculated the diameter of the shaft is needed in the machine.

4.4.3 Vertical Component Force Bending Moment Analysis on Pinion Gear

Shaft
Figure 3.4: reaction force analysis of vertical force pinion gear shaft

∑ Fy =RA+RC =839.2

∑MA =0 (in counter clockwise direction)

=-839.2*65+RC*130

= 130RC =54548
 =RC =419N and RA =419N

Bending moment, A and C =0

Bending moment at B

MB =419*65+419*65 =54470N-mm

4.4.4 Tangential Component Force Bending Moment Analysis on

Pinion Gear Shaft

Ft2=2305.7

A C

RA 130 RC

1152 N 1152N

Figure 3.5: reaction force analysis pinion gear shaft

∑Fy= RA+RC =2305

∑MA =0 = -2305.7*65+RC*130

130 RC =149870.5

RC =1152N and RA =1152N

Fr =839.2N

A B C

13 RC
0
RA
Bending moment at A and C are zero.

Bending moment at B

MB =1152*65+1152*65 =149760N-mm
The resultant bending moment is calculated as =
-mm

To calculate the diameter of pinion gear shaft using the material of steel
selected

Sut =2240Mpa
 4.4.5 Vertical Component Force Bending Moment Analysis of Larger Gear
Shaft
B Fr1 = 839.47 N

A 230 C
RA RC

Figure 4.3; Reaction force analysis larger gear shaft

∑Fy = RA + RC =839.47

∑MA =0 (clockwise direction is negative)

-839.47*115+RC*230

RC = 419.7

RA +RC =839.47

RA =419.7N

Bending Moment at A

-839.47*115+419.7*230=0

Bending Moment at C 419.7*230-839.47*115=0

Bending Moment at B, 419.4*115+419.7*115 =96537.8

4.5.5 Main Vertical Shaft Design

Bending Moment Analysis

2469.7

A C
∑Fy =RA+RC=2469.7N
MA =-2469.7×335+RC×670

RC=1234.85N

BM at A=0

BMatB=1234.85*335+1234.85*335=[Link]

BM at C=0

To calculate the diameters of main vertical shaft using shear max theory.

From analytical of shaft plain carbon steels are Syt =320Mpa

syt 320 mpa
τmax = = =53.3 N /mm ²
2n 2 ×3
16
3
d=
πτmax
√ M 2+T 2
16
d ¿
3
3.14 ×53.3
√ 2
827349.5 + 64580
2

d =42.9mm=44mm
τu 320
F.S= = =3
2 τ 2∗53.3
F.s >2 our design is safe
4.5 Design of Frame Holder
To calculate the surface area of the frame holder the data taken from the modern
hive frame dimensions’ parameters consideration. The two faces of frame holder
drill by jig in the area of 100mm2

 Width of the wood frame =25mm

 Height of the wood frame =480mm
 Length of the wood frame=220mm
Area of the frame holder to be calculated using the following formula.

Aframe =2[l×h + w×l +w×h]

= 2[220×480+26×220+26×480] =24.62M2

From density of material for frame holder stainless steel to calculate the volume

Vfh=Afhxtfh=24.62x0.026=0.00064m3

To calculate mass of frame holder (mfh)= =7850kg/m3x0.00064m3=5kg

4.5.1 Force Analysis of Frame Holder

P=Ft2+w ………………………………. [eq. 7]

=2305.7+mg

=2305.7+ (mass of wood +mass of wire+ mass of honey+ mass of container)

=2305.7+ [6.001+5] ×9.81 = 2413.6N

4.6 Cylinder Design

Cylinder is used as temporarily container of extracted honey. We are design the
part it includes this machine this cylinder we see the dimensions of other machine
related with our machine and by considering this we are given the diameter of
cylinder=540mm and height=550mm. this dimension consider to the leg of the
cylinder and the person high
 Figure 4.4; cylinder design

F1=F2=F but

F1+F2 =W …………………………………….[eq. 8]
2F=W, 2F=mg
2F=6kg×9.81+2305.7N
2F/2=2364.56/2 =1182.3N

F1=F2=1182.3N

Volume of cylinder =πr2h

=Π× [270]2×550=40095000mm3

4.7 Round bar Design

Round bar are solid bar with round or circular cross-section which are used to support the frame
holder to be out honey from the comb into the walls of the cylinder without vibration of the
holder. It is also used to place the frame incorrect position. They are produced from stainless
steel. It is manufacturing methods are by cold or hot rolling and drawing, which is expressed in
following.
The parameters to be considering for round bar are in our machine design: -
 The length of round bar(L) mm
 The diameter of round bar(D)mm
 When we rotate the handle of our machine to be consider the center of
gravity in x-direction
Y-direction of round bar as shown in fig

Figure 4.5; center of gravity of round bar

Table 4.8: moment analysis of round bar

Step1 Parameter/condition Symbol Equation
1 Cross sectional area A A=πd2/4
2 Area of inertia X-direction IXX IXX=πd4/64
3 Area of inertia Y-direction Yyy Yyy=πd4/64
4 Section of modules sxx SXX=2IXX/d
5 Section of modules syy Syy=2Iyy/d
6 Center of gravity xcog Xcog=d/2
7 Center of gravity ycog Ycog=d/2
8 Mass M M=AL
9 Polar moment of inertia J J=IXX+YYY

By considering the height of wood frame holder the diameter of round bar and length
is given by, d=10mm, and l=480mm
2 2
πd 10 2
Aroundbar = =π × =78.5 mm
4 4

Moment of inertia at X-direction,

4 4
πd 10 2
I xx = = π× =490.625 mm
64 64
Section of modules
2 I xx 2 ×490.625
s xx = = =98.125……………………… [eq. 8]
d 10
 d 10
Center of gravity [xcog] = =5 mm
2 2
d 10
Center of gravity of Y-[Ycog]¿ = =5 mm
2 2
Polar moment of inertia I =I xx +Y xx =2 × 490.625=981.25
Table 4.9: moment analysis of round bar result

No Parameter Result
1 A 78.5mm2
2 Ixx 490.625mm4
3 Yyy 490.625mm4
4 Sxx 98.12mm3
5 Syy 98.12mm3
6 Xcoy 5mm
7 Ycoy 5mm
8 J 981.625mm4

4.8 Design of rectangular hollow bar

It is one part of our machine which contains the larger gear shafts, pinion gear shafts
and connected to the cylinder bolt and nut in order to operate the machine without
vibration and misalignment of shafts. We use the material for this part Aluminum (6061)
Ust=300N/mm2, syt=241N/mm2

syt 241 N /MM 2

τ= =¿ =80.33N/mm 2
f .s 3

Ust
F.s= =3.7
τ

The length of rectangular hollow bar=570mm and width =100mm

Area [A]=Lxw=570mmx100mm=57,000mm2
F 260 N 2
τ= = =0.00456 N /mm
A 57000 mm 2

And also, the vertical rectangular hollow bar is length =210mm and width =100mm Area
[A]=100mmx210mm=21,000mm2
2
τ =0.0124 N /mm
The smallest shear is the design to be safe
 4.9 Design of Coupling
A coupling can be defined as mechanical device that permanently joins two rotating
shafts to each other [10][11].

The most common application of coupling is joining of the shafts two separately built
or purchased units so that a new machine can be formed; we are select in muff
coupling for our machine to be connected pinion gear shafts and the main vertical
shafts. The material for shaft and key is plain carbon steel which allowable shear and
crashing stress is 40Mpa and 80Mpa respectively and muff material is cast iron which
crushing stress and allowable stress is 15Mpa

Table 4.10; proportion of standard parallel tapered gib head keys

Shaft diameter Widt Thickness(mm)

(mm) h
(mm)

10 4 4

17 6 6

30 10 8

44 14 9

50 16 10

58 18 11

 It is the simplest form of coupling with only two parts, viZ; sleeve
and key. It’s simple to design and manufacture.
 It has no projecting parts except the key, head. the external surface
of the sleeve is smooth;
 It has compact construction with small radial dimension’s iv. It is
cheaper than other types of coupling
 Figure 4.6: coupling design

The diameter of main vertical shafts d =45mm, calculated then the dimensions of
sleeve [D]
D=2d+13=2x44+13=101mm
L=3.5d= 3.5x44mm=154mm, L=length of sleeve

To check the torsion shear stress

2 2
π D −d
T= τc ……………………………………………………………[eq. 9]
16 D

4 4
π 101 −44
9880Nmm= τc( )
16 101

τc=¿ 0.05N/mm 2

The induced shear stress in the muff (cast iron) is less than the permissible shear
stress of 15 N/mm 2, therefore the design of muff is safe.

Design of key

To calculate the length of the key is one half of the length of sleeve

L 154
l= = =77
2 2

From table 4.8; using shafts diameter=44mm

Key size w= 14mm

Key size T=9mm

Where w =width of key, L=length key h=height of key

Using the dimension of key we are check the shear and compressive stress in
the key
t σc∗d
T¿ *l* ……………………………………………….[eq. 10]
2 2
9880N/mm 2=9/2*l∗σc∗¿44/2
σc =1.296N/mm 2

Since the induced shear and crushing stresses are less than the permissible stresses,
therefore the design of key is safe.
The dimension of the key is, b x h x l=14mm x 9mm x 77mm

4.10 Bearing Selection

The shafts which are used for motion transmission in honey extractor are supported by
standardized machine element called bearing [10].

Depending up on the type of load coming up on the shafts the bearing can be classified
as radial or thrust bearing. Radial bearing load transverse to the shafts while thrust
bearing take up axial loads on shaft

4.10.1 Factors Affecting Choice of Bearing

Several factors to be considering before sliding contact or rolling contact
bearing is choice. Type of load, speed of rotation, available space to be
considered. This machine works mostly in rural areas with no adequate
lubrication. With twist in mind rolling contact bearing is selected [10].

Advantages

 Low starting and running friction

 Accuracy of shafts alignment
 Small over all dimensions
 Low cost of maintenance
 Reliability of service
  Can virtually run without lubrication
 Less sensitive to change in load, speed and operating temperature.

We select for this machine deep groove ball bearing.

Deep groove ball bearing is the following advantage.

• Due to relatively large size of the ball, deep groove ball bearing has
high load carrying capacity.
• It uses load in radial as well as axial direction
• Temperature rise less during contact between race ball
• It generates less noise due to point contact

To select the bearing is using the following formula

Fa
where Fa=axial force Fr=radial force
Fr

4.10.2. Selection of Bearing for Main Vertical Shaft

We select for main vertical shaft we think about axial direction force of the shaft is
not existed so only the centripetal force towards the center of the shafts which
164N. If there is no axial load we use the formula of Fr/CO but we didn’t know co
for using this formula the value of trust factor x and y is 1&0 respectively.
Equivalent dynamic load (p)

p=x F r + y F a=1 × F c +0 ×0=164 N

Load capacity (C) =P (L1O)1/3 but expected life of bearing is 10000h

L10 =60*120*104/106 =72 million. rev

164(72)1/3 =682.26N

Bearing load (c) >> dynamic load (p)

4036>>682.26N

We select the type of bearing B Inner diameter [d] =45mm

Outer diameter [D] =80mm
Width [B] =7mm

Load capacity = 4036

Table 4.11; All shaft bearing selection

No Shaft type D D B
1 Pinion gear shafts 15mm 42mm 13mm
2 Larger gear shafts 30mm 42mm 7mm
3 Vertical main shafts 35mm 47mm 7mm

4.11. Design of Bolt and Nut

A bolt is fastener with ahead and straight threaded shank and intended to be
used with nut to clamp two or more part

The load P supported by bolts, is the weight of the guide rods and imp actor
assembly, let’s take the allowable buckling load that the guide rods can support,
which

There are 2 bolts, the direct shear load on each bolt,

V = P/ n = 260N/ 2 =130N

The maximum tensile load, where L =95 mm, b =24 mm, c =44 mm.

Pt = P.L/ 4b = 130N × 95/ 2 × 24 = 257.29N

Also, the bolts are subjected to shear load as well as tensile load, the equivalent
tensile load,

1 1
2 2 √
Peq= [pt +√ ¿)]= [257.29+ (257.29 2¿ + 4∗1302 )¿ ]

=272.782N

Table 4.12; design of bolt and net (shaggily mechanical engineering 9th
edition)
Let’s assume as first trial that the size of the bolt lies in property class 4.6 (M5− M36),
then from figure 3.48, minimum tensile strength σt=400 MP a. The core diameter can
be calculated from bolt area,

π 2 Peq 272.782
Abolt= d = = =0.68*10−6
4 ρb 400

= 6.8*10−7 m2
−7
4∗6.8∗10
d=√ =0.0029m=2.9mm
π
The standard size of the bolt is M5

We select bolts fro

m the table[ 4.2] basic dimensions that are needed in our design M 5which
means that the nominal diameter of bolt is 16 and the pitch is 0.8mm
d=25mm, p=0.8mm dc =23.5mm D=23.75mm At=14.2mm2 width=8mm
heiht=3.58mm

Where d = nominal

diameter

P= pitch

dc=external thread minor diameter

Dc=internal thread minor diameter

Ats=tensile stress area

4.12 Design of Leg

Leg is one of part of our machine which is used for carrying the machine and on to the
ground. The weight of the machine resists by the ground the load is transmitted to it.
So keep in mind this idea we cannot determine the resistance force of legs. Simply we
select the material of legs and dimensions.

The material to be used for legs plain mild steel (syt=248N/mm2)

82.66N/mm2

The length of legs =560mm and width =60mm

Area [A]=560mmx60mm=16800mm2

Weight on the cylinder =2364.56N

N/mm2

The smallest stress to be our design to be safe.

4.13 Motor pulley & blower pulley and v belt design analysis

1) Center Distance (C) and Belt Length (L1) length of motor pulley and blower pulley:
 Blower pulley Motor

Figure 4.7: Center Distance and Belt Length of motor and blower pulley

1) Approximate center distance (C1):

The approximate center distance between the two pulleys expressed as;

……………………………………..……… [eq. 11]

120+80
C1= +80=180mm
2
2, Pitch length of v belt (L):

………………………………… [eq. 12]

2
π [120−80]
L= {120+80 } +2*120 + =556.22mm
2 4 [180 ]
The inside length of the of the v belt are obtained by minus from the pitch
length: 36 from type A, 43 from type B, 56 from type C, 79 from type D, 92
from type E.
Inside length of type A v belt is Li = L – 36 = 556.22– 36 = 520.22 mm
According to IS: 2494 – 1974, the nearest standard inside length of v belt type
A (from appendix table A: 2) is 925 mm.
Therefore, the pitch length of the belt,
L1 =925+36=961mm
New center design(c)

L1= (Dp+dp) +2C + = 961 = (120 + 80) + 2c +

961 * 4c = 314 *4c + 8c2 +1,600
C2 -323.5C + 200
C=

Taking positive sign,

C = 315.3mm

2) Peripheral velocity of the belt:

…………………………………………………………………….. [eq. 13]
Peripheral velocity of the belt on the driving pulley (V1)

V1 =
V1 =6.07m/s
Peripheral velocity of the belt on the driven pulley (V2)

V2 =
V2 = 6.07m/s
There is no slip, because V1 = V2.
3) Angle of contact

Figure 4.8: Geometry of V-belt drives

…………………….………………………..[eq. 14]

3.6349 = 176.365 = 3.07 rad

………………………….…………………[eq. 15]
 = 3.266rad

4) Velocity ratio of the drive belt (Vr):

It is the ratio between the velocities of the driver and the driven.

Vr = 120/80 = 1.5

……………………… [eq. 16]

5) Tension force analysis in the belt drive:

Driven pulley
Driving pulley T2 Slack side T2

A B

T1 T1 Tight side

Figure 4.9: power transmitted by a belt

The driving pulley (driver) A pulls the belt from one side and delivers it to the other
side. It is thus obvious that the tension on the former side (i.e. tight side) will be
greater than the latter side (i.e. slack side).

Where, T1 = tension in the tight side of the belt (N)

T2 = tension in the slack side of the belt (N)

 Table 4.12; coefficient of friction between belt and pulley (Source: Gupta and
Khurmi, 2005)

From the above standard table

T 1 0.3 ×2.5
=e
T2

T 1=2.12T 2 Equation 1

Design power (P’)

Equation 2

Substitute equation (1) in to equation (2),

2.12T2 − T2 = 315.79 ⇒ T2 = 282 N

6) Cross sectional area of the belt ( ):

Cross sectional area of the belt ( ) is calculated as;

7) Mass of the belt per meter length (M/l):

8) Work done in the belt (W):

9) Belt service life (hr):

The calculated average service life of the belt at a given speed is:

Figure 4.10: Typical relation between tension and fatigue rate for one V-belt cross
section and one speed

(Source: Gates Rubber Co.; reprinted from Kepner et al., 1978). From the figure total

fatigue rate is 500 (@ peak tension 598N)

 Dimension and strength analysis of pulley:

Figure 4.11 : solid cast iron pulley

From belt selection the smaller pulley diameter is 75mm and the larger pulley diameter
is 225mm.

i) Width of the pulley or face of the pulley (B):

B = 1.25b

Where, b is width of belt = 13 mm

B = 1.25 × 13 = 16.25 mm

ii) The thickness of the pulley

rim (t):

The thickness of the pulley rim (t) varies from for single belt.

120
t= +3
200

=3.6mm
iii) Number of arm

The number of arms may be taken as 4 for pulley diameter from 100 mm to 600 mm
and 6 for diameter from 600mm to 1500 mm.

Note: The pulley is less than 100 mm diameter are made with solid disk instead of
arms. The thickness of the solid web is taken equal to the thickness of the rim
measured at the center of pulley face.

Therefore, the number of arms for larger pulley are 4, because pulley diameter is 120
mm, which is between 120 mm and 600 mm. There is no arms for smaller pulley,
because pulley diameter is 80 mm, which is less than 100 mm.

10) Torque transmitted by the pulley (𝐓𝐩):

Torque transmitted by motor pulley (Tp1) = torque transmitted by motor = 9880 Nmm

Torque transmitted by the blower pulley are calculated as;

T 60× p
p 2=¿ ¿
2 πN

60× 1500
T p 2= =29.64=29640 Nmm
2 × π × 483.33

11) Tangential force of the pulley:

Tangential force transmitted by smaller pulley,

Wt1 = 247 N

Tangential force transmitted by larger pulley,

Wt2 = 494 N

12) Tangential load per arm (𝐖𝐭):

 Wt = 245.8 N

13) Maximum bending moment on the arm at the hub end (𝐌):
Maximum bending moment on the arm at the hub end are calculated as;

2T 2× 29.5
M= M= =14.75 Nm=14750 Nm
n 4

14) Major axis (a1) and minor axis (b1):

The cross section of the arms is usually elliptical with major axis (a1) equal to twice
the minor axis (b1). The cross section of the arm is obtained by considering the arm is
cantilever i.e. fixed at the hub end and carrying a concentrated load at the rim end. The
length of the cantilever is taken equal to the radius of the pulley. It is further assumed
that at any given time, the power is transmitted from the hub to the rim or vice versa,
through only half the total number of arms.

a1 = 2b1

Where, δb is allowable bending stress, δb = 15Mpa for cast iron pulley

M is maximum bending moment on the arm at the hub end, (14750Nmm)

Z is section modulus,

π 2 π 3 3
Z= ×b1 (a1) = × 2 b 1=0.2 b 1
32 32

Substitute those into equation (19);

14750 3
15= 3 b 1 =4916.67mm 3
0.2 b 1

b1 == √
3
4916.7 mm 3 =17 mm
Based on the above equation

calculate major axis

a1 = 2 × 17 = 34 mm

tangential load of the pully >

Tangential load of the arm so the

material is seaf

4.14. Welded Joints

Welding can be defined as a process of joining metallic parts by heating to a suitable
temperature with or without the application of pressure. Welding is an economical and
efficient method for obtaining permanent joint of metallic parts.

There are two distinct applications of welded joints

I. A welded joint can be used as a substitute for a riveted joint; and

II. A welded structure can be used as an alternative method for casting or
forging. Welded joints offer the following advantages compared with riveted
joints
 Cost of welded assembly is less than riveted joint.
 The design welded assemblies can be easily and economically
modified to meet the changing product requirements.
 The strength of the welded joint is high
 The quality and the strength of the welded joint depend up on the
skill of the welder.

We use the process of welding that are used heat alone is fusion welding. This
welding is important to weld the machine molten metal is supplied to the joint. We use
electric arc (electrode) type welding by generating heat in to welded joint.

To design a honey extraction machine parts to be need welded that is used filet joints.
4.14.1. Strength of Fillet Weld
A transverse fillet welded subjected to a tensile force (p) the minimum cross section of
the weld is at the throat. Therefore, the failure due to tensile stress will occur at the
throat section
(tl).

ðt= p/tl

Using the following table

Table 4.13 : permissible stress in different welding

Types of weld and stress Permissible stress Permissible
Static load Riveted load
But welds
Tension 110 55
comp ration 125 55
Shear 70 35
Filet weld 95 35

σt = 95N/mm , the thickness of the weld which is 0.7mm & length 200mm, then to
2

find the
tensile force applied in the welding. σt =p/tl =p= (σt) tl

95N/mm2*0.7mm*200mm

P=1330N

P=0.707hlðt where, h=leg size t=0.707h

1330N=0.707h*200mm*95N/mm2 h=1mm
10. Design of machine element VB Bhandari, second edition [2008]

11. Machine design second edition, [Link] [2010]

12. Richard G. Budynas; J. Keith Nisbett (2008). Shigley’s mechanical engineering design, ninth
edition, Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., New
York, Americas.
13. Text book of machine design KURMI and [Link] (2005)
14. [Link] [Link]/wiki/centrifugal force