DESIGN AND FABRICATION OF AN ELECTRIC

VIBRATING SCREEN.

WRITTEN BY
OGUNLEYE AYODEJI KAYODE
(b.tech Industrial design)
Contact :+2347069262049, ayodeji007@yahoo.com
 DEDICATION

This project is dedicated to God almighty, my parents Mr / Mrs Ogunleye, and to the
advancement of ceramics in Nigeria and every individual involved in ceramic in Nigeria.
 ACKNOWLEDGMENT
As much as this project has experienced some challenges it has also been greeted with
support from so many quarters even when some expected quarters happened to disappoint at the
most pressing time of their need.

The first gratitude goes to God Almighty the beginner of this project who saw me from
the inception through the project execution and finally to the end of the project. Special gratitude
to my parents; Mr. / Mrs. Ogunleye and Family for the support, guidance, sacrifices and above
all concern not only during the period of this project but also from my birth. Best of Gods plan is
what I wish and pray for you.

This project has been made approved and certified executed due to the professional and
intellectual supervision of Dr. I.B.Kashim of the department of Industrial Design Department of
the federal university of technology,akure not forgetting the unquantifiable support and
assistance most especially in acquisition of materials and information that has helped in the
realization of success in this project.

Appreciation goes to my Head of Department of the department; Dr. I.B.Kashim for the
meaningful contribution in managerial, academic and productive criticism. It has helped to
sharpen some crooked views and attitude. In this vein, I appreciate Prof. S. R. Ogunduyile, Prof.
E. B. Ojo, Mr. T.P. Ologunwa, and Mr. O. F. Kayode. Appreciation also goes to my lecturer and
secondary supervisor Mr. A. O. Fatuyi for the technical and moral support by virtue of his vast
and unflinching experience in the art and process of ceramics.

God bless and reward you all in his abundance and riches in glory.
 TABLE OF CONTENTS
Title page

Certification ……………………………………………………………………………. I

Dedication ………….………………………………………………………………… II

Acknowledgment ………….……………………………………………………………… III

Table of content ………….…………………………………………………………………VI

Abstract ………….………………………………………………………………………….VI

CHAPTER ONE

1.0 Introduction ………….…………………………………………………… 1

1.1 Statement of problem ………….……………………………………… 2

1.2 Aim and objective ………….……………………………………………….2

1.3 Justification ………….……………………………………………………. 3

1.4 Scope of study ………….………………………………………………… 3

1.5 Project Scope ………….………………………………………………… 5

CHAPTER TWO

2.0 Literature review ………….………………………………………………..6

2.1 Introduction..…….………..………………………………………………. 6

2.2 History of a Vibrating Sieve .…..………………………………………. 6

2.3 Transition in the method of sieving ceramics raw materials. .……..…… 7

2.4 Types Of Mechanical Screening .…………………………………..…… 8

 2.4.1 High-Frequency Vibrating Screens .…………………..…..…… 8

2.4.2 Circular Vibrating Screen .………………………………...……… 9

2.4.3 Range Of Applications Of Circular Vibrating Sieve In A Ceramics

Environment .……..…………………………………………….. 10

2.5 Types Of Sieves Used In An Electric Vibrating Screen .……..…..………. 10

2.5.1 Woven Wire Mesh Sieves .……..…………………………….…….11

2.5.2 Perforated Plate Sieves ……………………………..……..………. 11

2.5.3 America Standard Sieves .……………………………..…..……… 11

2.6 Operating Principle Of An Electric Circular Vibrating Sieve .……..…….. 11

2.7 Vibrating Screen Design Parameters ………………………..……..……… 13

2.7.1 Screen Surface Area .…………………………………..…..……….14

2.7.2 Aperture Size And Shape .…………………………….…..………. 13

2.7.3 Deck Screen Slope .………………………………………..………. 14

2.8 Processes Involved In The Fabrication Of An Electric

Vibrating Sieve Machine. .…………………………………………..…… 14

2.8.1 Welding .…………………………………………...…………… 14

2.8.2 Arc Welding (Shielded Metal Arc Welding) .…………………… 14

2.8.3 Metal Inert Gas Welding (Gas Metal Arc Welding) .………… 15

2.9 Drilling .…………………………………………………………..…..…… 16

2.10 Disc Cutter .………………………………………………………….…… 17

CHAPTER THREE

3.0 Methodology ………….……………………………………………….. 18

 3.1 Introduction ………………………………………………………………..19
3.1.2 Project Flow Chart ………………………………………………….. 19

3.2 Generating concept and design ………….…………………………...19

3.3 List of Materials for vibrating sieve construction .………….…………… 20

3.4 Prefect specified Requirement. ………….………………………… 22

3.4.1 Criteria.………….…………………………………………..…… 22
3.5 Dimension Of The Designed Sieve Machine ……………….……..…… 23

3.6 Design description .……..………….………………………..………… 25

3.7 Fabrication Process …………………………...…………………..… 27
3.7.1 Cutting, Welding And Assembling …..……………………………..... 27

CHAPTER FOUR

4.0 Result, Observation, Remedy, Findings And Challenges Encountered...… 30

4.1 Result ……………………………….….……………………………. 30

4.2 Observation ……………………….….…………………………….… 30

4.3 Remedy ……………….………….……………………………… 30

4.4 Findings ………….…………………….….……………………… 32

4.5 Challenges Encountered ………….………...….……………………...… 32

CHAPTER FIVE

5.0 Recommendation And Conclusion ………….……….......................……… 33

5.1 Recommendation ………….………...….………………..…………………. 33
5.3 Conclusion ……………………….………...….…………………………. 34

Conclusion ………….………...……………………………………………………….… 35

Reference ………….………………………………………………… …….……… ... 35

 LIST OF FIGURES AND PLATES

Figure 1 : Primitive wooden mesh nailed to a frame then attached to a roof key post ............... 5.

Figure 2 : : High frequency vibrating screens .............................................................................. 6.

Figure 3 :Circular vibrating screen .................................................................................... .6

Figure 4: High frequency vibrating screens ......................................................................... 8

Figure 5 : Circular vibrating screen ............................................................................................ 10

Figure 6 : Arc welding ................................................................................................................ 11

Figure 7; Arc welding ................................................................................................................

11

Figure 8; Drilling machine ..........................................................................................................12

Figure 9: Disc Cutter .................................................................................................................. 12

Figure 10: Flow Chart representing the execution of the project .............................................. 13

Plate 1: Parts needed for coupling and balls for the mesh ........................................................ 15

Plate 2 : Vibrating sieve and complete parts labelling ........................................................ 16

Plate 3: schematic diagram showing the actual dimensions ................................................. 18

Plate 4a, Plate 4b and Plate 4c Showing the adjustment and finishing

Of the gyratory motor compartment .............................................................................20

Plate 5 a and b; transistory images showing the process of

making the engine compartment .......................................................................... 21

Plate 6: Folding and welding of sieve frames ................................................................... 25

Plate 7: fixing of bottom frame ....................................................................................... 25
Plate 8: construction of feeding inlet ................................................................................. 25
Plate 9: construction of mesh frame........................................................................................ 25
 ABSTRACT

Product design and raw material preparation in Nigeria is supposed to be an industry that
is to steer the forefront of Nigeria economy and cause technological breakthrough and great
developmental strides but contra wise in spite of the endowed and rich potentials considering
resources both natural and physical which are available almost gratis, it has lacked the necessary
attention and also maintained an ebb among the league of sectors of the economy at a point when
the competition for survival and relevancy among sectors of the economy is hitting the roof.

This call should be made to in a way that it will be understood by professionals in the
field and concerned quarters not in the field of ceramics because this is a call for general concern
because ceramics involves both domestic and industrial application which is on a consumption
note and also an industry with a great potential, with the necessary and required inputs has the
capacity to be the foremost industry of Nigeria’s economy.

This paper reports on the design of an electric vibrating sieve. The coefficient of
uniformity is 1.11, thus the machine design does not sieve larger particles such as gravel. The
slip calculated is 36% which enabled the proper configuration of the V-belt. The theoretical
efficiency of the machine calculated is 97%. This project focuses in design, fabrication of the
mechanical part of machine and the system of the sieve machine. To achieve this project
objective, this sieve machine body structure and mechanical system needs to concern some other
criteria such as strength, safety and ergonomic design. This project flow must start from design,
analysis, and lastly fabrication process. Before developing the sieve machine, it must compare
with other product in market. It is because to study the customer need and to create a new design
with new feature.
This is also one of opportunity to student to show or to apply their knowledge also skill in
using manufacturing process and mechanical design software in complete this project. Time
management and a good planning also important to make sure the entire plan are in their way.
Lastly, discipline needed to complete this project.
 CHAPTER ONE

1.0 INTRODUCTION

Technology is a general term for the processes by which human beings fashion tools and

machines to increase their control and understanding of the material environment.Nigeria
industries, having been known for its excellence in science and technology should, therefore
been expressed the practical application of methods and techniques in combination with science
in other to produce repair and inquire into how raw material preparation and production can be
made conveniently through an electric rotary vibrating screen in order to enhance work, increase
production process and reduce strength in glaze preparation through a semi automated means.

As technology advances, the call for development cannot be over emphasized as it is

been experienced in the Department of Industrial Design, Federal University of Technology,
Akure. Ceramics raw material preparation also has been upgraded from the manual method of
sieving by shaking and stirring with the hands to semi automated means using electric motor on
vibrating sieve. It is noteworthy that not even potters in this part of the country can afford the
importation of this technology because of the high price of such facilities, so they prefer the
manual method of sieving by shaking and stirring with the hands using a net nail to a wooden
frame which are more complicated to fabricated with local materials. However, this process is
labor intensive and does not save time even in the production of ceramics wares in the industrial
Design Department as it is currently been experienced.

In pottery, an electric rotary vibrating screen is a mechanism used for separating particles
of various sizes. The screener is suspended on rugged springs that allow it to vibrate freely while
minimizing power consumption and preventing vibration transmission to the floor. The electric
sieve is equipped with one imbalanced-weight gyratory motor that creates multi-plane inertial
vibration for the purpose of controlling the flow path of material on screen surfaces, and
maximizing the rate at which material passes through the screen.
 An electric vibrating screen has been widely used in mining, construction, transportation,
energy, Ceramics industries and chemical industries. The vibrating screens have become a world
standard for small-to-high capacity, batch and continuous scalping, de-dusting and dewatering of
countless bulk products handled in virtually every processing application. They have also solved
numerous unusual and difficult manufacturing problems requiring high custom configurations.
Scientific management, advanced processing technology and innovative manufacturing theory
make Hongixng become the exporting base of slurry vibrating screen, high frequency vibrating
ore screen and famous grinding equipment in China. (Den Hurtog 1956).

There are different methods and techniques of production used, the best known is the
electric slurry vibrating screen produced in China, which uses Stainless steel (cylindrical),One
imbalance gyration motor (vibrator),Screen frame and screen mesh, Shield with feeding inlet,
Control switch,0.5mm metal sheet, Clamps, Springs.

1.1 Statement of Problem.

Locally Fabricated electric Vibrating screen seems not to be common due to the fact that
cogent factors like centring of the mesh and Rpm (Radius per minutes) control are difficult to be
put into consideration meticulously. Execution of projects lacks proper planning and prospects
which can be ameliorated by feasibly placing the various steps, methodology and study which
can enhance specialisation towards achieving a functional presentable project.

Now day’s people always prefer the most suitable way to cut their cost and time.
Example is in a ceramics industry where they have to finish thier work before the due date. Its
might be a problem, since we have been long waiting for the good to arrive. However, sometime
in big company such as Nigerite Ltd, Oba Akran,Lagos, Nipost Porcelain Ltd,Otta there are high
tech machine that can do the work sieving any sub stand or mixture.

1.2 Research Questions.

The research questions this study will solve are;

 1. How will this fabrication meet up with the standard of imported ones relative to
aesthetics, functionality and durability?
2. What will reduction in height in the design and fabrication of this project solve
with regards to the problem of not been able to separate slurry particles in
ceramics and;
3. How will this fabrication ameliorate the problem of stress of sieving clay during
preparation into workable bodies?

1.3 Justification

The need for this project is most imperative considering the conscious effort towards
capacity building in the area of self reliance and in the area of machine fabrication. For a country
to grow there need for concerted effort by the people and government for adequate exploitation
of human and natural potentials in the country.

According to World Bank Update on Global Economy Forecast (2009), its states that
developing economy is one that is being able to harness all factors of production in the country
and harness all forms of constructions and fabrications most especially as it can be applied to
fabricating sectors as well. With Nigeria in that category, the concern development of the
ceramic industry is a sure prerequisite for the development of the country.
Though, fabrication of the Vibrating sieve is not new to the Department but its
technological advancement cannot also be over emphasized as there is now an improvement in
the process of ceramic material processing. The manual vibrating sieve available in the
Department seems to be haphazard such that it limits efficiency level for total production. This
critically affects the rate at which the students make use of the sieve.
Because of the aforementioned most of the students resolve to other method of sieving
due to the challenges faced by the unavailability of this ceramics facility, thus the need to
fabricate potter’s wheels in providing an enabling environment for Ceramic students.
1.4 Aim and Objectives

The aim of this project is to design and fabricated functional and aesthetic electric
vibrating screen with a view of expressing the technological and scientific reputation of the
University. The objectives of this study are to;

a) identify a suitable type of material that can be used to construct electric slurry
vibrating screen.
b) design a vibrating sieve using stainless steel .
c) evaluate the efficiency of the working process of the sieve.
d) verification.

1.5 Scope of Study

The scope of this project will encompass sorting for stainless steel and electrical
appliances that can be used for the construction of a vibrating sieve.

1.6 Project Scope

From the title that has been given, the development of this project must include how to
design the mechanical part of machine using materials like Mild steel, stainless steel and how to
fabricate the system of this mechanical part. It also needs some knowledge and skill to finish the
project. There is some other guide must followed to finish this project.
 CHAPTER TWO

2.0 LITERATUREREVIEW

2.1 INTRODUCTION

Sieving according to McCave and Syvitcki, (1990) is of multiplayer and highly

efficient. It can screen the materials into multiple levels products according to the different
materials grain size. Earthen substance such as clay and sand is one of the most important raw
materials in industrial world. Nowadays the industry need the Earthen substance that are already
been process known as ceramics raw material. Ceramics substance are mixtures with variety of
other component such as hydrous alumina-silicate minerals formed by the weathering of
feldspathic rocks, such as granite.

A vibrating sieve is a mechanism used for separating particles of various sizes. The
screener is suspended on rugged springs that allow it to vibrate freely while minimizing power
consumption and preventing vibration transmission to the floor. The electric sieve is equipped
with one imbalanced-weight gyratory motor that creates multi-plane inertial vibration for the
purpose of controlling the flow path of material on screen surfaces, and maximizing the rate at
which material passes through the screen (Khurmi and Gupa, 2005).

There are different methods and techniques of production used, the best known is the
electric vibrating screen produced in China, which uses Stainless steel (cylindrical),One
imbalance gyration motor (vibrator),Screen frame and screen mesh, Shield with feeding inlet,
Control switch,0.5mm metal sheet, Clamps, Springs (Den Hurtog,1956).

2.2 History of a Vibrating Sieve.

The use and design of vibration absorbers has long history. First, as proposed by Frahm
in 1909, vibration absorbers consists of a second mass-spring device attached to the main device,
also modeled as a mass-spring system, which prevents it from vibrating at the frequency of the
sinusoidal force acting on the main device. Vibration absorbers are devices attached to flexible
systems, or dynamic systems in order to minimize the vibration amplitudes at a specific set of
points (Khurmi and Gupa, 2005).

Vibrating sieve is of multiplayer and highly efficient. It can screen the materials into
multiple levels products according to the different materials grain size. The size distribution is
often of critical importance to the quality of the particles size produced. A sieve analysis can be
performed on any type of non – organic or organic granular materials including sands, crushed
rock, clays, soil, granite, feldspar and coal, a wide range of manufactured powders, grains and
seeds, down to a minimum size depending on the exact method. Being such a simple technique
of particle sizing, it is probably the most common (McCave and Syvitcki, 199).

This process can as well increase thee production rate of cast products instead of the use
of the manual traditional way of sand throwing method through a mesh tray more over up to six
different sand sizes can be sample at a time depending on the arrangement of the trays. This
design can take four different sizes of sand grains, meaning four different sizes of mesh arranged
in layers of preference, from coarse at the top to the finest at the bottom.

The machine is to drive vibrator under the power of ordinary gyrating motor, so that the
screen body along the vibrating power direction to make a cyclical reciprocating, the material in
the screen surface to make round movement, so as to make the materials sieved (Alibaba,2010).

2.3 TRANSITION IN THE METHOD OF SIEVING CERAMICS RAW MATERIALS.

The diagrams below show the transition in the techniques of sieving over times from the
primitive method of sieving to the modern method of sieving.
Figure 1: Primitive wooden mesh nailed to a frame then attached
to a roof key post
Photography: Ogunleye Ayodeji

Figure 2: Traditional way to Sieve powdered clay (kaolin).

Source : Wikipedia (2015)
 Figure 3: Manual hand sieve vibrating equipment
Source: Wikipedia (2015)

Figure 2 above shows the process been use by people before the ancestor way to sieve
the clay and collect the clay they wanted. This process sieve the clay into it size depending on
the size of the net been used. This smooth ceramics particle or slurry usually uses as main
material in making pottery wares or as glaze ingredient. Smooth clay is required to achieve
better quality product example in making Plaster of Paris casting or making any product based
on quality for good finishing.

Figure 3 shows modified sieving method. It use handle to rotate and make the process
sieving more efficient mainly use in small manufactured process such as in small studio and lab.
Nowadays it has been upgrade using motor to replace the human power. Since this machine is
important in our daily life it has been upgrade one by one and been marked almost all over the
world.
 Figure 4: An electric rotary vibrating sieve powered by an Imbalanced gyrating motor
Source : Cinema 4D (2015)
\

Figure 4 above shows modern sieve machine, using the electrical motor it vibrate as it
mechanism. It has many different size layers so the sand comes in variety size. We just need to
choose the size.

2.4 Types of mechanical screening

There are types of mechanical screening equipment that cause segregation. These types
are based on the motion of the machine through its motor drive.
2.4.1 High-frequency vibrating screens

Figure 5: High frequency vibrating screens

Source : Design by Ayodeji (2015) on Cinema 4D

High frequency vibrating screens are the most important screening machines primarily
utilized in the mineral process industry. They are used to separate raw materials containing solid
and crushed ores down to approximately 200μm in size, and are applicable to both perfectly
wetted and dried feed. The frequency of the screen is mainly controlled by an electromagnetic
vibrator which is mounted above and directly connected to the screening surface. Its high
frequency characteristics differentiate it from a normal vibrating screen. The high frequency
vibrating screens usually operates at an inclined angle, traditionally varying between 0 to 25
degrees and can go up to a maximum of 45 degrees. It should operate at a low stroke and has a
frequency ranging from 1500 - 7200 RPM (Gupta and Yan, 2006).

2.4.2 Circular Vibrating screen

 Figure 6: Circular vibrating screen
Source : Wikipedia (2014)

Circular vibrating screen is a shaker or a series of shakers as to where the drive causes the
whole structure to move. The structure extends to a maximum throw or length and then contracts
to a base state. A pattern of springs are situated below the structure to where there is vibration
and shock absorption as the structure returns to the base state.
This type of equipment is used for very large particles, sizes that range from pebble size
on up to boulder size material. It is also designed for high volume output. As a scalper, this
shaker will allow oversize material to pass over and fall into a crusher such a cone crusher, jaw
crusher, or hammer mill. The materials that passes the screen by-passes the crusher is conveyed
and combined with the crush material (Gupta and Yan, 2006).

Also this equipment is used in washing processes, as material passes under spray bars,
finer material and foreign material is washed through the screen. This is one example of wet
screening used in wet preparation of raw material

2.4.3 Range of Applications of circular vibrating sieve in a ceramics environment.

 .This technique can achieve 99% high efficiency in the preparation ceramics raw material
with its circular movement. Machines with circular screening techniques are commonly used
because of its unique rush design, high life time utility, and the flexible angular velocity the
machines can achieve. However, this type of machine requires low feed flow rate and the
particles size for separation have to be controlled within a specific range. Furthermore, the
performance of the process also depends on the intensity of the vibration. On the other hand, the
water steam treatment is also an issue of this screening technique since this technique is applied
worldwide. Presently, the most effective and environment friendly way for processing of the
ceramics raw material is to classify the products. The products are usually split into four
categories, including organic, inorganic, and hazardous and recyclable. It is capable of
separating finer materials as compared to other methods, and is therefore more suitable to treat
fragile materials. Several applications in respective industries are shown in the table below.

Table 1: showing the application of circular vibratory sieve in the various industries

Industry Applications

Process Processing ceramics, pulp and paper mill, paints, sand, starch slurry

Screening of refined table salt, papaya cubes, turmeric pigment; clarification of

Food
alkaline extracts

Chemica Screening hydrate lime, effluent overflow from hydrocyclone; classification of

l polyester beads, anhydrous aluminum chloride

2.5 TYPES OF SIEVES USED IN AN ELECTRIC VIBRATING SCREEN.

According to (Donald 2005), the size distribution of ceramics raw materials is often of
critical importance to the type of size and shape of sieve to be constructed. The size analysis can
be performed on any type of non-organic materials including sands, clays, granite, feldspars, and
a wide range of manufactured glaze powder, down to a minimum size depending on the exact
method. These sieves are calibrated in micrometers and millimeters which are:
2.5.1 WOVEN WIRE MESH SIEVES.

Woven wire mesh sieves are according to technical requirement if ISO 3310-1. These
sieves are ranging from 20 micrometers to 3.55 millimeters, with Diameters ranging from 100 to
450 millimeters.

2.5.2 PERFORATED PLATE SIEVES.

Perforated plate sieve conform to ISO 3310-2 and can have round or square nominal
apertures ranging from 1 millimeter to 125 millimeters. The diameter of the sieves ranges from
200 to 450 millimeters.

2.5.3 AMERICA STANDARD SIEVES.

America standard sieves also known as ASTM E11 standard. The nominal aperture of
these sieves range from 20 micrometer to 200 millimeters, however these sieves have only 8 and
12 inch diameter.

2.6 OPERATING PRINCIPLE OF AN ELECTRIC CIRCULAR VIBRATING SIEVE.

Vibrating screen makes use of a wire frame to separate particles of different size. As
gravity and/or the oscillating motion of the screen transport particles over the screen deck,
particles whose sizes are smaller than the aperture size falls through the wire frame, while larger
particles are transported over the wire frame. If the vibrating screen is a of a double deck family
the undersized particles will undergo the same process (but with reduced aperture size) before
passing to a subsequent stage of processing (Mamlouk and Zaniewski,1999).
Vibrating screens are usually heavily loaded near the feed end, such that particulate
particles form a multilayer on the surface of the screen deck. Such behavior is responsible for
the reduced screening efficiency near the feed end. This is primarily due to the fact that
oversized particles in contact with screen deck would restrict undersized particles to fall through
the wire cloth. As the material moves along the length of screen the load reduces as some under
size particles fall though the wire cloth when given the opportunity to come in contact with
screen, until a monolayer is reached. These multilayer and monolayer regimes are known as
crowned and separated regime respectively.
Screen area develops its best capacity and efficiency when the material at the discharge
end is all oversize and has a monolayer. Therefore to optimize the operation of a vibrating
Screen, the deck motion should force the particles into the separated regime as soon as
Possible (Syvitcki,1991).

2.7 Vibrating screen design parameters

According to (Denzin and Lincoln,2000) the overall performance of any vibration
screen depends on the following general design parameters: Screen surface and open area, wire
cloth aperture size and shape, slope of screen deck (for inclined screens), the design parameter
are listed below for an aesthetic and functional electric vibrating sieve, which are :

2.7.1 Screen surface area

The larger the surface area the high the capacity of the screen, that is, the screen will be
able to process higher tons of material per hour. The same is true for efficiency provided that the
undersized particles are present within the feed. The surface area of the screen is limited by the
cloth wire’s strength. A low strength wire can only carry limited loads and thus its surface area
should be limited to that strength, or else the capacity would have to be reduced since the cloth
wire would have to support both its weight and the load.

2.7.2 Aperture size and shape

Small apertures increase the possibility of blinding and thus reduce the screen efficiency. A
reduced aperture size requires that the cloth wire diameter to also be reduced and ultimately its
strength would also be reduced. As discussed above the reduced strength will affect the capacity
negatively. Round shapes as compared to square and rectangle shapes are usually less blinded
by most material and thus provide better screening efficiency.
2.7.3 Deck screen slope
The higher the slope angle the higher the particles acceleration downhill resulting in
increased capacity. The projected aperture size of an inclined screen is given by the following
equation:
h = (h +d)cos *d (3)
Where h = Actual aperture size
d = Wire diameter
ϴ = Inclination
Since the inclination will always be less than 900, then according to equation the
projected aperture size will decrease as the angle increases.
Higher deck slope will have a negative impact on the screening efficiency as a result of
reduced aperture size, and also due to the fact that the material will be rushed over the deck and
thus won’t have time to be filtered.

2.8 PROCESSES INVOLVED IN THE FABRICATION OF AN ELECTRIC

VIBRATING SIEVE MACHINE.

2.8.1 Welding

Welding is a fabrication process that joins materials, usually metals or thermoplastics,

by causing coalescence. This is often done by melting the work pieces and adding a filler
material to form a pool of molten material (the weld puddle) that cools to become a strong joint,
with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is
in contrast with soldering and brazing, which involve melting a lower-melting-point material
between the work pieces to form a bond between them, without melting the work pieces
(Naresh, 2005). A weld occurs when pieces of metal are joined by causing the interface to melt
and blend prior to solidifying as a uniform metal joint. This process may be caused by heat,
pressure or a combination of both. When heat alone is used the process is called fusion welding.
2.8.2 Arc Welding (Shielded Metal Arc Welding)

Electric Arc welding is based on providing an electric circuit comprising the electric
current source the feed and return path, the electrode and the work piece. The arc welding
process involves the creation of a suitable small gap between the electrode and the work piece.
When the circuit is made a large current flows and an arc is formed between the electrode and
the work piece. The resulting high temperatures causing the work piece and the electrode to
melt the electrode are consumable. It includes metal for the weld, a coating which burns off to
form gases which shield the weld from the air and flux which combines with the nitrides and
oxide generated at the weld. When the weld solidifies a crust is formed from the impurities
created in the weld process (Slag). This is easily chipped away.

There are several work pieces material requirements for arc welding;

 Have a well defined melting point

 Must electrically conducting

 Have a reasonably high thermal conductivity.

2.8.3 Metal Inert Gas Welding (Gas Metal Arc Welding)

The Metal Inert Gas Process uses a consumable electrode of wire form and an inert
gas shield of carbon dioxide when welding carbon steel. The wire electrode provides a
continuous feed of filler metal allowing welds of any length without stopping. The inert gas
shield eliminates slag and allows cleaner and stronger weld. This process is used widely for
automated welding using robots.
 Figure 7; Arc welding, Source : Alibaba.com (2014)

There are four primary methods of metal transfer in GMAW, called globular, spray,
and pulsed-spray, each of which has distinct properties and corresponding advantages and
limitations.

2.9 Drilling

Figure 8; Drilling machine

Source : m.google.com
 A drill (from Dutch Drillen) is a tool with a rotating drill bit used for drilling holes in
various materials. Drills are commonly used in woodworking, metalworking, and construction.
The drill bit is gripped by a chuck at one end of the drill, and is pressed against the target
material and rotated (Frank, 2004). The tip of the drill bit does the work of cutting into the
target material, either slicing off thin shavings (twist drills or auger bits), grinding off small
particles (oil drilling), or crushing and removing pieces of the work piece (SDS masonry drill).

2.9.1 Drilling Process

A process and apparatus for drilling holes in hard materials similar to surgical
procedures, comprising driving a drilling tool with a movement of alternating rotation with
amplitude of less than one revolution. The tool can be driven from a motor having unidirectional
continuous rot table movement through a converter which transforms this movement into the
alternating rotation. The drilling tool can cover by a member which feeds the waste cutting
materials rearward into an enclosed chamber. The apparatus can also be provided with a
member that covers the drill during an insertion thereof through cut tissue prior to the drilling
operation.

2.9.2 Type of Drill

There are many types of drills: some powered manually, others using electricity or
compressed air as the motive power, and a minority driven by an internal combustion engine
(Fraenkel and Wallen, 1996). Drills with a percussive action (such as hammer drills,
jackhammers or pneumatic drills) are usually used in hard materials such as masonry (brick,
concrete and stone) or rock. Drilling rigs are used to bore holes in the earth to obtain water or
oil. Oil well, water well, or holes for geothermal heating are created with large drill rigs up to a
hundred feet high. Some types of hand-held drills are also used to drive screws. Some small
appliances may be drill-powered, such as small pumps, grinders, etc.
2.10 Disc Cutter

Figure 9: Disc Cutter

Source : Alibaba (2015)

The present invention relates to a disc cutter machine, in particular for cutting
sugar beet, comprising a machine frame, a disc cutter having a flat upper side and uniformly
distributed passages for the cut product preferably longitudinal and extending in the radial
direction, blade receivers arranged in the region of the passages, and a bearing and a drive for
the disc cutter (Enrol Kelly, 1982). In disc cutter machines of the known type, the disc cutters
usually consist of a steel Plate from which rectangular sections are removed to form the
passages for the cut product. In the passages, the blade receivers are inserted which carry the
blades for the cutting process. As a result of the displacement of the bearing from the region of
the center of the cutting disc moreover space is made available across the cutting disc for the
drive as a result of which the constructional height is reduced.

CHAPTER THREE
METHODOLOGY
3.1 Introduction
3.1.2 Project Flow Chart
In fabrication process, there is a planning of the overall progress to make sure the project
can be finished on schedule based on aesthetic and functionality as indicated in Fig.10

START

GET TITLE

MEETING WITH THE SUPERVISOR

AND DISCUSSING ABOUT PROJECT

DESIGN NO

YES

IDEA DESIGN

MATERIAL SELECTION

FABRICATION

PRESENTATION

FINISH

Figure 10: Flow Chart representing the execution of the project

 From the flow chart above, this project was conceptualized with initial discussion with
the supervisor about design. This discussion covering project design concepts was preceded onto
the next step, after which the best idea was adopted. Extensive literature review about the
research was carried out about the performance of a vibrating sieve. This includes a concept of
sieve machine, process to fabricate and material requirement. These tasks have been done
through study on the internet, book, and other related information that could assist the vibrating
sieve.

After gathering and collecting all related information about vibrating sieve, the project
started with the design process. At this stage, the sketching was commenced. After several
design sketched, the best design was chosen among previous design so that the project designing
could be started. Then the selected design would be transfer to engineering drawing using Solid
Work software in order to for analysis process.

3.2 Concept Development.

This concept was generated for a double deck vibrating screen and the assessment of
each concept was followed by the decision process to select the best concept for further
development. The design consideration must be done carefully so that the design can be fabricate
easily and the system functioning. Then the material used in each design influence the selection
because what was absolutely needed was a lightweight material suitable with product size. The
design is separated into three phases, firstly was to choose the proposed design that can be
produce from 4 different designs improved upon its functionality and the last one is a new design
with details including dimension using Solid Work software. Beside that the cost to design and
fabricate that must be reasonable, and not exceeding the budget given to reduce waste .The
criteria that must be considered in designing the sieve machine which are:
 Durability: sieve machine must be durable when it’s rotate and vibrate.
 Material: The material must be suitable to fabricate the Sieve machine and easy to get.
 Cost: It depends on material and manufacturing processes. It should reduce the cost to the
minimum.
3.3 List of Materials for vibrating sieve construction.

The following materials were used in the fabrication of vibrating sieve machine.

a. 2mm stainless steel plates SS304

b. 5mm mild steel plate
c. Metal Springs
d. Clamps with bolt and nut
e. Rubber seal rings
f. 2.0 HP vibro motor
g. Sieve meshes
h. Frame support (2x2)angle
i. Stainless steel electrode
j. Cutting and grinding stone.

Plate 11: Parts needed for coupling and balls for the mesh
 Plate 12 : Vibrating sieve and complete parts labelling.

Table 2: Summary of the material(s) used for the fabrication of the machine and the
criteria for their selection

S/N COMPONENT SUITABLE CRITERIA MATERIAL REMARKS

ENGINEERING FOR SELECTED
MATERIALS MATERIAL
SELECTION
1.0 Engine base Mild steel, high Strength, cost, Mild steel Rigid and
speed steel, stability/rigidity angle iron strong
stainless
steel, angle iron
or pipe
2.0 Mesh frames Stainless steel, Strength, stainless Strength,
aluminum, corrosion and steel corrosion
copper acidic reaction and acidic
resistance, reaction
workability, resistance
lightness, cost
3.0 Clamps with stainless steel, Strength, stainless Strength,
screw mild steel, corrosion and steel rigidity,
acidic corrosion and
reaction acidic reaction
resistance, resistance
workability,
lightness, cost

4.0 Bearing Pillow journal Axial and radial Pillow Accommodates

bearing, thrust load resistance journal both axial and
Bearing bearing radial loads

5.0 Springs Mild steel, high Strength, Mild steel Reliable,

speed carbon workability, strength,
steel, galvanized reliability, cost
steel,
stainless steel

6.0 Sieve meshes Mild steel, Strength, stainless Strength,

galvanized steel, corrosion and steel corrosion
high speed steel, acidic reaction and acidic
stainless steel resistance, reaction
sheet workability, resistance
lightness
7.0 Sieve meshes Mild steel, high Strength, stainless Strength,
speed carbon corrosion and steel corrosion
steel, galvanized acidic reaction and acidic
steel, resistance, reaction
stainless steel workability, resistance

Feeding inlet & Stainless steel, Strength, stainless

8.0 Strength,
shield aluminum,
corrosion and steel
copper corrosion
acidic reaction
and acidic
resistance,
reaction
workability,
resistance

Table 2: TOTAL COST OF FABRICATION OF SIEVE MACHINE

S/ MATERIALS QUANTITY RATE AMOUNT(N)

N
1. 5mm mild steel plate metal 1 18000 18000
2. (2mm) Stainless Steel plate (finished) 1 28000 28000
3. 0.1kw - 6kw Vibro Motor (1.5HP ) 1 25000 25000
4. Screen fame and mesh 1 27000 27000
5. Clamp with screw 5 6000 15000
6. Metal springs 6 1500 30000
7. Control switch 1 8000 8000
8. Flang 6mm thick 1 40000 40000
9. Electrode(Nigeria) 1 3500 3500
10. Workmanship(welder) 40000
11. Workmanship(painter) 1500
12. Logistics 15000
 13. Miscellaneous 10000
TOTAL 280,500

3.4 Prefect specified Requirement.

 The width, length and height of the screen deck should not exceed 4.5m, 8m and 3m
respectively.
 The design should be corrosion resistant.
 The drive mechanism should be coved with an acoustic box to reduce the noise level
up to 85 db or less.
 The device should be powered by a 4 pole electric motor that offers an acceleration
range between 4g-5g. The motor(s) should have regenerative braking system so that the
screen can be instantly stopped in case of power failure.
 The total weight of the design including the motor(s) should not exceed 200 kg.
 The maximum stroke should not exceed 8mm.
 The Bridge fatigue factor of safety should be greater than 2.5.

3.4.1 Criteria

The design should have/be:

 High life expectancy.
 Ease of maintenance.
 Low transmitted forces.
 Low power consumption.
 Standard parts.
 Low maintenance cost.

3.5 DIMENSION OF THE DESIGNED SIEVE MACHINE

 Plate 3: schematic diagram showing the actual dimensions

A:Ø865mm H: Ø350mm
B:Ø850mm I: Ø350mm
C: Ø150mm J: Ø550mm
D:Ø850MM K: Ø650mm
E: Ø50mm L; Ø700mm
F; Ø50mm M: Ø750mm
G: Ø350mm N:Ø800MM
Medium: Stainless steel.
Dimension (L*W*H): 850mm X 850mm X 800mm
Function: Vibrating screen for clay preparation.
Concept: Combination of a Cylinder and a cone.
Location: Industrial Design Department Studio (Ceramics Section)
Finishing: Painting (auto-base Nissan color).
Screen mesh: 100– 200 mesh.

3.6 DESIGN DESCRIPTION

 The Electric rotary vibrating sieve top case is built with a metal sheet of 5mm mild
steel plate metal and a (2mm) Stainless Steel which serve as the frame. The well reinforced unit
is powered by 0.1kw - 6kw Vibro Motor (1.5HP ) with an imbalance gyration on the pedal that is
being transferred to the vibration, as a result of heavy weight of the top, it tends to double the
vibration applied which then shake the sieve.
The electric vibrating sieve is held together with a coiled metal spring at the joint
between the mild steel basement and the stainless steel.

Plate 14a Plate 14b

 Plate 14c

Showing the adjustment and finishing of the gyratory motor compartment.

Photograph by : Ayodeji (2015)

The Gyratory motor compartment is made of mild steel formed into a round shape, which is

taken to a lathe machine for proper finishing which entails smoothing the surface and ringing of

the top to create friction for dimensioning.

3.7 FABRICATION PROCESS.

The fabrication process encompasses cutting, welding (assemblying) and covering.

3.7.1 CUTTING, WELDING AND ASSEMBLYING

The tools and machines used for this process are analyzed below
Try square- for marking, trying and checking of perpendicular and straight lines of marking

done on materials to be cut.

Hack saw - for cutting of the angle irons for the stanchions, top and bottom square frame, top

and bottom bearing seat, spindle and the pedal.

Welding machine – this machine was used for joining together of the integral parts

Lathe machine – this machine is engaged for the centering and boring of holes on the fly wheel,

top and bottom bearing seat.

Plate 15 a and b; transistory images showing the process of making the engine compartment
 Photograph by Ayodeji (2015)

Plate 16: Folding and welding of sieve frames Plate 17: fixing of bottom frame
Photograph by Ayodeji (2015)

Plate 18: construction of feeding inlet Plate 19: construction of mesh frame
Photograph by Ayodeji (2015)
Plate 20 : Spraying of the engine base Plate 21 : Assembling of the machine
Photograph by Ayodeji (2015)
 CHAPTER FOUR
4.0 RESULT, OBSERVATION, REMEDY, FINDINGS AND CHALLENGES
ENCOUNTERED
After testing the Electric vibrating sieve and trying to make sure the machine is ready for
use and in good condition, it is obviously that all these purposes that meant to serve has been
accomplished. In this process, the purpose results of making the machine were achieved and
some observations were noted.

4.1 RESULT
1. The Electric vibrating sieve machine functioned satisfactory for the production of making
slab in the studio
2. The Filterate and Residue (Dry and wet) produced from the machine are fine enough for
usage and recycling.
3. The adjustable of the machine was really effective and well satisfactory
4. The machine is faster and portable, hence, it reduce labour compare to manual vibrating
sieve.

4.2 OBSERVATION
In the process of testing the machine;
1. Some part of the machine especially around the spring section made noise.
2. The driven belt was not properly rotate and the adjuster knob was also difficult to rotate
due to the first time of using the machine.
3. The outlets find it difficult to dispense raw material in wet sieving because some raw
materials stick to the clamp.
4.3 REMEDY
1. The movable part of the vibrating sieve should be lubricated from time to time in other to
avoid noise, wearing and tearing part caused by friction.
2. Specific size and quantity of raw materials (wet and dry) should be used in order not to
overburden the pressure applied
3. The size of raw materials (dry) should be properly crushed to a coarse or fine state before
been poured in the vibrating sieve.
4. The machine must be properly clean after use

4.4 FINDINGS
1. It saves time and energy
2. The raw materials produced from the Electric Vibrating sieve was of more even fineness
compare to that of the one produced using a manual rotary sieve.
3. The extension of layers on it made raw materials of more fine particle size to be produced
which might be difficult compare to the manual rotary sieve
4. Fine particles are produced within a short period of time
5. It reduces labor

4.5 CHALLENGES ENCOUNTERED

In cause of the project execution, some challenges were encountered which includes;
1. Description of the project to the fabricator
2. Cutting the metal plates materials to precision was difficult
3. The insulation of mechanism control settings of the machine, connection of the driven
belt, the clamp, spring and the net rack was very technical
4. Body grinding and smoothing was very stressful
5. Transporting the machine down to the studio from ilorin was stressful and expensive.
 CHAPTER FIVE
5.0 RECOMMENDATION AND CONCLUSION
5.1 RECOMMENDATION
The whole processes of accomplishing this project right from the sourcing of materials
for the fabrication to testing of the machine became all exciting and fulfilling having devised a
self-reliant means of expanding our studio equipment’s and promote hand built production
techniques
Considering the importance and great benefit of this project to the Department, it is
recommended that this kind of project should be encouraged in the future projects to be done
in order to improve the rate of learning for the students of the Department and also the
productivity of the Department at large.
Having done through the different phases of this project with the relevant knowledge and
information, the following recommendations are indispensable:
1. The higher institutions in Nigeria should encourage the execution of concrete and
viable project that can meet the pressing needs of their immediate environment or
department.
2. The institution and department authorities should ensure proper use maintenance
of student’s project
3. Students should be encouraged to pursue a project, which will show that really
learn what is new and relevant to their course of study.
4. Student should be encouraged to research into areas that can contribute
significantly to self-reliance after the school.
5. Students should be rightly guided at first attempt on how to use the machine to
prevent damage.
 6. In the execution of technical research works which are capital intensive, the
federal Government should encourage and provide necessary assistance, as it
obtainable in the more developed world.
7. Maintenance services being an important factor in the use of any equipment both
in and out of ceramics context, should also be attended to as the culture of the
Department to our equipment, so that equipment bought or fabricated will be well
managed and used, thereby, increasing its durability and its appreciation.
Equipment should be serviced regularly in order to put off any form of fault ahead
of time.

5.2 CONCLUSION
As it has been clearly observed, hand built slab method production techniques though an
old method, is still preffered, embraced and practiced extensively by comtemporary local
potter more because of its uniquness in terms of hand creative effects which can never be
archived with any other method of production beside being economical in Nigeria and
beyond.

The following conclusion were drawn:

1. It is possible to conceptualize, design and execute a locally made slab roller machine
with two driven rollers.
2. That fabrication of a slab roller machine with two roller is archievable and is much
more effective compared to the hand rolling pin.
3. That the skill and manpower needed for problem solving within our environment is
available if only we can intently look into it and discover the hidden potential in us.

On a final note, these projects have been made to meet up to some expectations such
as being a reference point for future project that is in line with this kind of project. It will also
encourage giving preference to efficient manual equipment over the electric ones, and not to
be bothered with failure in power supply which happens to be the number one problem we
have in this part of the country. Especially the potter's wheel, being a very important machine
in the production of ceramic wares, and with this kind of porter's wheel, this project will be of
good use to the user in term of conveniences, absent in power supply and many other
benefits.
Finally, these projects should be placed regularly on service so as to enhance its
workability and durability.

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