SYNOPSIS FOR M.E.

DISSERTATION

1 Name of College : Tatyasaheb Kore Institute of Engineering And

Technology, Warananagar

2 Course : M.E. (Mechanical Design Engineering)

3 Name of Student : Mr. XXXXXXXX. (PRN No. XXXXXXX)

4 Date of Registration : August 2015

5 Name of Guide : Prof. XXXXXXXXX

6 Proposed Title : Design Development analysis and testing of

Wobble mixer machine

7 Sponsoring Organization : M/s Anil Industries Pimpri MIDC Pune.

8 Relevance:

In case of process industries, process of mixing and stirring forms and integral and
the important part of the total manufacturing process. Mixing is the process which determines
uniformity and over all quality of product .Process industries like chemical plants , food
processing plants, paint industry etc, largely employ mechanical mixers to carry out mixing
of powders , semisolid jelly fluids etc .Mixing is a process where powder or jellies are mixed
together through in the form of uniform mixture where stirring is the process to mix the fluid
and powder to dissolve the powder thoroughly in given mixture and form a uniform product
or output. In either of above cases thorough mixing of material is desirable to give and good
and uniform quality output . Mixing of powders of different material in order to form a
uniform product or a powder mix is quiet easy but when it is desirable to mix powder in a
fluid matter specially when the density of powder is high the problem occurs due to heavy
weight of particles of powder has a tendency to settle down.

STUDENT GUIDE
CONVETIONAL METHOD

In conventional method of mixing the metal oxide powder and vehicle mixing is carried out
on a vertical shaft mixer with a static mixer blade at the bottom ,this machine the motor is
driven on reduction gear box through coupling the output shaft of gear box is coupled to
stirrer shaft to which the blades are connected , when the motor rotates output shaft of gear
box rotates at slow speed. There by driving the stirrer. The stirrer rotates in one direction to
agitate the mixture to prepare paint.

THE PROBLEM
The stirrer of conventional machine rotates in one direction only which creates a particular
flow pattern in the fluids hence the particles tend to stick to the walls of container owing to
the centrifugal force rather than mixing thoroughly in mixture of paint , ultimately results into
poor quality mixture of paints there by poor quality output of paint .

Figure shows the blade profile of conventional mixer , the other prominent
issue is the vibrations , thrust and bending forces that create noise and high
maintenance of machine

STUDENT GUIDE
Present theories and practices:-

Mixing devices (Naranjan et al 1994) can be classified into two groups

with respect to segregation: segregating mixers—which have mainly diffusive
mechanisms, encouraging the movement of individual particles, making
segregation more significant, non-impeller type mixers tend to be of this type.
Less segregating mixers—have mainly convective mixing mechanisms. These
are typically impeller types in which blades, screws, ploughs, etc. sweep groups
of particles through the mixing zone. Mixing devices are chosen according to
the material mixed; therefore, it is important to know the particle size as well as
their flow properties. The variability of powders arises from the many ways in
which their flow properties may be changed such as: physical properties of the
powder particles such as their size, size range, shape, hardness, elasticity,
porosity, mass, interactions between particles, texture, angularity and so on.
Environmental factors that affect the powder bulk properties, such as the air or
moisture content, external pressure, vibration, etc. These factors modify the
physical distribution and arrangement of the particles in the powder mass.
Individual particle changes

In conventional method of mixing the metal oxide powder and vehicle

mixing is carried out on ‘UNI-DIRECTIONAL STIRRING MACHINE’

In this machine the motor is driven on reduction gear box through

coupling the output shaft of gear box is coupled to stirrer shaft to which the
blades are connected , when the motor rotates output shaft of gear box rotates at
slow speed. There by driving the stirrer. The stirrer rotates in one direction to
agitate the mixture to prepare paint or mixture.

The other type being the V-blender (figure 1) consists of two cylindrical
sections joined at an angle of around 90◦, it is designed for batch operation. The
angle between the cylinder and the centre line in the off-axis

rotating drum mixer is 40◦. The mixer is rotated about a horizontal axis, with
mixing resulting from the tumbling motion of the particles.

STUDENT GUIDE
 In a static mixer the main mechanism in laminar flow(Reynold’s
number< 2000) is the flow division. Element styles are three helical or pseudo-
helical, and are arranged in a series of alternating left and right hand 180◦ twists.
The leading edge of an element, which is on a diameter, is at 90◦ to the trailing
edge of the upstream element. In flow division, the leading edge of the first
element splits the material entering the mixer into 2 streams, which are then
rotated through 180◦. The second element splits the flow again, this time into 4
streams, followed by a further rotation, in the opposite direction, through 180◦.
The third element repeats the process by splitting into 8 streams, and so on. As
the number of streams

or layers increases, the layer thickness decreases. Mixture quality is a function

only of the mixer diameter and the number of elements and, in the laminar flow,
is independent of the flow rate or viscosity. In solid/solid mixing the unit is
usually vertical with the flow being by gravity only. The material is removed
below the mixer by an assembly line.
Present Theories and Practices:

Allen Edgar Bryson has studied the control of quality in the manufacture of paint. He had
given the brief introduction about composition of paint and its quality. He further presented
the manufacturing process of paints which consist of essential steps like Mixing, Grinding,
Thinning, and Tinting. Straining and canning operations takes place after the paint batch has
been tested and accepted as meeting the prescribed standard. Further he focused on the
Testing of paints, Measurement of quality of paints and controlling factors in manufacturing
of paints.

Ronal J. Weetman et.al. worked on the mechanical design of mixer with the emphasis on
the fluid forces that are imposed on the impellers by the fluid continuum in the mixing vessel.
According to them forces are the results of transient fluid flow asymmetries, acting on the
mixing impeller. These loads are dynamic and are transmitted from the impeller blades to the
mixer shaft and gear reducer. Fluid forces acting on the mixer that is bending loads on the
shafts caused by an effective force and torque can be calculated and same can be analyzed
with the help of CFD that is Computational Fluid Dynamics.

STUDENT GUIDE
 According to them power transmitted by the prime mover through the reducer and
shaft can be calculated. From applied power and mixer speed torque can be
calculated. Torque can be equated to a force at an effective radius.

O.S.Galaktionov et.al. applied the mapping approach to study the distributive mixing in the
industrial mixer. They have taken the Kenics Static mixer for study which is widely used in
industrial applications. According to them mapping method makes it possible to study and
compare thousands of different mixer layouts and perform optimization with respect to
macroscopic homogenization efficiency and interface generation. Mapping technique
comprises of computational domain, mixing modules and mapping matrices. They studied the
mixing efficiency in terms of blade twist angle.

David W Kammel [4]

has focused on design, selection and use of Total Mixed Rations
(TMR) mixers. According to him mixer design is still primarily a trial and error process with
due consideration given to prior experience. The manufacturer selects a specific mixer design
that is expected to perform, and field tests determine design changes and their effect on the
mix.

He highlighted on major aspect like Mixer design and options, Mixer testing, Batch
mixing, Mixing time, Safety, Mixer sizing, Mixer costs etc. He further said that since
‘Perfect mix’ is impossible, there will likely be some difference in the test results. The
test results should be looked at to determine the statistical significance of the
variability.

Rafique A. Memon et.al. [5]

have evaluated the numerical predictions for contra rotating
mixing flow within a cylindrical container. The behavior of fluid is compared against
previously simulated numerical results. According to them two dimensional incompressible
complex flow of Newtonian fluid is relevant to the food industries. The numerical method
adopted by them was finite element semi-implicit time –stepping Taylor-Galerkin/pressure-
correction scheme, posed in a cylindrical coordinate system.

STUDENT GUIDE
 They have further provided the physically realistic simulations for the complex
rotating flows. The contra rotating stirrer solutions display certain aspects of
symmetry. The streamlines and pressure isobars are localized in extrema in the
neighborhood of the stirrers. However, the power consumption is higher for the contra
rotating mixers.

Jan Skocilas et.al. [6]

have presented an analysis of the velocity field in an agitated fully
baffled cylindrical vessel with a down pumping four blade worn or unworn pitched blade
impeller under the turbulent flow region. CFD simulation was used to describe the ensemble-
average mean velocity field with worn and unworn impellers and their pumping capacity.
They showed from the simulation results that the wear rate of the impeller blade has a
significantly negative effect on the velocity distribution in an agitated liquid.
According to them, higher the destruction of the worn blade, the higher is the
deformation of the velocity field around the rotating impeller with a simultaneous
decrease in impeller pumping capacity. The deformation of the velocity field was
proved experimentally by them and confirmed by CFD simulation.

Jean Godat et.al. [7]

invented the ‘MIXER FOR HOMOGENIZING A MIXTURE OF
PRODUCTS CONTAINED IN A VESSEL’. Mixer having a detachable lid consists of a
helical blade. This helical blade is mounted upon a vertical shaft pivoting at its upper end
within the bearing member. Mixer can be used for homogenizing a mixture of products at
least one of which is present in the liquid phase.
Furthermore, in this mixer, the helical blade comprises at its base a scraping device
made up of a spring, or round wire. It exercises a uniform pressure on the bottom and
side of the vessel containing a mixture to be mixed.

STUDENT GUIDE
Objectives:

1. Estimation of the torque and power requirements of mixer for mixing of

specified viscous fluids for given volume of mixture considering fluid
friction in container , bearing friction in linkages etc.
2. Design Development & kinematic analysis of wobble linkage and stirrer
mechanism .
3. Design development of driving mechanism of mixing container , worm gear
drive

4. Test and trial on the mixer for production of 3.0 litres of ferrous oxide
paint, derivation of result as to viscosity (centistokes ) , spread-ability
(mm) , and quality of paint produced by mixer and its comparison to
productivity over the conventional mixer of same capacity. Parameters of
study

a)Reduction in cycle time of mixing

b) Improvement of viscosity and spread-ability
c) Productivity improvement owing to use of developed system
11 Proposed Work

STUDENT GUIDE
 I) Design and Development:

Following steps will be carried out

1. Estimation of torque and power requirements of wobble mixer for mixing

of specified viscous fluids for given volume.
2. Design and Development of profile of kinematic linkage for wobble action
as to geometry and strength.

3- D modeling and Analysis:

 3-D modeling of set-up using Unigraphix Nx-8.0
 CAE of critical component and meshing using Ansys ----ie the preprocessing part.
 Mechanical design validation using ANSYS …critical components of the system will be
designed and validated
Validation of strength calculations of critical components viz, drive eccentric
crank , connecting rod , damper piston , orifice plate etc using ANSYS.—Ie the
post processing part

Fabrication:

Suitable manufacturing methods will be employed to fabricate the components

and then assemble the test set-up.

II) Experimental Work:

Test and trial on the mixer for three liters of paint batch shall be carried out to
check various parameters such as viscosity (centistokes), spread-ability (mm) of
paint produced by mixer.
Comparison of results for cone mixer over a conventional mixer of same capacity
in terms of following parameters.
1. Cycle time of mixing
2. Viscosity and spread-ability
3. Productivity

STUDENT GUIDE
 Facilities Available:

The following facilities are available to carry out dissertation work.

1. Full pledged Modeling and Analysis lab. at Tatysaheb Kore Institute of Engineering
and Technology, Warananagar.
2. Machine tools to carry out fabrication work at Sponsor site.
Centre Lathe
Milling Machine
Jig Boring Machine
Electric arc welding

13 Expected Date of Completion : April 2016

14 Approximate Expenditure : Rs 34000/-

References:

1. Ronald J. Weetman & Bernd Gigas, “Mixer Mechanical Design-Fluid Forces”,

Lightnin Rochester, New York (2007).
2. O.S.Galaktionov, P.D. Anderson, G.W.M.Peters & H.E.H. Meijer, “Analysis And
Optimization of Kenich Static Mixers”, Materials Technology, Eindhoven
University of Technology, Eindhoven, The Netherlands, Hanser Publishers, Munich
Intern. Polymer Processing XVIII (2003).
3. Martin Robinson & Paul W.Cleary, “Flow and Mixing Performance in Helical
Ribbon Mixers”, CSIRO Mathematics, Informatics and Statistics (2012)
4. David W Kammel, “Design, Selection and Uses of TMR Mixers”, Biological
Systems Engineering Department UW-Madison (1998).
5. Rafique A. Memon, Mahera E Baloch, M. Anwer Solangi, Ahsanullah Baloch,
“Numerical Analysis of Rotating Mixing of Fluids in Container Induced by
Contra Rotating Stirrers”, International Journal of Modern Engineering Research
(IJMER) (2013).

STUDENT GUIDE
 6. Jan Skocilas, Ivan Fort, Tomas Jirout, “CFD Simulation Of Fluid Flow In An
Agitated System With A Pitched Blade Worn Impeller”, 14th European Conference
on Mixing Warszawa (2012).
7. Jean Godat, Daniel Parmenon, Alian Krzywdziak & Daniel Boudin, ”Mixer For
Homogenizing A Mixture Of Products Contained In A Vessel”, United State
Patent Godat (1983).
8. Allen Edgar Bryson, “Control of Quality In Manufacture of Paint”, Massachusetts
Institute of Technology (1950).
9. Chandra Shekhar, Kazunao Takahashi, Takuya Matsunga, Koichi Nishino,
“Tomographic PIV Measurement of Turbulence Energy Budget Equation Terms
in a Square Shaped Stirred Flow Mixer”, 17th International Symposium on
Applications of Laser Techniques to Fluid Mechanics Lisbon, Portugal (2014)
10. V.B. Bhandari, “Design Of Machine Elements”, Tata McGraw Hill Publication
Company Limited, third edition.

Date : 25th August, 2015.

Place : Warananagar

Mr. xxxxxxxxx Prof. xxxxxxxxxxx

Student Project Guide
Mechanical Engg. Dept.

Prof.xxxxxxxxxxxxxxxx Dr. xxxxxxxxxxxxx

Head, Mechanical Engg. Dept. Principal
T.K.I.E.T, Warananagar

STUDENT GUIDE
STUDENT GUIDE