Republic of the Philippines

BATANGAS STATE UNIVERSITY

Gov. Pablo Borbon Campus II, Alangilan Batangas City, Philippines
College of Engineering, Architecture & Fine Arts
www.batstate-u.edu.ph Tel. No. (043) 425-0139 loc. 118

DESIGN OF A MECHANICAL PRESS

Submitted by:
Batalla, Faith Angeline
Bacani, Jeedvicson S.
Dullaven, Geraldine P.

Submitted to:
Engr. Mary Grace Rivera

JULY 2021
 TABLE OF CONTENT

PAGE

TITLE PAGE i

TABLEOF CONTENT ii

LIST OF TABLES iv

LIST OF FIGURES v

CHAPTERS

I INTRODUCTION

General Introductory Statement 1

Objectives of the Design Project 2

Scope of the Design Project 2

II REVIEW OF RELATED LITERATURE

Related Literature 3

Related Studies 15

Synthesis 16

III DESIGN PROPER

Design Basis 18

Equipment Specifications 21

Capacity 31

IV OBSERVATIONS, CONCLUSIONS, AND RECOMMENDATIONS

Observations 34

Conclusions 34

ii
 Recommendations 35

BIBLIOGRAPHY vi

APPENDICES

A Schematic Layout of the Machine vii

B Tables and Figures used for Computation xii

iii
 LIST OF TABLES

TABLE NO. TITLE PAGE

1 Material Dimension and Conditions for Flywheel 21

2 Material Dimension and Conditions for Flat Belt 27

3 Ultimate Strength of the Material 31

4 Summary of the Calculated Design Specifications of 33

the Components of the Machine

iv
 LIST OF FIGURES

FIGURE NO. TITLE PAGE

1 Mechanical Press 3

2 Hydraulic Press 5

3 Crank Press 5

4 Knuckle Joint Press 6

5 Eccentric Press 7

6 Rack and Pinion Press 7

7 Screw Press 8

8 Belt Drive Mechanism 9

9 Sheet Metal 10

10 Flywheel 12

11 Belt Drive 12

12 Crankshaft 13

13 Motor 14

14 Isometric View of the Proposed Mechanical

Press 18

15 Schematic Diagram of the Flywheel 22

16 Schematic Diagram of the Belt Drive 28

v
 CHAPTER I
Introduction
Metal forming processes are an essential part of our society. The products and components

created by the different metal shaping techniques are used in creating everything from scaffolding

and heavy machinery, to designing and creating microprocessors and artificial intelligence.

Meanwhile, sheet metal is one of the fundamental forms used in metalworking and is used in a

variety of forms. Numerous numbers of objects fabricated every day with the utilization of sheet

metals. Nowadays, sheet metal forming based on presses is widely used and is being well-

developed.

Presses, commonly used for metal forming of different car and machine bodies, is one of

the most important manufacturing devices. It may be defined as the chip-less manufacturing

process by which various components are made from sheets. One of its major types is the

mechanical press. Mechanical press is a device designed to apply very high force to form, shape,

or cut materials, to compress solids or to extract liquids. It works on the principle of reciprocating

motion and the main components for power transmission are the flywheel, crankshaft, and belt-

drive. Moreover, due to its low cost of maintenance and high production rate, it is widely used in

the metal forming industry

The proposed mechanical press will be primarily used for forming sheet metal and will

be driven by a motor. Flywheel and belt drive will be the main components to be calculated and

cast iron will be the material used for the design of the flywheel.

1
Objectives of the Design Project

The main objective of the design project is to design a mechanical press. Specifically, this

aims to:

1. Determine the standard dimension to safely design a mechanical press.

2. Evaluate the design and performance of the mechanical press in relation with the

specification materials to be used as well as the components in terms of:

2.1. Flywheel Rim;

2.2. Flywheel Hub;

2.3. Flywheel Shaft;

2.4. Flywheel Arm;

2.5. Flywheel Key; and

2.6. Belt.

3. Apply the calculated parameters and analysis in the design of the mechanical press.

Scope of the Design Project

The proposed design project will deal with the design of a mechanical press and will mainly

focus on the design of the flywheel and belt drive. Detailed design layout will be created using a

computer aided program such as SolidWorks. The proposed machine, the mechanical press, will

function on the formation of metal sheets. This design project is only limited to the calculation,

analysis, and designing of the mechanical press.

2
 CHAPTER II

Review of Related Literature

Related Literature

Mechanical Press

A mechanical press is a machine press that is mostly used for forming sheet metal

and metal extrusion. Additionally, a mechanical press is ideal for impact extrusion

applications where the rapid and consistent application of force can be fully utilized over

a preset distance. Compared to other types of machine press, the application of force in a

mechanical press can vary from speed and magnitude throughout the stroke length.

Subtypes of mechanical press include stamping press, the screw press, the punch press, the

press brake, and etc (IMTS, 2020).

Figure 1. Mechanical Press

Source: https://ahshmt.en.made-in-china.com/

3
 The working principle of the mechanical press is to transform the rotational force

of a motor in a translational force vector that performs the pressing action. Therefore, the

energy in a mechanical press comes from the motor. An electric motor supplies power to a

flywheel that, when engaged by a clutch and brake, drives a gear train that transmits the

power to the crankshaft, which moves the press slide up and down. The motor then restores

the energy to the flywheel, and the process begins again. The working energy of the press

depends on the mass and speed of the flywheel (STAMTEC, 2019).

Typical Press Machines

1. Hydraulic Press - The basic working principles of the hydraulic press are simple, and rely

on differences in fluid pressure. Fluid is pumped into the cylinder below the piston, this

causes the fluid pressure under the piston to increase. Simultaneously, fluid is pumped out

of the top channel, causing the fluid pressure above the piston to decrease. A higher

pressure of the fluid below the piston than the fluid above it causes the piston to rise. In the

next step, fluid is pumped out from below the piston, causing the pressure under the piston

to decrease. Simultaneously, fluid is pumped into the cylinder from the top, this increases

the fluid pressure above the piston. A higher pressure of the fluid above the piston, than

the fluid below it, moves the piston downward.

4
 Figure 2. Hydraulic Press
Source: https://airpress.net/hydraulic-press-10-ton-79380-1

2. Crank Press - The crank press uses a crank link attached to a drive shaft. The crank link

rotates with the drive shaft and is attached to a connecting rod by a rotational joint. The

connecting rod rocks back and forth during the motion of the crank. The connecting rod is,

in turn, attached to a ram by a rotational joint. The ram operates in a slider joint and travels

a one dimensional path in both directions. It is through this path that the crank press delivers

its force. The crank press does allow for a stroke of a relatively long distance.

Figure 3. Crank Press

Source: https://thelibraryofmanufacturing.com/presses.html

5
3. Knuckle Joint Press - The knuckle joint press translates the energy of a motor through a

powerful linkage design, and is capable of delivering a tremendous amount of force. The

drive shaft crank rotates completely. The links are well grounded to support such pressure.

Figure 4. Knuckle Joint Press

Source: https://grabcad.com/library/knuckle-joint-press

4. Eccentric Press - It uses a motor to drive an eccentric shaft, rotating in a connecting rod.

The connecting rod moves a ram in a slider joint one dimensionally. The eccentric shaft

itself is round, therefore it may completely rotate within the connecting rod. The center of

the drive is not the center of the overall shaft. As the motor rotates, the center of the drive

remains stable but the overall center of the shaft changes. This causes the shaft to change

position, providing motion.

6
 Figure 5. Eccentric Press
Source: https://thelibraryofmanufacturing.com/presses.html

5. Rack and Pinion Press - The rack and pinion press delivers the motors energy from a gear

directly connected to the drive shaft. The rack is actually a round gear of infinite radius. A

rotating gear (pinion), provides force through the rack. This gives the one dimensional,

translational motion desired of press machines.

Figure 6. Rack and Pinion Press

Source: https://www.brauer.co.uk/rpp1-rack-pinion-presses-pr1837.aspx

6. Screw Press - Screw presses use the rotational energy of a motor to turn a large screw.

Typically, a friction disk is used to translate the force from the drive shaft to the screw's

head. The screw pushes a ram with great mechanical advantage. Screw presses are similar

7
to hydraulic presses in that they are relatively slow and require a longer contact with the

work.

Figure 7. Screw Press

Source: https://www.researchgate.net/figure/Screw-press-design-12_fig1_281447660

Belt Drive Mechanism

The belt drive mechanism is a rotation transmitting mechanism for transmission of

rotational drive force. The belt drive mechanism includes, for example, a drive pulley, a

driven pulley, and an endless belt wound between the drive pulley and the driven pulley

(Yamaguchi, 2013). A belt drive mechanism for transmitting torque between a driving

rotatable member and a driven rotatable member through a drive belt which is an automatic

belt tightener. Included is a freely-riding pulley assembly pivotable about the driving

member as a center and including two pulleys with outside diameter flanges and reduced

interior diameters having their longitudinal axes of rotation parallel and a fixed distance

apart. The driving member has its longitudinal axis of rotation parallel to the rotational

axes of the pulleys and is arranged in a wedge-like relationship therebetween. The flanges

of each pulley are in contact with the driving member and the drive belt passes over the

driving member and then over the reduced diameter of both of the flanged pulleys. By this

8
 arrangement, the belt has imparted to it a driving force delivered by the driving member

and both of the pulleys.

Figure 8. Belt Drive Mechanism

Source: https://assamtechnicalguru.blogspot.com/2019/05/mechanical-belt-drives.html

Sheet Metal

Metal sheets are thin, flat pieces of material in a range of materials and form a

suitable wide range of applications. Construction and fabrication industries are some of the

most common uses of metal sheets along with a range of uses within the DIY and hobby

space. The range of materials and forms available enable metal sheets to be used in

industrial and everyday use products. It has a thickness ranging from 0.4 mm to 6 mm.

9
 Figure 9. Sheet Metal
Source: hvrmagnet.com

Design Considerations for Sheet Metal Pressing

Sheet metals are generally classified as metal sheets that have a thickness ranging

from 0.4 mm to 6 mm. Different metals such as steel, aluminum and stainless steel can be

made into sheets. Design considerations for sheet metal includes the material selection,

wall thickness, bend radii, bend allowance, K Factor, Bend reliefs, and manufacturing

process. For material and size selection, it depends on the application, formability,

weldability, corrosion resistance, strength, weight, and cost. The thickness of the sheet is

decided on the requirements of strength. A detailed comparison can be made using the

available design data handbooks with different material specifications. Moreover, while

designing any geometry, it is always a good idea to maintain uniform wall thickness

throughout the body. Geometry with more than one wall thickness requires sheets of

different thicknesses, which requires reorientation and alignment of parts that consume

time. Parts with different thicknesses will have different bend parameters which may result

10
in the inaccuracy of the desired shape. Meanwhile, to avoid any fractures or distortions, it

is necessary to keep the inside bend radius at least equal to sheet thickness. The bend radii

should be maintained consistently throughout the part as keeping the same bend radii across

all bends makes the part cost effective. Whenever making a bend, it is always preferred to

make bends in a single plane as this will avoid any additional reorientation while

manufacturing that part. The K Factor in sheet metal working is the ratio of the neutral axis

to the material thickness. K Factor changes its value with respect to physical properties and

thickness of materials. Generic values for K Factor vary from 0.3 to 0.5.

Main Components of a Mechanical Press

Flywheel

Flywheel is a mechanical device that is used to store kinetic energy. The

stored energy in the flywheel, however, depends on both the weight distribution

and the rotary speed. Large diameter and heavy wheels store more energy than

smaller and lighter wheels, while flywheels that spin faster store much more energy

than the ones that spin slower. The force on a flywheel increases with speed, and

the energy a wheel can store is limited by the strength of the material by which it is

made. In presses, during the longer, inactive period, the speed of the flywheel is

11
built up slowly by a comparatively low-powered motor. Most of the required energy

is provided by the flywheel when the press is operating.

Figure 10. Flywheel

Source: Cooper, 2021

Belt Drive

Figure 11. Belt Drive

Source: Peng, et.al., 2017
Belt drives are power transmission systems. It is basically a pulley system

wherein two pulleys are connected by a belt that transmits power from one pulley

12
shaft to the other. There is one driving pulley and one driven pulley. The belt’s

movement is the one responsible for transmitting power from an engine to a

mechanical device. The mechanical power or rotary motion is transmitted from the

driving pulley to the driven pulley because of the frictional grip that exists between

the belt and the pulley surface. Increasing contact angle can be done by an open

belt type to increase the transmission capacity.

Crankshaft

Figure 12. Crankshaft

Source: learnmech.com

A crankshaft is defined as a shaft driven by a crank mechanism which

consists of a series of cranks and crankpins to which the connecting rods of an

engine are attached. It is a mechanical part that performs a conversion between

reciprocating motion and rotational motion. In mechanical presses, its function is

to convert the rotary movement of the motor into reciprocating movement of the

ram by crank and connecting rod, or many other mechanisms.

13
Motor

Figure 13. AC Motor

Source: hvhindiustrial.com

Presses are usually driven by electric motors. It transmits power from rotary

motion of the drive shaft to reciprocating ram affected by the crank. A flywheel is

attached to the drive shaft which stores energy during the period between strokes

of pulleys and delivers the energy to the shaft to operate and to eliminate much

required power capacity coming from the motor. As a component of the press

machine, alternating current motors will generate a higher amount of energy and

operate the machine at high speed.

14
Related Studies

In metal production, mechanical presses are often used. According to Hayashi, H.,

Nishimura, H., (2009) the traditional presses are not advisable to use in producing precise drawing

because it lacks the qualities of consistent operating velocity and sheet metal forming is a method

that combines a set of common techniques. As a solution, mechanical press manufacturers have

created multi – links presses in order to achieve a consistent working velocity. But then some study

had stated that the multi-links presses, however, do not have the flexibility for different drawing

technology and low projection to improve tool life, productivity, processing accuracy, noise and

vibration reduction, and the shortening of the forming operations.

Various researchers then have developed a flexible press with a servo motor as the prime

mover in order to produce more acceptable load – stroke characteristics. The servo press with a

flywheel can give flexible motions with energy – saving benefit, according to Tso, P., and Li, C.,

(2008), but its actual ability has not been studied in detail and validated. The stamping capacity

and energy distribution between the flywheel and the servomotor are analyzed in this work, which

focuses on the “hybrid – driven” servo press. The force capabilities of servomotors, on the other

hand, are frequently limited; that is why many researchers have chosen to just focus on developing

the hybrid – driven process.

According to Li, H., Zhang (2010) the main concept behind the hybrid – driven linkage is

to use a two – degree of freedom mechanism to combine the motion of a big constant velocity

motor with that of a small servomotor. The constant velocity of the motor supplies the majority of

the power and motion, while the servomotor offers low – power motion modulation. As a result,

hybrid – driven linkage is said to be good in producing a programmable motion.

15
 Li, H., Zhang, Y., and Zheng, H. (2008) then have presented in their study a unique hybrid

– driven mechanical press for precision drawing, this innovative press is made up of nine – bar

linkage with two degrees of freedom controlled by inputs from a dc constant speed motor and a dc

servomotor.

Synthesis

Mechanical press is a kind of machine press that is mostly used for forming metal sheets

and metal extrusions and even ideal for some impact extrusion applications. It has its own capacity

throughout the stroke length when it comes to its speed and magnitude. Mechanical presses have

various subtypes. The energy in a mechanical press comes from the motor. Its principle of

transforming rotational force of a motor in a translational force vector which performs pressing.

Mechanical press has its main components. The flywheel, which the main performance is

to store kinetic energy. Energy stored kinetic energy depends on the capacity of a certain

mechanical machine. The crankshaft, wherein the function is to convert the rotary movement of

the motor into reciprocating movement.

In some studies, many researchers have tried many attempts to meet and achieve some

expectations for a mechanical press performance level to a metal production. Like what Tso, P.,

and Li, C., (2008), have found in their study, a servo hybrid -driven press have many benefits to

the overall performance and production of the machine. Li, H., Zhang, Y., (2010) said that it is to

combine the motion of a big constant velocity motor with that of a small servo motor. Meanwhile,

Li, H., Zhang, Y., and Zheng, H. (2008) have done a unique one which is made up of nine – bar

linkage with two degrees of freedom controlled by inputs from a dc constant speed motor and a dc

16
servomotor. Some alternatives have also been made with some improvements of a machine and its

function and capability.

17
 CHAPTER III

Design Proper

This chapter presents the discussion of the employed method in order to attain the objective

of the design project. Through the selected parameters and analytical method, design specifications

of the flywheel, belt, and shaft of the mechanical press will be determined.

Figure 14. Isometric View of the Proposed Mechanical Press

Design Basis

This section states the different formulas and equations used in solving the necessary

parameters to safely design the machine component intended for the machine. Most formulas are

derived from the book A Textbook of Machine Design by Khurmi and Gupta.

1. Flywheel Rim

1.1. Method of Determining the Mass of the Rim

𝛥𝐸 = 𝑚𝑅2 𝜔2 𝐶𝑠 (Khurmi & Gupta, 2005)

18
 1.2. Method of Determining the Cross-Sectional Area of the Rim

𝑚 = 2𝜋𝑅𝐴𝜌 (Khurmi & Gupta, 2005)

1.3. Method of Determining the Thickness of the Rim

𝐴 = 2𝑡 2 (Khurmi & Gupta, 2005)

1.4. Method of Determining the Width of the Rim

𝑏 = 2𝑡 (Khurmi & Gupta, 2005)

1.5. Method of Determining the Velocity of the Rim

𝜋𝐷𝑁
𝑣= (Khurmi & Gupta, 2005)
60

2. Flywheel Hub

2.1. Method of Determining the Diameter of the Hub

𝑑 = 2𝑑1 (Khurmi & Gupta, 2005)

2.2. Method of Determining the Length of the Hub

𝑙=𝑏 (Khurmi & Gupta, 2005)

3. Shaft

3.1. Method of Determining the Diameter of the Shaft

𝜋
𝑇𝑚𝑎𝑥 = 16 𝜏(𝑑1 )3 (Khurmi & Gupta, 2005)

4. Flywheel Arm

4.1. Method of Determining the Section Modulus for the Cross-Section of the Arm
𝜋
𝑍 = 32 × 𝑎1 × (𝑏1 )2 (Khurmi & Gupta, 2005)

5. Flywheel Key

5.1. Method of Determining the Width of the Key

19
 𝑑𝑠
𝑤= + 3𝑚𝑚
4

5.2. Method of Determining the Thickness of the Key

𝑤
𝑡= (Khurmi & Gupta, 2005)
2

5.3. Method of Determining the Length of the Key

𝑑1
𝑇𝑚𝑎𝑥 = 𝐿 × 𝑊 × 𝜏 × (Khurmi & Gupta, 2005)
2

6. Belt Drive

6.1. Method of Determining the Belt Diameter

𝜋𝐷𝑁 𝑁2 𝐷
𝑣= and = 𝐷1 (Khurmi & Gupta, 2005)
60 𝑁1 2

6.2. Method of Determining the Belt Length

𝜋 (𝐷1 −𝐷2 )2
𝐿 = 2 × (𝐷1 + 𝐷2 ) + 2𝑥 + (Khurmi & Gupta, 2005)
4𝑥

6.3. Method of Determining the Mass of the Belt

𝑚=𝐴×𝑙×𝜌 (Khurmi & Gupta, 2005)

6.4. Method of Determining the Width of the Belt

𝑎
𝑏= (Khurmi & Gupta, 2005)
𝑡

20
Equipment Specifications

Table 1
Material Dimension and Conditions for Flywheel
Parameters Values

Type of Material Cast iron

Material Density 7300 𝑘𝑔/𝑚3

Coefficient of fluctuation of speed 0.15

Energy per sheet 20 N⋅m

Speed 600 rpm

Energy 650 N⋅m/min

Maximum diameter of the flywheel 1m

Allowable tensile stress for cast iron 30 MPa

Allowable shear stress for cast iron 40 MPa

Table No. 1 shows the parameters that were considered for the calculation of the flywheel

design. The flywheel will be made of cast iron since it is one of the most used and commonly

available types of flywheels. Also the flywheel will incorporate 6 arms. As the space consideration

limits the maximum diameter of the flywheel to 1 m, assume that mean diameter as d= 0.762 m or

r= 0.381 m.

21
 Figure 15. Schematic Diagram of the Flywheel

Calculation:

Power needed for the electric motor,

Assume an efficiency of 85%

𝐸
𝑃 = 60×𝜂

650 𝑁⋅𝑚/𝑚𝑚2
𝑃= 60×0.85

𝑃 = 12.75 𝑘𝑊

Energy of the Motor

20 𝑁⋅𝑚
𝐸𝑀 = = 23.53 𝑁 ⋅ 𝑚
0.85

Velocity of the Belt

22
 𝑣 = 𝜋𝐷𝑁

𝑣 = 𝜋 × 0.254 𝑚𝑚 × 600 𝑟𝑝𝑚

𝑣 = 478.78 𝑚/𝑚𝑖𝑛

Tension Acting on the Belt

𝑃×60
𝑇= 𝑣

12.75 𝑘𝑊×60
𝑇 = 478.78 𝑚/𝑚𝑖𝑛

𝑇 = 1.6 𝑁

Distance moved by the belt when forming metal sheet

= 𝑣 × 𝑡 = 478.78 𝑚/𝑚𝑖𝑛 × 0.0125

= 5.98 𝑚

Energy supplied by the belt

𝐸𝐵 = 𝑁𝑒𝑡 𝑡𝑒𝑛𝑠𝑖𝑜𝑛 × 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑒𝑙𝑡

𝐸𝐵 = 1.6 𝑁 × 5.98 𝑚

𝐸𝐵 = 9.57 𝑁 ⋅ 𝑚

Maximum fluctuation of energy

𝛥𝐸 = 𝐸𝑀 − 𝐸𝐵

𝛥𝐸 = 23.53 𝑁 ⋅ 𝑚 − 9.57 𝑁 ⋅ 𝑚

𝛥𝐸 = 13.96 𝑁 ⋅ 𝑚

23
Mass of the Flywheel Rim

Since the maximum diameter of the flywheel is 1 m, assume the mean diameter of

the flywheel as D= 0.762 m or R= 0.127 m.

Maximum Fluctuation of Energy

𝛥𝐸 = 𝑚𝑅2 𝜔2 𝐶𝑠
Angular Speed, 𝜔

2𝜋𝑁 2𝜋(600 𝑟𝑝𝑚)

𝜔= 60
= 60
= 62.83 𝑟𝑎𝑑/𝑠

Substituting,

13.96 𝑁 ⋅ 𝑚 = 𝑚(.0.127)2 (62.83)2 (0.15)

𝑚 =1.46 kg

Cross sectional dimension of the flywheel rim

𝑚 = 2𝜋𝑅𝐴𝜌

1.46 𝑘𝑔 = 2𝜋 × 0.127 × 𝐴 × 7300 𝑘𝑔/𝑚3

𝐴 = 0.0002506 𝑚2

Thickness of the flywheel rim

𝐴 = 𝑏𝑡 assuming 𝑏 = 2𝑡

𝐴 = 2𝑡 2

0.0002506 𝑚2 = 2𝑡 2

𝑡 = 0.01119 𝑚 = 11.19 𝑚𝑚, 𝑠𝑎𝑦 12 𝑚𝑚

Width of the flywheel rim

24
 𝑏 = 2𝑡 = 2(12 𝑚𝑚)

𝑏 = 24 𝑚𝑚

For Flywheel Hub,

Diameter of the flywheel hub, d

Maximum Torque, 𝑇𝑚𝑎𝑥

𝑇𝑚𝑎𝑥 = 2𝑇𝑚𝑒𝑎𝑛

𝑃×60 12.75 𝑘𝑊(60)

𝑇𝑚𝑒𝑎𝑛 = = = 0.203 𝑁 ⋅ 𝑚
2𝜋𝑁 2𝜋(600 𝑟𝑝𝑚)

𝑇𝑚𝑎𝑥 = 2 × 0.203 𝑁 ⋅ 𝑚 = 0.406 × 103 𝑁 ⋅ 𝑚𝑚

For Shaft,

Diameter of the shaft

𝜋
𝑇𝑚𝑎𝑥 = 16 × 𝜏 × 𝑑𝑠 3

𝜋 𝑁
0.406 × 103 𝑁 ⋅ 𝑚𝑚 = 16 × 40 × 𝑑𝑠 3
𝑚𝑚2

𝑑𝑠 = 37.25 𝑚𝑚, 𝑠𝑎𝑦 37.5 𝑚𝑚

𝑑 = 2𝑑𝑠

𝑑 = 2(37.5 𝑚𝑚) = 75 𝑚𝑚 = 0.75 𝑚

Length of the Flywheel Hub

𝑙 = 𝑏 = 24 𝑚𝑚

For Flywheel Arm,

Cross sectional dimensions of the flywheel arms

𝑎1 = 𝑚𝑎𝑗𝑜𝑟 𝑎𝑥𝑖𝑠

𝑏1 = 𝑚𝑖𝑛𝑜𝑟 𝑎𝑥𝑖𝑠 = 0.5𝑎1

25
 𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑟𝑚𝑠 = 6

Maximum Bending Moment

𝑇 𝑇
𝑀 = 𝑅𝑛 × (𝑅 − 𝑟) = 𝐷𝑛 × (𝐷 − 𝑑)

0.406 0.762 0.127

𝑀= 0.762 ×( 𝑚− 𝑚)
( )6 2 2
2

𝑀 = 0.05639 𝑁 ⋅ 𝑚 = 56.39 𝑁 ⋅ 𝑚𝑚

Section modulus for the cross section

𝜋 𝜋
𝑍 = 32 × 𝑎1 × (𝑏1 )2 = 32 × (0.5𝑎1 ) × 𝑎1 2 = 0.05𝑎1 3

𝑀 56.39 𝑁⋅𝑚𝑚 1127.8

Bending Stress = = =
𝑍 0.05𝑎1 3 𝑎1 3

1127.8 3
𝑎1 3 = = √281.95
4

𝑎1 = 6.56 𝑚𝑚, 𝑠𝑎𝑦 7 𝑚𝑚

𝑏1 = 0.5(7 𝑚𝑚) = 3.5 𝑚𝑚

For flywheel Key,

Design of the key

Width of the key

𝑑𝑠 37.5 𝑚𝑚
𝑤= + 3 𝑚𝑚 = + 3 𝑚𝑚 = 12.375 𝑚𝑚, 𝑠𝑎𝑦 12.5 𝑚𝑚
4 4

Thickness of the key

𝑤 12.5 𝑚𝑚
𝑡= = = 6.25 𝑚𝑚
2 2

Length of the key

𝑑𝑠
𝑇𝑚𝑎𝑥 = 𝐿 × 𝑤 × 𝜏 × 2

37.5 𝑚𝑚
0.406 × 103 = 𝐿 × 12.5 𝑚𝑚 × 40 𝑁/𝑚𝑚2 × 2

𝐿 = 0.04331 𝑚𝑚, 𝑠𝑎𝑦 1 𝑚𝑚

26
Velocity of the Rim

𝜋𝐷𝑁 𝜋(.762 𝑚)(600 𝑟𝑝𝑚)

𝑣= =
60 60

𝑣 = 23.94 𝑚/𝑠

Checking
4.935𝑅
𝜎 = 𝜌𝑣2 (0.75 + 𝑛2 𝑡
)

0.762
2 4.935( 2 )
𝜎 = (7300 𝑘𝑔/𝑚3 )(23.94 𝑚/𝑠) (0.75 + 2 )
6 ×0.01119 𝑚

𝜎 = 22665533.87 𝑃𝑎 = 23 𝑀𝑃𝑎

Since 23 MPa < 30 MPa, the design is safe.

Table 2
Material Dimension and Conditions for Flat Belt
Parameters Values

Type of belt drive Belt drive

Type of material for belt Rubber

Material Density 1140 kg/𝑚3

Velocity of the Belt 23 m/s

Distance between the two pulleys Twice the diameter of the large pulley

Safe Stress for the Belt 3 MPa

Power 15 kW

Speed of motor pulley 1800 rpm

Speed of large pulley 600 rpm

Coefficient of friction 0.3

27
 Table No. 4 presents the parameters that were considered for the calculation of belt drive

design. Open belt drive will be employed for the design of the flat belt since the rotational motion

of the both pulleys is in the same direction and parallel to one another. Rubber is the material used

since its highly flexible and can easily be made endless.

Figure 16. Schematic Diagram of the Belt Drive

Calculation:

Solving for 𝐷1

Using peripheral velocity of the belt,

𝜋𝐷1 𝑁1
𝑣= 60

𝜋(𝐷1 )(1800 𝑟𝑝𝑚)

23 𝑚/𝑠 = 60

𝐷1 = 244 𝑚𝑚

Solving for 𝐷2
𝑁2 𝐷
𝑁1
= 𝐷1
2

28
 600 𝑟𝑝𝑚 244 𝑚𝑚
=
1800 𝑟𝑝𝑚 𝐷2

𝐷2 = 732 𝑚𝑚

Length of the Belt

Center Distance

𝑥 = 2𝐷2 = 2(732 𝑚𝑚) = 1464 𝑚𝑚

𝜋 (𝐷1 −𝐷2 )2
𝐿 = 2 × (𝐷1 + 𝐷2 ) + 2𝑥 + 4𝑥

𝜋 (244 𝑚𝑚−732 𝑚𝑚)2

𝐿 = 2 × (244 𝑚𝑚 + 732 𝑚𝑚) + (2 × 1464 𝑚𝑚) + 4(1464 𝑚𝑚)

𝐿 = 4501.76 𝑚𝑚

Cross sectional area of the belt

a = cross sectional area of the belt

Angle of contact
𝐷2 −𝐷1
𝑠𝑖𝑛𝛼 = 2𝑥

732 𝑚𝑚−244 𝑚𝑚)

𝛼 = 𝑠𝑖𝑛−1 ( 2(1464 𝑚𝑚)
) = 9.5941°

𝜋
𝜃 = 180° − 2𝛼 = [180° − 2(9.5941°)] × 180

𝜃 = 2.8067 𝑟𝑎𝑑

Power Transmitted

𝑇1 =tension in the tight side of the belt

𝑇2 =tension in the slack side of the belt

29
 𝑃 = (𝑇1 − 𝑇2 )𝑣

15×103 𝑊
𝑇1 − 𝑇2 = 23 𝑚/𝑠

𝑇1 − 𝑇2 = 652.1739 𝑁 ……. (equation 1)

𝑇
2.3𝑙𝑜𝑔(𝑇1 ) = 𝜇𝜃 = (0.3)(2.8067)
2

𝑇1
𝑇2
= 2.3232 𝑁

𝑇1 = 2.3232 𝑇2 ……. (equation 2)

Substituting,

2.3232𝑇2 − 𝑇2 = 652.1739 𝑁

𝑇2 = 492.88 𝑁

𝑇1 = 2.3232 (492.88 𝑁)

𝑇1 = 1145.06 𝑁

Mass of Belt

𝑚=𝐴×𝑙×𝜌

𝑚 = 𝐴 × 1 𝑚 × 1140 𝑘𝑔/𝑚3

𝑚 = 1140 𝐴 𝑘𝑔/𝑚

Centrifugal tension

𝑇𝐶 = 𝑚𝑣 2 = 1140 𝐴 𝑘𝑔/𝑚 (23 𝑚/𝑠)2 = 603060𝐴 𝑁

Maximum or total tension

𝑇 = 𝑇1 + 𝑇𝑐 = 𝜎 × 𝐴

1145.06 𝑁 + 603060 𝐴 𝑁 = (3 × 106 𝑃𝑎) (𝐴)

30
 𝐴 = 4.77717423 × 10−4

𝐴 = 477.72 𝑚𝑚2

Width of the Belt

Assuming 12 mm thickness

𝐴 = 𝑏𝑡

𝐴 477.72 𝑚𝑚2
𝑏= =
𝑡 12 𝑚𝑚

𝑏 = 39.81 𝑚𝑚, say 40 mm

Capacity

The tonnage requirements can be calculated using the formula,

6𝑈𝑍
𝐹 = 2000𝐿

where:

F = force in tons

U = ultimate strength of the material in psi

Z = section modulus

L = distance

Table 3
Ultimate Strength of Material
Material Ultimate Strength (psi)

Steel 58015.1

Aluminum 42000

Stainless Steel 73200

31
 Table 3 presents values for the ultimate strength of each material. It is the utmost stress

that a specific material can endure before shattering or failing.

Calculations:

𝜋𝑑3
For round solid stock, 𝑍 = 32

Assume d = 3 in and L = 18 in

𝜋×33
𝑍= = 2.65
32

For steel,

6×58015.1 𝑝𝑠𝑖×2.65
𝐹= 2000×18

𝐹 = 25. 62TONS

For aluminum,

6×42000 𝑝𝑠𝑖×2.65
𝐹=
2000×18

𝐹 = 18.55TONS

For stainless steel,

6×73200 𝑝𝑠𝑖×2.65
𝐹= 2000×18

𝐹 = 32.33TONS

32
 Table 4

Summary of the Calculated Design Specifications of the Components of the Machine

Belt

Type of Belt Flat Belt (Rubber)

Diameter of the Pulley for the Motor 244 mm

Diameter of the Pulley for the Large Sprocket 732 mm

Length of the Belt 4501.76 mm

Thickness of the Belt 12 mm

Width of the Belt 40 mm

Flywheel

Mass of the Flywheel 1.46 kg

Thickness of the Flywheel rim 12 mm

Width of the Flywheel rim 24 mm

Diameter of the Flywheel hub 75 mm

Length of the Flywheel hub 24 mm

Thickness of the Flywheel key 6.25 mm

Length of the Flywheel key 1 mm

Shaft

Maximum Torque of the shaft 0.406 × 103 𝑁 ⋅ 𝑚𝑚

Diameter of the Shaft 37.5 mm

33
 CHAPTER IV

Observations, Conclusion and Recommendations

This section presents the observations and conclusions from the design of the mechanical

press. It also presents the recommendations for further improvement of the design.

Observations

The following design observations are noticed after designing the mechanical press along

with its main components:

1. Design of flywheel and belt drive were based on the preliminary data, particularly on the

energy required and material parameters.

2. Flat belt type was chosen as a belt mechanism to be used in the transmission of power

between the two pulleys as it is designed for high performance of the press.

3. Tonnage requirements differ depending on the type of material used. For steel, the

computed force is 25.62 tons, for aluminum, the force is 18.55 tons, and for stainless steel,

the calculated force is 32.33 tons.

Conclusions

The aim of this design project is to design a mechanical press which focuses on the flywheel

and belt drive mechanisms using the given preliminary data and to calculate the needed material

specifications appropriate for the machine. In line with the objectives of the study, the following

conclusions were obtained:

34
 1. The type of material and its nature of application, the material density, desired speed,

dimension, and condition of operation are among the design considerations necessary in

designing a flywheel.

2. The design for the flywheel is safe as the calculated value of the tensile stress which is 23

MPA is less than the allowable stress of the material.

3. After the calculation of the design, the overall machine dimensions, primarily the length,

width, height were identified. Also, the capacity of the machine was also determined.

Recommendations

The following recommendation were drawn:

1. Further research should be done to determine the most suitable specifications to be

incorporated in parameters like dimensions, and type of materials.

2. Further calculations and tests of other machine mechanisms that may help improve the

efficiency and feasibility of the overall design is recommended.

3. Use of other motors may be done, keeping in mind the capacity of the components, to

generate different amounts of power to perform other operations as well.

4. Consultations with professionals in terms of designing the machine to determine the most

appropriate parameters and operations of the machine.

35
BIBLIOGRAPHY

Li, H., Zhang, Y. (2010). Seven-bar mechanical press with hybrid-driven mechanism for deep

drawing; Part 1: kinematics analysis and optimum design. J Mech Sci Technol 24, 2153–2160.

https://doi.org/10.1007/s12206-010-0819-0

Pei-Lum Tso, Cheng-Ho Li. (2008). Study of servo press with a flywheel. Journal of Advanced

Mechanical Design, Systems, and Manufacturing 2 (1), 1-11. https://doi.org/10.1299/jamdsm.2.1

Hui Li, Yuping Zhang, Haiqi Zheng. (2008). Dynamics modeling and simulation of a new nine-

bar press with hybrid-driven mechanism. Journal of mechanical science and technology 22 (12),

2436-2444.

Hayashi H, Nishimura H. (2009). The application of servo press machines to forming sheet metals

with low formability. Annals of “ Dunarea de Jos” University of Galati, Fascicle V, Technologies

in machine building. Retrieved from:

https://www.gup.ugal.ro/ugaljournals/index.php/tmb/article/view/1925

STAMTEC. (2019). Mechanical Presses 101. Retrieved from:

https://www.stamtec.com/blog/mechanical-presses-101

IMTS. (2020). An Introduction to Mechanical Press. Retrieved from: https://www.imts-

exhibition.com/blog/an-introduction-to-mechanical-press.html

vi
 APPENDIX A

Schematic Layout of the Machine

vii
Front view

Back View

Frame

viii
Pressing Assembly

ix
Crankshaft Assembly

Flywheel

x
Belt Drive

Motor

xi
 APPENDIX B

Tables and Figures Used for Computation

xii
xiii
xiv