CHAPTER FOUR

DESIGN AND ANALYSIS OF MIXER

Material Selection

The selection of a proper material, for engineering purposes, is one of the most difficult
problems for the designer. The best material is one which serves the desired objective at the
minimum cost. The following factors should be considered while selecting materials:

1. Availability of the materials,

2. For the working conditions Suitability of the materials in service, and

3. The cost of the materials.

The important properties, which determine the utility of the material, are physical, chemical and
mechanical properties.(15)

From a sanitary design perspective, food contact surfaces should be smooth, impervious, free of
cracks and crevices, non-porous, non-absorbent, non-contaminating, non-reactive, corrosion
resistant, durable, and cleanable. Further, materials used in food contact surfaces must be non-
toxic, and materials containing heavy metals (e.g., lead, cadmium, hexivalent chromium or
mercury) or other toxic materials must be avoided. Finally, these surfaces should be fabricated,
operated, and maintained in a manner such that these criteria are not compromised. Stainless
steel is generally the most preferred and most commonly used material in the design,
construction and fabrication of food processing equipment and is specified in the 3-A Sanitary
Standards as well as in other commonly used food processing equipment standards throughout
the world.(16)

The general advantages of stainless steel over other materials for food contact are as follows:

 Corrosion resistance (ranging from fair to outstanding);

 High strength, high hardness, high modulus;
 Availability of a wide range of product forms; and
 Relative ease of machining and fabrication; (16)
A wide variety of stainless steel materials are available with widely varying composition, surface
finish, and functional properties. In addition, the functionality of stainless steel is impacted by
surface treatments and coatings. Thus, an awareness of the properties of the various stainless
steels is required by fabricators, as well as by potential users of food equipment.(16) From most
of the stainless steels used in the fabrication of food equipment austenitic AISI 300 series.
Approximately 50% of all stainless steel produced is 304 stainless steel, formulated at 18% Cr
and 8% Ni. So we decide to use 304 stainless steel for our mixer machine design. The chemical
composition of the 304 stainless steel is;

 Carbon 0.08%
 Manganese 2%
 Phosphorous 0.045%
 Sulfur 0.03%
 Silicon 1%
 Chromium 18% to 20%
 Nickel 8% to 10.5%

Mechanics of food waste mixer machine

During the development of this motor operated food waste mixer machine, it was kept in mind
that the equipment should be suitable for schools, hotels, restaurants, governmental and non-
governmental institutions generally for those who need small food waste processing machine.

Food waste mixer

In food processing industries mixing plays a vital role, of all in feed industries mixing of feed
ingredients and premixes becomes the vital issue. In our design we apply horizontal paddle type
mixer in order to mix food leftovers to increase the nutritional similarity of each pellet and to
increase the convection drying rate.
 Figure 4.1 Surface impingement of an array of slot jets.

Lower concave

Lower Concave is the component which provides space for mixing of the wet food waste and is
located beneath the rotating agitator. The whole concave was supported on the axial beams of the
main frame at the top using bolts and nuts.

Figure 4.2 Lower concave of mixer

Concave radius rc: - The concave radius is calculated as follows.

rc= hpaddle + cc Error! No

text of
specified
style in
document..1
Where:

rc= radius of lower concave, mm

hpaddle= paddle height from the central axis of the shaft, mm

cc= concave clearance, 1mm

rc= hpd + cc

rc = 1000mm + 1mm

rc= 1001mm

Power consumption

The total power is the power needed to run all the components of the mixer that need power
supply.

The power required is calculated as follows;

1. Power required to run the unloaded agitator;

2π × Nr × Mh Vt 2 Error! No
P1 = (g + ) text of
60 × 75 r
specified
style in
document..2
Where;

N = Speed of the rotating mixer 29 rpm. It’s shown that agitator speed of 29 rpm has enough
energy to mix the wet food waste.

M= Mass of agitator, kg
r = radius of agitator, 1000mm

Vt2 =peripheral or tangential velocity of the mixing mechanism, m/s

The tangential velocity is;

π
Vt = N × 30 × r Error! No
text of
specified
style in
document..3
π
Vt = 29rpm × × 1m
30

Vt= 3.0368m/s ≈ 3m/s

The mass of the agitator is calculated using the total volume of the material of the agitator and
the density of the material. The material is stainless steel with density which varies based on the
alloying constituents. For AISI 304 the density becomes 8060 kg/m3.(17)

To find the total volume of the material of the agitator mill:

I. Agitator Shaft
We assume the Shaft diameter to be 40 mm diameter and 1500 mm length:

VAs = πr2h Error! No

text of
specified
style in
document..4
VAs = (π × 202 × 1500)mm3

VAs = 1.885 × 10-3m3

II. Paddle Shaft

Diameter of the paddle shaft = 15mm

Length of the paddle shaft = 860mm

 VPS = πr2h Error! No
text of
specified
style in
document..5
VPS = (π × 152 × 860) mm3

VPS= 6.079 × 10-4m3

III. Paddle blade

We assume the paddle blade has rectangular shape which has 141mm length, 100mm width and
5mm thickness:

VPB = L × W × t Error! No
text of
specified
style in
document..6
VPB = 141mm × 100mm × 5mm

VPB = 7.05 × 10-5m3

Total volume of Agitator

Now, Vtotal= the sum of the above calculated values, which is

Vtotal = (1.885 × 10-3m3+ 6.079 × 10-4m3 + 7.05 × 10-5m3)

Vtotal = 2.5634 × 10-3m3

Mass of Agitator

The material is AISI 304 stainless steel with density 8060kg/m3.

Mass of miller, MA = Vtotal × ρsteel Error! No

text of
specified
style in
document..7
(ρsteel= 8060kg/m3)

MA = (2.5634 × 10-3m3) × (8060kg/m3)

 MA = 20.6606kg.

2π × N × r × Ma Vt 2
P1 = (g + )
60 × 75 r

P = 2π29rpm × 0.5 × 20.6606kg (3m/s)2

(9.81 + )
60 × 75 0.5m

P1 = 11.6327W = 0.011633KW

Paddle blade

Agitator shaft

Paddle shaft

Figure 4.3 Agitator and paddle shaft and paddle blade

2. Power required to run the loaded agitator;
To calculate the loaded power required first we should calculate the torque created to mix the
food waste then using the torque we can simply calculate the power. The mixing force of the
concrete was calculated as follows;

W = Mt × 𝑔 Error! No
text of
specified
style in
document..8
Where,

Mt = Total Mass = Mass of food waste + Mass of mixing Agitator

𝑔 = Acceleration due to gravity = 9.81m/sec2

Mass of wet food waste = 70kg

Mass of mixing Agitator = 20.6606kg

Mt = 70kg + 20.6606kg

Mt = 90.6606kg

Then the force of the agitator and the force of the wet food waste becomes the weight due to the
mass of the agitator and the food waste;

W = 90.6606kg × 9.81m/sec2

W = 889.3805N

Then the torque becomes;

T = F×L Error! No
text of
specified
style in
document..9
Where;

F = is the force which is equal with the total weight = 889.3805N

L = is the length of the paddle = 0.5m

T = 889.3805N × 0.5m

T = 444.6902Nm

Then the power required to mix the food waste is the power that turns the shaft and is calculated
as follow;

P = T×V Error! No
text of
specified
style in
document..10
Where,

P = power
T = torque

πDN Error! No
V = velocity, V= 60
text of
specified
style in
document..11

πDN
P= T×
60

π×1m× 29rpm
P = 444.6902Nm ×
60

P2 = 675.2339 W = 0.6752339KW

Total power requirement of the agitator

P = P1 + P2

P = 0.011633KW + 0.6752339KW

P = 0.687KW

Considering transmission and other losses a factor of safety of 1.2 was assumed.

Therefore the design power was P x 1.2

Pfinal = 0.687KW x 1.2

Pfinal = 0.8242KW

From motors specification 1.1 KW motor is labelled as a single phase 1.5 horse powers. Thus a
1.5 HP motor is selected the rpm of the motor is 1450rpm.(18)

For this mixer machine it is not feasible to use pulley for rotation reduction and power
transmission. So it is better if we use speed reduction gearbox. The reduction ratio will become
the division of the mixer rpm and the electric motor rpm;
 mixer rpm Error! No
Reduction ratio(Rr) =
electric motor rpm text of
specified
style in
document..12
29
= = 0.02
1450

Shaft design

A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft. In order to transfer the power from one shaft to another, the various members
such as pulleys, gears etc., are mounted on it. These members along with the forces exerted upon
them causes the shaft to bending. In other words, we may say that a shaft is used for the
transmission of torque and bending moment.(15) The material for the shafts is AISI 304 stainless
steel, as it has the following properties which are necessary for a shaft material to possess.

 High strength.
 Good machinability.
 Low notch sensitivity factor.
 Good heat treatment properties.
 High wear resistant properties.(15)
Mixer shaft: this shaft is subjected to combined twisting and bending moments, i.e. bending
moment due to the distributed weight of the agitator, and the weight of the wet food waste, and
twisting moment due to the transmitted power. Thus the determination of the hammer milling
shaft diameter is obtained from the ASME code relation.
 Figure 4.4 mixer shaft

Figure 4.5 free body diagram of mixer shaft

Perform free body diagram analysis to get reaction forces
Ray = Rby =22.7822 lbf
Raz = Rbz =77.188 lbf
T= 154.3763 x 19.685
=3038.8974 lbf.in
My = 680.87 in lbf.
Mz = 2306.86 in lbf
 Figure 4.6 shear-moment diagrams for two planes of mixer shaft

Combine orthogonal planes as vectors to get total moments, at C,

 √680.87 + 2306.86 = 2405.24 lbf · in
Start with Point B, where the bending moment is high, there is a stress concentration at the
shoulder, and the torque is present.
At B, Ma = 7.622 lbf in, Tm = 3038.8974 lbf in, Mm = Ta = 0
Safety factor (n)=1.5
Assume generous fillet radius for bearing at fillet.
From appendix Table A-18, estimate Kt = 1.7, Kts = 1.5. For quick, conservative first pass,
assume K f = Kt, K f s = Kts.
Choose steles steel, 304, with Sut = 82.4 kpsi (appendix Table -18). For Se,
ka = aSut b = 2.7(82.4)-0.265 = 0.83877(appendix Table A-11)
Guess kb = 0.9. Check later when d is known.
kc = kd = ke = 1
Se = (0.83877)(0.9)(0.5)(82.4) = 31.1 kpsi

For first estimate of the small diameter at the shoulder at point B, use the
DE-Goodman criterion of Eq. (7–8). This criterion is good for the initial design,
since it is simple and conservative. With Mm = Ta = 0, Eq. (7–8) reduces to

1 Error! No
1 3
16n 2(KfMa) [3(KfsTm)2 ]2 text of
d={ ( + )} specified
π Se Sut
style in
document..13

1
1 3
16(1.5) 2(1.7)(7.62)) [3((1.5)(3038.89))2 ]2
d={ ( + )} = 0.9038 in
π 31100 82400

All estimates have probably been conservative, so select the next standard size below 0.9038 in.
and check, d=1.0 in
A typical D/d ratio for support at a shoulder is D/d= 1.2, thus, D= 1.2(1.0) = 1.2 in. Increase to D
=1.2 in. A nominal 1.2 in. cold-drawn shaft diameter can be used. Check if estimates were
acceptable
D/d = 1.2/1.0 = 1.2
Assume fillet radius r = d/10 ∼ = 0.1. in. r/d = 0.1
Kt = 1.62 (Fig. A–15–9), q = 0.80 (appendix Table A-12)
K f = 1 + 0.80(1.62 - 1) = 1.496
Kts = 1.30 (Fig. A–15–8), qs = 0.82 (appendix Table A-13)
K f s = 1 + 0.82(1.30 - 1) = 1.246
ka = 0.883 (no change)
d −0.107 1.0 −0.107
b=( ) =( ) = 0.879
0.3 0.3

Se = (0.883)(0.879)(0.5)(82.4) = 28.11 kpsi

32KfMa Error! No
σa = text of
πd3
specified
style in
document..14

32(1.496)(7.622)
= = 116.145 psi
π(1.0)3

1 Error! No
2
(16KfsTm) 2 text of
σm = [3 ( ) ]
πd3 specified
style in
document..15

2
(16(1.246)(3038.89)) 1/2
= [3 ( ) ] = 33776.6257psi
π(1.0)3

Using Goodman criterion

 1 σa σm Error! No
= +
nf Se Sut text of
specified
style in
document..16
116.145 33776.6
= + = 0.414
28110 82400
nf = 2.415

Also, check this diameter at the end of the shaft at keyway. From moment diagram, estimate M
at end of keyway to be equal to M = 7.662 lbf-in
Assume the radius at the bottom of the keyway will be the standard r/d= 0.02,
r =0.02d = 0.02 (1.0) = 0.02in
Kt = 2.30 (Table 7–1), q= 0.65 (Fig. 6–20)
K f = 1 + 0.65(2.30 - 1) = 2.30
Kts = 2.95 (Table 7–1), qs = 0.68 (Fig. 6–21)
Kf s = 1 + 0.68(2.95 - 1) = 2.326
32KfMa 32(2.30)(7.622)
σa = = = 178.574psi
πd3 π(1.0)3

2 2
(16KfsTm) 1/2 (16(2.95)(3038.89)) 1/2
σa = [3 ( ) ] = [3 ( ) ] = 52273.34psi
πd3 π(1.0)3

1 σa σm 178.574 52273.34
= + = + = 0.64
nf Se Sut 28110 82400

nf = 1.56

Then D = 1.2 in or 30 mm And d = 1.0 in or 25 mm

Key and keyway selection

Selecting rectangular key and determine dimension key and keyway from shaft diameter and
selected standard table.

Key size, W=1/4 inch or 6.5 mm

 H= 3/16inch or 5.0 mm
Key material = UNS G10200 cold –drawn steel ( Sy=65 kpsi)( appendix Table A-12)
Keyway depth = 3/32inch or 2.5 mm
To determine length of key
The force F at the surface of the shaft is

T Error! No
F=
r text of
specified
style in
document..17
3038.89
= = 6077.78 lbf
0.5

By the distortion-energy theory, the shear strength is

Sxy = 0.577Sy Error! No

text of
specified
style in
document..18
= (. 0577)(65) = 37.5kpsi

Failure by shear across the area ab will create a stress of τ = F/tl. Substituting the
strength divided by the factor of safety for τ gives

Ssy F Error! No
=
n wl text of
specified
style in
document..19
37500 6077.78
= =
1.5 0.25l

l = 0.972 in or 25 mm
 Bearing selection

Rolling contact bearings, in which the contact between the bearing surfaces is rolling, are used
here to support the agitator shaft. Advantages of a rolling contact bearing are that
these bearings have a low starting friction, require no lubrication while in service, have
small overall dimensions, are reliable during service, are easy to mount and erect and are
clean.

Mixer bearing

The shaft speed is taken to be 100 rpm for safety, the bearings are to have 99% reliability
corresponding to a life of 10 years, and the bearing is subjected to an equivalent radial load
of.

Figure 4.7 Free body diagram of mixer shaft

Where,
WA = weight of the agitator
WA = 202.6804N

Consider life adjustment factors for operating condition and material as 0.9 and 0.85
respectively.

RA = R𝐵 = 101.3402N

Since the average life of the bearing is 8 years at 17 hours per day and 275 day a year,
therefore life of the bearing in hours is,
 LH= 8 × 275 × 17 = 37,400 hours

And life of the bearing in revolution is,

L = 60 N × 𝐿𝐻 Error! No
text of
specified
style in
document..20
= 60 × 100 × 37,400 = 224.4 × 106 rev

L 1⁄ Error! No
C = W( ) K
106 text of
specified
style in
document..21
where k = 3 for ball bearings

224.4 × 106 rev 1⁄

C = 101.3402N( ) 3
106

C = 615.8232 = 0.6158232KN

From Table (R.S.Khurmi, 2005), let us select the bearing No. 200 which has the following basic
capacities;(15)

C0= 2.24 KN = 2,240 N and C = 4 KN = 4,000 N(appendix Table A-6)

Dimensions, Db= 10mm, Do=30mm W= 9mm where, Db= bore diameter, Do=outer diameter,
bearing width;

But from the agitator shaft diameter calculation we find out that the diameter should has to be
minimum of 25 mm therefore we are forced to select bearing with bore diameter that can fit the
shaft. So the bearing becomes light bearing No. 205 which have the following dimensions;

Db=25mm, Do=47mm W= 14mm

 CHAPTER FIVE
DESIGN AND ANALYSIS OF HAMMER MILL

Materials Selection and Mechanics of the hammer mill components

Materials Selection

The selection of a proper material, for engineering purposes, is one of the most difficult
problems for the designer. The best material is one which serves the desired objective at the
minimum cost. The following factors should be considered while selecting materials:

1. Availability of the materials,

2. For the working conditions Suitability of the materials in service, and

3. The cost of the materials.

The important properties, which determine the utility of the material, are physical, chemical and
mechanical properties.(15)

Appropriate material selection plays an important and crucial role in an effective manufacturing
system for superior production quality, cost optimization and improved productivity. Systematic
selection of materials for a given engineering application begins with the study of different
material selection properties and their related costs with specific application capabilities.
Wrong selection of materials often leads to huge cost contribution and eventually drives an
organization towards early product failure. So, the designers need to identify and select proper
materials with specific functionalities in order to get the desired output with minimum possible
cost involvement.

While choosing the proper material, there is not always a single definite criterion and the
designers need to take into account a large number of materials selection attributes. The main
requirement may be the material strength for designing and manufacturing of a particular
mechanical component, but depending on the working environment and functional performance,
several other factors may have to be considered simultaneously.

Materials of various components of the hammer mill were selected based on strength,
availability, durability and costs. Mild steel (MS) metal sheet of different gauges, were selected
for the construction of components of the hammer mill which need sheet metal as a stock while
Mild steel RHS, CHS and round and flat bars for the other components of the hammer mill like
the main frame and shafts. The selection was based on the resistance to all possible stress which
may be subjected to during operation. Mild steel is an alloy made by mixing iron and non-metals.
Sometimes a pure metal cannot fulfill all the properties needed for manufacturing product. So
additives are included in the pure metal to obtain some specific properties necessary for the
production. Mild steel is made by adding carbon and other elements in the iron. These elements
improve the hardness, ductility and tensile strength of the metal. The chemical composition of
mild steel used here is;

 carbon 0.16 to 0.18 %

 Manganese 0.70 to 0.90 %
 Silicon maximum 0.40%
 Sulfur maximum 0.04%
 Phosphorous maximum 0.04%
AISI 1018 mild (low carbon steel) has excellent weldability and produces a uniform and harder
case and it is considered as the best steel for machine parts. This steel offers a good balance of
toughness, strength and ductility. Provided with higher mechanical properties, this steel also
includes improved machining characteristics and Brinell hardness.
Mild steel is especially desirable for construction due to its weldability and machinability. It can
instantly be welded by all the conventional welding both to itself and to other types of steel. Low
carbon welding electrodes are to be used in the welding procedure, and post-heating and pre-
heating are not necessary. It is used to improve drilling, machining, threading and punching
processes. Because of its high strength and malleability, it is quite soft, that is it can be easily
machined compared to harder steels.

The metal sheets of the hammer mill component materials were selected by considering failure
due to shearing and crushing and will be justified at each component’s design.

Mechanics of hammer mill components

During the development of this motor operated food waste miller, it was kept in mind that the
equipment should be suitable for schools, hotels, restaurants, governmental and non-
governmental institutions generally for those who need small food waste processing machine.

The methodology and procedure adopted in development of different components of the hammer
mill are presented in this section under following subsections.

Main frame

The material for the main frame of the hammer mill is selected to be mild steel (considering
properties discussed on the above section).

Upper concave

This component is a cover above the hammer mill. Mild steel sheet metal 1.15 mm thickness is
selected for the construction of feed hopper and top hammer mill cover considering the scrap
impact and scratching effects during hammer milling. As mild steel is resistant to both
indentation and impact by the dry food waste and it is also easy for fabrication.

In order to enhance the easy flow of the dry food waste and create more abrasion, the top drum
cover was made cylindrical in shape using MS sheet of 482 mm length, 250 mm diameter and
1.15 mm thickness.
Hammer mill

The hammer mill of the machine consisted of a flat peg hammer for hammer milling. The
circular disk used to hold the hammers and the pivot shafts. The pivot shafts are used to connect
the disks and the hammers. A hole on the hammers is drilled at the bottom of each hammer,
using twist drill, to enable it to be put into position on the pivot shaft.

Figure 5.1 shear-moment diagrams for two planes of mixer shaft

Hammer mill specification

The hammer mill is made of mild steel with 5 mm thickness and 40 mm width and welded to the
disks on the shaft to give the required shape. The feed rate (Q) is taken as 150 kg/hr (0.0416 kg/
s) to 400 kg/hr (0.1111kg/s) for feeding food waste continuously to the machine. Permissible
feed rate (Q0) is taken as 0.0316kg/s per meter length of the cylinder.

𝑄 = 𝑄o × 𝐿 × 𝑀 Error! No
text of
specified
style in
document..22
Q
L=
QoM

0.1111
L=
0.0316 × 7

L=0.502m ≈ 500 mm
Lower concave

Lower Concave is the component which provides space for milling of the dry food waste and is
located beneath the rotating hammer mill. The whole concave was supported on the axial beams
of the main frame at the top using bolts and nuts.

Concave radius rc: - The concave radius is calculated as follows.

rc= rd + hpd + cc Error! No

text of
specified
style in
document..23
Where:

rc= radius of lower concave, mm

rd= radius of rotating disk, mm

hpd= peg height above the disk, mm

cc= concave clearance, 10mm to 15 mm it is shown that a concave clearance of 10 to 20mm

rc= rd + hpd + cc

rc = 50mm + 80mm + 10mm

rc= 140mm

Figure 5.2 hammer mill casing, and sieve

 Power consumption

The total power is the power needed to run all the components of the hammer mill that need
power supply.

The power required is calculated as follows;

1. Power required to run the unloaded hammer mill

2π × Nr × Mh Vt 2 Error! No
P1 = (g + ) text of
60 × 75 r
specified
style in
document..24
Where;

N = speed of the rotating hammer mill, 500rpm. It’s shown that a drum speed of 500 rpm has
enough energy to mill the dry food waste in to the specified size.

M= Mass of hammer mill, kg

r = radius of hammer mill, 130mm

Vt2 =peripheral or tangential velocity of the milling mechanism, m/s

The tangential velocity is;

π
Vt = N × 30 × r Error! No
text of
specified
style in
document..25
π
Vt = 500rpm × 30 × 0.13m

Vt=6.81m/s

The mass of the hammer mill is calculated using the total volume of the material of the hammer
mill and the density of the material. The material is mild steel with density which varies based on
the alloying constituents but usually ranges between 7,750 and 8,050 kg/m3. The 8050kg/m3 is
selected here for safety purpose.
To find the total volume of the material of the hammer mill:

IV. Hammer
L=80mm

t= 5mm

w=40mm

Vh=l × w × t × n Error! No
text of
specified
style in
document..26
= 80 × 40 × 5 × 100

= 1,600,000mm3 = 1.6 × 10-3m3

V. disk
Let us assume the shaft diameter will be 30mm

Vd = (π/4× (Ø100mm)2 × 3mm × 50 pcs) - (π/4× (Ø14mm)2 × 3mm × 200pcs.) - (π/4×

(Ø30mm)2 × 3mm × 50pcs.)

Vd = 979,705.669 mm3 = 9.7971× 10-4m3

VI. pivot shaft

Vps = πr2h Error! No
text of
specified
style in
document..27
Vps = (π72 × 500 × 4pcs) mm3

Vps = 307,876 mm3= 3.07876 × 10-4m3

VII. Shaft
Vps = πr2h Error! No
text of
 specified
style in
document..28
Vps = (π152 × 500) mm3

Vps = 353,429.17 mm3=3.5343 × 10-4m3

Total volume of hammer mill

Now, Vtotal= the sum of the above calculated values, which is

Vtotal = (1.6 × 10-3m3 + 9.7971× 10-4m3 + 3.07876 × 10-4m3 + 3.5343 × 10-4m3)

Vtotal = 3.2410 × 10-3m3

Mass of hammer mill

The material is mild steel with density which varies based on the alloying constituents but
usually ranges between 7,750 and 8,050 kg/m3. The 8050kg/m3 is selected here for safety
purpose.

Mass of miller, Mh = Vtotal × ρsteel Error! No

text of
specified
style in
document..29
(ρsteel= 8050kg/m3)

Mh = (3.2410 × 10-3m3) × (8050kg/m3)

Mh = 26.09 kg.

2π × Nr × Mh Vt 2
P1 = (g + )
60 × 75 r

P = 2π500rpm × 0.130 × 26.09 kg (6.81m/s)2

(9.81 + )
60 × 75 0.130m

P1 = 867.9348W = 0.8679KW

2. Power requirement due to air resistance

 P2 = Kf × Fr × vt2 Error! No
text of
specified
style in
document..30
Kf = constant which is equal to 0.06

Fr = feed rate, 400 kg/hr = 0.1111kg/s. (if we consider the smallest feeding rate value)

P2 = 0.06 × 0.1111kg/s × (6.81m/s)2

P2 =0.309W

3. Power required to hammer mill the dry food waste

It was calculated by the following formula.

3 3 Error! No
3 Vs2 fr2 text of
P3 = k ( )
2 e ρω2 L c specified
style in
document..31

Where: Ke = A constant (scrap size characteristics).

Poultry feed has the same grain size characteristics with that of sorghum. The current industry
practice of using highly processed, pelleted diets masks the influence of particle size, but some
reports suggest that the effects of feed particle size on performance may be maintained even after
pelleting. There appears to be a general consensus that particle sizes of broiler diets based on
maize or sorghum, optimum particle size should be between 600 and 900 µm.(19)

It is 1.42 for millet and 0.26 for sorghum. We take 0.26 because we prefer this feed for meat
poultry farm. For meat poultry farm the grain size characteristics has the same grain size
characteristics with that of sorghum.

Lc = concave length (500 mm)

Vs = Speed of the grain dry food waste which is approximately equal to the peripheral velocity
of the hammer milling mechanism (6.81m/s).
fr = feed rate 400 kg/hr = 0.1111kg/s

ρw = Bulk density (Wet basis)

The average particle density and bulk density of pellet chicken feed were about 363 kg/m3 and
726 kg/m3.(20)

Dry food waste ρw =726 kg/m3 at 10% moisture content

3 3
3 6.81m/s2 0.1111 kg/s2
P3 = 0.26 ( )
2 (726 kg/m3 )2 0.5

P3= 9.7389 × 10-7W

Total power requirement of the hammer mill

P = P1 + P2 + P3

P = 867.9348W + 0.309W + 9.7389 × 10-7W

P = 868.2438 W = 0.8682438 KW

Considering transmission and other losses a factor of safety of 1.2 was assumed.

Therefore the design power was P x 1.2

Pfinal = 0.8682438 KW x 1.2

Pfinal = 1.0419 KW

From motors specification 1.1 KW motor is labelled as a single phase 1.5 horse powers. Thus a
1.5 HP motor is selected the rpm of the motor is 1450rpm. (18)

Diameter of pulleys

Electric motor pulleys

The pulleys’ material for electric motor is aluminium (6063 aluminium alloy or AA 6063),
which is easy for machining and since the load on the pulley is not that much intense this
material is selected for the motor pulley. AA 6063 is an aluminium alloy, with magnesium and
silicon as the alloying elements. The standard controlling its composition is maintained by the
Aluminium Association. It has generally good mechanical properties and is heat treatable and
weldable. AA 6063 has a tensile strength of 130 MPa (19,000 psi), and no specified maximum
yield strength. The material has elongation (stretch before ultimate failure) of 18%.

The alloy composition of AA 6063 is:

 Silicon minimum 0.2%, maximum 0.6% by weight

 Iron no minimum, maximum 0.35%
 Copper no minimum, maximum 0.10%
 Manganese no minimum, maximum 0.10%
 Magnesium minimum 0.45%, maximum 0.9%
 Chromium no minimum, maximum 0.10%
 Zinc no minimum, maximum 0.10%
 Titanium no minimum, maximum 0.10%
 Other elements no more than 0.05% each, 0.15% total
 Remainder Aluminium (21)

Figure 5.3 Electric motor pulleys

Hammer mill pulley

For the hammer mill pulley grey cast iron is selected. The hammer mill pulley is also needs to
serve as a fly wheel during hammer milling of the dry food waste. Thus to have enough weight
to serve as a fly wheel the material of the pulley should be grey cast iron. The chemical
compositions of this material are:
  Carbon = 3 to 3.5%;
 Silicon = 1 to 2.75%;
 Manganese= 0.40 to 1.0%;
 Phosphorous = 0.15 to 1% ;
 Sulphur = 0.02to 0.15% ;
 And the remaining is iron.(22)
And due to the functional requirement of the design the following properties should be selected
accordingly;

 It should possess High resistance to wear

 It should possess High fluidity at casting temperature
 It should possess Excellent bearing & damping properties
 It should possess Excellent machinability and it is available in the market
 It should possess Excellent frictional characteristics
Material properties of mill pulley

Table 5.1 material property of mill pulley

s/n Material type strength damping fluidity cast ability Rank

1 Steel High low low high 2
2 aluminum low low high high 3
3 Gray cast iron high high high high 1
4 copper low low low high 4
Motor pulley is taken as a reference and it is taken to be 100 mm diameter at the periphery.
Because from the table below for 500 rpm and 1.1 KW electric motor is it is recommended to
take 90 mm as a minimum pulley diameter so we take 100 mm diameter for the motor pulley.
The relationship between the motor and the hammer mill pulleys (their speeds and diameters) is
from Appendix Table A-20 ; (23)

N1D1 = N2D2

N1=speed of motor pulley

D1=diameter of motor pulley

N2=speed of hammer mill pulley

D2 =diameter of hammer mill pulley

The speed of the motor is 1450 rpm and the speed of the hammer mill for optimum milling is
500rpm.

Thus;

1450 rpm × 100mm = 500rpm × D2

D2 = 290mm

Belt selection

Reason for choosing V-belts

 The V-belt drive gives compactness due to the small distance between centers of pulleys.
 The drive is positive, because the slip between the belt and the pulley groove is
negligible.
 Since the V-belts are made endless and there is no joint trouble, therefore the drive is
smooth.
 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.
 The high velocity ratio (maximum 10) may be obtained.
 The wedging action of the belt in the groove gives high value of limiting ratio of
tensions. Therefore the power transmitted by V-belts is more than flat belts for the same
coefficient of friction, arc of contact and allowable tension in the belts.
 The V-belt may be operated in either direction, with tight side of the belt at the top or
bottom. The center line may be horizontal, vertical or inclined.(15)
Therefore the drive is smooth v-belts can be used for smaller center distance drives without
idlers, for speed ratios as high as 10:1 and for belt speeds to 15ft/min.

The belts are made of fabric and cords molded in rubber and covered with fabric and rubber. And
let us assume the density of this belt is 1000 kg / m3, coefficient of friction, µ 0.25 and the
allowable stress, σall, is 1.7 MPa.

We can also select the belt type depend on the power and the motor rpm so from the below
selection chart, for P = 1.1 KW and N1 = 1450 rpm it is appropriate to choose section A type V-
belt.(24)

(24)

Figure 5.4 Belt selection specification

The peripheral velocity of the belt on the motor pulley is:

Vb1 = N1 × π/60 × D1 m/s Error! No

text of
specified
style in
document..32
Vb1 = 1450 rpm × π/60 × 0.100m

Vb1 = 7.59m/s

Figure Electric motor and pump pulley center to center distance

The drive is an open belt drive, and for open belt drive; r2

O2M
sinα =
O1O2

r2−r1 D2−D1
sinα = =
x 2X

0.29 − 0.1
sinα =
2 × 0.5

sinα = 0.19
 ∴ α = 10.953˚

And angle of lap on the smaller pulley (i.e. pulley on the motor shaft),

θ = 180° – 2α

θ = 180° – 2 × 10.953˚

θ = 158.09˚

π
θ = 158.09˚ × rad
180

θ = 2.759 rad

From the above ISO 1813 we can define the groove angle is 400 therefore 2β = 400 then β = 200.

The mass of the belt per meter of length;

We can find from the above table the mass of A type V-belt mass per meter length becomes
100gm/m=0.1kg/m or using the area of A type V-belt we can calculate the mass per unit meter of
the belt.

Figure 5.6 A- type V- belt dimensions

The dimensions are in mm.

m = cross-sectional area × length × density

Ac= 0.013m × 0.008m = 1.04 × 10-4m2

m = 1.04 × 10-4m2× 1m × 1000kg/m3

m = 0.104kg/m ≈ 0.1kg/m
Centrifugal tension,

TC = m × V22 Error! No
text of
specified
style in
document..33
TC = 0.1 kg/m × (7.59m/s)2

TC = 0.759 kgm/s2= 0.759 N

And the maximum allowable tension in the belt,

S = allowable stress × cross sectional area

S = 1.7 N/mm2 × 100 mm2

S = 170 N

Therefore, tension in the tight side of the belt, S1

S1 = S − TC Error! No
text of
specified
style in
document..34
S1= 170 N − 0.759 N

S1 = 169.241 N

Tension in the slack side of the belt, S2 will be calculated as follows;(15)

S1 Error! No
2.3log = μθcosecβ
S2 text of
specified
style in
document..35
169.241 N
2.3log = 0.25 × 2.759 rad × csc20
S2

169.241 N
2.3log = 2.02
S2
 169.241 N S1
log = 0.8768 Or = 7.53 … (Taking antilog of 0.8768)
S2 S2

169.241 N
= 7.53
S2

S2 = 22.4756 N

Number of V-belts:

We know that the power transmitted per belt, Pb

Pb = (S1 − S2) Vb1

Pb = (169.241 N − 22.4756 N) 7.59m/s

Pb = 1113.9494 W = 1.113949 KW

∴ Number of V-belts;

Total power transmited Error! No

Nb = text of
Power transmitted per belt
specified
style in
document..36
1.0419 KW
Nb =
1.113949 KW

Nb = 0.9353

∴ One V-belt of the above specifications is required to transmit the given power.

The length of the belt was calculated based on the diameters of the driver and driven pulleys and
center to center distance between the pulleys. The formula used for calculating the length of the
belt is,

π (D2−D1)2 Error! No
Lp = 2C + 2 (D1+D2) + 4C text of
specified
style in
document..37
Let us also assume the center to center distance between the motor and hammer mill pulleys, x,
is 500 mm.

π (0.29−0.1)2
Lp = 2 × 0.5 + 2 (0.1+0.29) + 4×0.5

Lp = 1.631m = 1631mm

But we can’t find 1631mm length manufactured V-belt so from Fenner Classic PB V-Belt
standard belts we take A 1640mm V-Belt.(23)

So the center to center distance will be modified and it becomes 504.75mm in order to use
1640mm A type V-Belt.

Shaft design

A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft. In order to transfer the power from one shaft to another, the various members
such as pulleys, gears etc., are mounted on it. These members along with the forces exerted upon
them causes the shaft to bending. In other words, we may say that a shaft is used for the
transmission of torque and bending moment.(15) The material for the shafts is carbon steel of
grade 40 C 12, as it has the following properties which are necessary for a shaft material to
possess.

 High strength.
 Good machinability.
 Low notch sensitivity factor.
 Good heat treatment properties.
 High wear resistant properties.(15)
Material used for Shafts:

The material used for shafts should have the following properties:

1. It should have high strength

2. It should have good machinability.

3. It should have low notch sensitivity.

4. It should have good heat treatment property.

5. It should have high wear resistant property.

Depending on the requirement, select plain carbon steel 1040 (,Sut = 92 kpsi)

Hammer milling shaft: this shaft is subjected to combined twisting and bending moments, i.e.
bending moment due to the distributed weight of the hammers, the weight of the hammer mill
pulley and the belt tension; and twisting moment due to the transmitted power. Thus the
determination of the hammer milling shaft diameter is obtained from the ASME code
relation.(15)

Figure 5.7 Electric motor pulleys

Figure 5.8 free diagram of hummer mill shaft

Where Wh= weight of the hammer mill per unit meter, N/m

Mh = 26.09 kg

W h × L = Mh × g
L= length of the hammer mill shaft in between the two bearings, 0.500m

Wh × 0.5m = 26.09 kg × 9.81m/s2

Wh × 0.5m = 255.9429 N

Wh = 511.8858 N/m

S = 169.241 N

To calculate the weight of the pulley first we should find the volume of the pulley then using the
density of cast iron we can calculate mass of the pulley then we can easily calculate the weight of
the pulley.

Wp = Mass of pulley × Gravity

Mass of pulley = Volume of the pulley × density of pulley

Mp = Vp × ρp Error! No
text of
specified
style in
document..38
Vp = Vw - (Vg + Vh + Vb) Error! No
text of
specified
style in
document..39
Where Vw: Volume of the wheel

Vg: Volume of the grove

Vh: Volume of the hub

Vb: Volume of the bore

Vw = πr 2 t Error! No
text of
specified
style in
document..40
Vw = π(145mm)2 × 18mm
 Vw = 1.1889 × 10-3m3

Vg = π[(145mm)2 −(137mm)2 ] × 13mm

Vg = 9.2136 × 10-5 m3

Vh = π(125mm)2 × 5mm

Vh= 2.4544 × 10-4 m3

Vb = π(15mm)2 × 18mm

Vb= 1.2723 × 10-5 m3

Total volume of the pulley:

Vp = Vw - (Vg + Vh + Vb)

Vp = 1.1889 × 10-3m3 - (9.2136 × 10-5 m3 + 2.4544 × 10-4 m3 + 1.2723 × 10-5 m3)

Vp = 8.386 × 10-4m3

Mass of the pulley:

Mp = Vp × ρp Error! No
text of
specified
style in
document..41
Mp = 8.386 × 10-4m3 × 7200 kg/m3

Mp = 6.0379 kg

Weight of the pulley:

Wp = Mass of pulley × Gravity

Wp = 6.0379 kg × 9.81 m/s2

Wp = 59.2321 N

Perform free body diagram analysis to get reaction forces

Ra = 92.05 N or 20.69 lbf
Rb = 119.53 N or 26.864 lbf

Figure 5.9 shear-moment diagrams for two planes of hummer mill shaft

60 × P Error! No
T=
2πN text of
specified
style in
document..42
60 × 1041.9
= = 19.898 Nm or 176.12 in lbf
2π(500)

M =30.718 Nm = 271.877 in lbf

Start with Point B, where the bending moment is high, there is a stress concentration at the
shoulder, and the torque is present.
At I, Ma = 2.74164 Nm or 24.265 in lbf , Tm = 176.12 in lbf, Mm = Ta = 0
Safety factor (n)=1.5
Assume generous fillet radius for bearing at fillet.
From Appendix Table A-18, estimate Kt = 1.7, Kts = 1.5. For quick, conservative first pass,
assume K f = Kt, K f s = Kts.
Choose Plain Carbon Steels 1040, with Sut = 92 kpsi(appendix Table A-9). For Se,
ka = aSut b = 2.7(90)-0.265 = 0.819 (appendix Table A-14)
Guess kb = 0.9. Check later when d is known.
kc = kd = ke = 1
Se = (0.819)(0.9)(0.5)(90) = 33.18 kpsi
For first estimate of the small diameter at the shoulder at point B, use the
DE-Goodman criterion of Eq. (6.22). This criterion is good for the initial design,
since it is simple and conservative. With Mm = Ta = 0,

1 Error! No
1 3
16n 2(KfMa) [3(KfsTm)2 ]2 text of
d={ ( + )} specified
π Se Sut
style in
document..43
1
1 3
16(2) 2(1.7)(2.74)) [3((1.5)(176.12))2 ]2
d={ ( + )} = 0.379in
π 33180 90000

All estimates have probably been conservative, so select the next highest standard size above
0.34478 in because there have keyway on the smallest shaft and check, d=0.4 in A typical D/d
ratio for support at a shoulder is D/d= 1.2, thus, D= 1.2(0.40) = 0.48 in. Increase to D =0.50 in. A
nominal 0.50 in. cold-drawn shaft diameter can be used. Check if estimates were acceptable
D/d = 0.50/0.40 = 1.25
Assume fillet radius r = d/10 ∼ = 0.1. in. r/d = 0.1
Kt = 1.75 (appendix Table A-17), q = 0.82 (appendix Table A-12)
K f = 1 + 0.82(1.75 - 1) = 1.615
Kts = 1.35 (appendix Table A-16), qs = 0.84 (appendix Table A-13)
Kf s = 1 + 0.84(1.35 - 1) = 1.294
ka = 0.883 (no change)
d −0.107 0.4 −0.107
kb = ( ) =( ) = 0.969
0.3 0.3

Se = (0.883)(0.969)(0.5)(90) = 38.53 kpsi

32KfMa 32(1.615)(2.74)
σa = = = 704.28psi
πd3 π(0.4)3

1 Error! No
2 2
(16KfsTm) text of
σm = [3 ( ) ]
πd3 specified
style in
document..44

2
(16(1.294)(176.12)) 1/2
= [3 ( ) ] = 31411.86 psi
π(0.40)3

Using Goodman criterion

1 σa σm Error! No
= + text of
nf Se Sut
specified
style in
document..45
704.28 31411.86
= + = 0.3672
38530 90000

nf = 2.72

Note that we could have used Eq. (7–7) directly. Check yielding.
Sy Sy Error! No
ny = >
σmax σa + σm text of
 specified
style in
document..46

53000
= = 1.65
704.28 + 31411.86

Also, check this diameter at the end of the shaft at keyway. From moment diagram, estimate M
at end of keyway to be equal to M = 2.74 lbf-in
Assume the radius at the bottom of the keyway will be the standard r/d= 0.02,
r =0.02d = 0.02 (0.40) = 0.008
Kt = 2.6 (appendix Table A-11), q= 0.50 (appendix Table A-12)
Kf = 1 + 0.50(2.6 - 1) = 1.80
Kts = 2.5 (Table 7–1), qs = 0.55 (appendix Table A-13)
Kf s = 1 + 0.55(2.5 - 1) = 1.55
32KfMa Error! No
σa = text of
πd3
specified
style in
document..47
32(1.80)(2.74)
= = 784.95 psi
π(0.40)3

1 Error! No
2 2
(16KfsTm) text of
σa = [3 ( ) ]
πd3 specified
style in
document..48
2
(16(1.55)(176.12)) 1/2
= [3 ( ) ] = 37626.267psi
π(0.4)3

1 σa σm Error! No
= +
nf Se Sut text of
specified
style in
document..49
 784.95 37626.267
= + = 0.3995
38530 90000
nf = 2.28

Then D = 0.50 in or 13.0 mm And d = 0.40 in or 11.0 mm

With the diameters specified for the critical locations, fill in trial values for the rest of the
diameters, taking into account typical shoulder heights for bearing and gear support.

D1=0.40 in or 10.0 mm
D2= D4 = 0.5 in or 12.0 mm
D3 = 0.6 in or 15.0 mm

1.1 Key and keyway selection

Selecting square key and determine dimension key and keyway from shaft diameter and selected
standard table.

Key size, W=3/32 inch or 2.5 mm

H= 3/32 inch or 2.5 mm
Key material = UNS G10200 cold –drawn steel ( Sy=65 kpsi)
Keyway depth = 3/64 inch or 1.25 mm
To determine length of key
the force F at the surface of the shaft is
T Error! No
F=
r text of
specified
style in
document..50
176.12
= = 880.6 lbf
0.20
By the distortion-energy theory, the shear strength is

Sxy = 0.577Sy = (. 0577)(65) = 37.5kpsi

Failure by shear across the area ab will create a stress of τ = F/tl. Substituting the
strength divided by the factor of safety for τ gives

Ssy F Error! No
=
n wl text of
specified
style in
document..51
37500 880.6
= =
2.0 (3/32)l

l = 0.50 in or 13.0 mm

Bearing selection

Rolling contact bearings, in which the contact between the bearing surfaces is rolling, are
used here to support the hammer mill shaft. Advantages of a rolling contact bearing are
these bearings have a low starting friction, require no lubrication while in service, have
small overall dimensions, are reliable during service, are easy to mount and erect and are
clean.

Hammer mill bearing

The shaft speed is tak20=en to be 800 rpm for safety, the bearings are to have 99% reliability
corresponding to a life of 10 years, and the bearing is subjected to an equivalent radial load
of.

Figure 5.10 Free boy diagram of hummer mill shaft

Where,
Wp + S = weight of the pulley and the belt tension
(Wp + S) = 59.2321 N + 169.241 N = 228.4731 N

Wh= weight of the agitator

Wh = 255.9429 N

The reaction forces are;

R𝐵 = -114.2631 N (𝑑𝑜𝑤𝑛𝑤𝑎𝑟𝑑𝑠)

RA = - 370.1529 N (𝑢𝑝𝑤𝑎𝑟𝑑𝑠)

Then the highest reaction force becomes our W;

⸫ W = 370.1529 N

Since the average life of the bearing is 8 years at 1 hours per day and 275 day a year,
therefore life of the bearing in hours is,

LH= 8 × 275 × 1 = 2,200hours

And life of the bearing in revolution is,

L = 60 N × 𝐿𝐻 Error! No
text of
specified
style in
document..52
= 60 × 800 × 2,200 = 105.6 × 106 rev

L 1⁄ Error! No
C = W( ) K
106 text of
specified
style in
document..53
where k = 3 for ball bearings
 105.6 × 106 rev 1⁄
C = 370.1529 N ( ) 3
106

C = 1451.81 = 1.45181KN

From appendix Table A-14, let us select the bearing No. 201 which has the following basic
capacities;(15)

C0= 2.24 KN = 2,240 N and C = 4 KN = 4,000 N

Dimensions, Db = 12 mm, Do = 32 mm W= 10 mm where, Db= bore diameter, Do = outer

diameter, W = bearing width;