CAREER EPISODE 3

DESIGN AND ANALYSIS OF AN ELECTRICAL GRINDING MACHINE

3.1 Introduction

 Title: Design and Analysis of an Electrical Grinding Machine

 Chronology: Insert Chronology
 University: Gujrat Technological University
 College: Alpha College of Engineering & Technology
 Address: Gujrat, India
 Project Type: Academic
 Team position: Project Head
 Supervised by: Insert supervisor name

3.2 Background

3.2.1

Grinding is the process of converting large-sized objects into smaller particles ranging from few
millimeters to nanometers. The grinding process is based on the principle of shear force. Shear
force resulted due to abrasive surface breaks the objects and converts them into smaller particles.
Grinding is applied in a wide range of industries ranging from the food industry for grinding
grains into finer particles to metal industries, cement industries, etc. Traditionally, stones having
abrasive surfaces were used for grinding grains. Such grinding machines were run using human
effort by rotating the stone by hand. This process requires a lot of effort from human beings, and
the productivity of grinding is very low. Therefore, using a motor for powering the grinding
machine can increase its productivity and decrease the requirement of human effort.

A mechanized cereal grinder machine of stone was designed for this project. Parts of the
machine such as its frame, pulley drive, hand stone, motor, and bolts were selected for designing
a mechanized grain grinder machine. Mild steel was picked for the frame material, whereas high
carbon steel was used in the nuts and bolts. The torque provided by the motor required, the
length and number of belts, and the size of bolts was computed analytically. The CAD model of
a mechanized grain grinder machine of stone was prepared using SolidWorks. Analysis of
mechanized grain grinder machine was done in ANSYS. Results of analysis of mechanized grain
grinder machine of stone were discussed.

3.2.2 Objectives

The main objective was to design a mechanized grain grinder machine of stone. The other
objectives were:
  To improve the productivity of the grain grinder machine.
 To provide an easy method of grinding grains without using human effort.
3.2.3 Organization chart

Gujarat
Technological
University

Alpha College of
Engineering &
Technology

Department of
Mechanical
Engineering

Project
Supervisor

Akashbhai
Nareshbhai Patel Team members
(Team Leader)

Figure 1: Organization chart

3.3.3 Duties

 To understand the theory and procedure for designing and analyzing a grinder by
reviewing several literatures.
 To choose the parts, materials, and software required in the project.
 To compute the required design parameters and dimensions of the grinder parts.
 To develop a CAD structure of the machine in SolidWorks.
 To evaluate the structural properties of the designed grinder machine in ANSYS.
3.4 PEA

3.4.1

I gathered information about the main components of a traditional stone grain grinding machine.
I understood the process of grinding grain using the grinding machine of stone. I learned about
the principle of operation of the grain grinding machine. Then, I studied about the use of motors
for driving a machine. I learned to add a motor in a traditional machine for mechanizing the
process so that electricity could be used to operate the grain grinding machine. After that, I
acknowledged the method of calculating the design parameters of the grain grinding machine.
Then, I acquired skills for preparing the CAD model of the grain grinding machine in
SolidWorks. I also gained an understanding of the method of using ANSYS for analyzing grain
grinding machines using finite element analysis.

3.4.2

I selected parts for designing a mechanized grain grinder machine of stone. I selected a frame for
supporting the grinder, drive system, and motor. I selected a hopper for putting grain to the
grinder. Then, I selected a motor for powering the grain grinding machine and belt and pulley
drive system. For grinding grain, I selected a stone. I also selected handler and long bolts for the
grain grinding machine. Then, I selected materials for the grain grinding machine. For designing
the frame of the machine, I selected mild steel because of its high strength and good
machinability. I also found that mild steel was cheaper and commercially used. For nut and bolt,
I selected high carbon steel because of its high strength and resistance to corrosion. Likewise, I
selected a rubber V-belt due to its high friction properties and low price. I also chose cast iron
pulleys because of their better frictional properties and better strength. For preparing a CAD
model of a grain grinding machine, I nominated SolidWorks. For analyzing the design of the
grain grinding machine, I nominated ANSYS.

3.4.3

Then I conducted mathematical calculations of the design parameters of the grain grinding
machine. I selected a motor having 1.8 HP power and 1400 rpm. Using the power and rpm of the
motor, I determined the torque of the motor. Then, I calculated the design power of the grain
grinding machine using the rated power of the motor and correction factor 1.2. I used an ‘A’ type
belt for transmitting power. I obtained pitch width, nominal top width, nominal height, and
minimum pitch diameter of the small pulley using a standard design book. After that, I
determined the pitch diameter of the big pulley using the speed ratio. Using the diameter of the
small pulley and big pulley and center distance of the pulley, I calculated the pitch length of the
belt. Using the power rating of a single v-belt, I determined the number of belts required for the
grain grinding machine. Considering the center distance between bolt and stone, I calculated
external torque. Using external torque and diameter of the bigger pulley, I determined shear
stress on two long bolts. Then, I determined the nominal diameter of the bolt.
Insert calculations

3.4.4

I prepared a CAD model of the grinding machine in SolidWorks. I prepared four walls of the
frame of the grinding machine by extruding rectangles. Then, I created a circular hole on the top
of the frame to support the hopper of the grinding machine. Then I created a stand for supporting
the stone of the grinding machine. After that, I created a 2D model of the funnel-shaped hopper
and extruded the 2D model for preparing the 3D model of the hopper. Similarly, I prepared
models of motor, stone, long bolt and nut, pulleys, and handler. After that, I assembled the parts
of the grain grinding machine of stone. I attached a stand, motor, and hopper to the frame of the
grinding machine. Then, I assembled the belt and pulleys of the grinding machine. I attached a
handler to the bigger pulley. I assembled bolt and nut to the stone and bigger pulley for
transmitting power to the hand stone from the bigger pulley.

Insert design

3.4.5

Then, I analyzed the grinding machine of stone using FEA. I brought design of the grinding
machine to ANSYS, and I assigned the materials of the grain grinding machine components.
After that, I initiated the mesh generation of the numerical model. I designated a medium sizing
factor of the mesh and assigned an element size of 2 mm. Then, I assigned boundary conditions
of the grain grinding machine. I used a fixed boundary condition at the base of the frame. I also
defined the magnitude of the force in the machine. Consequently, I started the analysis. After
that, I observed the distribution of stress on the grinding machine and the deformation of the
machine. I found maximum equivalent stress, maximum equivalent strain, and maximum
deformation of the grinding machine to be x mpa, x mm/mm and x mm respectively, which were
within allowable limits, so I found the design of the grinding machine to be successful.

Insert Analysis

3.5 Technical Problem and Solutions

3.5.1

I encountered a problem while assembling parts of the grinding machine in SolidWorks. I found
that bolts of the grinding machine were not vertical in assembly, which indicated misalignment
of the holes of the bigger pulley and hand stone. Such arrangement of the parts of the grain
grinding machine could break the bolts and cause accidents as well, so I started to correct the
design. I measured the distance of the two holes from the center of the bigger pulley and the
distance of the two holes from the center of the stone. I found that the distance of the two holes
from the center of the bigger pulley and that of the two holes from the center of the stone were
not equal, due to which the problem occurred. Then, I modified the distance of two holes of the
bigger pulley is equal to that of the two holes of hand stone. After that, I assembled the pulley
with the other components of the grain grinding machine and found that the assembly was
proper.

3.5.2

While analyzing the design of the mechanized grain grinding machine in ANSYS, I found high
stress in the handler of the grinding machine. Such high stress could cause the failure of the
handler, so I optimized the design of the handler. I asked about the problem of high stress in the
handler of the grinding machine to the supervisor, and he suggested me that the problem was due
to the mall diameter of the handler, and increasing the diameter of the handler would solve the
problem. Then, I modified the design of the handler of the grinding machine by increasing its
diameter in SolidWorks. I assembled the parts of the mechanized grain grinding machine and
analyzed them in ANSYS. After modifying the dimension of the handler of the grinding
machine, I found that stress on the handler was decreased. I observed that maximum equivalent
stress on the handler of the grinding machine was lower than the permissible limit of
deformation.

3.6 Creative activities

I used a larger diameter of handler for designing a mechanized grinding machine. Using a larger
diameter of the handler decreased stress on the handler. I prepared holes on the pulley and stone
of the grinding machine to be aligned to each other properly so that there would not be high
stress on bolts connecting the two parts.

3.7 Team management and codes

This project was completed with me as the team leader. As a result, I coordinated several aspects
of the overall project’s work. Following a conversation with the project supervisor, I established
the program objectives and a number of tasks, which I then allocated to project team members.
While working on this project, I provided a suitable working environment for my teammates.
During the completion of this job, I resolved technical issues that members had. I talked with my
seniors and coworkers about how to solve the project’s technical problems. I talked about the
project’s progress and the technical issues that this project had. I compiled the findings of the
design and analysis and drafted the final project report.

I explored and studied the IS 2122-2 (1991) code for the selection of standard belts, nuts, and
fasteners. Moreover, I reviewed ISO 603-14:1999 to find the several types of abrasive products
and their advantages.

3.8 Summary

This project designed an alternative and low-cost system that can be used for grain grinding. This
project was primarily aimed at rural communities, and it significantly minimized the physical
effort required by users to rotate those heavyweight hand stones, as well as enhance grinding
quality over manual methods. The manual effort was reduced by using an electric motor. This
also increased the productivity of the grinding machine. For the components, mild steel and high
carbon steel were used in the frame and fasteners, respectively. The torque provided by the
motor, dimensions of belts and the size of bolts were computed analytically. SolidWorks was
preferred to design the geometry of the grinder components. Analysis of mechanized grain
grinder machine was done in ANSYS. The stress and deformation results demonstrated that the
material and design of the components were safe.

After finishing this project, I developed project management and interpersonal skills. I learned
how to communicate with others to solve the problems in this project. I worked as a team and
improved the productivity of the team. I also enhanced my professional skills in SolidWorks,
ANSYS, and technical writing. I also understood how to use standard codes in a design project.