AGRO TECHNICAL AND TECHNOLOGY

COLLEGE

Department of Manufacturing Technology

Design and Manufacturing of Belt Sander Machine

Project submitted to Manufacturing Technology Department in partial
fulfilment of the requirements for the award of degree of Bachelor of
Science in Manufacturing Technology

Group Members ID No.

1.ASHENAFI TESSFAYE…………………………………………………………... MTD/003/17

2.AYMEN YOUSUF…………………………………………………………………..MTD/005/17

3.MEHARI NIGUS……………………………………………………………………MTD/020/17

4.NARDOS HABTAMU…………………………………………………………....…MTD/026/17

5.SAMSON BIRAHANU…………………………………………………………...…MTD/031/17

6.YOSEPH WORKNEH ……………………………………………………………...MTD/034/17

7.ZEMED BIHONEGN ………………………………………………………….……MTD/035/17

Advisor: Ato Tshome Bogale

Co – Advisors
Ato Jegnaw Tesfaye

Ato Merwan Aha med

2021 Harar Ethiopia

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 CANDIDATES’ DECLARATION
We hereby declare that the work which is presented in this paper entitled “Belt sander” in partial
fulfillment of the requirements for the award of Degree of Bachelor of Science in Manufacturing
Technology is an authentic record of our own work carried out from “Aug, Year to Month,
2021” under the supervision of “Ato Teshome Bogale” in the Department of Manufacturing
Technology, Agro-Technical and Technology College, Harar, Ethiopia.
The contents embodied in this project were not submitted by us for the award of any other degree
or diploma. All relevant resources of information used in this project have been duly
acknowledged.

Name of students Signature

1. ASHENAFI TESSFAYE
2. AYMEN YOUSUF
3. MEHARI NIGUS
4. NARDOS HABTAMU
5 SAMSON BIRAHANU
6. YOSEPH WORKNEH
7. ZEMED BIHONEGN

This is to certify that the above statement made by the candidates is correct to the best of our
knowledge and belief. This project has been submitted for examination with our approval.

Advisor’s Name Signature

Ato Tshome Bogale

II
 APPROVAL BY BOARD OF EXAMINERS

We, the undersigned, members of the Board of Examiners of the final open defense have read
and evaluated the senior project entitled “Belt sander” and examined the candidates. This is,
therefore, to certify that the senior project has been accepted in partial fulfillment of the
requirement for the award of the Degree of Bachelor of Science in Manufacturing Technology.

Chairperson, Signature

Examiner Signature
Ato Robel Mitiku

Examiner Signature
Ato Tesfaye Kassahun

III
Table of Contents
Table of Contents......................................................................................................i
List of figure........................................................................................................iii
List of table..........................................................................................................iii
Abstract....................................................................................................................v
CHAPTER ONE......................................................................................................1
1. INTRODUCTION............................................................................................1
1.1 Problem Statement.........................................................................................2
1.3 General Objective...........................................................................................3
1.4 Specific Objective...........................................................................................3
1.5 Limitation........................................................................................................3
1.6 Delimitation.....................................................................................................4
1.7 Beneficiary group...........................................................................................4
1.8 scope of the project.........................................................................................4
CHAPTER TWO.....................................................................................................5
2. Literature Review.............................................................................................5
2.1 Belt Grinding Machine..................................................................................7
2.2 Abrasive Process.............................................................................................8
2.3 Conclusion on Literature Review.................................................................9
CHAPTER THREE...............................................................................................10
3. Methodology...................................................................................................10
3.1 General Objective.........................................................................................10
3.2 Data Collection Method...............................................................................10
3.3 Design Analysis Method (Approach)..........................................................11
CHAPTER FOUR.................................................................................................12
4. Design Analysis and Material Selection.......................................................12
4.1 Design Approach..........................................................................................12

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 4.2 Force analysis................................................................................................13
4.2.1 Force created by feed................................................................................13
4.2.2 Force created by belt tension....................................................................14
4.2.3 Force created by bearing load..................................................................15
4.3 Shaft Design..................................................................................................16
4.4 Material Selection.........................................................................................19
4.4.1 Frame material selection...........................................................................19
4.4.2 Base Plate and Motor Plate Selection......................................................20
4.4.3 Shaft material selection.............................................................................20
4.4.4 Bearing selection........................................................................................21
4.4.5 Roller Material Selection..........................................................................22
4.4.6 Motor Selection..........................................................................................23
CHAPTER FIVE...................................................................................................24
5.1 Processes Planning and Coast Analysis......................................................24
5.1.1 Processes planning sheet...........................................................................24
5.2.1 Approaches to Cost Analysis....................................................................25
5.2.2 Material Cost.............................................................................................26
5.2.3 Labor Cost.................................................................................................27
5.2.5 Machine cost..............................................................................................27
5.2.6 Total cost....................................................................................................28
CHAPTER SIX......................................................................................................29
6.1 Manufacturing Process................................................................................29
6.1.1 Introduction to Manufacturing Process..................................................29
6.1.2 Manufacturing of Riser............................................................................31
6.1.3 Manufacturing of trucking pillar.............................................................32
6.1.4 Manufacturing Processes of Motor Plate................................................33
6.1.5 Manufacturing Process of Base Plate......................................................34
6.1.7 Manufacturing Process of Tooling Arm..................................................35
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 6.1.8 Manufacturing Process of Working Plate...............................................36
6.1.9 Manufacturing Process of Roller Wheel.................................................37
6.1.10 Manufacturing Process of Receiver Tube.............................................38
6.1.12 Manufacturing Process of D-Plate.........................................................39
6.1.13 Manufacturing Process of Shaft.............................................................40
CHAPTER SEVEN...............................................................................................42
7. Conclusion and Recommendation................................................................42
7.1 Conclusion.....................................................................................................42
7.2 Recommendation..........................................................................................43
Reference................................................................................................................44
Appendance.........................................................................................................45
Detail drawing....................................................................................................45
Assembly Drawing With Bill of Material.........................................................46

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List of figure
Figure 1.......................................................................................................................................................9
Figure 2.....................................................................................................................................................10
Figure 3.....................................................................................................................................................16
Figure 4.....................................................................................................................................................17
Figure 5.....................................................................................................................................................17
Figure 6.....................................................................................................................................................18

List of table
Table 1.......................................................................................................................................................19
Table 2.......................................................................................................................................................21
Table 3.......................................................................................................................................................23
Table 4.......................................................................................................................................................24
Table 5.......................................................................................................................................................25
Table 6.......................................................................................................................................................26
Table 7.......................................................................................................................................................28
Table 8.......................................................................................................................................................29
Table 9.......................................................................................................................................................30
Table 10.....................................................................................................................................................33
Table 11.....................................................................................................................................................34
Table 12.....................................................................................................................................................35
Table 13.....................................................................................................................................................36
Table 14.....................................................................................................................................................37
Table 15.....................................................................................................................................................38
Table 16.....................................................................................................................................................39
Table 17.....................................................................................................................................................40
Table 18.....................................................................................................................................................41
Table 19.....................................................................................................................................................42

IV
While bringing out this project to its final form, we came across a number of people whose
contributions in various ways helped our project and research and they deserve special thanks. It
a pleasure to convey our gratitude to all them.

First and foremost, we would like to express our deep sense of gratitude indebtedness to our
advisor Ato Teshome Bogale for his invaluable encouragement, suggestions and support from an
early stage of this project and providing us extraordinary experiences throughout the work.

We would also like to acknowledge with much appreciation the crucial role of instructor Ato
Tesfaye G/Michael who has provided assistance at various occasions. His presence with us is
more important and beneficial than anything else. Next, thanks to our co-advisor Ato Merwan
Mohamed and Ato Jegnaw Tesfaye to their suggestions and support from an early stage of this
project and providing us better experiences throughout the work. And last but not least thanks to
all Manufacturing Technology Department staff for their continuous support.

Abstract
Machining processing have continuously developed and improved technologies and processes to
transform finished product to obtain better super finished product, quality and mass production.

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Abrasive machining is one of the most important of these Processes. Belt grinding is an abrasive
machining process used on metals and other materials. It is typically used as a finishing process
in industry. The main objective of this project is to design and fabricate an abrasive belt grinding
which can be used as versatile grinding machine, the work area can be rotated from 0 degree 90
degree. The 0 degree work area can be used for bottom grinding of component, the 90 degree
work area can be used for vertical grinding of component. The Machine we composed and
manufactured is utilized for pounding any state of protests like Circular, Rectangular, and
Polygon. To design the machine the project implement various formulas. The design included
force, frame, and shaft analysis. Based on the calculated forces the project select appropriate
material that included motor, shaft, frame, wheel, plate etc... To analyze these parameters the
project uses engineering mechanics, dynamics and machine element knowledge. Finally, As per
the problem identified during survey in company, case study of problem, and also with help of
research papers, international journals; we conclude that Abrasive Belt Oblique Grinding is
effective than wheel grinding.

Key words, grinding, oblique, orthogonal, abrasive belt, cost, sander

VI
 CHAPTER ONE
1. INTRODUCTION
Grinding has played a more and more important role with the increasing requirements of modern
industrial technology and high-performance technological products in respect of part precision,
surface integrity, machining efficiency and batch quality stability. It becomes an important part
of advanced machining technology and equipment, and is a research frontier in manufacturing
science.

Grinding is the process of removing metal by the application of abrasives which are bonded to
form a rotating wheel or belt. When the moving abrasive particles contact the work piece, they
act as tiny cutting tools, each particle cutting a tiny chip from the work piece. It is a common
error to believe that grinding abrasive wheels remove material by a rubbing action; actually, the
process is as much a cutting action as drilling, milling, and lathe turning.

Since the beginning of manufacturing, producers had developed a strong necessity of making
products to become better and better. Quality is indispensable and finishing essential to deliver
Quality products. When it comes to finishing raw materials such as wood, steel or leather,
sanding may be a very important step depending on the type of final product desired.

The first recordings of sanding being applied as finishing method as we know today come
actually from China. In the 13th century, sand, crushed seeds or shells were used to sand raw
materials, as they were bonded to parchment with natural gum. This would later develop in what
became sand paper. Surprisingly, shark skin was also a common material used as sandpaper.

Sanding was always a long work process, whether for larger areas or for small object that
requires more precision. Manual sanding was an exhausting process and the demanding amount
of work created the necessity of a sanding machine. The first sanding machines were actually
entirely human-operated. A pedal was used to spin a drill thus making sanding an easier process.

With electricity, sanding machine drills started to be powered by electric motors making the
process even easier. However, it was in the post war period, in which big factories emerged and
mass production took place, that sanding machines really developed.

It’s very hard to find recordings about which company (or companies) produced the first models
of sanding machines or exactly when, but they were soon established as essential pieces of
machinery to several brands of industry, particularly timber and wood furniture production, shoe
industry and even some metal grinding processes.
 After this period several companies developed the exact opposite: portable sanding machines
which could be used for nonprofessional work in small scale. The portable sanding machines
were very important for the development of other specific types of business such as flooring

The first one, which looked remarkably like a modern belt sander, was invented in 1926 by Art
Emmons at the Porter-Cable factory in Syracuse, N.Y

1.1 Problem Statement

As we know in industrial machine shops there are various manufacturing processes performed.
These are machining (on milling, lath, shaper….etc..), welding (arc, gas, MIG MAG, ….etc.…),
drilling, forging, casting…etc… are manufacturing processes that done in industrial machine
shop. Also in our collage (ATTC) machine shop. These all process have their own significant
effect on product quality. However, every product must pass through finishing process that give
a good surface finish for the product, if not, the surface quality not as such good, even if you use
sophisticated machines as much as you can.

These very important stage of manufacturing process so called finishing, performed in different
ways. Those are, grinding, Honing, lapping…etc. In most machine shops thus finishing operation
are performed. Based on work shape and material property they are preferred accordingly. In our
collage (ATTC) machine shop grinding wheel is available sufficiently and it has its own purpose.
In most case it use as tool grinding, the works to be grinded in shape they are bigger and working
area only horizontal relatively. The machine cannot use for small and soft material and also
vertical working area, it mostly use for Carbide, HHS, drill bit .etc. and horizontal working area.
In other word it mean in our machine shop dose not perform finishing operation of small and soft
materials and which has vertical working area.

Because of these several reasons this project could be prepared. This project so called “BELT
SANDER” have significant role over grinding wheel. The abrasive belt grinding which is used
currently has the working area as fixed one. And it has a rotating wheel not belt and it mostly
grinds cutting tools for machines. In this project we are going to design and fabricate an abrasive
belt grinding which can be used as versatile grinding machine, the work area can be rotated from
0 degree to 90 degree. The 0 degree work area can be used for horizontal grinding of component;
the 90 degree work area can be used for vertical grinding of component. And also it can grind
not only cutting tools but also wood and metal work pieces.

Machines shops workshops and garages around the Harar has difficulty to finish vertical object
or small part.

We strongly believe that this project can solve our collage (ATTC) machine shop basic problem
and other working areas.

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 1.3 General Objective
The Objective of this project is to design and fabricate an abrasive belt grinding which can be
used as versatile grinding machine by changing its work area from 0 to 90 degree.

1.4 Specific Objective

1. It effectively grinds, sands, and finishes the material with neatness.

2. for removing roughness and preparing woodwork for less aggressive tools
3. It can grind with horizontal and vertical position.
4. Their performance are strong enough for performing heavy duty tasks for applications
like sanding wood, cutting, edging, drilling or dealing with metal work.
5. To apply what we from fresh man to now.
6. To show the problem solving abrasive belt grinding machine to small scale work shop.

1.5 Limitation
 The abrasive belt should be changeable one for different material. This process takes more
time

 Hand or clothing, which can become entangled with moving parts

 very fine metal chips which can be inhaled, affects the respiratory system

 without proper safety preparation starting of the machine can lead to accidental contact

 The abrasive belt can break up and lash out

 Assembly and disassembly is need skillful operator.

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1.6 Delimitation
 The machine is compact and rigid in size.

 Maintenance is less.

 It can be used on any place of small grinding application

 Removes unwanted surface residue. If you want to remove paint or some unwanted residue on
a surface, use a belt sander

 When it produce in mass small shop can perched the machine.

1.7 Beneficiary group

1.8 scope of the project

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 CHAPTER TWO
2. Literature Review
In this section the various modification and development in the grinding machine technology are
mentioned.

Kyle Odum discuss issue relating to the power supply, occupational Health hazard and
advertised sustainable feature of abrasive power tool and abrasive media option in market today.
The most common power sources are electricity through the universal motor are lightweight easy
to control, and have desirable operating characteristic. It will operate at less than 50% efficiency
due to friction between commentator and brush in a universal motor cause wear and limit
inspection of motor. Also another source of motor is Brushless Permanent magnet motor which
has very high efficiency 80-90% more than universal motor. Aside from
electric power tool, pneumatic power tool that run on a compressed air are the most common in
the U.S.

Some advantages are: the lack of electric shock Hazards, absence of spark or ignition sources
and lightweight during operation. [3]

In this paper the main objective is development of grinding machines to improve the
productivity. In this paper the detailed study of grinders is explained. The various key
points like peculiarities of grinding machines, classification, trends in development of abrasive
processes, grain technology, cost, market developments, maintenance, digitization, trends for
grinding machine, grinding machine material structures, machine concept and simulation,
adaptive and Mechatronics system for grinding, energy efficiency, trends in auxiliary devices,
special machine developments such as ultra-precision machines 1195 and its principle
applications, hybrid machines, combined machines which are capable of executing different

Locations. The author has concluded day to day in recent years for getting more productivity in
manufacturing. [4]

In this paper surface roughness inspection is an off-line operation which is time consuming in
robotic abrasive belt machining process with Support Vector Machine (SVM). Predictive model
such as ANN, ANFIS and SVM were developed in this researches and correlation were
established between predicted surface roughness values .The technical features based on SVM
such as Linear SVM, Quadratic SVM, Cubic SVM with four different surface roughness. By
performance testing it is observed that Quadratic SVM and Cubic SVM were the best in terms of
predictive ability. The accuracy of SVM’s is 94.5%, 96.9% and 96.9% respectively.

5
This technique is established on planar surfaces while machining free from surfaces is subject to
research. [5]

In this paper discussed a new structure of robotic grinding system in which a new robot frame
including active work piece frame and passive tool frame was presented. In the industrial robot
are recently introduced to the belt grinding of complex shape surfaces to obtain high productive
efficiency and constant surface quality. The early development of robotic grinding focused on
the robot holding a grinding wheel to finish a part with simply geometries and with relatively
low accuracy requirements. The dexterity optimization ends are first, the establishment of an
appropriate coordinate system for the general theoretical analysis; second, the robot placed in
reasonable relative position to grinding machine ensuring that the robot has enough dexterous
space of grinding. [6]

The robotic belt grinding system is widely used to grind the sculptured surfaces and the grinding
is generated by off-line planning method. In this paper the effective method for the linear
approximation error is to reduce the step forward distance and increase the number of cutter
locations.’

Generally, the curve length between the neighboring cutter locations on the target surfaces must
be 1-2mm by the robotic belt grinding system. With the optimization algorithm the accuracy and
efficiency of belt grinding are integrated. [7]

This paper aims at the analyzation of grinding technology development research as per industrial
demand. The author has totally focused on the grinding challenges in industries. The very
important driving force developments of grinding are automotive application. There were many
problem presented by industries needs at the time include today well developed technology such
as fast and automotive wheel balancing system, flexible and prediction systems, more application
of CNC in grinding process, multiple grinding on one step and other. [8]

This paper highlights on belt grinding machine also it will explain the material used in a belt
grinder. In next step it will explain abrasive process: An abrasive is material that is used to shape
and finish a work piece through rubbing which lead to part of work piece 1196being worn away.
In final stage it will discuss on Grit, Grate and structure: The grains, commonly called grits,
have rough edge, often terminating in point which will decrease surface area and increase
localized contact pressure. [9]

This paper discussed the belt abrasive machining process and included substances final
background work, which provide a solid base under condition of behavior of the abrasive
machining process can be monitored. The abrasive belt can electively be cleaned by the

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appropriate cleaning technique. Thus, the system is able to super finish the shaft key, coupling
keys etc. [10]

This paper described two types of abrasive belts. First one is Conventional abrasive belt and
structured abrasive belt. Structured abrasive are increasingly used in practice, due to, this
abrasive saves and reduces working time and guarantees cutting costs. [11]

The aim of this paper was to explore the correlation between the sanding efficiency and the
surface quality, provided a standard for judging the end of belt life in the actual production.
The highest sanding efficiency was obtained by MDF when sanded with 60 grits abrasive belt,

While Manchurian ash acquired the lowest sanding efficiency when sanded with 100 grit
abrasive belt in longitudinal direction. The smaller granularity belt seemed to be more suitable
for precise sanding of wood products, while the bigger granularity abrasive belt was more
appropriate to improve productivity in the wood processing industry. [12]

2.1 Belt Grinding Machine

Figure 1

Belt grinding is an abrasive machining process used on metals and other materials. It is typically
used as a finishing process in industry. A belt, coated in abrasive material, is run over the surface
to be processed in order to remove material or produce the desired finish. The belt grinding
process is variable by adjusting certain parameters such as belt speed, grinding pressure, feed
speed, size of the contact drum and the abrasive belt that is used.

7
2.2 Abrasive Process

An abrasive is a material, often a mineral that is used to shape or finish a work piece through
rubbing which leads to part of the work piece being worn away. Abrasive Process is a
designation for the material removing process with hard mineral (abrasive) grains being used as
the cutting tool. The grinding technique, which adopts abrasive wheel or belt to remove
materials, is the most widely applied

Figure 2

Abrasive belt grinding is a common finishing process in the metal and wood working industries.
Coated abrasive belts are used in the same speed range as bonded wheels, but they are not
generally dressed when the abrasive becomes dull. The wide spread application of coated
abrasive belts and long standing operating practices have led to different kinds of quality
requirements. The abrasive belt machining technique is more significant for precision machining
and finishing.

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2.3 Conclusion on Literature Review
From the above literature review the recent development in grinding machine by implementing
various power tools and smart intelligence robotic system to increase the efficiency, productivity,
accuracy in surface finish and various beneficial parameters are observed. The effect of this
developments on the cost of system is also considered. Also the typical robot belt grinding
system an industrial manipulator, belt grinder and work piece is studied. The technology
development is highlighted in this review section.
However, we consider various parameters based on our environmental condition. These
considerations are:

1. Cost effectiveness
2. Affordability
3. Easiness to operate the machine. (It should not need high skilled labor.)
4. Availability of material those needed for constructing the machine.

The above literatures those state in <<literature review>> does not satisfied these
considerations. They are expense in cost, sophisticated in use, have high selling price. So, the
fabrication and design of this project is reasonable.

9
 CHAPTER THREE
3. Methodology

3.1 General Objective

The objective of this project is mentioned above repetitively. As we mention the main objective
of this machine is to overcome the problem of the department of manufacturing technology
machine shop of ATTC College. The problem that we found in our machine shop that, among
finishing machines the available finishing process machine in our shop is only wheel grinding
machine. This machine has specific task in machining process that is it recommended only for
tool grinding operation. Is means it is not recommended for other materials such as work pieces,
different parts, etc. so the fabrication of this belt sander has significant benefit to our machine
shop and other working areas.

3.2 Data Collection Method

To solve certain problem initially researchers can should identify the problem around them.
When identified the problem then they can design the solution based on the identified problem.
In identifying certain problem and in designing the solution process one can should set a method
of identifying the problem. Without setting the method one cannot properly reach on the
problem. So, the researcher must set a method of identifying the problem.
The method of identifying the problem or data collection method of this project is primary data
collection method that is observation. The project uses observation as method to obtain the
problem.
The data collection through observation included the area around the researcher’s community.
Such as, garages, welding shops, small scale industry and also our ATTC machine shop.

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3.3 Design Analysis Method (Approach)
We use different methods to analysis every needed parameters. Among from this method are
some of them are ፦

 Simple trigonometry
Our analysis use this method to solve frame of full structure and some of forces that
apply on shaft.
 Torque – force relation formula
To solve the force on shaft

Torque = FORCE * RADIUS * sin θ

torque
FORCE =
radius∗sin θ

 Resistance force of material formula

shear force
µ= hence, Shear force of material =from table of material property
yield strenth

Yield strength of material = from table of material property

 Bending moment and shear force diagram

To analysis moment and force to determine where maximum and total moment and
force on shaft.
 Equilibrium equation of moment and force
To determine moment by the percent force on shaft and reaction force at bearing.
 Shaft diameter formula
Simply to calculate diameter of shaft

[ √( ) ( )]
1
2 2 3
D2= 32 N KtM
+
3 T (1)
π Sn' 4 SY

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 CHAPTER FOUR
4. Design Analysis and Material Selection
4.1 Design Approach
To design the required parameters the designer sets different considerations.
 For Feed Force: to calculate feed force the designer considered two main parameters
1. The strength of the material to be sand on the machine
In this case the material considered is Tungsten Carbide. This material is not
machine part (element), it is cutting tool. And our belt sander machine cannot be
sand cutting tools. However, the designer consider this material sack of
calculation. Because if the machine with stand such greater strengthen material it
can with stand materials which have smaller strength. The designer included this
material in to calculation by inputting its coefficient of friction (µ). And its
formula is,

shear force ( τ ) Tungsten Carbide

µ=
yeild strength ( Sy ) Tungsten Carbide

2. The operator force exerted on the machine.

But the operator force cannot be the same, it differs with deferent operators. So
the designer take the average of them by taking the experimental friction force
ratio of the material. The formula is

FN = FC * µ
FN = normal force toward the machine (belt). This force consider as the feed force of
the operator.
FC = friction force, that found from experimental data. Frictional force ratio is about
25 based on the experiment that corresponding to 750 RPM. This data present below.

12
 The source of this data is the web engine stated below.

[13]

µ = friction coefficient of the material to be sand. (Tungsten Carbide, in our case)

 For Motor Selection: to decide our motor the designer starts from considering the
recommended SFPM (relative velocity between sanding belt and for belt sander. That is

SFPM = RPM X 6.55 X Roller Diameter  recommended SFPM is (2000 – 3500) for belt sander
So if we use RPM 1800 from the market (1440-2880) we take the average. By implementing this
we select our RPM 1800. And the power calculated from the above feed force.

4.2 Force analysis

The reason to analysis force is that, to analyze shaft diameter there is a main parameter called
force, this is the force that act on shaft due to different load. Our approach of design is the
following

4.2.1 Force created by feed

These force found from work feed. The feed force relate with the material strength witch sand on
the belt sander and the force of the operator. So to analyze the force we take most strengthen
material that is Tungsten Carbide. Now we use the following formula

τ 156
µ= = = 0.4727 = Hence- τ = shear force of mater
Sy 330
Sy= yield strength of material

13
From the above considerations we have 1800 RPM so our frictional force ratio become 60.

- FN = FC * µ = 60 (from the table) * (4, four rollers we have) * 0.4272 = 105.528N

Based on this force the designer calculate the required motor Power.
P = feed force * linear speed of the machine

Feed force = 105.528 N

N 1 D1 1800 100
= = = = N1 = 1800 * 1.667 = 3000.6 rpm
N 2 D2 N1 60
π∗D∗N π∗0.06∗3000.6
Linear speed (n) = velocity of roller (nylon plastic) = n = = = 9.4266
60 60
m/s

P = 105.528 * 9.4266 = 994.77watt

HP = 994.77 / 746 = 1.3334, so the required horsepower is = 2hp

4.2.2 Force created by belt tension

Belt force created tension force that determine by trigonometry relation.

360
r= = (0, 90) we take θ = 45°
sin θ

r = 509.1mm

-From force torque formula we have

T = F.rsin θ=¿ θ=¿angle between F and r (2)

T
F= , but we have T = HP / n = (2 * 746) / 188.4955 = 7.915 Nm
sin θ .r

7.915
Fb = = 0.02199N force by belt tension……………………… eq (2)
sin 45 ° . 509.1

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4.2.3 Force created by bearing load
We choose ball bearing for the rolling mechanism. From the estimation of diameter of shaft we
determine bearing mass or load.

√
3
16 T /(
π
£ max
)= from this formula we found max required diameter of shaft.

τ max = Sy /2 we select shaft material 1040 hot rolled as initial guess. So it has Sy = 290 then

τ max = 290/ 2 = 145MP…………………………… eq (3)

Now we calculate initial estimation of shaft diameter

√
3
16 T /(
π = when we substitute equ (3) we found that,
£ max
)

D = 18.01 ~ 20mm. so based on this our bearing internal diameter is 20mm. So we select 6004
bearing No. and its internal diameter is 20mm. mass of this selected bearing type is 0.069 kg.

Now we can calculate force created by this bearing load.

Weight force (Fw) = (0.069kg * 10m/s2) * 2 = 1.38N

Summary of force analysis

Belt force and bearing force treated as weight load and at the same direction (both are in vertical
direction). So we can add them and we make them one force.

Total weight = Belt force (Fb) + bearing force (Fw)

FW = 1.38N + 0.0208N = 1.40199 N (Y axis) and we have feed force that is 105.528N in
horizontal direction (X axis)

15
4.3 Shaft Design
X-Z plane
Figure 3

F fB

A 0.1m C

B
RXA

C.C + ∑MA= 0

- 0 = FfB (0.1) + MA

- 0 = 105.528 (0.1) + MA

MA = 10.5528Nm
To the right (+) ∑ FX = 0

0 = - FFB + RXA

0 = - 105.528 + RXA RXA = 105.528N

SHEAR FORCE DIAGRAM

500
400
300
200
100
0
A B C

A B C

16
 Figure 4

Y – Z PLANE

FWB

A B C

RYA
Figure 5

C.C (+) ∑ MA = 0

= - FWB (0.1) + MA = 0

= - 1.40199 (0.1) + MA = 0
= MA = 0.140199Nm

Upward is (+) ∑ FY = 0

= - FWB + RYA = 0

= -1.4008 + RYA = 0

= RYA = 1.40199N

17
 bending moment diagram
0
A B C

-0.07004

-0.14008

Series 1 Series 2 Series 3

Figure 6

The resultant moment in both planes is

MA = 10.5258Nm

MA = 0.14008Nm

MA= √ 47.27 2+ 0.140082 = 10.5267Nm

Now we can calculate our shaft diameter

We take Kt= 3, sack of safety

Material 1040 hot rolled Sy = 290MP , Sn’ = Sn * 0.81 * 0.9 435 * 248 = 189.53MP

[ √( )]
1

) (
2 2 3
D= 32∗3 3∗10.5267
+
3 7.915
π 189.53 4 290

D = 22mm ~ 20mm

Part D in Dcalcu Dst Dfinal Bear. Bear. Dynamic Douter of bear.

name mm No. Width load
(kN)

Bearing D 22mm 20mm 20mm 6004 12 9.36 42

Table 1
Checking of force

 RA = √ 472.7 2+1.40082 = 472.7N =472.7N <9369N CHECKED

18
4.4 Material Selection
The material that work with must be selected based on the reliable load that calculated above.
The reason to select material is to design the properly functioning machine.

4.4.1 Frame material selection

We select the frame material based on

 Cost
 Availability
 Weight reduction
 Rigidity (that resist the motor vibration)

Parameter Material

RHS Angle iron

Cost Good (5) High (0)

2455.65 2891

Availability Good (5) Less (0)

Weight reduction Good(5) Less (0)

60kg 100kg

Rigidity Less (0) Good (5)

Total Evaluation 15 5

Table 2
Also there are many different size of RHS. So we can select from them based on our design
calculation and standards.

19
4.4.2 Base Plate and Motor Plate Selection
As we all know the material selection process performed based on different parameters. One of
them is the DESIRE TASK OR FUNCTION of the material. You should answer <what is the
function of the part> before select the material. This parameter is considered in our base and
motor plate material selection.
- For base firstly we decided to choose the flat material, it is functional requirement. The
material that used for base must be has flat orientation. So this flat material is PLATE. Now
we select metal plate material. But still it is not specific, because metal plats has different
thickness. So we choose 12mm thick plate based on weight force calculation.
- The other plate is MOTOR PLATE. It also another flat material, the motor bolted on it and it
clamp on the machine. So this plate is 4mm thick according to weight force apply on it by
motor.

4.4.3 Shaft material selection

Availability, standard recommendation, and design analysis are our base to select shaft material.

The Available shaft material in our shop is round steel bar. Round bar has several specification,
they are:
 AISA 1020
 AISA 1040
 AISA 1050
 AISA 1117
 AISA 1137 etc. and they have different treatment conditions under them

So we select among them after calculating initial guess of shaft diameter is AISA 1050 OQT
round steel bar. And it has tensile strength and yield strength.

20
4.4.4 Bearing selection
There is different bearing type to use. They have their own capacity to loads. Their comparison is

Bearing type Radial load Thrust load Misalignment Cost (ETB)

capacity capacity capacity before tax

Single-row, deep-groove Good Fair Fair 327.58

ball

Double-row, deep-groove Excellent Good Fair 2368.9

ball

Angular contact Good Excellent Poor 1859.36

Cylindrical roller Excellent Poor Fair

Needle Excellent Poor Poor

Spherical roller Excellent Fair/good Excellent 7418.5

Tapered roller Excellent Excellent Poor 5327.18

Table 3

 Our radial load on bearing is created by rotating belt or plastic roller.

3.958
RL = F b = = 0.01099N force by belt tension.
sin 45 °. 509.1

 Our thrust load created by shaft weight load.

21
  So from this calculation and cost decision we can simply choose single row deep groove
ball bearing.

4.4.5 Roller Material Selection

Functional requirement of roller is to transmit rotational power from any power source to bearing
and other machine element. In our case the roller transmits the motor rotation or motion to the
grinding operation or to the belt. So we choose the material for this function. Now we prepare
the comparison table between several material those are,
 Nylon plastic
 Aluminum

NO. Material Heat Weight (kg) Availability Cost Total

resistivity based on
(degree F) Dia

1 Nylon plastic 900 (0%) 491.9 (5%) V.good (5%) Fair (5%) 15

2 Aluminum 1220 (5%) 1152 (0%) Less good Expensive 5

(0%) (0%)

Table 4

 From comparison table we decide to choose plastic nylon material for our desired
function.

22
4.4.6 Motor Selection
Our selection based on local market availability of the motor because for belt sander any type of
motor can be used, but single phase is preferable. Our selection not only the availability also the
calculation decision is included. Our required input power that needed from the motor is,

SFPM = RPM X 6.55 X Roller Diameter  recommended SFPM is (2000 – 3500)

So if we use RPM 1800 from market (1440-2880) we take the average.

SFPM = 1800 * 6.55 * 0.19 = 2240.1 so the calculated SFPM is right.

N 1 D1 1800 100
= = = = N1 = 1800 * 1.667 = 3000.6 rpm
N 2 D2 N1 60

(Pin) = F * n
π∗D∗N π∗0.06∗3000.6
- hence, n= velocity of roller (nylon plastic) = n = = = 9.4266
60 60
m/s
- F = force of feed. = 102.5 it calculated above.

Power = 102.5 9.4266 = 966.2329 watt

966.2329
Hp = = 1.29
746

 So we need 2hp input power.

Motor selection

Name Size Qty Type Power(hp Speed(rpm) Mass(kg)

)

Motor 400*200mm 1 Single phase 2 1800

Table 5

Selection of motor

23
  A single phase motor and power switch
 2 hp, 1800rpm 220-240V (to match our shop’s power)
 It’s cheap
 We used 1800rpm motor b/c it has better torque at low speed
 For fast and aggressive grinding we recommend high rpm (up to 4000rpm)
 Our motor torque is T in = 746/ n hence, n = (N*2*π) / 60 = 188.4955
Tin= 2*746 / 188.4955 = 7.915Nm

CHAPTER FIVE

5.1 Processes Planning and Coast Analysis

Process planning is the relationship between design and manufacturing in the manufacturing of a
product.

5.1.1 Processes planning sheet

Part description: 1. tooling arm, 2.nylon, 3.shaft, 4.trucking pillar part No.

Drawing number assembly No.

material specification material size lot size

quantity required per unit issued by

(including scrap)

SI Dept. Machine tools Labor Speed(rpm) Feed(mm) Setup Std

time(mn
No. code code ) time

1 Pipe cutter R, A,A2 80 0.5 10

2 Lath HSS, Z, Y, M 240 1 15

boring
tool

3 Lath HSS S, Y, Z, 350 2 15

M

4 Pipe cutter 80

24
 Table 6

5.2.1 Approaches to Cost Analysis

Cost analysis is one of the most important steps in project management. A cost analysis
establishes the base line of the project cost at different stages of development of the project. A
cost estimate at a given stage of project development represents a prediction provided by the cost
engineer or analysis on the basis of available data. According to the American Association of
Cost Engineers, cost engineering is defined as that area of engineering practice where
engineering judgment and experience are utilized in the application of scientific principles and
techniques to the problem of cost analysis.

Three types of costs during the calculation of total cost

They are
 Material cost
 Labor cost
 Machine cost

Now we see one by one each of them in the next page.

25
5.2.2 Material Cost
Material cost is the cost of materials used to manufacture a product or provide a service.
Excluded from the material cost is all indirect materials such as cleaning supplies used in the
production process. Follow these steps to determine the amount of material cost to assign to a
unit of production (such as a completed finished goods, item): Before calculating the profit we
have to ascertain the standard quantity of the material used to manufacture one unit. Add the
standard amount of scrap associated with manufacturing one. If there is any scrap then sold, that
can reduce the wastages

Item Size Quant Material type Designation Price in ETB

RHS 50*50,4,6m 01 Mild steel 2455.65

RHS 40*40,4,6m 01 Mild steel 1877.31

Sheet metal (plate) 1000*2000 01 Mild steel 4700

Motor 01 2HP,2880RPM 4300

Bearing 20*42*12 06 6004 ZZ 2146.8

Nylon 100*480 01 N6 1238

nylon 60*480 01 N6 904.6

Round bar 25 01 Mild steel 1020 cold drown 1503.4

Electrode 3 1 pkt 1360 345

Belt 2500mm 01 175

Total 19645.76
Table 7

26
5.2.3 Labor Cost
The cost of labor is the sum of all wages paid to employees, as well as the cost of employee
benefits paid by an employer. The cost of labor is divided into direct and indirect costs. Include
wages for the employees that produce a product, including workers on an assembly line, while
indirect costs are associated with support labor, such as employees who maintain machine
equipment.

According to Ethiopian daily labor payment for one person is 256 ETB

The product lasts eight days to finish with seven person then the total labor cost will be

= Daily labor cost * day on to work * labor No. = labor cost

= 256*8*7 =14,336 ETB

5.2.5 Machine cost

It is important for budgeting purposes but also for determining how much a machining must
charge for its products to make a profit.

Machining costs depend on the type of machine and the number of hours it will run, typically
referred to as machine time. Shops set an hourly rate for running different types of machine.

According to Ethiopian investment commission power rate is categorized under different

categories so that the cost is 0.4995ETB per Kwh monthly.

Cost of power = Motor power X 746 X Total machine hours X Power rate (kWh)/1000

Machine type HP Operating time(Hrs) Cost ( ETB)

Lath 12.55 4 18.7
Milling 8 1 2.98
Angle grinder 3 8 8.94
Drilling 6 3 6.7
Welding 35.6 10 132.6
Pip cutter 5 1 3.7
Total 173.6

27
 Table 8

5.2.6 Total cost

Total cost is the sum of all costs charged by a firm in producing a certain level of output. It is
typically expressed as the combination of all the three costs which charge with the production of
all machine parts, they may be fixed cost or variable cost; In other words, in the long run;
progressively fewer units of output will be yielded by additional inputs of variable cost.

Material Labor Machines Total cost(ETB)

cost(ETB) cost(ETB) cost(ETB)

19645.76 14,336 ETB 173.6 34155.2

Table 9

28
 CHAPTER SIX

6.1 Manufacturing Process

6.1.1 Introduction to Manufacturing Process
Manufacturing processes are consisting of devising, selecting and specifying processes, machine,
tools and equipment’s to convert raw materials in to finish and assembled products. The purpose
of this process planning is to determine and describe the beset process for each job so that

1. Specific requirements are established for which machine, tools and others equipment can
be design or select
2. The efforts of all engaged in manufacturing the product are coordinated.
3. A guide is finished to show the best way to use the existing or the providing facility.
4. Part size, shape and thickness of the material.
5. Material characteristics and properties of the material (cast ability, formability,
machinability, weld ability hardness, toughness, etc.)
6. The dimensional tolerance and surface finish requirement.
7. The function requirement of the part.
8. The production volume (quantity)

Parts of the belt sander machine is categorized in to two, these are purchased part and
manufacturing part.

Purchased part includes

 Bearings
 Electrode
 Motor
 Sand paper
 Some standard parts like bolt nut etc.

29
Manufacturing part includes:

 Riser
 Trucking pillar
 Motor plate
 Base plate
 Tooling arm
 Working plane
 Shaft
 Table
 Roller wheel ( plastic nylon)
 Receiver tube
 D – plate

30
6.1.2 Manufacturing of Riser
The riser is the part that holds the body or the frame of the grinder. It’s well welded to the base
plate. It is 250mm long and 50*50mm 5mm thick and it has 20mm diameter hole for the shaft.

Part Name – Riser

Material – RHS wall tube steel

Blank Size – 50mm * 50mm-5mm

Quantity – 2

Operation Operation Cutting Machine Cutting FEED

step all in
Number (mm) Tool tool Speed(rpm) (mm/rev)

1 Measuring Saw blade Band saw - -

and layout

2 Shear to Shear blade Combine - -

desired shape shear

3 Tack electrode welding - -

4 weld electrode welding - -

Table 10

31
6.1.3 Manufacturing of trucking pillar
Part Name – Trucking pillar

Material – wall tube steel

Blank Size –50mm*50mm-5mm
Quantity – 1

Operation Operation Cutting Machine Cutting FEED

step all in
Number (mm) Tool tool Speed(rpm) (mm/rev)

1 Measuring and Saw blade Band saw - -

layout

2 Shear to Shear blade Combine shear - -

desired shape

3 drill Twist drill Drill machine - -

Table 11

32
6.1.4 Manufacturing Processes of Motor Plate
Part Name – Motor plate

Material – milled steel

Blank Size –200mm*200mm

Quantity – 1

Operation Operation Cutting Machine Cutting FEED

step all in
Number (mm) Tool tool Speed(rpm) (mm/rev)

1 Measuring Shear blade - - -

and layout

2 Shear to Shear blade Gekal - -

desired shape machine

3 Grind Grind disc Hand grinding - -

4 Drill Twist drill Drill machine - -

Table 12

33
6.1.5 Manufacturing Process of Base Plate
Part Name – base plate

Material – milled steel

Blank Size –250mm*250mm

Quantity – 1

Operation Operation Cutting Machine Cutting FEED

step all in
Number (mm) Tool tool Speed(rpm) (mm/rev)

1 Measuring and Shear blade - - -

layout

2 Shear to Shear blade Gekal - -

desired shape machine

3 Grind Grind disc Hand grinding - -

Table 13

6.1.7 Manufacturing Process of Tooling Arm

Part Name – tooling arm

34
 Material – milled steel

Blank Size –40mm*400mm

Quantity – 2

Operation Operation Cutting Machine Cutting FEED

step all in
Number (mm) Tool Tool Speed(rpm) (mm/rev)

1 Measuring and Shear blade - - -

layout

2 Shear to Shear blade Gekal - -

desired shape machine

3 Drilling Twist drill Drill 800 200

machine
Table 14

6.1.8 Manufacturing Process of Working Plate

Part Name – working plate

Material – mild steel

35
 Blank Size – 200mm*150mm

Quantity – 1

Operation Operation Cutting Machine Cutting FEED

step all in
Number (mm) Tool tool Speed(rpm (mm/rev)
)

1 Measuring Shear blade - - -

and layout

2 Shear to Shear blade Gekal - -

desired shape machine

3 Grind Grind disc Hand grinding - -

Table 15

6.1.9 Manufacturing Process of Roller Wheel

Part Name – Roller wheel

Material – plastic nylon

Blank Size – 150mm*60mm
Quantity – 3

36
Operation Operation step Cutting Machine Cutting FEED
all in (mm)
Number Tool tool Speed(rpm) (mm/rev)

1 Measuring and layout Saw blade Band saw -

2 (1st center) Facing HSS Lathe 315 0.2

(5mm) to 145mm

4 Turn to 59.5mm HSS Lathe 315 0.2

5 (2nd center) Facing HSS Lathe 315 0.2

(5mm) 140mm

6 Centre drill to support Centre drill Lathe 460 0.2

the nylon

7 Turn to 59mm2nd HSS Lathe 315 0.2

Table 16

6.1.10 Manufacturing Process of Receiver Tube

37
Operation Operation Cutting Machine Cutting FEED
step all in
Number (mm) Tool Tool Speed(rpm) (mm/rev)

1 Measuring and Shear blade Gekal - -

layout machine

2 Shear to Shear blade Gekal - -

desired shape machine

3 Drilling Twist drill Drill 800 200

machine
Table 17

6.1.12 Manufacturing Process of D-Plate

Part Name – D-plate

Material – milled steel

38
 Blank Size –400mm*150mm-6mm

Quantity – 1

Operation Operation Cutting Machine Cutting FEED

step all in
Number (mm) Tool Tool Speed(rpm) (mm/rev)

1 Measuring and Shear blade Gekal - -

layout machine

2 Shear to Shear blade Gekal - -

desired shape machine

3 Drilling Twist drill Drill - -

machine

4 Grind Grind disc Hand - -

grinding
Table 18

6.1.13 Manufacturing Process of Shaft

Part Name – Shaft
Material – 1050 OQT 400 Round Steel Bar
Blank Size – 25mm * 252mm
Quantity – 3

39
Operation Operation step Cutting Machine Cutting FEED
all(mm)
Number Tool tool Speed(rpm) (mm/rev)

1 Measuring and layout Saw blade Band saw -

2 (1st center) Facing HSS Lathe 315 0.2

(1mm) to 251

3 Centre drill to Centre Lathe 460 0.2

Support the shaft Drill

4 Turn to 20.5 1st 2 2nd HSS Lathe 315 0.2

2 3rd 0.5(20.5)

5 Chamfer HSS Lathe 215 0.2

6 (2nd center) Facing HSS Lathe 315 0.2

(1mm) 250

7 Centre drill to support HSS Lathe 460 0.2

the shaft

8 Turn to 20.5 1st 2 HSS Lathe 315 0.2

2nd 2 3rd 0.5 (20.5)

9 Chamfer HSS Lathe 215 0.2

10 Making of tread 16Ø HSS Lathe 80 0.2

* 25 length
Table 19

6.4 Testing and Evaluation

When we finish our first assembly we test our machine as its first operation and we disassemble
again. According to this we test two times our machine and evaluate its performance defect.

 First test and evaluation, we check by putting the abrasive belt on to the
roller wheel to test the machine functionality. However, it slides down and it not
40
 rotate properly. We take different simple techniques to overcome the operational
defect. Then we grind the motor nylon plastic to keep the parallel between motor
rotation and plastic rotation. But this solution not functional. So it required
another test and evaluation.
 Second test and evaluation, now we take the proper solution. That is the
nylon needs additional geometrical orientation. So finally we done the exact
solution and the machine works properly.

41
 CHAPTER SEVEN
7. Conclusion and Recommendation

7.1 Conclusion
As per the problem identified during survey in company, case study of problem, and also with
help of research papers, international journals; we conclude that Abrasive Belt Oblique Grinding
is effective than wheel grinding. Abrasive belt oblique grinding and polishing combines many
operations for efficient surface finishing. And it can fulfill the accuracy for super finishing of key
which required for company as per their design. Also this paper can use the surface belt oblique
grinder and can obtain the different super finishing quality with the help of using different grade
abrasive belt. This Grinding machine has the versatile operations and achieves the operations of
all other Belt grinding methods.

42
7.2 Recommendation
This belt grinder can be easily modified so it can be made to more stable and rigid and also other
attachments can be installed on it. For the rollers part we recommend you to use the plastic nylon
roller because it is light weighted and the cost is less than aluminum.

43
Reference

1. Robert L-Mott machine design 6th edition.

2. Shigley. Mechanical Engineering Design 10th Edition

3. Kyle Odum, Mara Celeste Castillo, Jayanti Das, Barbara Linke,. Sustainability analysis of
grinding with power tools, 6th CIRP International Conference on High Performance Cutting, CIRP. 14
(2014) 570-57

4. Konrad Wegener, Friedrich Bleicher, Peter Krajnik, Hans-Werner Hoffmeister, Christian

Breecher, , CIRP-1703. Recent development in grinding machines.

5. VigneashwaraPandiyan, TegoehTjahjowidodo, MeenaPeriyaSamy, 7th HPC CIRP Conference

on High Performance Cutting. , In-Process Surface Roughness Estimation For Complian13t Abrasive
Belt Machining Process. 2016. CIRP 46 (2016) 254-257.

6. Dong Zhang, Chao Yun, Dezheng Song. Dexterous space optimization for robotic belt grinder,
Procedia Engineering. 15 (2011). 2762-2766. .

7. Wang Wei, YUN Chao. A path planning method for robotic belt surface grinding, Chinese journal of
aeronautics. 24 (2011) . 520-526..

8. J.F.G. Oliveria, E.J. Silva, C. Guo, F. Hashimoto,. Industrial Challenges in grinding, Manufacturing
Technology . 58 (2009) . 663-680.

9. A. Robert Henry, R. Anbazhgan, A. Kevinraj, M. Sudhagar, G.S. NIvas,. Design and Fabrication
of Abrasive Belt Oblique Grinding Machine, Vol 5, Special Issue 8, . May 2016.

10. Awhale M.J, Chinchlkar N.C, Gunjawate V.P, Phule N.S, Prof. Amrute A.V,. Surface Belt
Grinder for KeysA Review, vol 2, Issue 2, . October 2015- March 2016. .

11. Lubica ELEKOVA, Zdenko LIPA, Comparison Of Conventional And Structured Abrasives.
Comparison Of Conventional And Structured Abrasives. 2009.

12. Titan Miao. Study on Influencing Factors of Sanding Efficiency of Abrasive Belts in wood Material
Sanding. 59 (5); 2014 835-842..

44
Appendance
Detail drawing

1 RISER

2. Tracking pillar

2 Tracking pillar tube

Receiver’s tube

3 Tooling arms
4 D-plate

5. Rollers
 Shafts

 Base plate

 Motor plate

Hinges

45
  Platen plate

Tracking pillar tab or connector

 Working table

Assembly Drawing With Bill of Material

46
47
48