K I

O T
Title: - Design of automatic sand sieving
machine for foundry purpose
1,Melkame Atinafu

2, Desalegn Abebaw

3, Abel Mulugata

4, Umer Ayemo

A Thesis Submitted to Department of Mechanical Engineering Institute

of Technology in Partial Fulfillment of the Requirements for the Degree of Bachelor
of Science in Design stream

Bachelor science thesis

WOLLO UNIVERSITY

Kombolcha Institute of Technology

Department of Mechanical Engineering

Design Stream

20/2015 BSC kombolcha, Ethiopia

0
 DECLARATION

K I Bachelor of Science Thesis: 20-2015-BSC

Design of Automatic sand sieve machine for foundry
O T purpose

1,Melkame Atinafu
2,Desalgn Abebaw
3,Abel Mulugata
4,Umer Ayemo

Approved by Examiner: (i any) Advisor:

Signature Name Name

Date: Chairperson: Co-advisor: (if any)

20/06/2015 Name Name

I
 Abstract
Idea to develop of sieve machine is comes from the problem in foundry that gives a task and a little
for this project. This project focuses in design 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 and analysis be for develop the sieve machine, it
must compare with other product in market. It is because to study the customer need and create a
modified design. Manufacturing is the art of transforming raw materials into finished products.
Foundry work deals with manufacture of products from molten metal and the products obtained are
called castings. Castings are produced when the molten metal is poured into mold cavity and left to
solidify. Casting and molding process is one of the cheapest methods of producing parts to a given
shape in various forms represents the most important metal shaping process used in engineering
manufacture. Non-ferrous metals do not contain iron constituent. Generally, they are weaker than
ferrous metals but have other important properties such as corrosion resistant, high electrical
strength, thermal conductivity and special magnetic properties.

The project mainly contains design analysis, manufacturing process, selection of material and joint
mechanism. The design analysis depends on the material and the type of load applied on parts.

From the joint mechanism some parts are bolted and other parts are wielded. We select arc wielding.

It is based on providing an electric circuit comprising the electric current source the feed and return
path.

II
 Acknowledgement
We would like to thank our G. by the means of help an idea and initiate group
members by taking an appointment and telling the way we have been followed.

We would also like to thank in order to help the idea about

foundry and purpose of quality sand for molding and casting in the factory.

Generally thanks to God all things performs by him

ITR/637/03, ITR/0031, ITR/1117/03, ITR/1214/03

BSC MECHANICAL Engineering (design stream)

KOMBOLCHA INSTITUITE OF TECHNOLOGY 2015

III
Contents page
DECLARATION .......................................................................................................................................................I
Abstract ................................................................................................................................................................II
Acknowledgement ..........................................................................................................................................III
List of figure ....................................................................................................................................................... VI
List of table........................................................................................................................................................ VII
List of acronym ................................................................................................................................................. VII
List of conversion factor................................................................................................................................... VIII
Chapter One .........................................................................................................................................................1
Introduction .........................................................................................................................................................1
1.1 Project background ....................................................................................................................................2
1.2 statement of problem ................................................................................................................................3
1.3 OBJECTIVE OF PROJECT ..............................................................................................................................3
1.3.1 General Objective ...................................................................................................................................3
1.3.2 Specific objective ....................................................................................................................................3
1.4 Significant of the project ..........................................................................................................................3
1.5 Project scope ...........................................................................................................................................3
1.6 Methodology ................................................................................................................................................4
1.7 PROJECT ORGANIZATION ...........................................................................................................................4
Chapter two .....................................................................................................................................................6
2 Literature review ...........................................................................................................................................6
Introduction .....................................................................................................................................................6
2.1 History of sieve machine ............................................................................................................................8
2.2 Type of patterns ...................................................................................................................................... 11
2.3 Molding sand........................................................................................................................................... 12
CHAPTER THREE ............................................................................................................................................ 17
RESULT AND DISCUSSION ............................................................................................................................. 17
3.1 SELECTION OF MOTOR ............................................................................................................................ 17
3.2 DESIGN ANALYSIS OF SIEVE..................................................................................................................... 18
3.3 Geometric representation of machine.................................................................................................. 21
3.4 DESIGN ANALYSIS OF FRAME .................................................................................................................. 23
3.5 Design of sieve support link ........................................................................................................................ 25

IV
 3.6 DESIGN ANALYSISE OF SHAFT ................................................................................................................. 27
3.7 DESIGN ANALYSIS OF CAM ...................................................................................................................... 32
3.8 SELECTION OF FOLLOWER ...................................................................................................................... 35
3.9 DESIGN OF FLAT BELT PULLEY ................................................................................................................. 36
3.10 DESIGN OF FLAT BELT ........................................................................................................................... 39
3.11 DESIGN AND SELECTION OF BEARING .................................................................................................. 45
3.12 Design and selection of sunk key .......................................................................................................... 49
3.13 Selection of bolt and nut........................................................................................................................... 50
3.14 MANUFACTURING PROCESS ............................................................................................................... 51
3.15 WELDING ............................................................................................................................................ 51
3.16 RESULT ...................................................................................................................................................... 53
3.17 WORKING PROCEDURE ......................................................................................................................... 55
CHAPTER FOUR ................................................................................................................................................. 57
CONCULUSION, RECOMMENDATION AND FUTUR WORK................................................................................ 57
4.1 Conclusion: .............................................................................................................................................. 57
4.2 Recommendation:............................................................................................................................. 58
Reference ...................................................................................................................................................... 59

V
 List of figure page
2.1 sieve analysis……………………………………………………………………..6

2.2 hydrometer analysis……………………………………………………………….6

2.3 sieve opening and particle size…………………………………………………….7

2.4 manual sand sieve …………………………………………………………………8

2.5 manual screw sieve………………………………………………………………...9

2.6 throw sieve……………………………………………..........................................10

2.7 horizontal sieve…………………………………………………………………...11

2.8 solid pattern………………………………………………………………………12

3.1 sieve………………………………………………………………………………21

3.2 geometry of machine…………………………………………………………….22

3.3 frame……………………………………………………………………………...25

3.4 sieve support link…………………………………………………………………28

3.5 schematic representation of shaft…………………………………………………32

3.6 shaft ………………………………………………………………………………33

3.7 cam profile………………………………………………………………………..36

3.8 cam with follower………………………………………………………………..36

3.9 geometry of pulley……………………………………………………………….38

3.10 pulley……………………………………………………………………………40

3.11 geometry of belt…………………………………................................................45

3.12 ball bearing……………………………………………………………………...49

3.13 shaft with sunk key……………………………………………………………...50

3.14 bolt and nut…………………………………………………………………….51

VI
3.15 wielding process………………………………………………………………...53

List of table page

2.1 characteristics of pattern material……………………………………………...12

3.1 standard type of motor …………………………………………………………17

3.2 sieve analysis……………………………………………………………………18

3.3 standard sieve opening………………………………………………………….21

3.4 end condition of frame………………………………………………………….24

3.5 mechanical property of steel used for shaft…………………………………….29

3.6 standard width of pulley………………………………………………………..39

3.7 density of belt material …………………………………………………………41

3.8 list of bearing for various machines ……………………………………………47

3.9 standard dimension of ball bearing…………………………………………….48

3 .10 result …………………………………………………………………………54

List of acronym
Critical load

40c8=Indian standard designation of carbon steel

T=twisting moment

J= polar moment

ASME=American society mechanical engineering

ISO=international certified organization

AISI= American international standard institution

E =modules of elasticity

VII
Le=effective length

t=yield strength

=ultimate tensile strength

KIOT= kombolcha institute of technology

List of conversion factor

1psi=6.8948kpa

1in=2.54cm

f=0.004KN

1in3=16.387cm3

1MJ=1000kJ

1GJ=1000MJ

VIII
 Chapter One

Introduction
This final year project is part of the required subject to be taken during BSc of mechanical
engineering course. This is done during the final semester be for advancing into the Industrial
training program. Therefore, it is vital to complete this project in order to receive a final grade
depend on the effort put in.

The final year project is also to give students the individual ability and confidence to complete a
task with under less supervision of lectures. With this, students can learn problem solving skills in
areas of design and analysis as well as learn to do a complete formatted project which is important
for future technical writing.

Sand or any mixture substance usually comes in different size and grad since some product
required different size of sand or mixture that why this machine been design to sieve the sand or sub
sand into different size depend on requirement needed. Foundry works deals with manufacture of
products from molten metal and the products obtained. Sand casting and molding is very old
techniques but with improved methods it can still compute with other production process. Roughly
75 percent of the total output of the castings are made in sand molding through they do not fully
satisfy the required surface finish and accuracy. Therefore more advanced methods such as shell
molding investment castings, die castings, centrifugal castings e t c are finding wider application.

1
 1.1 Project background
For the characterization of bulk goods of different forms and sizes. The knowledge their
particle size is essential the number of particle of different size is responsible for important physical
and chemical property such as flow ability and surface reaction. In many industries such as food,
pharmaceutics and chemistry traditional sieve analysis is the standard for production and quality
control of sands and granules.

Advantage of the sieve analysis include easy handling ,low investment costs ,precise and
reproducible results in comparability short time and the possibility to separate the particle size
fractions. The sieve shakers and accessories have to fulfill the requirement of national and
international standards. This means that test sieves, sieve shakers and all other measurement
instruments. Sand: The sand is commonly known as the basic material use in construction side or
any other product. Comes with few type and different size comes in mixture. Sieve machine:

 To design sieve machine that can sieve sand to different size.

 Problem that often faced is that some product required different size of sand to fulfill
the quality level needed.
 Through this design user can save time sieving sand and cut the cost to order the
required size of sand.
 This product may sieve the sand with safety and quick over use conventional way.

2
 1.2 statement of problem
Ethiopia has so many problems on technological transferring, from those problem we have
seen the problem of automatic sand sieve machine in industry, know a day’s people uses for sand in
order to perform the process of molding and casting. But there is the problem of quality of sand due
to traditional sieve process and also sieve mechanism is tedious and sieve by human force. We try to
solve the problem of the above and modify the machine in order to supply for construction site and
foundry purpose for industry.

1.3 OBJECTIVE OF PROJECT

1.3.1 General Objective

To modify sand sieve machine for foundry purpose in order to change traditional sieve to
automatic way.

1.3.2 Specific objective

 To get the required pattern
 To get quality sand for casting and molding
Identify the different parts of patterns
 To design sieve and other component
 Identify the mechanism of sand sieve

1.4 Significant of the project

The project is to design the sieve machine and after the fabrication this sieve machine, all
the industry in purpose of molding, save time and increase productivity.
As we know the traditional sieve it is tedious and less productive but this study improve the
above factors.

1.5 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 advance software like AutoCAD and solid
works. It also needs some knowledge and skill to finish the project .There is some other
guide must follow to finish this project

3
 1.6 Methodology
The materials we prepared our project were drawing materials, computers and we have gotten
data from different resource like .written books, internet and literature reviews. In the process of idea
generation and make a planning of the overall progress to make sure the project can be finished on
schedule. The method used for this sand sieve was chosen because it takes a logical systematic
approach to solving a problem in a metal working factory and Industry using fact from start to finish.
In the current data was analyzed and determine the problem was the biggest contributor according to
data and problem definition. The processes of the sieves are studied from several angles. The
approaches are used to determine what the problem that was being seen was really. Any foundry’s
sieve sand system is very complex and difficult. This complexity must always be kept in balance or
the sand sieve system will cause production trouble. We collect the data from book, internet and by
asking peoples who know about foundry. The sample and standard value were continued to be sent
out for analysis. The design part used software’s like auto CAD and solid work.

1.7 PROJECT ORGANIZATION

This project is organized by four chapters. The first chapter introduces the background,
statement of problem, objective, scope and methodology of the study.

From the background there is a foundry works for manufacturing of products from molten metal and
products obtained.to consider sieve analysis advantage that is easy handling, low investment costs
precise and reproducible

The second chapter states an overview of sand sieve four foundry purposes that is initial point of the
project that deals about result and discussion. From the literature review the point that stated about
mechanical sieve determination, two methods of sieve and sand particle size. Two method of sieve
are: sieve analysis and hydrometer analysis.

Sieve analysis used for particle size larger than 0.075mm diameter but hydrometer analysis used
particle size smaller than 0.075mm diameter.

Sand particles are most important thing for foundry purpose and construction site area.to performs
the required human needs.

This chapter more deals about mechanism of sieve from past years and different material to be
sieved. From different sieve mechanism we have to be select the mechanism and according to the
material that sieved. From the overview there are horizontal sieve, vertical sieve, manual sieve and
vibratory sieve.

For foundry sand sieve is essential to make different patterns for different materials. The need of
sand to make patterns mainly three types of sands is required:

 Core sand
 Face sand and

4
Chapter three discusses in detail about result and discussions.

From the discussion, that listed all parts of machine, such as:

 Dc motor
 Shaft
 Sieve
 Came profile
 Transmission belt
 Pulley
 Bearing and
 Frame

All the required parameter of the above components is determined, such as length diameter, width,
thickness…etc.

The type of material that used for each components are selected according to its function required
performance.

The type of motion determined according to sieve mechanism.

Chapter four this is final chapter which illustrates the recommendation and future work of study.

5
 Chapter two

2 Literature review

Introduction
Sand substance is one of the most important thing in industrial world .nowadays the industry need
the sand sub stand that already been process known as sand product. As we know the sand sub stand
are mixtures with variety other component such as dirt and metal.

 The sand is been collected still used the conversional way such as sieving using hand or
machine. And human energy is needed to run the process. So to make the process more
efficient new technology is needed to help increase the productivity so human power can be
reduce and also can cut the cast of the process.

Mechanical analysis is the determination of the size range of particles present in a soil expressed as a
percentage of the total dry weight.

There are two methods generally used to find the particle size distribution of soil.

1) Sieve analysis for particles size larger than 0.075mm in diameter

2) Hydrometer analysis ; for particle size smaller than 0.075mm in diameter

Fig 2.1 Sieve analysis fig 2.2 hydrometer analysis

Soil has four constituent parts

6
  Sand is any soil particle larger than 0.06mm or 0.002inches
 Silt is any soil particle from 0.006-0.06mm
 Clay is any soil particle below 0.002mm, including colloidal clay so small it does not settle
out of suspension in water.

Sieve analysis consists of the shaking the soil sample through asset of sieve progressively smaller
opening. In order to clear the idea the following figures are important.

Fig 2.3 sieve opening and particle size

7
 2.1 History of sieve machine
From years sand has been the most important thin g in human community. Most sediments including
sand are made up of the fragment that result when rock is broken down by wind and rain
(weathering).generally, they start as larger fragments (grovel) which are broken down as a river
carry them downstream the finer the particle, the future it has traveled .in other words, large bits of
grovel are plentiful on the banks close to the head of a river.

As you travel downstream, grovel becomes finer in to cobble, pebble granular, and eventually
turning into sand, and finally flowing into the ocean .where this sediments deposit. That is why by
carefully analyzing the mineral content and chemical composition of sand river banks, beats and
ocean floors.

Most sediment once formed in the ocean sub duct to the earth’s interior (mantle) from trench with a
sub duct tectoniqu plat. However same pieces tear loss from the hole, and accreted to the hanging
wall continental plate, once again becoming part content.

Fig 2.4 manual sand sieve

During sieving the sample is subjected to horizontal or vertical movement in accordance with the
chosen method this causes a relative movement between the particle and the sieve, depending on
their size the individual particle either pass through the sieve mesh or are retained on the sieve
surface.

The likelihood of particle passing through the sieve mesh is determined by the ratio of the particle
size to the sieve openings

Different sieving methods

Depending on the material and demand placed on the sieve result, various sieving method is used for
determining the particle size and distribution.

8
The basic difference is manual and mechanical sieving

Today, manual sieving is only used where no electricity supply is available, e.g. for rapid on site,
random checking for oversize and under size.

Fig 2.5 manual screw sieve

Throw action sieving

Throw action sieve shakers are also known as vibratory sieve shakers. An electromagnetic device
sets spring mass system in motion and transfer the oscillation to the sieve stack. The amplitude can
normally set continuously in the range from 0.2

9
 Fig 2.6 throw sieve

Horizontal sieving
In horizontal sieve shaker the sieve moves in the horizontal circles in one plane. Horizontal sieve
shakers are preferable used for needle shaped, flat, long, or fibrous, the large sieve area makes it
possible to sieve large amount of sample. For example as encountered in the particle size analysis of
construction material and aggregates.

10
 Fig 2.7 horizontal sieve

Dry and wet sieving; most sieving process is carried out on dry material. However, there are many
applications in which wet sieving cannot be avoided e g when a material to be tested is already
present as suspension or when Avery fine sample that tends to agglomerate has to be sieved. From
sand sieve machine, the quality sand is used for making a required pattern. Pattern: is the replica or
full size model of the castings to be made, it gives its shape to the mold cavity where molten metal
solidifies to the desired form and size the design of casting should be simple as possible to make the
pattern easy to draw from the sand and avoid more core than necessary.

2.2 Type of patterns

The type of pattern depends on the design of casting, complexity of shape, the number of casting
required molding process, surface finish and accuracy.

Common types of pattern are:

 solid pattern
 split pattern
 shell pattern
 Sweep pattern etc.

Example solid \single piece pattern are in expensive and best suited for limited production in simple
type of solid pattern, one side is mode flat which serves as a parting surface.

In this case, the molding cavity will be entirely in the drag.

11
Fig 2.8 Solid pattern

Characteristics of pattern material

Characteristic Mach Strength Weight Resistance Resistance Resistance
of material inability to wear to corrosion to swelling
Wood Excellent Fair Excellent Poor excellent Poor
Aluminum Good Good Good Good excellent Excellent
Steel Fair Excellent Poor Excellent poor Excellent
Cast iron Good Good Poor Excellent poor Excellent

Table 2.1 characteristics of pattern material

The pattern maker, before making the pattern should study the way to be handled and important
consideration .because the molding cost depends to a great extent on paper construction of a pattern.

The following factor should be considered while making a pattern.

 Types of metal to be cast

 Number of casting required to be produced
 Method of moldings
 Pattern allowance
The sequence operations involved in pattern making are pattern lay out and shaping the
pattern. [3, page 8-15]

2.3 Molding sand

Various materials are used in foundries for making casting molds. Among the mold
materials, sand is used more than all others.

12
A wide range of alloys can be cast in to sand as it has high tolerance for thermal shock. Thus
relatively low melting point aluminum and manganese alloys are sand cast as well as alloy
steel. Furthermore, the mass of casting is not a limited.
The majority of sand can be re used after castings .this is particularity in the case of green
and dry sand molding.
Sand is formed by the disintegration of rocks under the action of frost wind and rain .in
natural condition, both large and small sand particles settle down on the bottom of water
basins. Sand suitable for molding consists of silica (sio2) grains to gather with sufficient clay
to act as a binding material. [3, page 23-24]
Classification of molding sand
Molding sand is classified as under
1) According to native of its origin
 Natural sand
 Synthetic sand
 Special sand

Natural sand: is collected from natural resource like river beds or it dug from pits. Natural
sand containing required proportion of clay (5-20) percent is referred as green sand .it is used
as mined. it requires only mixing water with aggregate (sand-clay mixture).the clay develops
the strength and plasticity for molding .they are less refractory than synthetic sand but they
have the advantage of maintain moisture content for a long time, and permitting easy
patching and finishing of mold.
This sand is used for non-ferrous castings and grey iron castings.
Synthetic sand; is sand is essentially high silica grains contain no clay in natural form .they
are mixed with clay (3-5 Mennonite) percent and water (3-4) percent to develop required
molding properties. It is used for steel castings.
The advantage of synthetic sand over natural sand is
 More uniform grain size
 High permeability and refractoriness
 Mold ability with less moisture
 Requires less binder
 Suitable for different kinds of casting
However, synthetic sands have the following disadvantage
 High initial cost
 Patching is difficult
 Workable over a narrow moisture range
 Dry out more rapidly,
 More skill is necessary for mold

13
Special sand: are high refractory materials used for obtaining smoother surface of castings. They
include zirconium (ZrsiO4), olivine (MgsiO4) and chromite’s (Feo.Cr2O3), magnetite (MgCO3) and
Chalmette (3Al2O3SiO2).

Zirconium sand is costlier than silica sand and it is used for core brass and bronze casting.

Olivine is valuable for steel castings. Its refractoriness is high and improves the surface smoothness
of castings.

Chromite is suitable for facing mixtures in mold for large steel castings .it has high refractoriness
and volume stability.

Magnetite is suitable for facing mixtures employed in castings high manganese steel.

Chalmette has high refractoriness and it is used for dry sand molding of large steel castings.

2) According to their initial condition (i.e. green or dry and use)

A. Greensand
B. Dry sand
C. Loam sand
D. Facing sand
E. Backing sand
F. System sand
G. Parting sand and
H. Core sand

Green sand :Foundry sand containing moisture is known is green sand ; green refers to the
moisture content and not the color of the sand .it consists of silica sand ,clay(18-30 percent)and
water(6-8percent).clay and water furnishes required strength for green sand. It is used for making
small and medium size castings. The advantage of green sand is that it can be reused many times by
recondition with water, clay and other material, however, the sand is not suitable for intricate
castings and the castings which require dimensional accuracy.

Dry sand: sand free from moisture is called dry sand .it possesses greater strength than green sand
and can be employed for making larger castings.

Dry sand mixtures for various castings are given below.

Sand mixtures Application

-Silica sand with7 percent bentonite general steel

14 percent other additives (silica flour, water casting

14
 Malison)

-Silica sand with 7-8 percent fire clay, heavy steel

1-2 percent betonies, 2-3 percent silica flour castings

Silica sand is (40 new sand + 60 used sand) grey cast

With 3to6 betonies, 1to2 pitch, 1to1.5 creals iron casting

Loam sand: loam sand is a mixture of sand clay (5o) percent .it is used for making large castings
.such as cylinders, papers rolls and bells.

Facing sand: facing sand is applied to the pattern to obtain castings of smooth and clear surface. It
forms the face of the mold and is in direct contact with molten metal. 20-25percent of coal dust or
graphite is used to prevent the metal from burning in to the sand. The layer of facing sand in a mold
usually range from 20-30mm.it should have sufficient strength and refractoriness so that the mold
can with stand to the pressure and heat of molten metal during pouring.

Backing sand: the backing sand is porous mixture of used sand .it is used to support (i.e. back up
the facing sand and to fill the reset of flask).

System sand: it is reconditioned sand (i.e. prepared from used sand) employed in a mechanized
foundries. It is used to fill the complete flask. It possesses greater strength, permeability and
refractoriness than backing sand.

Parting sand: parting sand is used to prevent the molding sand from sticking to their surfaces.
Powders free from clay are used for the purpose. Very fine brick powder can be used as parting sand.

Core sand: it is silicon sand mixed with organic component. Such as line seed oil, resins and other
binding materials. It is used for making cores .the cores are subject to severe conditions in the mold.
For these reason cores sand must have refractoriness, dry strength, permeability and good
collapsibility.

Binders
A binder is any material that imparts strength to the sand. This material may be added to sand or
provided by nature. The founder sand binders may be classified into 3 types:

1. Clay binder
2. Organic binder
3. In organic binder

15
Clay binder: clay is the earthy material that becomes plastic when water is mixed. Clay
type binders are used for both green sand and dry sand molds to increase their strength,
hardness and toughness. But increased clay content reduces flow ability and permeability.
Betonies and kaolinite (fire clay) are commonly used binders for molding sands.
Organic binders: organic binders are quite in expensive and more commonly used for
core making. These binders give strength after baking and therefore organic binders are
usually referred as baked binders.
The more commonly used organic binders are dextrin, cereals, linseed oil resins, pitch etc.
Cereals binders are in expensive and impart good flow ability and collapsibility for core
sands. Sands with these binders are baked at 190 degree centigrade to develop strength
.Dextrin is used to increase dry strength.
Linseed oils are most commonly used for core sands .they speed up the process of drying.
Resins develop high strength. Many synthetic resins do not require baking in ovens, as they
harden on exposure to air. But they are expensive.
Pitch (by product of coke) improves dry strength, decrease expansion and contraction of the
mold.
Sand additives
Although sand is a very important molding material .it cannot be expected to perform
satisfactory unless its properties are adequately controlled.
Additives of various materials to sand make them acceptable for many diverse castings
applications. Other than binders, all materials are added to molding sand for special purposes
are called additives.
The following materials are widely used as additives
I. Coal dust
II. Wood flour
III. Silica flour, and
IV. Iron oxide
Coal dust :( sea coal) is finely pulverized bituminous coal. It is mixed with facing to
improve surface finish and prevents burning on sand. Its amount varies from 2-6 percent for
thin walled castings (5-15mm thick), while for thick walled castings it amounts to 12 percent.
Wood flour is a ground soft wood and is mixed with sand to improve surface
finish of the casting and collapsibility of cores. It also reduces the effect of sand
expansion during pouring .the amount of wood floor in sand various from 0.5-1
percent.
Silica flour: is a finely ground silica sand. It is a good refractory material and is
mixed with facing sand to reduce the metal penetration during pouring.
Iron oxide: powder is added to molding sand to increase strength. It is also
added to core sand to improve collapsibility. [3, page 25, 27]

16
 CHAPTER THREE

RESULT AND DISCUSSION

3.1 SELECTION OF MOTOR

The motor selected for our design purpose is DC motor used for make rotation
motion by supplying the power and also motor output shaft connected with the
cam shaft by the belt.

The cam shafts develop reciprocating motion by getting the power from the motor

DJM INDUCTION MOTOR

Type Power Rated Rated Rated Output Output Short

source( frequency( power( current( torque(N rotating team
v) HZ) W) A) m) speed(Rp rotation(
m) min)
DJM30 220 50 250 2.5 165 50.2 7
0-3P
DJM60 220 50 370 3.5 412 50.2 7
0-3P
DJM60 380 50 250 1.0 412 50.2 14
0-3P
DJM80 220 50 400 4.0 650 30.4 7
0-3P
DJM80 380 50 300 1.1 650 30.4 14
0-3P
DJM1.0 380 50 400 1.5 810 30.8 14
T-3P
DJM1.3 380 50 600 1.8 1050 30.8 14
T-3P
DJM1.5 380 50 800 2.0 1220 30.8 14
T-3P
Table 3.1 standard type of motor

From the table we select the motor types which have the following parameters.

17
Type-DJM600-3p

Power source-220V

Frequency-50HZ

Rated power-370W

Rated current-3.5A

Output toreque-412Nm

Output rated speed-50.2Rpm

Short team rotation-7min [10, page 600 - 756]

3.2 DESIGN ANALYSIS OF SIEVE

Sieve analysis: for particle sizes larger than 0.075mm in diameter.

Sand: Are any soil particles larger than 0.06mm or 0.02inches.

The result of sieve analysis is generally expressed in terms of the percentage of total weight of soil
that passes through different sieves.

Sieve Diameter(mm) Mass of soil Percent Cumulative Percent

retained on retained( retained( finer(
each sieve(g)
10 2.00 0.00 0.00 0.00 100
16 1.180 9.90 2.20 2.20 97.8
30 0.600 24.66 5.48 7.68 92.32
40 0.425 17.60 3.91 11.59 88.41
60 0.250 23.90 5.31 16.90 83.10
100 0.150 35.10 7.80 24.70 75.30
200 0.075 59.85 13.30 38.00 62.00
Pan 278.99 62.00 100.00 0.00
Sum =450

Table 3.2 sieve analysis

Percent retained on any sieve=( )x100

18
Cumulative percentage retained on any sieve =

Percentage finer than any sieve size 100 ∑

∑ ∑

0.00

3rd 2.20

4th =2.20

5th=11.59

Percent finer 100 ∑

100

Particle size distribution curve

Sieve number 200 100 60 40 30 16 10 100

80

60

Sand 40

Silt with clay mixture 20

Percentage fine

0.001 0.01 0.10 1.00 10.00

Particle diameter

For reliable and reproducible results in the context of quality assurance, the use of test sieve which
cross pond to the standards ISO33100 ASTME ll.

The technical requirements and monitoring for test sieves are laid down in this standard.

From the literature review sieve analysis for particle size larger than 0.075mm diameter and also
from the soil content, we call it sand the particle larger than 0.06mm or 0.002inches.

From the specification of sand particle size, larger than 0.075mm, we take the range between
0.075mm to1.00mm and also1.8mm to 2.0mm

19
The material we have selected for the sieve is stainless steel by considering corrosion resistance.

The density of material is 0.29lbs/in3

1in3=16.387cm3

1pon =0.4539Kg

By the above relation density in Kg/m3can be 8025.869Kg/m3

We need three most important sieves to perform foundry purpose.

Sieve one; this sieve have small opening compared to the other two sieves because it sieves the sand
which is finnier in order to use facing sand. The opening are determined by particle size
(0.293mm).facing sand is applied to the pattern to obtained castings of smooth and clear surface.
Sieve two; this sieve is moderate opening diameter to get core sand from the mixture. The sand used
for making cores, the cores is subjected to serve conditions in the mold. According to particle size
we need the opening sieve are 0.853mm.

Sieve three; this sieve have large opening compared to the other two sieves. Because of the opening
is large due to the need of sand which is backing sand. Backing sand used for support or back up the
facing sand and to fill the rest of flask. The opening is 1.65mm.

From the data determination of grain size of sand, taking experiment 50g sand for the sieve shakers.

The experiment includes the following steps;

 50g of sample sand washed and dried

 Sample placed in the sieves shaker
 The shaker started vibration for 10-15 minutes
 The shaker switched of and the vibration slipped
 The screens are discharged one another
 The sand is distributed based on size and the gram size of the sand [2,page 15-20]
s.n Sieve no Opening(mm) Amount(g) Retained( )
o
1 6 3.353 0 0
2 12 1.651 0 0
3 20 0.853 0 0
4 30 0.590 0 0
5 40 0.414 1.5 3.0
6 50 0.295 0.3 0.6
7 70 0.205 2.5 5.0
8 100 0.147 0.5 1.0
9 140 0.104 8.20 16.4

20
 10 200 0.074 13 26.0
12 270 0.053 12.8 25.6
13 Pan 5.60 11.2
Total 44.4 88.8
Table 3.3 standard sieve opening

Fig 3.1 sieve

3.3 Geometric representation of machine

Weight

200mm

W y

600mm 1000mm

L=1000mm
Fig 3.2 geometry of machine

1500mm

To determine the angle of inclination using sin or cosine law

21
 =opposite/adjacent

= = 0.1333 ,

We assume that the shaft mounted at midpoint of frame and the link is fixing the center of sieve
guide. = ,

To calculate the length of link y=

y=900mm

To determine the height of the machine we consider human factors.

Means ergonomic property (height),so to put the sand from machine the height of machine less than
average human height h=1200mm

Length of machine= 1500mm

Width of machine =800mm

To consider the loads that apply on the machine, calculate force analysis.

We take sample of sand 5Kg and the frame carry weight of sieve as well as sieve support sheet
metal. Sieve made from stainless steel density is 8025.869Kg/m3.

The sieve considered as sheet metal which thickness=2.5mm

Due to the above given, density=mass/volume

Mass=12Kg at maximum

Sieve support sheet metal for steel have the grade SAE 50, the density is 8050Kg/m3.

To calculate mass thickness=1.5mm because it is sheet metal.

Total mass=sieve mass+ sheet mass+ mass of sand

Mass of sieve=density volume

=8025.869kg/m3 1m 0.6m 0.0025m=12Kg

Mass of sheet=density volume

=8050kg/m3 0.6m 1m 0.0015m=7.245Kg

Total weight= (12kg+5kg+7.245kg) 9.81=237.84N

22
To calculate the force exert for each point can be

WT=237.84N

Ra f Rb

∑ , R a+ R b +fsin33.7=273.84N

∑Mo=0, Ra (0.5)-R b (0.5) =0

∑Ma=0, Ra 1-273.84 0.5+0.5fsin33.7

Ra=143.7N=R b

3.4 DESIGN ANALYSIS OF FRAME

The frame material made from mild steel for stability and rigidity, this structure is seated 1500mm
length of machine and 1200mm height and 800mm width. Each frame jointed from the base by
welding the frame supports the entire weight of sieve and also sieve support.

The bearing house bolted from the frame and holds shaft with cam, the weight of sand we can sieve
and also from the standard of the material we have to be selected. Determine the dimensions of the
frame. Material mild steel which have height 1000mm

E=210Gpa, SY=250Mpa

A buckling response leads to instability and collapse of the members. It is the ability of a structure to
support a given load without sudden change in configuration.

For the failure occurs by yielding or crushing without buckling, at stress above proportional limit. [1,
page 232-247]

23
Table 3.4 end condition of frame

Le= =500mm both ends of the frame are fixed

= = √

=91.05

=250.014Mpa

Radius of

a=b

690.87a4=0.25a2, a=21.5mm we say 25mm

We assume b=t =a=25mm -critical load

=crushing stress

By Euler’s formula the frame used as a bar and the dimension based on analysis

24
 25mm by 25mm

Fig 3.3 frame

3.5 Design of sieve support link

Material selection:-due to the nature of the load applied on the material we select high strength low
alloy steel which have the following properties.

345Mpa

=485Mpa E=200Gpa [1, page 240]

Compressive stress ( = P/A or

To calculate buckling load of the link, both ends are considered as hinged. Therefore effective length
of the link is Le=total length/2

Le=500mm

This links are carrying the load of sieve and sheet metal which used to move the sieved sand.

Working stress per unit area =167.14N/mm2

=167.14Mpa

25
F s=

= 345Mpa/167.14 =2.06

The Rankin constant a=1/7500=0.0001333

Buckling load =P f s

P=

=172.5Mpa b 1m= 172.5Mpab, 345/2=172.5Mpa b

Moment of inertia for rectangular section

I=b h3

=13 b /12

=b/12

According to Rankin formula K= A

√
=

K=1/12=0.0833

( )

= 171.657Mpa b

Le/r=3.14√ =24.07

b= 19.8 we have known before width of the links are three times its
thickness.

b =3 t, t=b/3

26
t=20/3=6.667mm

Fig 3.4 sieve support link

3.6 DESIGN ANALYSISE OF SHAFT
The shaft is cylindrical and solid in cross section

The material used for shafts should have the following properties:

 It should have high strength

 It should have high machine ability
 It should have low notch sensitivity factor
 It should have good heat treatment properties
 It should have high wear resistant properties
The material used for ordinary shaft is carbon steel of grades 40c8, 50c4 and 50c12.the
mechanical properties of the grades of carbon steel are given the following table.
Table 3.5 mechanical properties of steel used for shafts
Indian standard Ultimate tensile Yield
designation strength(M pa) strength(M pa)
40c8 560-670 320
45c8 610-700 350
50c4 640-760 370
50c12 700 min 390

27
 Types of shaft Transmission shaft: These shafts transmit power between the source and
the machine absorbing power. Since these shaft carry machine parts such as pulleys, bearings etc.
Therefore they are subjected to twisting moment only.

Standard size of transmission shaft

The standard size of transmission shaft are 25mmto60mmwith 5mmsteps; 60mm to
110mmwith10mmsteps; 110mm to 140mm with 15 steps.
Shaft subjected to combined twisting and bending moment
There are strengths and rigidity of shaft to design their parameter .among the above
consideration means strength analysis the shaft to select transmit power from the source to
the machine are subjected to twisting moment and bending moment.
Due to the above reason the shaft must be designed on the base of two moments
Symentaniously.
There are two type of theory important for design this type of shaft.
 Maximum shear stress theory or Guests theory
. it used for brittle material like mild steel
 Maximum normal stress theory or Rankin’s theory
It used for ductile material like cast iron

The twisting moment (t) may be calculated that by power transmitted (W) for shaft.

P= Where: T=twisting moment in Nm it is constant for motor=412Nm

torque N= speed of shaft in Rpm
For shaft under definite physical specification ,the permissible shear stress may be taken 20-
30 of elastic limit in tension but not more than 18 of the ultimate tensile strength( ) in
othere words ;
Shear stress ( ) =0.3
=0.18 whichever is less.
For shaft we select carbon steel for the grade of 40c8 and =320Mpa and
Then 320Mpa,
=96Mpa =100.8Mpa
By the principle of ASME code select small value.
,

We assume factor of safety=2,

2

=1/2 2802+4 962

=169.75Mpa
To get maximum bending moment, calculate bending at each point
The weight that exert on shaft are pulley weight and link force
Pulley weight=density volume gravity =499.26N

28
499.26N 90N

200mm 100mm 800mm

Rb
Ra ∑
Ra + R b=499.26+90=589.26N…………………………….1
∑Mo=0,499.26×0.2-90×0.4+Rb×0.8=Mo
99852Nm-36000Nm=0.8Rb………………………………2
R b=79.8N, R a=509.445N
To know M max using section method

499.26N Mo ∑
∑
x
When x=0
Mo
∑
200mm x ∑
When x=0
499.26N
90N Mo
∑
300mm 400mm x ∑M=0,
509.44N
499.26 (700+x)-509.44 (400+x)+90 x=-Mo
When

29
 The bending moment diagram is as shown below.

[6, page 531-551]

499.26N 90N

509.44N 79.8N

M max= 149.778Nm

Bending moment diagram

To calculate the diameter use the formula of

D3=16 222.6Nm
2
=16 =23246.77
D=
= 28.54mm we can say 35mm from the standard diameter of shaft.

To check the power P=2

=2 /60
=2165w

To calculate the length of shaft =twenty times diameter of shaft.

L shaft=20 but with the width of machine and standard of shaft length it
should be 1.2 meter.(standard given 1.2 to1.8m).

30
 Shaft key

dia

Length of shaft

Fig 3.5 schematic representation of shaft

The, or angle of twist has great role to distinguish the safety of the shaft torsion rigidity is very
crucial in case of cam shaft when timing would be affected. The permissible amount should not
excess, 25 per meter length of such shaft. This may obtain by using the torsion equation
so, = Where, =torsional deflection, or angle of twist in radians

T =twisting moment or torque of the shaft =412Nm

Ј=polar moment of inertia of the cross sectional area about the axis of rotation=

9
G=modules of rigidity or the shaft materials, G=72.2 N/m2

L=length of the shaft =1.2 m

J= (0.035)4=1.47 1o-7m4

2
420 / (1.47 )

=0.188

The angular twisting between the bearings is less that o.250 So that the shaft based on the torsion
rigidity is safe.

31
 Fig 3.6 shaft

3.7 DESIGN ANALYSIS OF CAM

A cam is an irregular rotating machine element which gives reciprocating or oscillating

motion to another element known as follower.
The cam and the follower have a line contact and constitute a higher pair.
The follower may be classified as follow
 According to the surface in contact
 According to the motion of follower
 According to the path of motion of follower

We select the follower according to surface contact, flat faced or mushroom follower

According to motion we need reciprocating motion according to path, radial follower

Cam geometry

Displacement, velocity and acceleration diagram

When the follower moves with simple harmonic motion

1. Draw a semicircle taking the followers stoke as diameter

2. Divide the semicircle any number of even equal parts(say 6 or 8)
3. Divide the angular displacements of cam during out stroke and return stroke into the same
number of equal parts
4. The displacement diagram is obtained by projecting the points.
The process of the cam to make sieve is perform uniform acceleration and retardation.

32
Due to this reason we calculate the velocity and acceleration of the cam and followers.
Time return during out stroke to=
Time required for the follower during return
Mean velocity of the follower during out
Mean velocity of the follower during return
The maximum velocity of the follower is equals to twice the mean velocity.
Therefore maximum velocity of the follower during out and return strokes are;

The maximum acceleration during out and return strokes

1200 300 1200 900

2π*r

Displacement diagram

VO

VR

33
 Velocity diagram

Now draw the pitch circle using minimum diameter of the cam, 38mm dividing this circle to 120, 30,
120, and 90 degrees. And divide 1200 by six, =120/6

=200 .We have calculate the parameter of cam .there is speed of motor output N=50.2R/min

From the given f= where, f=frequency

T=period

T=1/f=1/50

T=0.02seconds

=2

Velocity during return and forward motion;

We have assume that 50mm long to be pushed and return by the angle of 120 then o and
R=120

120 =2.09

VO=

VR=2 R =15.03m per sec

34
 Fig 3.7 cam profile

3.8 SELECTION OF FOLLOWER

Camshaft and follower have an intermittent motion mechanism.

For the position indicated the cam exert a force on the follower

According to the type of motion and the cam profile we select flat faced follower and the material is
AISI 1096 at 650c .

Arborized on the surface, it quenched and tempered at 650c .

To determine the required parameter

[1, page72-75]

Fig 3.8 cam with follower from geometry length =900mm

Material AISI1096 which have E=29 106Psi=199.94Mpa

Determine maximum force exert by camshaft

N2=300 50.5/200=75.3RPm

From output speed we can get power output

Pout= N2T/60=3.14 75.3 412/60

35
 =1624.39W

Maximum pressure develop P max=p/v=1624.39w/15.03

=108.29N

To determine the half width (a) of contact patch since E1=E2=E, and u=2/E=1.00285 10-8

a=1.076√
-8
=1.076 /40

= 7.4 10-4m

To calculate rectangular patch area =2 a L

=13.32 10-4m2

Maximum contact

Po=2/3.14 108.29/ (7.4 10-4 0.04

=232.9 104pa=2.329Mpa

Deflection of cam and follower ( ) =

= 0.0000328m= 0.0328mm

Comments the contact stress is determine to be less than the yield strength and the design is
satisfactory.

The calculated deflection between the cam and the follower is very small and does not affect the
system performance.

3.9 DESIGN OF FLAT BELT PULLEY

The pulleys are used to transmit power from one shaft to another by means of flat belts. The pulleys
made of cast iron. The cast materials should have good friction and wear characteristics. The pulleys
are generally made of cast iron due their low cost. The arms may be straight or curve as shown

36
below.

Fig 3.9 geometry of pulley

The diameter of the pulley may be obtained from velocity ratio. Centrifugal stress induced in the rim
of the pulley,

t= v2 where, =density of rim material

=7200kg/m3forcast iron

V=velocity of rim

= DN/60

N=is speed of pulley

D=is diameter of pulley

Standard diameter of pulley

40,45,50,56,63,71,80,90,100,112,125,140,160,180,200,224,250,280,,…..4000,5000 in mm.

The width of pulley (B) =1.25b

Where, b=width of belt

B=width of the pulley

Flat belt width of cast iron and mild steel pulleys in mm.16,20,25,40,50,63,71,80,90,100…..

37
Thickness of the pulley (t) varies from D/300 2mm to D/200 3mm for single belt and
D/200 6mm to for double belt.

We select the diameter of pulley and thickness of pulley.

D1=200mm

D2=300mm from standard above

Then, thickness of pulley rim =300/300 2mm=3mm to 300/200+3mm =4.5mm for single belt.

The number of arms may be taken as 4 for pulley diameter 200 to 600mm and 6 for diameter for 600
to 1500mm.

Table 3.6 standard width of pulley

Belt width in Width of pulley

mm to be greater
than belt width
by mm
Upto125 13
125-250 25
250-375 38
475-500 50
Width of pulley =25mm

B=1.25b where b= belt width

25mm=1.25b then we can get belt width from

this relation

b=20mm

NOTE; the pulley less than 200mm diameter

are made with solid disc instead of arms. The
thickness of the solid web is taken equal to
the thickness of rim measured at the center of
the pulley face. Therefore the pulley we use
for motor shaft is 200mm diameter and
thickness3mm.

38
 Fig 3.10 pulley

3.10 DESIGN OF FLAT BELT

The belt is used to transmit power from one shaft to another by means of pulleys which rotate at the
same speed or at different speeds. The amount of power transmitted depends upon the following
factors;

1. The velocity of the belt

2. The tension under which the belt is placed on the pulley
3. The arc of contact between the belt and the pulley
4. The conditions under which the belt is used

To select the belt the following important factors should be considered

 Speed of driving and driven shaft

 Power to be transmitted
 Positive drive requirement
 Space available
 Shaft layout
 Service condition and
 Center distance

TYPE OF BELT
To select flat belt for our design purpose due to the functions of moderate amount of power is to be
transmitted from one pulley to another, when the two pulleys are not more than 8m apart.

39
The material used for the belt must be strong, flexible and durable. The most important material for
flat belt is leather. The best leather belts are made from 1.2m to 1.5m long strips cut from either side
of the back bone of the top grade steer hides. The hair side of the leather is smoother and harder than
the flesh side. The ultimate strength of leather belt varies from21 to 35MPaand factor of safety may
be taken as 8 to 10.howevere the wear life of a belt is more important than actual strength. [6, page
699-720]

Table 3.7 density of various belt material are given below

Material of belt Mass density in

kg/m3
Leather 1000
Canvass 1220
Rubber 1140
Balata 1110
Single woven 1170
belt
Double woven 1250
belt
for efficient transmit ion of power, the belt speed 20m/s to 22.5m/s may be used. Then we can take
v=21m/s. The coefficient of friction of friction between belt and pulley are depends upon the
following factor;

 The material of belt

 The material of pulley
 Speed of belt
 Slip of belt

According to C.G Barth, the coefficient of friction ( ) for leathere belt on cast iron pulley at the
point of slipping is given by;

=0.54

Where, v=speed of the belt in m/min

=0.54

=0.26

The standard belt thickness and width are given below.

a) 5mm for nominal belt width 35 to 63mm

b) 6.5mm for nominal belt width 50 to 140mm
c) 8mm for nominal belt width 90 to224mm

40
 d) 10mm for nominal belt width 125 to 400mm
e) 12mm for nominal belt width 250 to 600mm

To join the belt the cemented joints are preferred to others joints like laced joint and
hinged joint because cemented joint made by the manufacturer to form an endless belt.

BELT ANALYSIS
Length of flat belt-in flat belt drive which is open belt, both the pulleys rotate in same direction.

(In term of pulley radius)

= (in term of pulley diameter)

The power transmitted by the belt is calculated as follows

Power transmitted = (T1 T2) V in watt.

A little consideration will show that the torques exerted on driving pulley is equal to the torque
exerted on driven pulley.

Therefore

Where, T1andT2=tension in tight side and slack side respective

r1and r2=radius of driving and driven pulley respectively

v=velocity of belt

41
Tension for flat belt drive as shown the figure below

Resolve all forces horizontally

Since is very small, therefore putting sin =

RN= (T

=T ………………………………………………………………………. (1)

Resolving the force vertically,

= (T

, then;

RN=T =

RV=

To determine the angle of contact for open belt is given by;

Sin =r1 r2/x

(180 2 )

Length of flat belt can be calculated as follows

42
 = (300+200)/2+300

=550mm

L= (300+200)+2 +(300-200)

=1889.98mm

To determine tension of belt

To calculate angle of contact

=r1-r2 x

150-100 =0.127

=179.7 180

𝚹= 3.136

=2.25

From the torque

(T1-T2) 0.15 =412Nm

T1-T2 =2746.667N

T2- 2.259T2= 3458.05N

T2=2746.667N

43
T1=2.259×2746.667

=14016.46N

The belt speed is more than 10m/s, therefore the tension must be taken in to consideration assuming
leather belt for which density 1000Kg/m3.

Assume belt thickness 15mm=0.015m

Mass of belt per meter length M=area length density

M=b 0.015 1000

M=15bKg/m

Centrifugal tension (TC) =m v2

TC=15b 212

=6615 b N

For the belt the safe stress selected 2.5Mpa

T=T1+TC = b t

14016.46+6615b=2.5Mpa 0.015 b

14016.46=30885b

b=0.453m

From standard belt width b=450mm.

Motor shaft transmission belt cam shaft

r1 X r2

44
 Fig 3.11 geometry of belt

3.11 DESIGN AND SELECTION OF BEARING

Bear type for cam shaft at both end of shaft or on frame are used to support the rotating shaft by
preventing wear. The bearing type is selected a ball bearing of radial ball bearing. Since the load is
not extremely high ball bearing could not select.

The ball bearing has the following merits;

 Accuracy of shaft alignment

 Reliability of service
 Low cost of maintain ace as no lubrication is required while it is in service
 Small overall dimension
 Ability with stand momentary shock loads
 Clean lines
 Easy to mount and erect

Now let see the analysis;

The basic load rating (Co) in Newton for ball bearings, may be obtained as follow

Where=number of rows of ball take

D=nominal angle of contact between the line of action ball and a plane perpendicular to the
axis of bearing, =15

Z=number of balls per row

F o =factor depend upon the type of bearing (12.3 for radial and angular contact groove bearing)

Bearing is a machine element that manufactures to take radial loads, thrust loads or a combination of
both.

The bearing life is depending upon the number of revolution or house of life a given bearing at a
rated load.

Rating life; life at which 90 of a group of bearing pass or exceed level of performance-termed
L10 or B10 life.

Medium bearing life is typically 4 to 5 times the L10 life.

The graph is shown below

45
 Bearing operation L10life

Medium life

50 .

0 bearing life

Bearing life at various loadings can be approximately the relationship is

Where L 1 -bearing life at load level, 1000,000 revolution or hours of operation at constant
speed.

Fi=radial load

= 3 for ball bearing

=3.33 for roller bearing

The bearing life can be calculated

Ni=60LIni where LI- bearing life in hours

N i- operating speed of bearing (rev/min)

Ni- bearing life in revolution

For our design purpose ball bearing is selected. [6, page 998-1010]

Life of bearing for various types of machine

46
 s.no Application of Life of bearing
bearing in hour
1 Machine work 40,000-60,000
24 h r like
separator,
compressor and
pump
2 Machine work 8 12000-20000
h r per day
3 Air craft engine 1000-20000
Table 3.8 list of bearing for various machines

For ball bearing L=60 N LH

60 50.2=40000hr

L=40000hr 50.2=200800

The material used for ball bearing are high carbon steel ,chromium steel and the ball manufactured
by hot forging on hammers from steel rods .

Principal dimensions for radial ball bearing

Bearing No. Bore(mm) Outer dia. (mm) Width(mm)

202 15 35 11
302 15 42 13
203 17 40 12
303 17 47 14
403 17 62 17
204 20 47 14
304 20 52 14
404 20 72 19
205 20 52 15
305 25 62 17
405 25 80 21
206 30 62 16
306 30 72 19
406 30 90 23
207 30 72 17
307 35 80 21
407 35 100 25
Table3.9 standard dimension of ball bearing

47
From the above standard table for diameter of shaft 35mm

Diameter of ball is 21mm

Outside diameter is 80mm

Width is 21mm, serial number of 307(bearing number).

LUBRICATION PURPOES OF BALL BEARING

 Reduce friction and wear

 Prevent resting
 To dissipate heat
 To protect the bearing surface from water and dirt

48
 Fig 3.12 ball bearing

3.12 Design and selection of sunk key

For a good design result the width of the key is made one-quarter of the diameter of the shaft .the
thickness of the a key for equal strength of the key in failure by shearing of the key ,and compression
on the key may shearing is determined by the corresponding allowable stresses in shear and
compressions .[6, page 480-500]

The length of the key can be calculated as

L= =1.57d
Where, d =diameter of the shaft

49
 Givens:
o Shaft diameter, d=35mm

o Key materials must mild steel having the following specifications

 Crushing stress and shear stress, τ=44Mpa

The width of key

Thickness Where D=diameter of shaft

From the above formula

L=35/2=17.5mm

W=35/4=8.75mm

t=35/6=5.833mm

Fig 3.13 Geometry of shaft with sunk key

3.13 Selection of bolt and nut

Bolts, nuts and pins are temporary fasteners that used to fasten the two parts highly loaded small
bolts studs and nuts are made from free cutting steel high strength

Bolt Nut Fig 3.14 bolt and nut

50
Material for bolts, nuts and pins are highly loaded small bolts studs and nuts are made from free
cutting steel, high strength bolts often fail in fatigue they are made of plan carbon steel like 40c8
,45c8, or alloy steel like 40Ni10cr3Mo6 stainless steel is used for threaded fasteners where corrosion
resistance is required

3.14 MANUFACTURING PROCESS

Shaft is made of low carbon steels. They are produced by hot rolling and finished to size either by
cold drawing or by turning and grinding. Cold drawing produces a stronger shaft than hot rolling.
However, cold drawn shafts have certain disadvantages .the tolerances on their diameter and
straightness are not very close compared with shafts finished by turning and grinding process and
also cold drawing produces residual stress and near the surface of the shaft.

During machine operations like slotting and milling, required to make the key slot, the residual stress
are partially released causing distortion of the shaft. [10, page 324]

Nut material should be soft and comfortable. The wear is always restricted to softer surface.
Therefore, if at all a component is to be replaced, it should be the nut. The material for nut is tin,
bronze and phosphor bronze. [10, page 214]

Generally in these manufacturing processes, the material is removed by means of sharp cutting tools.
Turning, milling, drilling shaping, grinding etc. Examples transmit ion shaft, key, bolts and nuts.
[10, page 63]

Belt is made of leather, canvass, rubber, or rubberized fabric and synthetic material. But in this
project we use leather belt.it is best quality leather obtained from either sides of the back bone of a
steer. The main advantage of leather belt is high coefficient of friction and consequently, high power
transmitting capacity. Belts are specified according to the number of layers or plies, example single
ply, double ply, triple ply etc. [10, page 499]

Pulley is one part of our machine, in these process molten metals such as cast iron, copper,
aluminum or non-metals like plastic are poured in to the mold and solidified into desired shapes.
Example, machine tool beds and guides. [10, page650]

3.15 WELDING
Welding is a fabrication process that joins materials, usually metals or thermo plastics, 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 a melting the work pieces.

51
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 heat, pressure or a combination of
both. When heat alone is used the process is called fusion welding.

Pressure welding usually involves heating the surfaces to a plastic state and then forcing the metal
together. The heating can be by electric current of by friction resulting from moving one surface
relative to the other. The methods and equipment used for welding metal are also associated with
cutting metal. There are a large number of welding and allied processes including the following.

Arc welding (shield 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. 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 way.

There are several work pieces material requirements for arc welding;

 Have a well-defined melting point

 Must electrically conducting
 Have a reasonable high thermal conductivity[5,page 125]

52
 Fig 3.15 wielding process

3.16 RESULT
The automatic sand sieving machine has been designed mainly for dry sand of size between
0.075mm-1.53mm.the operation of this machine is very straight forward and rotation motion from
the motor.

It is simple and does not require any special expertise, skill or knowledge to set up the machine
operation.

 Fill the sample of sand in to screen or sieve or mesh (5kg)

 Turn on the electric motor after ensuring that there is no loosed part on the machine
 The movement of the mesh does the shaking of the entire place in different
segmentation.
 The fine sand will be at the bottom of sieve and follow dawn ward on inclination of
sheet metal.
 The coarse will be set on top and drop to the ground.
 The left extra which cannot find its way through the sieve is remove and throws
away.
 Disassemble the sieve and remove each segment.

53
Shaft Material-carbon steel 40c8
Diameter=35mm
Length=1.2m
Frame Material-mild steel
Height=1000mm
Width=25mm
Thickness=25mm

Sieve Material-low alloy steel

link Height =1000mm
Le=500mm
Width=25mm
Sieve Material –stainless steel
Length=1000mm
Width=600mm
Opening=0.293mm,0.853mm,
1.65mm
Motor Type-DC motor
Power source=220V
Rated power=370W
Output speed=50.2RPm
Output torque=412Nm
Pulley Material –cast iron
Diameter for shaft=300mm
Diameter for motor=200mm
Width=25mm
Belt Material- leather
Type- flat
Speed of belt=21m/s
Coefficient of friction=0.26
Center distance=500mm
Length of belt=1890mm

Bearing Material high carbon steel

Type –ball bearing
Diameter=21mm

Key Material –mild steel

Length=17.5mm

54
 Width=8.75mm
Thickness=5.833mm
Bolt material –plain carbon steel
Table 3.10 result

3.17 WORKING PROCEDURE

The working principles of this machine /sand sieve machine are; first, check all components of the
machines to be tighten and put the sieve to the sieve support. Second, came up the dry sand to fill the
sample of sand in to mesh or sieve (5kg). For the next turn on the electric motor after ensuring that
the movement of sieve does the shaking and reciprocating of the entire place in different segment.
Finer ones well be at the bottom of sieve to sheet metal while the coarse will be on top of sieve and
remove by the inclination in order to throws away.

Finally we take the required sand particle and disassemble the sieve from the machine after stopping
the power source.

55
9 Pulley 2 Cast iron
8 Motor 1 Dc motor
7 Follower 1 Carbon steel
6 Belt 1 Leather
5 Shaft 1 Carbon steel
4 Cam 1 Carbon steel
3 Frame 4 Mild steel
2 Link support 4 Alloy steel
1 Sieve support 1 Sheet metal
S.NO Part name quantity Material

56
 CHAPTER FOUR

CONCULUSION, RECOMMENDATION AND FUTUR WORK

4.1 Conclusion:
We conclude that general aspect of our project contains mainly material selection, design analysis,
manufacturing process, welding in order to join each parts and other required parameters.

Generally before we start the analysis and design consideration discussed detail about the
mechanism by referring many books as well as asking teachers in order to reach the simple and
acceptable mechanism.

As far as concerning purpose of foundry, to make different pattern three type of sand are required
these are face sand, core sand and back sand.

To make patterns by molding and casting process the materials to be make a pattern aluminum and
steel .mainly the machine used for dry sand to be sieved because for foundry there is no need of
large amount of sand.

The driving mechanism of our designed machines is turning on the electric motor to start the motion
of shaft. Due to shaft rotation the cam makes reciprocate by the help of follower to sieve the sand.

Main parts that transmit power for motor to shaft belt, this belt are flat belt made from leather.

The discussion parts are the main body of the project that deals all about design analysis and
parameter of the parts are determined which required for our designed machine.

Among the main parts of machine frame, belt, pulley, motor etc. are included.

Each component has different material selection due to their different purposes.

57
 4.2 Recommendation:
We recommended that general thing about project; the machine is easy to make molding in order to
clarify for the customer. In days past, before all foundries has standardized lab testing tools, foundry
man used to mix and sieve the sand manually and go by the feel of the sand, One of the things that
we trying to achieve to give the sand which is sieved automatically. It was common belief that is the
sand felt silky then it would flow better and make better molds. Would be in prove in the delivery
system of the additives ,the company perform the foundry purpose use this automatic sand sieve
machine and improve the quality of pattern you have to be mold. The construction site would have
used this machine in order to increase productivity of sand products such as concrete.

58
 Reference
[1], Ansel.c.ugural, mechanical design an integrated approach by McGraw- Hill
Americans, 1991

[2], Pune, Foundry and forging operations course books MEC215, work shop tasting,
Vishwakarma institute of technology

[3], Industry oriented mini project on non-ferrous sand casting for mechanical engineering

[4], Hutter, Michael J., Green sand additive trial report from university of Wisconsin-stout,

[5], htt: // www. John winter .co.uk, John winter foundry and detail supplier

January 11.2012

[6], R.S Khurmi, J.K Gupta, Text book of machine design first edition

2005, EURASIA

[7], Text book of principle of foundry technology Fourth edition

[8], the West Indian journal of engineering January, 2013

[9], V.b bhandari , Design of machine element, second edition

[10], V.B Bhandari ,Design of machine element second edition Retired professor and head
department of mechanical engineering.

59
60
61