Final Project These

DESIGN MODIFICATION OF TOP ROLLER CLEANER AND
VACUUM CLEANING MACHINE
NAME OF CANDIDATES:
ABDUSOMED EBRAHIM SEID (1687/07),
BINIAM DEREJE SHIFERAW (1863/07)
GEBREKIDAN SOLOMON BIZUALEH (2032/07)
HARAMAYA INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
NAME OF ADVSIOR:
Mr. HABTAMU G/MARIAM
HARAR, ETHIOPIA
18/06/2019
Design Modification of Top Roller Cleaner and Vacuum Cleaning Machine for 2011E.C
Textile Industry
JUNE, 2019
DECLARATION
We hereby declare that the thesis, entitled “Design Modification of Top Roller Cleaner and
Vacuum Cleaning Machine for Textile Industry.” submitted to the Department of Mechanical
Engineering, HARAMAYA INSTITUTE OF TECHNOLOGY (HiT), in partial fulfillment of the
requirements for the award of the Degree of Bachelor of Science is a record of original research
work done by us during 2011(E.C), under the supervision and guidance of Mr. Habtamu
G/Maraim. It has not formed the basis for the award of any Degree / Diploma / Associate ship /
Fellowship or other similar title of any candidate of any university.
Place: Harar
Date:
Signature
Abdsomed Ebrahim Seid (1687/07) __________________
Biniyam Dereje Shiferaw (1863/07) __________________
Gebrekidan Solomon Bizualeh (2032/07) __________________
Haramaya Institute of Technology, Department of Mechanical Engineering Page I

Textile Industry
HARAMAYA INSTITUTE OF TECHNOLOGY

(HiT)
Department of Mechanical Engineering
APPROVAL SHEET
Design Modification of Top Roller Cleaner and Vacuum Cleaning Machine for Textile Industry.
By:
ABDUSOMED EBRAHIM SEID

BINIYAM DEREJE SHIFERAW
GEBREKIDAN SOLOMON BIZUALEH
Approved by Board of Examiners
Mr. HABTAMU G/MARIAM _______________
Main Advisor Signature
______________________________ _______________
Examiner (1) Signature
_______________________________ _______________
Examiner (2) Signature
. ______________________________ _______________
Co-Examiner (1) Signature
. ______________________________ _______________
Co-Examiner (2) Signature
Haramaya Institute of Technology, Department of Mechanical Engineering Page II

Textile Industry
ACKNOWLEDGEMENT
We would like to express our sincere gratitude to M. Habtamu G .(MSc) our advisor, for his
constructive criticisms, insightful comments and unreluctant follow-up of the progress of the
study. We wish to express our special gratitude to Mr. Ayele Legesse, Mr. Werkalmahu, Mr.
Addis, Mr. Beruk and Dr. V. Suresh and other our teachers, for their contribution for grasping
knowledge of the subject matter during academic classes. Our very special thanks go to the
Community of Kombolcha Textile Share Company for their valuable and considerable support
and cooperation during data collection. Our gratitude also goes to HARAMAYA University,
Department of Mechanical Engineering in particular for providing the educational opportunity.
We never forget the contribution of our best classmates for their precious help, encouragement,
support and commitment throughout our study. Last but not least. We thank to all our families,
friends as well as all other parties who support us in order to accomplish this thesis writing.
Haramaya Institute of Technology, Department of Mechanical Engineering Page III

Textile Industry
TABLE OF CONTENTS
CONTENTS PAGE NUMBER

DECLARATION ........................................................................................................................ I
APPROVAL SHEET ................................................................................................................. II
ACKNOWLEDGEMENT ......................................................................................................... III
TABLE OF CONTENTS ......................................................................................................... IV
LIST OF TABLES .................................................................................................................. VII
LIST OF FIGURES ............................................................................................................... VIII
LIST OF ACRONYMS .............................................................................................................. X
ABSTRACT ............................................................................................................................ XI
1. INTRODUCTION...................................................................................................................1
1.1. Background of the project ....................................................................................................1
1.2. Statement of problem ...........................................................................................................3
1.3. Objective of the project ........................................................................................................5
1.3.1. General objective ........................................................................................................5
1.3.2. Specific objectives ......................................................................................................5
1.4. Significance of the project ....................................................................................................5

1.5. Scope of the project ..............................................................................................................6
1.6. Organization of the project ...................................................................................................6
CHAPTER TWO ........................................................................................................................7
2. LITERATURE REVIEW ........................................................................................................7
2.1. Introduction ..........................................................................................................................7
2.2. Previously made Approaches ................................................................................................7
2.2.1. Manually operated clearer roller cleaning machine .....................................................7
2.2.2. Lakshmi ring traveller-LRT ........................................................................................8
2.2.3. Flocked clearer roller cleaning machine, GAYATRI ...................................................8
2.2.4. Wooden clearer roller cleaning machine, MAYUR .....................................................9
CHAPTER THREE................................................................................................................... 10
Haramaya Institute of Technology, Department of Mechanical Engineering Page IV

Textile Industry
3. MATERIAL AND METHOD ............................................................................................... 10

3.1. Material .............................................................................................................................. 10
3.2. Software used to accomplish the desired model .................................................................. 11
3.3. Methods ............................................................................................................................. 12
3.3.1. Data collection .......................................................................................................... 12
3.3.2. Component design .................................................................................................... 12
3.3.3. Modeling of the machine .......................................................................................... 13
3.4. Load and Force Analysis .................................................................................................... 13

3.4.1. Design of rotating roller shaft one ............................................................................. 13
3.4.2. Design of rotating roller shaft two ............................................................................. 20
3.4.3. Design of shaft three ................................................................................................. 26
3.4.4. Motor selection ......................................................................................................... 29
3.4.5. Design for bevel gear ................................................................................................ 31
3.4.6. Selection of ball bearins ............................................................................................ 38
3.4.7. Selection of v- belt .................................................................................................... 41
3.4.8. Design of v-grooved pulley ....................................................................................... 45
3.4.10 Selection Bolt .......................................................................................................... 49
3.4.11. Selection of fan ....................................................................................................... 52
3.5 Manufacturing process ........................................................................................................ 56

3.6. Assembly process ............................................................................................................... 57
3.7. Working principle .............................................................................................................. 58
4. RESULT AND DISCUSSION .............................................................................................. 59
4.1 Summary of Findings .......................................................................................................... 59
4.2. Cost Analysis ..................................................................................................................... 61
4.3. Limitations ......................................................................................................................... 61
CHAPTER FIVE ...................................................................................................................... 62
5. CONCLUSIONS AND RECOMMENDEDATIONS ............................................................ 62
Haramaya Institute of Technology, Department of Mechanical Engineering Page V

Textile Industry
5.1 Conclusions ......................................................................................................................... 62

5.2 Recommendations ............................................................................................................... 63
References................................................................................................................................. 64
APPENDICES .......................................................................................................................... 65
LIST OF PART DRAWINGS AND ASSEMBLY .................................................................... 65
Haramaya Institute of Technology, Department of Mechanical Engineering Page VI

Textile Industry
LIST OF TABLES
TITLES PAGE NUMBER

Table 3.1. General Specification of component ........................................................................ 12
Table 3.2. Software used .......................................................................................................... 12
Table 3.3. AC motor voltages .................................................................................................... 31
Table 3.4. Selected motor specification ..................................................................................... 31
Table 3.5. Standard dimensions of Roller bearing ..................................................................... 38
Table 3.6. Basic static and dynamic capacities of various types of radial ball Bearings………...40
Table 3.7. Standard pitch lengths of V-belts according to IS: 2494-1974………………………41

Table 3.8. Dimensions of v belts according to IS: 2494-1974…………………………………..42
Table 3.9. Density of belt material……………………………………………………………….43
Table 3.10. Specifications for Steel Used in Millimeter Series Screws and Bolts………………48
Table 3.11. Basic Dimensions of ISO Metric Screw Threads…………………………………...49
Table 3.12. Manufacturing process………………………………………………………………54
Table 4.1. Summary of finding…………………..………………………………………………58
Table 4.2. Cost analysis …………………………………………….……..…………………….61
Haramaya Institute of Technology, Department of Mechanical Engineering Page VII

Textile Industry
LIST OF FIGURES
TITLES PAGE NUMBER
Figure 1.1. Rig frame Machine ................................................................................................... 1
Figure 1.2. Clearer roller (top roller clearer) ……………………………………………………...2
Figure 1.3. Manually operated clearer roller machine .................................................................. 3
Figure 3.1. 3D Model of rotating roller Shaft one .................................................................... 14
Figure 3.2. Vertical bending moment diagram of shaft one ...................................................... 19
Figure 3.3. Horizontal bending moment diagram of shaft one ................................................... 19
Figure 3.4. Resultant bending moment diagram of shaft one …………………………………..20
Figure 3.5. 3D Model of rotating roller shaft two…………………………………………….….21
Figure 3.6. Vertical bending moment diagram of shaft two………………………………..……24
Figure 3.7. Horizontal bending moment diagram of shaft two ………………………………….25
Figure 3.8. Resultant bending moment diagram of shaft two……………………………………25
Figure 3.9. 3D Model of shaft three ……………………………………………………………..28
Figure 3.10. 3D Model of bevel gear…………………………………………………………….32
Figure 3.11. 3D Model of bearing ………………………………………………………………40
Figure 3.12. 3D Model of v-belt ………………………………………………………………...42
Figure 3.13. 3D Model of larger pulley………………………………………………………….44
Figure 3.14. 3D Model of smaller pulley………………………………………………………...45
Figure 3.15. 3D Model of key……………………………………………………………………46
Figure 3.16. Pillow block attached by two machine screws……………………………………..49
Figure 3.17. 3D Model of Base frame……………………………………………………...……52
Haramaya Institute of Technology, Department of Mechanical Engineering Page VIII

Textile Industry
Haramaya Institute of Technology, Department of Mechanical Engineering Page IX

Textile Industry
LIST OF ACRONYMS
ASME American Society of Mechanical Engineers

ASI American Iron and Steel Institute
ASTM American Society for Testing and Materials
IS Indian Standard
ISLS Indian standard designation of low and medium alloy steels
ISO International Standard Organization
KTSC Kombolcha Textile Share Company
2D Two Dimensional
3D Three Dimensional
Haramaya Institute of Technology, Department of Mechanical Engineering Page X

Textile Industry
ABSTRACT
The aim of the project was to design the modified top roller/ clearer roller cleaning and vacuum
cleaning machine for textile industry. The project was guided by design of machine elements,
necessary design procedures and analyses. The project’s target populations were Textile
industries, located in Ethiopia. This report contains mainly design of clearer roller cleaning
machine for textile industry. It contains a literature review about the experience of clearer roller
cleaning machine used in Kombolcha Textile Share Company, Ethiopia and other previously
made approaches concerning the clearer roller machine. The introduction part tries to discuss
briefly about the role of textile industries for one country. And it incorporates the statement of
problem which motivates as to do the study, the objectives describing what we aim to design. The
main part of the report which is the methods and materials contains methods followed, the
appropriate materials selected and the design of the major parts of the clearer machine that is
the design of clearer roller (rotating roller shaft), selection of required motor, fan, belt drive and
calculations for the different machine components. The clearer roller (rotating roller shaft) is
designed to clean 18 top rollers at once which was formerly limited to clean only seven. The
report also contains manufacturing process, taking that the clearer roller is manufactured in
textile industries workshop. The conclusion part also incorporated interpreting that the project
tried to solve problem and putting major findings. The main components of the cleaning machine
are clearly shown in the assembly and detail drawings which are included in the report.
Key Words: top roller / clearer roller, cleaning, textile, clearer roller, machine, motor, fan,
workshop.
Haramaya Institute of Technology, Department of Mechanical Engineering Page XI

Textile Industry
CHAPTER ONE
1. INTRODUCTION
1.1. Background of the project

Solving the problems observed in any aspect of life and giving for that matter a solution is one of
the critical issues expected from one person (or group of person) who is believed to be an
educated. In case of Mechanical engineering the matter is to be expected to solve the problems in
a mechanical way to achieve creating suitable environment and ease the work.
The problems may be observed in anywhere specially in our houses, work place, industry or
company etc., Nowadays industries are becoming the back bone of economic growth for one‟s
country. Due to the increment of industries the problems also increase which initiate the engineer
for adding further improvement and solve the problem. In case of Ethiopia textile industry is now
the leading industry especially in creating job opportunities and supporting the economic growth.
The textile industry is the largest manufacturing industry in Ethiopia. It is a beneficial for
economic growth especially in developing countries like Ethiopia. Textile is a fabric that is
knitted or woven and made from yarn. Thus textile industry is the industry responsible for taking
a raw material like cotton or wool and spinning it to yarn that is late used to create a fabric. It has
different sections in which the product is made through various sequential processes.
Among those sections the spinning section is provided next to Blow room section. Spinning is
the twisting together of drawn-out strands of fibers to form yarn, and is a major part of the textile
industry. The yarn is then used to create textiles, which are then used to make clothing and many
other products. There are several industrial processes available to spin yarn, as well as hand-
spinning techniques where the fiber is drawn out, twisted, and wound onto a bobbin.
The yarn issuing from the drafting rollers passes through a thread-guide, round a traveller that is
free to rotate around a ring, and then onto a tube or bobbin, which is carried on a spindle, the axis
of which passes through a center of the ring. The spindle is driven (usually at an angular velocity
that is either constant or changes only slowly) and the traveller is dragged around a ring by the
loop of yarn passing round it. If the drafting rollers were stationary, the angular velocity of the
traveller would be the same as that of the spindle and each revolution of the spindle would cause
Haramaya Institute of Technology, Department of Mechanical Engineering Page 1

Textile Industry
one turn of twist to be inserted in the loop of yarn between the roller nip and the traveller. In
spinning, however the yarn is continually issuing from the rollers of the drafting system and,
under these circumstances, the angular velocity of the traveller is less than that of the spindle by
an amount that is just sufficient to allow the yarn to be wound onto the bobbin at the same rate as
that at which it issues from the drafting rollers. Each revolution of the traveller now inserts one
turn of twist into the loop of yarn between the roller nip and the traveller but, in equilibrium, the
number of turns of twist in the loop of yarn remains constant as twisted yarn is passing through
the traveller at a corresponding rate
In a spinning mule, the roving is pulled off bobbins and sequentially fed through rollers
operating at several different speeds, thinning the roving at a consistent rate. The yarn is twisted
through the spinning of the bobbin as the carriage moves out, and is rolled onto a cop as the
carriage returns. Mule spinning produces a finer thread than ring spinning.[5] Spinning by the
mule machine is an intermittent process as the frame advances and returns. It is the descendant of
a device invented in 1779 by Samuel Crompton, and produces a softer, less twisted thread that is
favored for fines and for weft.
Figure 1.1. Rig frame Machine
Starting from spinning section up to finishing/garment department, there are so many machines
used for fulfilling the required task. Among these machines the Top roller (clearer roller)
cleaner machine is one of the important machines used for cleaning the top roller which is

Textile Industry
found in ring frame machine for drafting purpose in spinning section. The clearer roller is a fiber
made circular material used for smoothing the yarn and clearing it from cotton tufts while
passing over it in drafting zone.
Figure 1.2. Clearer roller (top roller clearer)
The project we are going to carry out is concerned to this machine (top clearer roller cleaning
machine). The problem was observed during our internship period in textile factory. During this
period, our group had many brainstorming sessions in order to generate ideas for our project.
From a list of many ideas, we narrowed it down and eventually settled on the most interesting,
innovating and useful device called clearer roller cleaning machine.
By thinking over it now, we realized that we can really do something for the workers of the
factory by modifying the machine and upgrading it to create flexible performance and also save
energy (man power) and a big deal of time. So we decided to implement our course study and
some extra knowledge to develop our project with electrical and mechanical concepts.
1.2. Statement of problem
Using the primitive and manually actuated machines it is too hard to improve a company‟s
performance and/or efficiency. Because these kinds of machines need and consume large amount
of energy (manpower) since they are of manually operated and waste labor time. Due to their
spadework and tiresomely the workers in the company reflect some unobservance and lack of
interest towards that kind of task. This has its own side effects on the production process of the
company. In order for ease up this kind of problem we tried as a mechanical engineering student
as much as we can and contribute some our effort.

Textile Industry
The clearer roller cleaning machine now we are going to modify it is operated manually by
human being. At the time of cleaning the operator is exposed to the dust from the machine, this
may harm the health of the operator.
Fig 1.3. Manually operated clearer roller machine
Generally the previous top roller cleaning machine has the following problems or limitations
 It take long time

 It is manually operated so it need high human effort
 The clearer roller is being cleaned with a stiff material like metal wires which
damage the fiber of the clearer roller (top roller)
 It hurt the health of the operator
To overcome all thus problems we design and develop an automatic top roller cleaning machine
which replaces the stiff like metal wires of the clearer roller by the special grade rubber brush
which softly go into the bottom surface of the top roller and remove the fluff and dust
accumulated there.
Such gentle and through cleaning of clearer roller at regular intervals ensures longevity of the
clearer roller.

Textile Industry
1.3. Objective of the project
1.3.1. General objective
The main objective of our project is to design a clearer roller cleaning and vacuum cleaning
machine in textile industry.
1.3.2. Specific objectives
 To design bevel gear
 To select bearing
 To design shafts
 To design v- grooved pulley
 To select v- belt
 To select the proper motor for the machine
 Force and strength analysis for basic machine element
 To draw 2D drawings of each components
 To draw the 3D models of the components and assembly of them
1.4. Significance of the project
In the present time not everything is automatic but seeing towards progress of present
technologies, In future everything will be operated automatically. So this project will serve as
one of the advanced technology in future and will be installed in every textile company.
This study is significantly done for the following purposes:
 To facilitate the production process
 To reduce work load on the person who cleans the top roller
 To save time
 To safe and sound the worker‟s health
 To get accurate cleaning

Textile Industry
 It also used to clean the floor by vacuum cleaner

 To assure technology transfer
1.5. Scope of the project
The scope of the project is clearly define the specific field of the research and ensure that the
entire content of this thesis is confined the scope. This project is start with the literature review
on the product specification in order to satisfy the project objectives. After obtaining the product
survey detail, this project is done based on the scope below:
1. Project will focus on design of the modified clearer roller cleaning and vacuum cleaning
machine for textile industry
2. Designing clearer roller cleaning and vacuum cleaning machine that fulfills the project
objective.
3. Machine design to suit the regular cleaning machine.
4. The project goes until detail design of the cleaning machine.
5. The major output of this project is to produce detail drawings and assembly drawing (or 3D
Modeling) for the machine design.
6. Fabrication (prototype) of the machine is NOT included in this project.
1.6. Organization of the project
The thesis is organized in four chapters. The first chapter introduces background information and
justification, statement of the problem, objective including its general and specific, methodology,
scope of the study. The second chapter states an overview of literature review on clearer
roller/top roller cleaning machine and its properties, advantages and disadvantages. The main
body of our project is briefly described in the third chapter which incorporates the methodology
and design parameters of clearer roller cleaning and vacuum cleaning machine. The fourth
chapter includes the design analysis of each machine components and parts. The fifth and sixth
chapters incorporate the result and discussion and conclusion, recommendation for clearer roller
cleaning and vacuum cleaning machine respectively.

Textile Industry
CHAPTER TWO
2. LITERATURE REVIEW
2.1. Introduction
Top roller cleaning machine is one of the oldest technology used in many area of textile
companies in Ethiopia. Even there are a very good innovations developed countries regarding in
clearer roller cleaning machine, unfortunately our country is not using these product due to their
high cost.
2.2. Previously made Approaches
2.2.1. Manually operated clearer roller cleaning machine
The commonly used clearer roller cleaning machine we are going to modify is manually operated
roller that covered by metal wire throughout its circumference. It can clean only 6 clearer rollers
or top roller at once, since there are 1200 clearer rollers is used at one speed frame machine it is
boring and time consuming to clean the top roller with this machine.
Disadvantage of manually operated clearer roller cleaning machine:
 It operates manually
 It produce dusty material and trash which is very hard to human health
 It can clean limited amount of top roller at a time
 The wire material hurt the fiber of the top roller which reduces the life time of the
top roller.

Textile Industry
Fig 2.1. Manually operated clearer roller cleaning machine
2.2.2. Lakshmi ring traveller-LRT
A part of THE LMW group, is among the recent ring traveler manufacturing companies in the
world. From a trend setting start in 1974 the companies try to produce LRT clearer roller
cleaning machine.
The machine consist a wooden roller with a metal wire at different angle and nylon brushing
roller at the bottom rotating at different speed. During the cleaning process the metal wire softly
goes in to the surface of the top roller and cleans it.
2.2.3. Flocked clearer roller cleaning machine, GAYATRI
Manually operated for cleaning of comber nocked clearer rollers with metal wires, without
damaging or spoiling the surface of the clearer roller and the cotton fibers and fluffs are collected
in chamber. Machine is fixed on trolley wheel to move one place to another place.
It is manual and has net/gross weight of 165 kgs.

Textile Industry
2.2.4. Wooden clearer roller cleaning machine, MAYUR
Clearer roller cleaning machine with motor driven brush roller for clean, there clearer roller. In
built pneumatic/suction unit with electric motor. Mounted on castor wheel for transportation in
alley between ring frames.
The removed short fibers and fluffs would be collected in chamber provided, by the help of
dynamically balanced efficient suction fan.
This innovation is very important and less time consuming relative to manually operated
cleaning machine. But its expensiveness is the main problem to purchase. To solve this problem
we develop user friendly, low cost top roller cleaning machine.
Our machine has two rollers which rotate at the same speed. It operates automatically when the
motor is switched on. We use rubber brush rather than meal wire for the cleaning purpose that
covers the whole circular circumference of the rollers to reduce biting of the top roller fiber
during cleaning.
Advantages of the modified clearer roller (top roller) cleaning machine
 It is time saving
 It can clean 16 top roller at a time
 It have a cover which prevent the operator from dust and trash
 It works automatically
 It assures worker‟s comfort
 It also does extra work (i.e. it sack dust and trash from the floor)

Textile Industry
CHAPTER THREE
3. MATERIAL AND METHOD
3.1. Material
One of the most important tasks for a designer is the specification of the material from which any
individual component of a product is to be made. The decision must consider a huge number of
factors, many of which have been discussed in this chapter. The process of material selection
must commence with a clear understanding of the functions and design requirements for the
product and the individual component. Then, the designer should consider the interrelationships
among the following:
 The functions of the component

 The component's shape
 The material from which the component is to be made
 The manufacturing process used to produce the component
Overall requirements for the performance of the component must be detailed. This includes, for
example:
• The nature of the forces applied to the component

• The types and magnitudes of stresses created by the applied forces
• The allowable deformation of the component at critical points
• Interfaces with other components of the product
• The environment in which the component is to operate
• Physical size and weight of the component
• Aesthetics expected for the component and the overall product
• Cost targets for the product as a whole and this component in particular
• Anticipated manufacturing processes available

Textile Industry
Table3.1. General Specification of component

Serial Component Material Quantity
number
1 Motor Standard 1
2 Bevel gear Steel 2
3 Bearing Standard 5
4 Shafts Stainless steel 3
5 Belt Rubber 1
6 Roller Steel 2
7 Key Mild Steel 5
8 Pulley Cast steel 3
9 fan Standard 1
10 Base Frame steel 1
3.2. Software used to accomplish the desired model
Table 3.2. Software used

S. No. Components Software Version
1 Motor SOLID WORKS 2016 2016.0.2.24

2 Bevel gear SOLID WORKS 2016 2016.0.2.24
3 Bearing SOLID WORKS 2016 2016.0.2.24
4 Shafts SOLID WORKS 2016 2016.0.2.24
5 Belt SOLID WORKS 2016 2016.0.2.24
6 Roller SOLID WORKS 2016 2016.0.2.24
7 Key SOLID WORKS 2016 2016.0.2.24
8 Pulley SOLID WORKS 2016 2016.0.2.24
9 Base frame SOLID WORKS 2016 2016.0.2.24
10 Belt SOLID WORKS 2016 2016.0.2.24

Textile Industry
3.3. Methods
3.3.1. Data collection
Good data are essential to designing an efficient system on schedule. We define data as
information, preferably quantitative, on the characteristics of the product, the production process,
and the physical facility. The data-gathering phase of the project will include collecting
information, opinions, doing experiment and requests on many factors from different sources.
Data can be obtained from several sources. The system designer must determine which data are
needed and the best source for getting that data accurately and quickly. He should also verify that
the data are what it needs and that there are no errors or biases, accidental or deliberate.
We find the data from two resources:
a) Primary resources: gathering from literature, observing, visiting, interviewing other

persons that are helpful to our project.
b) Secondary resources: by referring different books and search different website as well
as conducting questioners.
When we collect data from different sources, we face different problem. From this data we saw
different things that should be corrected.
3.3.2. Component design
In designing a machine component, it is necessary to have a good knowledge of many subjects

such as mathematics, Engineering Mechanics, strength of materials, heat transfer, Workshop
processes and Engineering Drawing. When a new machine or its elements are to be designed, no
rigid rules can be specified for a design to follow the problem can be specified for many ways.
However the designer may proceed as follows: Make selection of the possible mechanisms
which will give the designed motion or group of motions. Determine the forces acting on and the
energy transmitted by each element of the machine. Select the material best suited for each
element of the machine. Determine the allowable or design stress considering all the factors that
affect the strength of machine part.

Textile Industry
3.3.3. Modeling of the machine
Then after the modeling is to be made. It is achieved through different software including
AUTOCAD, CATIA, and SOLID WORKS etc., In our case AUTOCAD and SOLID WORKS
are used.
3.4. Load and Force Analysis
3.4.1. Design of rotating roller shaft one
 Calculate torque transmitted by the shaft

 Calculate the maximum bending moment on the shaft
 Calculate the equivalent twisting moment
 Calculate the diameter of the shaft
Shaft is rotating part which is used to transmit power from one place to another. The standard
sizes of transmission shafts are:
 25 mm to 60 mm with 5 mm steps; 60 mm to 110 mm with 10 mm steps ; 110 mm to 140
mm with 15 mm steps ; and 140 mm to 500 mm with 20 mm steps.
 The standard length of the shafts is 5 m, 6 m and 7 m.
Figure 3.1. 3D Model of rotating roller Shaft

Textile Industry
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 factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties.
Based on the above requirements we select stainless steel especially for its high strength and
wear resistant.
Design considerations for shaft one

External diameter of drum, Dd = 80mm
Length of steel drum, Ld = 1000mm
Length of solid shaft, LS = 1130mmssss
Shear stress,
Bending stress,
The shaft is subjected to shear stress due to transmission of torque (due to torsional load) and
bending due to the forces acting upon.
Torque transmit by the shaft

The torque T transmitted by the shaft can be calculated from:
Where P = power
N = rotational speed
Assuming the rotational speed of shaft to be 250rpm (from various specifications) and power
4.5kw, then the torque developed on the shaft,
T= = = 172N-m

Textile Industry
Weight of pulley
Wp1 = where is density of pulley.
Since the pulley is made of cast iron, density of cast iron is 7200 kg/m3.
The volume of pulley V = A*B where B is width of pulley.
Similarly
A = d2 where d is diameter of pulley = 150mm
2
= = 17662.5mm2
Volume V = A B
For one grooved pulley the width of the pulley can be calculated as,
B = 1.25b where b= width of v- belt
Selecting v belt having width of 20mm, thus B = 1.25×13mm = 16.25mm
V = 17662.5×16.25 = 287015mm3
Mp = 7200×2.87×10-4 = 2kg where Mp is mass of pulley
Then weight of pulley becomes
Wp1 = 2×10 = 20N
Vertical load (Weight) on the shaft by steel drum

Area of steel drum Ad = Ld×Bd where Bd = width of drum which is equals to the
circumference 2 = 2×3.14×40 = 251.2mm
Ad = 1000×251.2 = 251200mm2
Volume of drum Vd = Ad×td where td is thickness of drum = 3mm
Vd = 251200×3 = 753600mm3

Textile Industry
Weight of drum Wd = take the density of steel to be 7800 kg/m3

Wd = 7800×7.536×10-4×10 = 60N
Horizontal load acting on the shaft by the pulley
T1
T2
In case of belt drives, the twisting moment ( T ) is given by

T = (T1 – T2) R
where T1 and T2 = Tensions in the tight side and slack side of the belt respectively,
and
R = Radius of the pulley.
Since the torque on the pulley is same as that of shaft (i.e. 128.8Nm), therefore
172×103 = (T1 – T2)*75
T1 - T2 = 2293N
T2 = T1 – 2293 . . . . . . . . . . . . . . . . . . (i)
And it‟s know that
2.3log ( ) =
Where is coeffient of friction between belt and pulley. In case of cast

iron it is 0.3.
is angle of lap of the belt = 180 =
2.3log ( ) = 0.942
log ( ) = 0.40956 OR = 2.568 (taking antilog of 0.40956)
T1 = 2.568T2 . . . . . . . . . . . . . . . . .(ii)
Combining equation (i) and (ii)

Textile Industry
T1 = 2.568(T1 – 2293)
1.568T1 = 5888.4
T1 = 3755N and also T2 = 1462N
Therefore, horizontal load acting on the shaft by the pulley is
WD = T1 + T2 = 3755 + 1462 = 5217N
Shaft subjected to bending moment
Taking Moment at point A,

MA= 0; 60(540) – RC(1080) + 20(1113)
RC = 50.6N
Vertical reactions,
+ ƩFy = 0; RA + RC – 60 – 20 = 0
RA = 29.4N
Maximum bending moment

Now let us find the maximum bending moment for vertical and horizontal loading. The vertical
reactions RA and RC at the bearings are known to be 24N and 236.1N respectively.
We know that bending moment at point A and D,
MAV = MDV = 0
Bending moment at B, MBV = RAV × 540 = 15876Nmm

Bending moment at C, MCV =20×33 = 660Nmm

Textile Industry
15876
660
A D
B C
Figure 3.2. Vertical bending moment diagram
Now consider the horizontal loading at B and D. Let RAH and RCH be the reactions at the
bearings A and C respectively. We know that
RAH + RCH = 5217N
Taking moments about A,
RCH×1080 = 5217×1113
RCH = 5376N
RAH = 5376 – 5217 = -159.4N
And we know that B.M. at A and D,
MAH = MDH = 0
Bending moment at B, MBH = RAH×540 = -86080 N-mm
Bending moment at C, MCH =5217 ×33 = 172161 N-mm
172161
B C
A D
-86080
Figure 3.3. Horizontal bending moment diagram
We know that resultant B.M. at B,

MB = √ =√ = 87531Nmm
And the resultant B.M. at C,

Textile Industry
MC = √ =√ = 172171Nmm
The resultant B.M. diagram is shown in Fig. We see that the bending moment is maximum at C.
Maximum bending moment,
M = MC = 172171N-mm
172171
87531
E G H F
Figure 3.4. Resultant bending moment diagram
Let dS = Diameter of the shaft.

We know that the equivalent twisting moment,
Te = √
= √ = 214.9 × 103 N-mm
We also know that equivalent twisting moment (Te),
214.9 × 103 = d3s
Assume the torsional shear stress for shaft with key allowance is, τ= 42N/mm2
ds = √ = 29.5 say 30mm
Again we know that equivalent bending moment (Me),
Me = √
= (172171 + √ )
= 171.9× 103 =
Assume the allowable working bending stress for shaft with key allowance is 84 N/mm2
ds = √ = 24.5 mm say 25mm.
Therefore, taking the maximum value the shaft diameter is ds = 30mm.

Textile Industry
3.4.2. Design of rotating roller shaft two
Design considerations
External diameter of drum, Dd = 80mm
Length of steel drum, Ld = 1000mm
Length of solid shaft, LS = 1130mm
Distance between two pulleys, x = 325mm
Shear stress,
Bending stress,
Figure 3.5. 3D Model of rotating roller shaft two

In similar way the second shaft is supported by to bearings carrying roller jacket at the mid of the
shaft. The only difference is that the second pulley mounted on this shaft is having two grooves
(but equal diameter) one of which is used to connect the belt to the motor pulley and the other for
the first shaft pulley.

Textile Industry
Horizontal and vertical loadings acting on the shaft by the pulley
T1
T2
T4
T3
Weight of pulley,
WP2 =
V = A×B
Where B is width of pulley
B = 1.25b b is width of belt = 13mm
= 1.25×13 = 16.25mm.
Since the pulley‟s width is larger twice than the former because it is double grooved,
B = 2×16.25 = 32.5mm say 35mm
A=
2
=
Volume of pulley,
VP2 = A×B = 17662.5×35 = 618187.5mm3
Weight of pulley,
WP2 = where is density of pulley (cast iron) = 7200kg/m3
g is gravitational force = 10m/s2

= 7200×6.2×10-4×10 = 44.6N

Textile Industry
Tension on belts
Let T1 is tension in tight side of the belt on pulley D = E.
T2 is tension in slack side of the belt on pulley D = E.
T3 is tension in tight side of the belt on pulley E.
T4 is tensions in slack side of the belt on pulley E.
We know that T1 and T2 are 3755N and 1462N respectively. i.e., the horizontal loading acting on
the shaft by the pulley E,
WE = T1 + T2 = 5217N
Torque transmitted (T ),
172×103 N-mm = (T3 - T4)RP
Where RP is radius of pulley = 75mm
T3 - T4 = 2293N
T4 = T3 – 2293N ………………………….(i)
2.3log ( ) =
Where is coeffient of friction between belt and pulley In case of cast

iron it is 0.3.
is angle of lap of the belt
And sin
Where, r1 = radius of larger pulley

r2 = radius of small pulley
x = the distance between the center of two pulleys
sin = = 0.112
. thus,
= (180-2×6.62) = 2.9rads
Therefore,

Textile Industry
2.3log ( ) = = 0.378
= 2.389 ……… (Taking antilog of 0.378)
T3 = 2.389T4 ………………………………………………………… (ii)
Equating the two equation,

T3 = 2.389(T3 - 2293)
T3 = 3943.8N and T4 = 16508N
The total vertical load acting on the shaft by the pulley,
WT = T3 + T4 + WP2 = 1650.8+3943.8+44.6 = 5638.4N
Now taking moment at point E,

ME = 0; 60(540) – RH(1080) + 5638.4(1113)
RH = 5840.6N
Vertical reactions,
+ ƩFy = 0; RE + RH – 60 – 5638.4 = 0
RE = 142N

We know that bending moment at point E and F,
MEV = MFV = 0
Bending moment at G, MGV = REV × 540 = 76680Nmm
Bending moment at H, MHV =5638.4×33 = 186067Nmm

Textile Industry
186067
76680
E G H F 76680
Figure 3.6. Vertical bending moment diagram of shaft two
Now consider the horizontal loading at G and F. Let REH and RHH be the reactions at the bearings
E and H respectively. We know that
REH + RHH = 5217N

Taking moments about E,
RHH×1080 = 5217×1113
RHH = 5376.4N
REH = 5217 – 5376.4 = -159.4N
And, we know that B.M. at E and F,
MEH = MFH = 0
Bending moment at G, MGH = RGH*540 = -86080.5 N-mm
Bending moment at H, MHH = 5217*33 = 172161 N-mm
172161
E G H F
-86080.5
Figure 3.7. Horizontal bending moment diagram of shaft two
We know that resultant B.M. at G,

Textile Industry
MG = √ =√ = 97300N-mm
And the resultant B.M. at H,
MH = √ =√ = 211580N-mm
The resultant B.M. diagram is shown in Fig. We see that the bending moment is maximum at H.
Maximum bending moment,
M = MH = 211580N-mm
211580
97300
E G H F
Figure 3.8. Resultant bending moment diagram of shaft two
Let dS2 = Diameter of the shaft two.

We know that the equivalent twisting moment,
Te = √
= √ = 272.6× 103 N-mm
We also know that equivalent twisting moment (Te),
272.6× 103 = d3s
ds = √ = 29.8 say 30mm
Again we know that equivalent bending moment (Me),
Me = √

Textile Industry
= (211580 + √
= 199 × 103
Me =
Assume the allowable working bending stress for shaft with key allowance is 84 N/mm2
ds = √ = 28.9mm say 30mm.
Therefore, ds = 30mm.
3.4.3. Design of shaft three
Design considerations:
Length of shaft, l = 300mm
Maximum permissible shear stress of material = 42MPa
Maximum permissible bending stress of material = 84MPa
Torque transmit by the shaft

The torque T transmitted by the shaft can be calculated from:
Assuming the rotational speed of shaft to be 500rpm (from various specifications) and power
3.5kw, then torque on the shaft,
T= = = 67N-m.
Weight of pulley
Wp1 = where is density of pulley.

Textile Industry
Since the pulley is made of cast iron, density of cast iron is 7200 kg/m3
The volume of pulley V = A×B where B is width of pulley
Similarly
A = d2 where d is diameter of pulley
2
= = 4415.6mm2
Volume V = A×B
B=1.25b where b= width of v- belt
Selecting v belt having width of13mm, thus B = 1.25×13mm = 16.25mm
V = 4415.5×16.25 = 71753.9mm3
Mp = 7200×71753.9= 0.5kg where Mp is mass of pulley
Then weight of pulley becomes
Wp1 = 10×0.5 = 5N
Figure 3.9. 3D Model of shaft three

Since the torque acting at the gear A and C is the same as that of the shaft therefore, the
tangential force act on the gears A is
= where = tangential force acting on gear A (N)
T = torque applied on the shaft (N-mm)

RA= radius of gear A
= = 992.5N

Textile Industry
Assume the weight of gear A=10N

The total load acting downward on the shaft at point A
WTA = + where =weight of gear A (N)
= 992.5 + 10N = 1002.5N
In case of pulley, the vertical loading acting on the shaft at point C by the pulley is determined as
follows:
Let, T 1 = belt tension in tight side
T2 = belt tension in slack side
R = Radius of the pulley.
The twisting moment ( T ) is given by
T = (T1 – T2) R
Since the torque on the pulley is same as that of shaft (i.e. 67N-m), therefore
67×103 = (T1 – T2)×37.5
T1 - T2 = 1786.5N
T2 = T1 – 1786.5 . . . . . . . . . . . . . . . . . (i)
2.3log ( ) =
Where is coeffient of friction between belt and pulley. In case of cast

iron it is 0.3.
is angle of lap of the belt = 3rads
2.3log( ) = 0.9
Log( ) = 0.3913 OR = 2.46 (taking antilog of 0.3913)
T1 = 2.46T2 . . . . . . . . . . . . . (ii)
Combining equation (i) and (ii)
T1 = 2.46(T1 – 1786.5)
1.46T1 = 4395N
T1 = 3139N and also T2 = 1276N
Therefore, vertical load acting on the shaft by the pulley is

Textile Industry
WTC = T1 + T2 = 3139 + 1276 = 4415N
Let = reaction at bearing B

= +
= 1002.5 + 4415 = 5417.5N
Now assuming the shaft as a simply supported beam as shown in fig above. We know the
maximum bending moment is at point B,
MB = 0; 4415(120) – 1002.4(180)
MB = 349368
Equivalent twisting moment

We know that the equivalent twisting moment is calculated by,
=√
=√
= 233×103N-mm
Diameter of the shaft

We also know that the equivalent moment
135×103 =
d=√ mm = 29.8mm say d = 30mm
3.4.4. Motor selection
Required motor specification

As a minimum, the following items must be specified for motors:
 Motor type: DC, AC, single-phase, three-phase, and so on

Textile Industry
 Power rating and speed

 Operating voltage and frequency
 Type of enclosure
 Frame size
 Mounting details
In addition, there may be many special requirements that must be communicated to the vendor.
The primary factors to be considered in selecting a motor include the following:
 Operating torque, operating speed, and power rating. Note that these are related by the
equation
Power = torque x speed
 Starting torque.
 Load variations expected and corresponding speed variations that can be tolerated.
 Current limitations during the running and starting phases of operation.
 Duty cycle: how frequently the motor is to be started and stopped.
 Environmental factors: temperature, presence of corrosive or explosive atmospheres,
exposure to weather or to liquids, availability of cooling air, and so on.
 Voltage variations expected: Most motors will tolerate up to ± 10% variation from the
rated voltage. Beyond this, special designs are required.
 Shaft loading, particularly side loads and thrust loads that can affect the life of shaft
bearings.
Since Industrial and large commercial installations use AC three phase power for the larger
electrical loads because smaller motors are possible and there are economies of operation, our
design tend to select an AC induction motor.

Textile Industry
Table 3.3. AC motor voltages

Motor voltage ratings
Single phase Three phase
System voltage
120 115 115
120/208 115 200
240 230 30
480 197 460
600 134 575
Source: MACHINE ELEMENTS IN MECHANICAL DESIGN
Fourth Edition, Robert L. Mott, RE, University of Dayton
Based on the above load and force analysis and mentioned specifications, we select a four pole,
3-phase 3.5kw, 1500rpm, 60Hz and 230V AC enclosed, with double-end shaft motor. Purpose to
select double end shaft motor is that a fan is mounted to one end of the shaft to provide suction
of dust particles and cotton tufts whenever the motor is started on.
Table 3.4. Selected motor specification

Motor Number of Number of Power Frequency Voltage Frame
type Poles phases (Watt) (Hertz) (Volts) type
AC, 4 3 3500 60 230 Enclosed,
Induction Double-end
shaft
3.4.5. Design for bevel gear

 Know diameter and number of tooth of driven and driving gear
 Calculate tangential tooth load
 Calculate dynamic tooth load
 Calculate static tooth load
 Calculate wear tooth load
 Calculate Force acting on the bevel gear

Textile Industry
Figure 3.10. 3D Model of bevel gear
The bevel gears are used for transmitting power at a constant velocity ratio between two shafts
whose axes intersect at a certain angle. The pitch surfaces for the bevel gear are frustums of
cones.
Design consideration
 Speed of driving bevel gear=speed of motor ,N1= 1500rpm
 Speed of driven bevel gear,N2 = 500rpm
 Number of tooth for driving bevel gear,T1=18
 Pitch angel for driving bevel gear, = 450
 Pitch angel for driven bevel gear, = 450
0
 Angel between two shaft axes,
 Module, m=2.5mm
 Bevel gear made from steel
Diameter and number of tooth of both gears

We know that the velocity ratio is given by
V.R = = =3
And we know that,

V.R = then T2 = 18×3 = 54

Textile Industry
Let M = module
M= =
D1 = 2.5×18 = 45mm and D2 = 2.5×54 = 135mm.
Tangential tooth load

The strength of the bevel gear tooth is obtained by modified form of Lewis equation for the
tangential tooth load is given as follows;
( )
where = allowable static stress

= velocity factor
V = peripheral speed
b = face width
m = module
y‟= tooth form factor
L = slant height of the pitch cone
We know that the allowable static stress for steel, 120
Since both driving and driven gears are made from the same material the driving gear is
considered as the weaker gear and the Lewis equation is used to the weaker gear.
The velocity factor for a gear generated with precision machine given by;
= but, v= = = 3.53m/s
= = = 0.63
The module of the gear, m = 2.5

The slant height of pitch cone can be calculated as
L √ where = diameter of the gear
= diameter of the pinion
L √ = 71mm

Textile Industry
Let TEP and TEG are formative number of teeth for pinion and gear respectively
TEP = TP where Tp = number of tooth of pinion gear
p1 = angle of pitch of pinion gear
TEP = 18×sec45 = 25.45
Similarly,
TEG = TG where TG = number of tooth of gear
pitch angle of gear
TEG = 54×sec45 = 76.36
Tooth form factor for the pinion
yp‟ = 0.124 - = 0.124 - = 0.097
and tooth form factor for the gear,
yp‟ = 0.124 - = 0.124 - = 0.115
Since the allowable static stress ( ) for both the pinion and gear is same (made of similar
material) and y'p is less than y'G, therefore the pinion is weaker. Thus the design should be based
upon the pinion.
Assuming the face width b is of the slant height L
b= = 23.6mm say 24mm
therefore, the tangential tooth load
= 914.56N
Calculating dynamic tooth load

The dynamic load for the bevel gear may be obtained in the similar manner as spur gear
=
= +
√
Where,

Textile Industry
dynamic tooth load (N)

= tangential tooth load (N)
= increment load due to dynamic action (N)
V= pitch line velocity ( )
b = tooth face width (m)

C = dynamic load factor
Assume b = 24mm = 0.024m
C = 220MPa
From above calculation we know that the velocity at pitch line = 3.53m/s
= +
√
= 914.56 +
√
WD = 914.56 + 30.34 = 944.9N
Calculating static tooth load

The static tooth load or endurance strength of the tooth for bevel gear is calculated by following
formula
Where is flexural endurance limit. From the table flexural endurance limit of steel, =
252N/mm2 then,
1920.5N
For safety, against tooth breakage, the static tooth load (WS) should be greater than the dynamic
load (WD). is greater than the design is safe

Textile Industry
Diameter of pinion gear

First of all, find the torque acting on the pinion. It is given by
T= N-m
Where P = power transmitted in watts = 5500watts and

Np = speed of the pinion in rpm = 1500rpm
then T= = 35N-m
The tangential force (Wt) acting at the mean radius (Rm) of the pinion
Wt =
But, Rm = (L - ) = (71 - ) = 18.69mm
Wt = = 1872.66N
The resultant bending moment on the pinion shaft as follows:

The bending moment due to WRH and WRV is given by
M1 = WRV overhang - WRH m
0
Assuming 14 ⁄ pressure angle of tooth
WRH = WT tan sin p = 914.56×tan(14 ⁄ )×sin45 = 169.07N
WRV = WT tan cos p= 914.56×tan(14 ⁄ )×cos45 = 167.24N
Assume the overhang to be 150mm
M1 = 167.24 21926.08N-mm
and bending moment due to WT,
M2 = WT overhang = 914.56 150 = 137184N-mm
Resultant bending moment,
M=√ =√ = 138925N-mm
Since the shaft is subjected to twisting moment (T ) and resultant bending moment (M), therefore
equivalent twisting moment ,
Te = √ =√ = 143266N-mm
Now the diameter of the pinion shaft may be obtained by using the torsion equation. We know
that

Textile Industry
Te = taking
d=√ = 25.9mm say 30mm.
Calculating wear tooth load

The wear load on the tooth can be calculated by using the following relation;
= ×b×Q×K where = wear tooth load (N)
= pitch circle diameter of driving gear (mm)
b = face width (mm)
Q = ratio factor
K = load stress factor (N/ )
From above calculation, we know that b = 24mm
= 2Lsin = 2×71×sin45 = 100.4mm
Ratio factor, Q = = = 1.5
The load stress factor is calculated by the following formula
K= ( )
where = surface endurance limit (N/ )

= pressure angle
E1 = young‟s modules for driving gear material
E2 = young‟s modules for driven gear material
Since both driving and driven gears are made from steel, E 1 = E2 = 200,000N/
And for steel, the flexural endurance limit ( ) may be obtained by using the following
relation:
= 1.75×B.H.N = 1.75×280 = 490MPa
= 14 ⁄ 0
K= ( )
⁄
K= ( ) N/ = 0.49N/mm2
= ×b×Q×K = (100.4×1.5×0.49×24)
= 1771N

Textile Industry
 Since is also greater than the design is safe
3.4.6. Selection of ball bearins
 Know the equivalent dynamic load

 Know the dynamic load rating
A bearing is a machine element that constrains relative motion between moving parts to only the
desired motion. It permits relative motion between the contact surfaces of the members, while
carrying the load
 Speed of selected bearing ,N =500rpm
 Internal radius of bearing = radius of shaft =30mm
Let = outer radius of roller bearing
= inner radius of roller bearing
= radius of shaft = 30mm
From standard dimension of roller bearing at =30mm, = 62mm
Table 3.5. Standard dimensions of Ball bearing

Bore, OD, Width, Load rating, Kn
Mm Mm mm C0 C10
25 52 15 8.8 16.8
30 62 16 12 22.4
35 72 17 17.6 31.9
40 80 18 24.0 41.8
45 85 19 25.5 44.0
50 90 20 27.5 45.7
55 100 21 34.0 56.1
60 110 22 43.1 64.4
Calculate equivalent basic dynamic load

W= X×V×WR + Y×WA
Where

Textile Industry
V = rotating factor =1(for inner race is rotating)

X, Y = constants
WR =radial load
WA = axial load
From above, maximum axial tangential load from both bevel and spur gear is, WT = 914.56N
And the maximum radial load, WR = WA×tan = 914.56N×tan14.5 = 236.5N
Let we assume the radial force on the bearing = radial force on pinion = 236.5N
Axial force on bearing = axial force on pinion = 914.56N
To determine X and Y first let we calculate the ratio of WR and WA and compared with “e”.
e = 0.32 for spherical roller bearing
= = 3.867 and say
Since e is less than , from table X= 0.56 and Y= 1 therefore,
W = X×V×WR+Y×WA
W = (0.56×1×236.5+1×914.56) N
W = 132.44N + 914.56N
W= 1046.7N
Figure 3.11. 3D Model of bearing

Textile Industry
Dynamic load rating on the bearing
C =W where L = rating life
C = basic dynamic load rating

W = equivalent dynamic load
K = 3 for ball bearings
L = LH×60N (in revolution)
Where N = speed in rpm =500rpm
LH = life of bearing in hour.
Let average number of life of year of bearing = 5year
Number of working day per year = 300days
Average working hour per day = 10 hours
LH = 5×300×10
LH = 15,000hours
L = 15,000×60×500rpm
L = 15,000×60×500
L = 450,000,000 revolutions
C=W
C = 1046.7N = 8004N
Therefore, from standard table below, the bearing number 302 having C = 8.8kN, is selected.
Table 3.6. Basic static and dynamic capacities of various types of radial ball
bearings.(Source: Textbook of Machine design, Khurmi and Gupta)
Bearing Basic capacities in KN
No. Single row deep Single row Double row Self-aligning
groove ball angular contact angular contact ball bearing
bearing ball bearing ball bearing
Static Dynamic Static Dynamic Static Dynamic Static Static
(C0) (C) (C0) (C) (C0) (C) (C0) (C0)
(1)

Textile Industry
(2) (3) (4) (5) (6) (7) (8) (9)

200 2.24 4 - - 4.55 7.35 1.80 5.70
300 3.60 6.3 - - - - - -
201 3 5.4 - - 5.6 8.3 2.0 5.85
301 4.3 7.65 - - - - 3.0 9.15
202 3.55 6.10 3.75 6.30 5.6 8.3 2.16 6
302 5.20 8.80 - - 9.3 14 3.35 9.3
203 4.4 7.5 4.75 7.8 8.15 11.6 2.8 7.65
303 6.3 10.6 7.2 11.6 12.9 19.3 4.15 11.2
403 11 18 - - - - - -
204 6.55 10 6.55 10.4 11 16 3.9 9.8
304 7.65 12.5 8.3 13.7 14 19.3 5.5 14
404 15.6 24 - - - - - -
3.4.7. Selection of v- belt

Calculate:
 the length of the v- belt
 power transmitted by the belt
 cross sectional area of the belt
 total mass of the belt
 tension of the belt
Figure 3.12. 3D Model of v-belt

Textile Industry
The belts are used to transmit power from one shaft to another by means of pulleys which rotate
at the same speed or at different speeds. Though there are many types of belts used these days,
yet the following are important from the subject point of view:
1. Flat belt. The flat belt is mostly used in the factories and workshops, where a moderate
amount of power is to be transmitted, from one pulley to another when the two pulleys
are not more than 8 meters apart.
2. V- Belt. The V-belt is mostly used in the factories and workshops, where a great amount
of power is to be transmitted, from one pulley to another, when the two pulleys are very
near to each other.
3. Circular belt or rope. The circular belt or rope is mostly used in the factories and
workshops, where a great amount of power is to be transmitted, from one pulley to
another, when the two pulleys are more than 8 meters apart.
Of these belts, we select v-belt because the two pulleys are very near to each other.
Power to transmit by the shaft, P = 5.5kw
The distance between two pulley, X = 325mm
Large Pulleys diameter = 150mm
Small pulley diameter D2 = 75mm
Tension ratio = 2.389
The belt is made from rubber
Length of v-belt
Since the belt is open belt the total length of the belt can be calculated by
L= ,
= 1042.19mm = 1.04219m
From standard v belt lengths, the nearest is 1051mm or 1.501m is selected.

Textile Industry
Table 3.7. Standard pitch lengths of V-belts according to IS: 2494-1974.( Source: Textbook of
Machine design, Khurmi and Gupta)
Type of belt Standard pitch lengths of v-belts in mm

645, 696, 747, 823, 848, 925, 950, 1001, 1026, 1051, 1102, 1128, 1204,
1255, 1331, 1433, 1458, 1509, 1560, 1636, 1661, 1687, 1763, 1814,
1941, 2017, 2068, 2093, 2195, 2322, 2474, 2703, 2880, 3084, 3287, 3693.
A
Power transmitted by the belt

We know that the coefficient of friction between rubber belt and dry cast iron pulley = 0.3
And also we know that the power from the shaft, =5.5kw
Then the power transmit by the belt is given by
P = power of shaft×Coefficient of friction
= 3.5kw×0.3 = 1.05kw
Assuming the overload factor to be 1.3, then the belt is to be designed for 1.65×1.3 = 2.145kw.
Since the V-belt is to be designed for 2.145kW, therefore from standard belt types, we find that
an „A‟ type of belt should be used.
Table 3.8. Dimensions of v belts according to IS: 2494-1974 (source: Textbook of Machine design,
Khurmi and Gupta)
Type of belt Power ranges Minimum Top wide (b) Thickness (t) Weight per
in KW pitch diameter mm mm meter length
of pulley (D) in newton
mm
A 0.7 – 3.5 75 13 8 1.06
B 2 – 15 125 17 11 1.89
C 7.5 – 75 200 22 14 3.43
D 20 – 150 355 32 19 5.96
E 30 – 50 500 38 23 -
Cross sectional area of the belt

We know the cross sectional area of the belt is can be calculated by
A = b×t where b = width of the belt = 13mm

Textile Industry
t = thickness of the belt = 8mm
A = 13mm×8mm = 104
Total mass of the belt
The total mass of the belt per meter length can be calculated by the following formula
m = Area ×Length ×Density
We know the density of rubber = 1140
Table 3.9. Density of belt material (source: Textbook of Machine design, Khurmi and Gupta)
Material of belt Mass density in kg/m3
Leather 1000
Convass 1220
Rubber 1140
Balata 1110
Single woven belt 1170
Double woven belt 1250
m = 1140 ×0.000104m2×1.0429m
= 0.1236kg/m
Tension of belt
We know that the power transmit by the belt is given by
P= ( V where = tension in tight side
= tension in slack side
V = speed of belt
And we know that, V= = =1.9625
P=( V=( ) 1.9625
1.65kw = ( ) 1.9625
= 1.184KN………………………………………………. (1)

Textile Industry
From tension ratio, = 2.39 =2.39 ……………...…………………….…. (2)
From equation (1) and (2)

2.39 - = 1.184KN
= 1.206kN
= 2.39 = 2.39×1.184kN = 2.83kN
3.4.8. Design of v-grooved pulley
 Calculate dimension of pulleys

 Calculate the centrifugal stress induced at rim of the pulley
Pulley is a mechanical component used to transfer the rotation of one component to the other
with the help of belt. It may be made from different material for different specific operation. We
select grooved pulley for the v- belt operation.
Power to transmit, P = 5.5kw
Velocity ratio, V.R = 2
The pulley is made from cast iron
Figure 3.13. 3D Model of one grooved larger pulley

Dimension of pulley
 Diameter of the pulley
According a standard v-belt dimension the minimum pitch diameter is 75mm for the power
range from 0.7-3.5kw. So let we take diameter of small pulley = 75mm

Textile Industry
To calculate diameter of large diameter pulley
V.R = 2 = where = diameter of large pulley
= diameter o0f small pulley

= 75mm×2 = 150mm
 Width of the pulley

B = 1.25b where b = width of v- belt
Since the selected belt has width of 13mm,
B = 1.25×13mm = 16.25
But, the first pulley take double belt so that,
B = 2×1.25×b = 32.5mm say 35mm.
Figure 3.14. 3D Model of smaller pulley
Calculate the centrifugal stress induced at rim of the pulley

The centrifugal stress induced can be calculated by the following relation
= where  = density of rim material=7200 for cast iron
V = velocity of rim
For large pulley, V= = =1.96m/s
= = 7200 *(1.96 )2 = 27.73

Textile Industry
For small pulley, V= = = 1.96m/s
= = 7200 (1.96 m/s) 2 = 27.73
Figure . 3D Model of two grooved pulley
f3.4.9. Design for key for shaft one

 Calculating the length, width and thickness of the key
 Calculating tangential shear force
Perhaps the most common of these torque-transmitting shaft-to-hub connections are keys, of
which the most common type is the square key. Standard proportions call for the key width to be
approximately one-fourth the shaft diameter. Keys are usually made of cold-finished low-carbon
steel (as SAE or AISI 1020), but heat treated alloy steels are used when greater strength is
required.
In our case, square sunk key is appropriate which provided half in the keyway of the shaft and
half in the keyway of the hub or boss of the pulley.
Figure 3.15. 3D Model of Squaresunk key

Textile Industry
 Diameter of shaft 1, d = 30mm
Length of the key
In order to find the length of the key to transmit a full power of the shaft, the shearing strength of
the key and the torsional shear strength of the shaft must equal. So the length of the key can be
calculated as follows:
Let l = Length of key.
The permissible crushing stress for the usual key material is at least twice the permissible
Shearing stress. Therefore from equation , we have w = t. In other words, a square key is equally
strong in shearing and crushing.
Considering shearing of the key. We know that shearing strength (or torque transmitted) of the
key,
T = l×w
Taking assumption of shearing and crushing stress of the square key to be 42N/mm2 and
84N/mm2
T = l×7.5×42×15 N-mm
= 4725l ………………………………………….…….... (i)
and torsional shearing strength (or torque transmitted) of the shaft,
3
T= × = 172000 N-mm ……………….................. (ii)
From equations (i) and (ii), we have

l = 46.4mm say 47mm.
Width and thickness of the key
A square sunk key is made in shaft and hub with the following proportion. We know that in case
of a square sunk key is the width and thickness of key are equal, i.e.
w=t=d/4
w= where d = diameter of the shaft
= = 7.5mm . w = width of the key
So, t = 7.5mm. t = thickness of the key

Textile Industry
Tangential shearing force acting at the circumference of the shaft (considering shearing of the
key)
Ft = l×w×τ where τ = torsional shear stress = 36N/mm2
Ft = tangential force act on the circumference
of the shaft
l = length of the key
w = width of the key
Ft = l×w×τ = 7.5mm×47.13mm×36N/mm2
Ft = 12.7kN
Effect of Keyways
A little consideration will show that the keyway cut into the shaft reduces the load carrying
capacity of the shaft. This is due to the stress concentration near the corners of the keyway and
reduction in the cross-sectional area of the shaft. It other words, the torsional strength of the shaft
is reduced. The following relation for the weakening effect of the keyway is based on the
experimental results by H.F. Moore.
e = 1- 0.2( ) – 1.1( )
where e = Shaft strength factor. It is the ratio of the strength of the shaft with
keyway to the strength of the same shaft without keyway,
w = Width of keyway,
d = Diameter of shaft, and
h = Depth of keyway =
e = 1- 0.2( ) – 1.1( ) = 0.8375
3.4.10 Selection Bolt
The primary loading applied to bolts is tensile, shear, or a combination of the two. Moreover,
some bending is usually present because the clamped surfaces are not exactly parallel to each
other and perpendicular to the bolt axis and because the loaded members are somewhat
deflected.

Textile Industry
Consider the rotating shaft two, supporting one end of a rotating shaft. The shaft applies a static
load of 5.7kN to the pillow block as shown below.
5.7kN
Figure 3.16. Pillow block attached by two machine screws
Decisions
1. A relatively inexpensive class 5.8 steel is chosen for the screw material.
2. The load of 5.7kN is shared equally by each screw.
3. No bending of the machine screws (bolts) takes place; that is, the bolt load is axial
tension.
TABLE 3.10. Specifications for Steel Used in Millimeter Series Screws and Bolts
(Fundamentals of Machine Component Design ROBERT C. JUVINALL, KURT M. MARSHEK)
SAE Class Diameter Load Yield Tensile Elongation
Strength strength
d (mm) proof (strength ) Minimum
Sy (MPa) Su (MPa)
Sp (MPa) (%)
4.6 5 thru 36 225 240 400 22
4.8 1.6 thru 16 310 -- 420 --
5.8 5 thru 24 380 -- 520 --
8.8 17 thru 36 600 660 830 12
9.8 1.6 thru 16 650 -- 900 --

Textile Industry
10.9 6 thru 36 830 940 1040 9

12.9 1.6 thru 36 970 110 1220 8
Selection procedure:
1. Any class of steel could have been used, but there appears no reason to specify a costly
high-strength steel. Class 5.8, with a proof strength of 380 MPa (Table 10.5), is chosen.
2. The nominal load for each of the two bolts is 2.9 kN. If screw failure would not endanger
human life, cause other damage, or entail costly shutdown, a safety factor of 2.5 would be
reasonable. Since in this case the cost of using a larger safety factor is trivial, and since
failure might prove rather costly, let us use “engineering judgment” and increase the
safety factor to 4. Then, the “design overload” for each bolt is 2.9 kN × 4, or 11.6kN.
3. For static loading of a ductile material, stress concentration can be neglected and the
simple “ = P/A” equation used, with s being equal to the proof strength when P is equal
to the design overload:
380MPa = or At = 30.5mm2
4. Reference to Table below indicates an appropriate standard size of class 5.8 screw to be
M8×1.25 (for which At = 36.6 mm2).
Table 3.11. Basic Dimensions of ISO Metric Screw Threads.

Nominal Diameter Coarse threads
Pitch Minor diameter Stream Area
D(mm)
P(mm) Dm (mm) At (mm2)
3 0.5 2.39 5.03

3.5 0.6 2.76 6.78
4 0.7 3.14 8.78
5 0.8 4.02 14.2
6 1 4.77 20.1
7 1 5.77 28.9

Textile Industry
8 1.25 6.47 36.6

10 1.5 8.16 58.0
12 1.75 9.85 84.3
14 2 11.6 115
16 2 13.6 157
Source: Fundamentals of Machine Component Design ROBERT C. JUVINALL, KURT M. MARSHEK
3.4.11. Selection of fan
 Speed of the fan at the tip

 Inlet area of the fan
 Discharge of the fan
 Suction pressure developed by the fan
 Speed of the fan, N = 1500rpm
 Power of the motor = 3.5kw
 Type of fan = centrifugal fan
 Inlet diameter of the fan, D = 150mm
Speed of impeller
We know that the rotation of the motor shaft is equal to the rotation of the impeller. So speed at
the tip of impeller,
V= = = 11.775
The inlet area of the fan can be calculated by
A=
= × = 17662.5

Textile Industry
Discharge of the fan

We know that the discharge, Q of air can be calculated by the following formula
Q = A×V
= 0.0177625 ×11.775 = 0.2
Suction pressure developed by the fan

The suction pressure p of the fan can be calculated by following the formula
p=
Considering 10% extra accommodate flow recirculation and impeller inlet hydraulic loss
Power of fan = 10%×3.5kw = 0.35kw then,
p= =
p = 1.75kPa
3.4.12. Design of Base Frame
Figure 3.17. 3D Model of Base frame
The design of machine frames and structures is largely art in that the components of the machine
must be accommodated. The designer is often restricted in where supports can be placed in order

Textile Industry
not to interfere with the operation of the machine or in order to provide access for assembly or
service. But, of course, technical requirements must be met as well for the structure itself. Some
of the more important design parameters include the following:
 Strength
 Corrosion resistance
 Size
 Vibration limitation
 Stiffness
 Cost to manufacture
 Weight
 Noise reduction
 Life
Because of the virtually infinite possibilities for design details for frames and structures, this
section will concentrate on general guidelines. The implementation of the guidelines would
depend on the specific application. Factors to consider in starting a design project for a frame are
now summarized:
 Forces exerted by the components of the machine through mounting points such
as bearings, pivots, brackets, and feet of other machine elements
 Manner of support of the frame itself
 Precision of the system: allowable deflection of components
 Environment in which the unit will operate
 Quantity of production and facilities available
 Availability of analytical tools such as computerized stress analysis, past experience
with similar products, and experimental stress analysis
 Relationship to other machines, walls, and so on
Recommended Deflection Limits
Actually, only intimate knowledge of the application of a machine member or a frame can give a
value for an acceptable deflection. But some guidelines are available to give you a place to start.
Deflection Due to Bending
General machine part: 0.0005 to 0.003 in/in of beam length

Textile Industry
Moderate precision: 0.00001 to 0.0005 in/in

High precision: 0.000 001 to 0.000 01 in/in
Deflection (Rotation) Due to Torsion

General machine part: 0.001° to 0.017in of length
Moderate precision: 0.000 02° to 0.00047in
High precision: 0.000 001° to 0.000 02°/in
Suggestions for Design to Resist Bending
Where
P = load
L = length between supports
E = modulus of elasticity of the material in the beam
I = moment of inertia of the cross section of the beam
K = a factor depending on the manner of loading and support
Here the length of the frame is 1080mm and the width and height is 490mm and 760mm
respectively. The material selected for the frame is mild steel for its high shock absorbing
capability resistance to bending. The

Textile Industry
3.5 Manufacturing process
Table 3.12. Manufacturing process

Part name Manufacturing procedures
Bevel gear  Take the circular solid bar from steel and cut it by hydraulic cutter
 Place the circular bar in to lathe and hold it by jaws. And Facing action is
performed
 After that the cut work piece is shaped in to a gear blank with turning action
 Then gear cutting is done with the gear hobbing machine
 Since the hobbing machine always leaves burs on the teeth of the gear it had
to remove with deburring machine
 Finally black oxide finish to prevent it from rust
Shafts  Take the circular solid bar from staidness steel and cut it by the hydraulic
cutter with our need length with some clearance for holding it with tooth of
the jaws
 place the circular sold bar in to the lathe and hold it by jaws
 Face both end of the bar by facing action
 Decrease the outer diameter of the bar to 30 mm by turning action
Pulley  Take the circular solid bar with large diameter from cast iron
 Cut it with our need width with some clearance for holding purpose
 Face one end of the solid bar and decrease the diameter to desire value
(75mm and 150mm for small and large pulley respectively)
 Groove the width of the pulley 15 mm depth at 380
 Bore it with 30mm diameter up to our desire width
 Cut the other end to remove the clearance length we use for holding purpose
 Take it again to the lathe and face the both ends

Textile Industry
Drum  Take a plate of 3mm thick with desired width and length above the desired
length.
 Make a plenty of holes in an equi-spaced series by drilling for the purpose of
stabbing the brush in it
 Bend the plate to make a perfect round of 80mm diameter drum
 Stab the brushes on the drum
3.6. Assembly process

1. Connect the four L-shaped plates by welding to form the bottom face of the body
2. Connect one end of the motor to the fan
3. Take and place the motor and the fan to the welded bottom frame and fastened it to
the plates with screw mechanism for the sake of disconnecting or removing it without
damage during service inspection, repair or replacement of components.
4. Insert the small bevel gear on the other end of motor shaft
5. Insert large bevel gear, bearing (bearing inserted in bearing house) and small pulley
with their appropriate position.
6. Fastening the bearing house to the base frame to reduce vibration and momentum of
the shaft by meshing the bevel gear perfectly.
7. Weld the four L-shaped metal plate vertically from each corner of the bottom face of
the body.
8. Cover the front by wood for support the bearing and the back with metal sheet to
reduce total weight of the machine.
9. connect the fan case and the dust holder by tube to transfer sacked dust to the holder
10. attach the rubber brushes on the surface of the rollers
11. insert the larger pulleys and bearings on the shafts and insert the shafts into the
rollers
12. Fastened each bearing with screw to make the roller stable
13. Tie the belts over the groove of the pulley
14. Insert a metal sheet which have a hole bellow the roller to accumulate and send the
dust to the dust holder through the hole.

Textile Industry
15. Cover both side of the body with metal sheet by welding action
16. Connect the half cylinder cover of the roller by hinge, which used to protect the
workers from dusty material
17. Finally finish switch and other electrical installation
3.7. Working principle

When the motor is switched on the rotation of the motor rotor is transfer to the both end of the
motor shafts. One end of the motor shaft rotates the fan directly to suck the dust particles and
cotton tufts from where the machine is around in applicable area. The dust particles and cotton
tufts from the section‟s floor are sucked to the dust collector container provided near to the motor
through the inlet hose.
The other end of the motor shaft used to derive the bevel gear which is connected
perpendicularly to each other. This motion is transfer from the bevel gear to the smaller pulley
by means of shaft. After that the pulley on the shaft of the bevel gear transfers the rotation to the
upper pulleys. These pulleys connected to the cleaning roller by shaft. The cleaner roller has a
series of stabbed rubber brushes on it for the purpose of top roller cleaning.
The top rollers are getting in touch with the cleaner roller by the help of guide plate on which the
top rollers are put.
In time of rotating of the cleaner roller, the top rollers, which are in touch with the the brush,
also rotates relatively so that the cotton tufts get away of it and remainded on the brush. The tufts
and fluffs get remainded on the brush are not remainded any more rather they deprive by means
of the comb which is set in one edge of the roller touching the brush. These fluffs are then
stacked in the dust collector chamber provided below the cleaner roller. In this way clearer roller
and vacuum dust collector machine perform its action.

Textile Industry
CHAPTER FOUR
4. RESULT AND DISCUSSION
4.1 Summary of Findings
Table 4.1. Summary of findings

Serial Determined parameters Symbols Values Unit
number
1 Diameter of small bevel gear 45 Mm
2 Diameter of large bevel gear 135 Mm
3 Tangential tooth load on bevel gear 914.56 N
4 Dynamic tooth load on bevel gear 944.9 N
5 Static tooth load on bevel gear WS 1920.5 N
6 Wear tooth load on bevel gear WW 1771 N
7 Torque transmit by shaft one T 172000 N-mm
8 Maximum bending moment on shaft one 172171 N-mm
9 Equivalent twisting moment on shaft one 214900 N-mm
10 Diameter of shaft one D 30 Mm
11 Torque transmit by shaft two T 172000 N-mm
12 Equivalent twisting moment of shaft two 272600 N-mm
13 Diameter of shaft two D 30 Mm
14 Length of the key l 37 Mm
15 Width of the key w 7.5 Mm
16 Tangential shear force on the key Ft 12700 N
17 Diameter of small pulley D 75 Mm
18 Diameter of large pulley D 150 Mm
19 Centrifugal stress induced by both pulley 27.73
20 Length of the belt L 1051 Mm

21 Power transmitted by the belt P 1.05 Kw

Textile Industry
22 Cross sectional are of the belt A 104 mm2

23 Total mass of the belt M 0.1236 Kg/m
24 Tension in tight side of the belt T1 2.83 KN
25 Tension in the slack side of the belt T2 1.206 KN
26 Equivalent dynamic load on bearing W 1046.7 N
27 Dynamic load rating C 8004 N
28 Speed of the fan V 22.38 m/s
29 Inlet area of the fan A 17662.5 mm2
30 Discharge of the fan Q 0.4 m3/s
31 Suction pressure developed by the fan p 1.87 kPa
32 Area of Stream of Bolt At 36.6 Mm2
33 Nominal diameter of Bolt D 8 mm
34 Pitch diameter of Bolt p 1.25 mm
35 Minor diameter of Bolt Dm 6.47 mm
The above information is about all the analyzed results of the design of clearer roller machine
components. The components that must acquire their dimensions and parameters through
engineering calculations are designed based on the required analysis. The other parts which can
be provided merely from standard are selected based on the design considerations and
specifications. This is therefore; our newly designed machine followed the critical engineering
design principles in order to achieve entire design.

Textile Industry
4.2. Cost Analysis
Table 4.2. Cost analysis

Material Quantity Unti cost Total cost
(in Birr) (in Birr)
Motor 1 12,000 12,000
Shaft 2 86 per kg 696.6
Pulley 3 544 1088
v-belt 2 25.5 per meter 102
Bevel gear 2 227.5 455
Bolt 22 13.5 297
Bearing 5 195 975
Fan 1 750 750
Base frame 1 1600 1600
Others 1200 1200
Total cost 19,163.6 Birr
4.3. Limitations
Finally the problems that we face in order to accomplish the project can be stated as:
 The lack of reference materials concerning clearer roller machine was a huge problem.
 Absence of power (electricity) and internet connection was an obstacle for not
completing the project at the required time

Textile Industry
CHAPTER FIVE
5. CONCLUSIONS AND RECOMMENDEDATIONS
5.1 Conclusions
Textile industry is now becoming the leader industry in Ethiopia for economic growth as well as
in creating vast job opportunities for the nations of both educated and uneducated. Using
obsolescent machines and equipment may not suit for facilitating the production process and be
the cause to the company to produce below its capacity and planned products. This is therefore,
what makes us to contribute all we can in order to facilitate the production process.
The project is tried to encompass the different methods of design concepts and design analysis
for the clearer roller cleaning Vacuum cleaning machine. In our design we add some
improvements on the roller by increasing its length so as to clean many top rollers at once.
Furthermore, we added in our design vacuum dust collector, which is not part of current clearer
machines not even the advanced ones, by using one end of motor shaft for fan mounting.
The project concluded that our newly designed machine can surely solve the problems related to
clearer machine. This machine helps to minimize the efforts required by workers to clean top
roller & the floor of the room (department). This machine is ecofriendly, user-friendly & low
capital cost.
We confidently conclude that our machine solved many problems of old top roller cleaning
machine in our host company. It has the following advantage relative to the old one,
 It is not manually operated
 It take less time to clean the whole top rollers and simplifies work which is currently
tiresome for the personnel
 It is not dangerous to workers health
 It is cost effective
 It introduces new technology transfer

Textile Industry
 It can be easily repair or maintain locally which is impossible for the current machine
unless full machine is or some spare parts are imported with high amount of foreign
currency.
5.2 Recommendations
The design of clearer roller cleaning and vacuum cleaning machine is by adding some
improvements like increasing number of rollers and for additional purpose the fan also mounted
to the motor shaft for dust collecting. By then it facilitates production process and create comfort
work environment. Beside this there are some problems that need to attention for successful
journey of the textile industries.
 It is recommended that for the next generation this particular thesis should be focused in
order to accomplish the utilization of advanced clearer roller cleaning machine by using
two or more rollers that are used to clean the top rollers.
 And it should be used some special mechanisms of protecting the personnel from cotton
tuft cause side effects.
 Also it is recommended that the textile industries shall motivate the engineers employed
in it to solve the problems concerning the clearer roller cleaning machine.

Textile Industry
References
1. Collier, Ann M. (1970), A Handbook of Textiles, Pergamon Press, 258 pp.

2. Saxonhouse, Gary, "Technological Evolution in Cotton Spinning, 1878–1933" (PDF),
SST Seminars, Stanford University
3. Khurmi R.S and J.K. Gupta (2005) Machine design, Chand and co-publisher, Fifth
edition, Eurisia Publishing House (PVT.) Ltd, Ramangar, New Delhi, 1230 PP.
4. Richard G. Budynas and J. Keith Nisbett (2015) Shigley‟s Mechanical Engineering
Design,Tenth Edition, McGraw-Hill Education, 2 Penn Plaza, New York, 1082 PP.
5. Ansel C. Ugural (2004) Mechanical Designs An Integral Approach, McGraw-Hill
Education, New York, 810 pp.
6. Robert L. Mott, RE. Machine Elements In Mechanical Design, Fourth Edition, Pearson
Education, New Jersey, 866 pp.
7. ROBERT C. JUVINALL and KURT M. MARSHEK (2012) Fundamentals of Machine
Component Design, Fourth edition, John Wiley & Sons, Inc, 929 pp.
8. G.K. Vijayaraghavan and S. Vishnuprian (2009) Design of Machine Elements, Fourth
edition, Lakshmi publications, Arpakkan, 26 pp.
9. FERDINAND P. BEER, E. RUSSELL JOHNSTON, JR., JOHN T. DEWOLF and
DAVID F. MAZUREK (2009), Mechanics of Materials, Fifth edition, McGraw-Hill
Education, New York, 813 PP.
10. R. C. HIBBELER (2009) MECHANICS OF MATERIALS, Eighth edition, Pearson
prentice Hall, 885 pp.

Textile Industry
APPENDICES
LIST OF PART DRAWINGS AND ASSEMBLY

Textile Industry
PART DRAWING (1)

BEARING

Textile Industry
PART DRAWING (2)
V-GROOVED PULLEY

Textile Industry
PART DRAWING (3)

FAN

Textile Industry
PART DRAWING (4)
ROLLER SHAFT

Textile Industry
PART DRAWING (5)
CHAMBER

Textile Industry
PART DRAWING (6)
BEVEL GEAR

Textile Industry
PART DRAWING (7)
V-BELT

Textile Industry
PART DRAWING (8)
FRAME

Textile Industry
ASSEMBLY (TWO DIMENSIONAL)

Final Project These

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Final Project These

Uploaded by

Copyright:

Available Formats

DESIGN MODIFICATION OF TOP ROLLER CLEANER AND

VACUUM CLEANING MACHINE

HARAMAYA INSTITUTE OF TECHNOLOGY

Haramaya Institute of Technology, Department of Mechanical Engineering Page I

HARAMAYA INSTITUTE OF TECHNOLOGY

ABDUSOMED EBRAHIM SEID

Approved by Board of Examiners

Mr. HABTAMU G/MARIAM _______________

Main Advisor Signature

Examiner (1) Signature

Examiner (2) Signature

Co-Examiner (1) Signature

Co-Examiner (2) Signature

Haramaya Institute of Technology, Department of Mechanical Engineering Page II

Haramaya Institute of Technology, Department of Mechanical Engineering Page III

CONTENTS PAGE NUMBER

1.3.2. Specific objectives ......................................................................................................5

1.4. Significance of the project ....................................................................................................5

2.2.2. Lakshmi ring traveller-LRT ........................................................................................8

2.2.3. Flocked clearer roller cleaning machine, GAYATRI ...................................................8

2.2.4. Wooden clearer roller cleaning machine, MAYUR .....................................................9

Haramaya Institute of Technology, Department of Mechanical Engineering Page IV

3. MATERIAL AND METHOD ............................................................................................... 10

3.3.2. Component design .................................................................................................... 12

3.3.3. Modeling of the machine .......................................................................................... 13

3.4. Load and Force Analysis .................................................................................................... 13

3.4.2. Design of rotating roller shaft two ............................................................................. 20

3.4.3. Design of shaft three ................................................................................................. 26

3.4.4. Motor selection ......................................................................................................... 29

3.4.5. Design for bevel gear ................................................................................................ 31

3.4.6. Selection of ball bearins ............................................................................................ 38

3.4.7. Selection of v- belt .................................................................................................... 41

3.4.8. Design of v-grooved pulley ....................................................................................... 45

3.4.10 Selection Bolt .......................................................................................................... 49

3.4.11. Selection of fan ....................................................................................................... 52

3.5 Manufacturing process ........................................................................................................ 56

Haramaya Institute of Technology, Department of Mechanical Engineering Page V

5.1 Conclusions ......................................................................................................................... 62

Haramaya Institute of Technology, Department of Mechanical Engineering Page VI

TITLES PAGE NUMBER

Table 3.7. Standard pitch lengths of V-belts according to IS: 2494-1974………………………41

Haramaya Institute of Technology, Department of Mechanical Engineering Page VII

Haramaya Institute of Technology, Department of Mechanical Engineering Page VIII

Haramaya Institute of Technology, Department of Mechanical Engineering Page IX

ASME American Society of Mechanical Engineers

Haramaya Institute of Technology, Department of Mechanical Engineering Page X

Haramaya Institute of Technology, Department of Mechanical Engineering Page XI

1.1. Background of the project

Haramaya Institute of Technology, Department of Mechanical Engineering Page 1

Figure 1.1. Rig frame Machine

Haramaya Institute of Technology, Department of Mechanical Engineering Page 2

Figure 1.2. Clearer roller (top roller clearer)

1.2. Statement of problem

Haramaya Institute of Technology, Department of Mechanical Engineering Page 3

Fig 1.3. Manually operated clearer roller machine

 It take long time

Haramaya Institute of Technology, Department of Mechanical Engineering Page 4

1.3. Objective of the project

1.3.1. General objective

1.3.2. Specific objectives

 To design bevel gear

 To design v- grooved pulley

 To select the proper motor for the machine