Design of Revesing Concrete Mixer

Design of Reversing concrete mixer MU/FST/MED
Table of content page
Acknowledgment..............................................................................................................................III
Abstract...........................................................................................................................................IV
Objectives........................................................................................................................................V
Chapter one......................................................................................................................................V
1.Literature review.............................................................................................................................1
1.1Introduction..............................................................................................................................1
1.1.1cement................................................................................................................................1
1.1.2Aggrerates..........................................................................................................................1
1.1.3Water.................................................................................................................................2
1.2 Mixer efficiency........................................................................................................................2
1.3 Wear and tear and cleanness.....................................................................................................3
1. 4 Hardware: the Mixers..............................................................................................................3
1.4.1 Batch Mixers......................................................................................................................3
1.4.2 Drum Mixers......................................................................................................................3
1.5 Pan Mixers...............................................................................................................................5
1.6 Continuous Mixers....................................................................................................................5
Chapter two.......................................................................................................................................6
2.Design of reverse gear box...............................................................................................................6
2.1Working mechanism (operation) of reverse gear box....................................................................7
2.1.1 Forward rotation................................................................................................................7
2.1.2 Reverse rotation.................................................................................................................7
2.2 Synchronizing mechanism.........................................................................................................8
2.3 Coupling..................................................................................................................................9
Chapter three...................................................................................................................................18
3.Design of speed reduction Gear box................................................................................................18
3.1Design of the shaft...................................................................................................................23
3.2 Design of Keys.......................................................................................................................26
3.3 Bearing selection....................................................................................................................28
Chapter four....................................................................................................................................30
4. Design of belt..............................................................................................................................30
4.1 Design of V-belt......................................................................................................................31
4.2 Selection of Pulley..................................................................................................................33
Chapter five....................................................................................................................................35
5. Design of the Drum......................................................................................................................35
I
Senior project By: Yoseph Y. & Melesse S.
5.1 Design of blades.....................................................................................................................38

5.2 Design of the weld for the blade...............................................................................................41
Chapter six......................................................................................................................................46
6. Design of ring gear and the pinion.................................................................................................46
6.1 Design of the bolt...................................................................................................................49
Chapter seven..................................................................................................................................50
7. Design of hydraulic cylinder.........................................................................................................50
7.1 Piston Rod Design..................................................................................................................54
7.3 Flow control..........................................................................................................................56
Chapter eight...................................................................................................................................57
8. Design of frames..........................................................................................................................57
Chapter nine....................................................................................................................................58
9. Design of the axel........................................................................................................................58
Chapter ten......................................................................................................................................61
10. Details of casing Dimension........................................................................................................61
Chapter Eleven................................................................................................................................62
11. Cost analysis..............................................................................................................................62
11.2 Manufacturing process required.............................................................................................66
11.3 Assembly procedure..............................................................................................................67
Recommendation.............................................................................................................................68
Bibliography...................................................................................................................................69
II
Acknowledgment
It is a great honor for us to work with MIE staff member Ato.Jaafar and be advised by our
instructor Ato.Abraha.There were a difficulties while we were doing our project but theses
difficulties were solved by the help of Ato.abraha our instructor, who was with us devoting his
time and money to explain the prototype which is found in MIE store. he also gave us moral
which was a great help for our strength .and next Ato.Jaafar MIE staff who was with us and let us
to see the prototype of the mixer and for his explanation .He did not only devoted his time and
explain for us but gave us a book and data’s which were holding a great information for the
project. Again tanks for your precious time and priceless advice, with out your advise and help
our project would have been only a dream.
III
Abstract
This project deals about the design of reversing concrete mixer machine. The report contains the
design analysis of reversing gear box ,speed reducing gear box ,belts ,drum ,blades ,ring gear and
the pinion ,piston cylinder ,frames ,axel ,and components that are necessary for the mixer. It has
also the costal analysis, conclusions and recommendation in different chapter.
Objectives
The objective of this project is to produce the machine in our country using a material which is
found in locally. This has a great advantages like, reducing the cost and also doing this will create
IV
a job opportunities for many people. Since we considered the situations of our countries working
behavior, the machine will be durable .Producing the machine will not be good only for us but our
neighbor countries buying our product at good price. This also creates a good relation ship with
our neighbor countries.
V
VI
Chapter one
1. Literature review
1.1 Introduction
Properties of Concrete products
Concrete is a mixture of cement, water, and fine and fine and find and coarse aggregates. The
concrete mix has to be cohesive comprehensive strength enough to be transported and placed with
out segregation by the means available i.e. the requirement is a satisfactory compressive strength
and properties related to be comprehensive strength like density, durability, resistance, to
sulphates and other.
As for all of material the performance of concrete is determined by its microstructure, Its micro
structure is determined but its composition, its curing condition, and also by the mixing method
and mixer condition used to process the concrete.
1.1.1cement
Cement shall be of a specified type and quality and delivered to the site in the manufacturers
original scaled bags; which is fresh not older than six months. One bag of cement contains about
50Kg.
1.1.2Aggrerates
Sand (fine aggregate)
Fine aggregate shall clean river or pit sand of approved quality. It should consist of hard, dense
durable uncrated rock fragments. It should not contain harmful amount of clay, silt, dust, mica,
organic matter or other impurities to such an extent that either together or separately, they render
it impossible to attain the required properties of concrete when employing normal proportions of
the ingredient.
Coarse aggregate
As shall be crushed basaltic or gravel of approved quality. It consists of hard ,dens ,durable and
uncoated rock fragment.
1
1.1.3 Water
The next important aggregate of concrete material is water. It is used for mixing concrete which
should be clean and free from injurious amount of oils, acids, and organic materials or other
significantly affect the hydration reaction of port land cement, there by reducing the strength of
the concrete and drum and blades of the concrete mixer. The sequence of concrete mixing is that
the correct quantities of cement, aggregate, and water possibly also admixture, are batched and
mixed in a concrete mixer. This produces fresh concrete dense mass which allows hardening.
The material shall be placed in to the mixer in the following order,
-Half the volume of water
-coarse aggregate
-fine aggregate
-cement
-the rest of the water
1.2 Mixer efficiency

The concept of mixer efficiency is used to qualify how well a mixer can produce a uniform
concrete from its constituents.
Performance attributed as indictors of efficiency are the following points,
-workability of the concrete as defined by the slump.
-Density of the concrete
-Air content
-compressive strength
-distribution of cement, fine aggregates and coarse aggregates in the mixer
-variation in compressive strength and
-variations in consistency as measured by the slump test with increased mixing time.
2
1.3 Wear and tear and cleanness

In determine mixer efficiency the main focused has been determining the homogeneity and the
quality of the concrete produced .It was assumed the mixer was operating as designed by its
manufacturer .at long usage of a mixer leads wear of the blades and/or scraper, or the build up of
materials (hardened mortar or cement paste) on the blades, the container, and/or the pattern of the
concrete and may lead to the changes in the concrete product. To avoid this situation the concrete
mixer should be thoroughly cleaned at the end of each days of operation and the blades and/or
scarper changed on a regular schedule. It can be argued the criteria for mixer selection should be,
-ease of cleaning
-cost and difficulty of replacing the blades or parts
-sensitive of the mixer to wear and tear of the blade
1. 4 Hardware: the Mixers
There are two main categories of mixer: batch mixers and continuous mixers. The first type of
mixer produces concrete one batch at a time, while the second type produces concrete at a
constant rate. The first type needs to be emptied completely after each mixing cycle, cleaned (if
possible), and reloaded with the materials for the next batch of concrete. In the second type, the
constituents are continuously entered at one end as the fresh concrete exits the other end. The
various designs of each type of mixer will now be discussed.
1.4.1 Batch Mixers
Two main types of batch mixer can be distinguished by the orientation of the axis of rotation:
horizontal or inclined (drum mixers) or vertical (pan mixers). The drum mixers have a drum, with
fixed blades, rotating around its axis, while the pan mixers may have either the blades or the pan
rotating around the axis.
1.4.2 Drum Mixers
All the drum mixers have a container with a cross section similar to that shown in Fig. 1. The
blades are attached to the inside of the movable drum. Their main purpose is to lift the materials
as the drum rotates. In each rotation, the lifted material drops back into the mixer at the bottom of
the drum and the cycle starts again. Parameters that can be controlled are the rotation speed of the
3
drum and, in certain mixers, the angle of inclination of the rotation axis. There are three main
types of drum mixers:
* Non-tilting drum;
* reversing drum;
* tilting drum.
The non-tilting drum mixer implies that the orientation of the drum is fixed. The materials are
added at one end and discharged at the other
The reversing drum is similar to the non-tilting mixer except that the same opening is used to add
the constituents and to discharge concrete. The drum rotates in one direction for mixing and in the
opposite direction for discharging the concrete. There are two types of blades attached to the inner
walls of the drum. One set drags the concrete upwards and toward the center of the mixer when
the drum rotates in one direction; the second set of blades pushes the concrete toward the opening
when the drum rotates in the other direction. The blades have a spiral arrangement to obtain the
desired effect for discharge and mixing.
The truck mixers belong to the reversing category of drum mixers. The driver of the truck can
control the speed of rotation with a clutch in the cabin. The speed depends on whether the
concrete has been well mixed prior to being placed in the truck or whether the truck has to do
most of the mixing. Typically the speed for mixing is 1.57 rad/s (15 rpm), while the transport of
pre-mixed concrete uses only 0.2 rad/s (2 rpm) to 0.6 rad/s (6 rpm). In a tilting drum mixer the
inclination can be varied. When the drum is almost horizontal (inclination [approximate]
0[degrees]), more energy is provided to the concrete because more concrete is lifted to the full
diameter of the drum before dropping. It is during the drop that the concrete is knitted and mixed.
Therefore, the higher the drop, the higher the energy imparted to the concrete. If the axis of
rotation is almost vertical the blades cannot lift the concrete and the concrete is not well mixed.
The drum axis usually stays at an angle of about 15[degrees] from horizontal during mixing. To
discharge the concrete the drum is tilted downwards below the horizontal plane. The tilting drum
is the most common type of drum mixer for small batches both in the laboratory and in the field
4
1.5 Pan Mixers
All pan mixers work on basically the same principle .A cylindrical pan (fixed or rotating) contains
the concrete to be mixed, while one or two sets of blades rotate inside the pan to mix the materials
and a blade scrapes the wall of the pan. The shapes of the blades and the axes of rotation vary.
The other element of the mixer is the scraper. Sometimes the axis of rotation of the blades
coincides with the pan axis. To discharge the mixer, the pan is usually emptied through a trap on
the bottom. For small mixers (less than 20 L or 0.02 [m.sup.3]), the blades are lifted and the pan
can be removed to empty the mixer.
1.6 Continuous Mixers
The second category of mixers is continuous mixers. As the name indicates, the materials are
continuously fed into the mixer at the same rate as the concrete is discharged. They are usually
non-tilting drums with screw-type blades rotating in the middle of the drum. The drum is tilted
downward toward the discharge opening. The mixing time is determined by the slope of the drum
(usually about 15[degrees]).
These mixers are used for applications that require a short working time, long unloading time,
remote sites (not suitable for ready-mix) and/or small deliveries. A major use of these types of
mixers is for low slump (non flow able) concretes (e.g., pavements). Due to the short mixing time,
the air content is not easily controlled even with the addition of air entraining admixtures .
5
Chapter two
2. Design of reverse gear box

The input and output shafts locations are in different locations. This may well be acceptable or
even desirable in some case, depending on other packaging constraints in the overall machine
design. Such a gearbox, whose Input and output shaft are not coincident, is called a non reversed
compound train.
In some case, such as reverse concrete mixer and automobile transmissions, it is desirable or even
necessary to have the output shaft concentric with the input shaft. This is referred to as “reverting
the train” or “bringing it back on to itself”. The design of a reverted compound train is more
complicated because of the additional constraint that the center distances of the stages must be
equal.
Compound reverted gear train: are commonly used in manual transmission to provide user
selectable ratios between the engage and the drive drum for direction change. These gearboxes
have one clock wise rotation (forwarded) and one anti clock wise rotation (reverse).
All gears in these gear box are spur gear according to there cost. These gears are moved in to and
out of engagement when shifting from forward speed to a reverse speed.
The input shaft is at top left. The counter shaft has two gears integral with it, which mesh with
output gear by the reverse idler gear between them. The output shaft has two gears integral with
it, which mesh with output gear by the reverse idler gear between them. The output shaft is
concentric with the input shaft, making this a reverted train.
For forward rotation the input and output shafts are directly coupled together with a synchromesh
clutch for a 1:1 ratio.
The synchromesh clutches are beside each gear on the output shaft and are partially hidden by the
shifting collars that move them left and right in response to the driver’s hand on the shift lever.
this clutches act to lock one gear to the out put shaft at time to provide a power path from in put to
out put of 1:1 ratio. Reverse gear, on the lower right, engages an idler gear which is physically
shifted in to and out of mash at the standstill.
6
2.1Working mechanism (operation) of reverse gear box

Here, in reverse gear box there is no torque multiplication and speed reduction. The only work in
this gear box is changing of direction of rotation.
2.1.1 Forward rotation

Its power flow runs straight through the transmission from the input shaft to the out put shaft. The
synchro sleeve moves to the front of the transmission to engage the dog teeth on the back of the
input shaft. This attaches the input shaft to the output shaft.
Fig During the out put and input shaft have the same rotation
2.1.2 Reverse rotation

The lower reverse sliding gear moved back until it engages the reverse idler gear. As the reverse
idler is revolving in the same direction as the input shaft, it will impart a reverse rotation to the
output shaft. This will cause the out put shaft to drive the drum backward rotation. The gear
reduction or torque multiplication is zero because of the diameter and orientation of the gears.
7
Fig During the output and input shaft has different rotation
2.2 Synchronizing mechanism

It is obvious that for one gear to mesh with another quietly and with damage, both gears must be
rotating at nearly the same speed. Modern manual transmissions and transaxles have synchronized
gears, with special internal clutches to prevent gear clash when shifting. The purpose of the
synchronizer is to move ahead of the unit that is to be meshed, seize the other unit, and bring the
rotational speed of both units together. Once both units are rotating at the same speed, they may
be meshed.
Fig Synchronizer meshing mechanism
8
2.3 Coupling
Specifications:
 Motor speed 3000rpm
 The output and the input shaft speed is equal no reduction of speed
The input shaft of the gear box coupled with the motor shaft by sleeve coupling.
In engineering applications there arise several cases where two shafts have to be connected so that
power from driving shaft is transmitted to drive shaft is transmitted to driven shaft with out any
change of speed. Such shafts are normally coaxial with slight or no misalignment can be
connected through devices known as coupling.
Here in our design a permanent coupling connecting coaxial shafts of an electric motor and a
reverse gear box.
Several types of couplings are used in practice we select the simplest form of a permanent
coupling, consisting of a steel or cast iron sleeve fitted on the shafts by means of keys. This is
muff or sleeve coupling.
The length of sleeve can be taken as 3.5 to 4 diameter of shaft while the outer diameter of the
muff or sleeve.
9
Analysis
 The motor shaft transmits 12kw of power at 3000 rpm
 Assume a factor of safety 5
 Ultimate shear strength for shaft 300N/mm2
 Ultimate shear strength for key 200N/mm2
 Ultimate shear strength for muff 50N/mm2
 Ultimate compressive strength for key 500N/mm2
The shaft transmits a torque T (N.m) at w (rad/sec), then the power transmitted by the shaft
P=T*w in watt
W= 2πN/60
=2π 3000/ 60 = 314.2 rad/sec
P=T w
12 103 = T 314.2
T= 38.2 N.m
The torque transmitted by shaft is related to diameter, d of the shaft as
T = πd3τs/ 16
Where τs is the permissible shearing stress in the shaft.
τs = 300/ 5 = 60 N/mm2
Since the shaft will be weakened by the key by 25%, the effective permissible shearing stress in
the shaft will be 0.75τs
38.2*103 =
d = 16.3 mm
10
Assuming the width of the key to be 0.25d
W = 4.1 mm
If F is tangential force on the shaft, causing shearing of the key, then
F= w l τs
Where L is the length of the key and τs’ is the permissible shearing stress in the key
F= T / d = 38.2 103 / 16.3
F= 2343.5 N
And 2343.5 = 4.1 L 200 /5
L =14.3 mm
The height of the key can be calculated by considering its compression under force F.
F= (h/2) L σc
Where h is the height of the key and σc , the permissible compressive strength.
2343.5= (h/2) 14.3 (500/5)
h= 3.3 mm
The muff is designed as a hallow shaft with internal diameter as the diameter of shaft.
In case of muff also the key way causes a reduction of strength by 25%. The muff will transmit
the same torque as the shaft.
Where d is the outer diameter of muff and τs” is the permissible shearing stress.
38.2*103 =
11
After the design of coupling we design the reversing gear box:
The reversing gear box will interposed between a motor and reducing gear box in the concrete
mixer and should have a life of 70Khr with 99% reliability.
For better strength take grade 2 steel pinions to be made from hardened 52 HRS and wheel made
from hardened 360 BHS.
For 52 HRC steel (pinion)
1. Allowable bending stress Sb=380Mpa.

2. Allowable contact stress Sc=1320Mpa.
Life in cycle
For pinion =70×103×60×3000
=1.26×1010
For wheel =70 103 60 1000
=4.2 109
Life factor Cl
Clp=0.67
Clw=0.713
For pinion Scp =1320Mpa
For wheel Scw=made from 360BHM and grade 2
Scw=2.51B+186
=2.51 360+186 =1089.6Mpa
Sbw=B (1.2-B 1150) +43=362.3Mpa.
(Sc×Cl) p=884.4Mpa.
12
(Sc×Cl) w=777Mpa.
From this the minimum one is selected.
m3= (Ka Kv Km KR2 E P) (Sc Cl)2 π2 B N2 z22 I
Ka application factor for driven machinery called mixer with single cylinder combustion engine
the appropriate value of Ka =1.5.
E is use 113 Gpa – if identical material used for both pinion and wheel
KR reliability factor 99 % survival (KR =1)
Dynamic factor Kv =1.7 it is guess
Load distribution factor Km
Km = 1 + Cpf + Cma
Cpf = 0.1max (0.5, f/D1) + max
Cma =A + f/B – (f/c)2 neglect f/B and f/c because there are very small
For commercial A = 0.127, B= 1600, C= 2400
Cma =0.127
Km = 1+0.127 =1.127 by adding some value say Km = 1.2
Pitting resistance geometry factor
I = (0.0404 + 0.1127ρ) (1 + 0.7 ρ)
ρ= Zw Zp =60 20 = 3
I = 0.122
m3= (Ka Kv Km KR2 E P) (Sc Cl)2 π2 B N2 z22 I
m= 2.35 mm from standard table the appropriate value m = 3 mm
Pitch diameter for the pinion Dp = m Zp = 3 20 = 60 mm
13
Pitch diameter for the wheel Dw = m Zw = 3* 60 =180
V = π Dp Np = π 0.06 50 = 9.42 m/s
For general purpose of reduction gears the advisable degree of accuracy is from 6 to 9 , so let’s
take Q = 8
Kv = (1 + )B
B = 0.25*(12 - Q) 2/ 3 = 0.63 substitute this value in the above equation we get Kv = 1.72,this
value approaches with the assumption.
Km = 1 + Cpf + Cma
To be more economical take 9 B 15
Let B = 9
f =m B = 3 9 =27
Substitute this value in Cpf and Cma equation we get Cpf = 0.026, Cma = 0.144 and Km =1.175
this is good approach with 1.2
Check for B using the pitting equation
B= (Ka Kv Km KR2 E P) (Sc Cl)2 π2 m3 N2 I Z22
By substituting the exact values in the above equation we get
B = 10.43
From this the actual face width will be
f =B m = 10.43 3
f = 31.28 mm
Checking for failure by bending
(J Sb Kl) p,w (π m3 B N1 Z1) (Ka Kv Km KR P)
(J Sb Kl)i = (Ka Kv Km KR P) / (π m3 B N1 Z1)
14
Bending strength geometry factor for pinion and wheel (Jp and Jw)
Jp = [0.535 + ]+[
Jp = 0.51
By the same procedure we find the value of Jw
Jw = 0.56
We know the value of (Sb)p= 380Mpa
(Sb)w =362.3Mpa
(J Sb Kl)p = 41Mpa
(Kl)p = = = 0.21
(J Sb Kl)w = 41Mpa
(Kl)w = = 0.2
0.21 And 0.2 are less than 0.8 (0.8 is the minimum value of bending life factor Kl)
So it is safe at 0.8 will have 1010 life (number of load cycles)
2.4 Design of counter shaft
P = 12Kw
N=1000 rpm
Dc = 180 mm
DD = 60 mm
The maximum permissible shear stress for shaft with allowance for keyways 42Mpa.
15
The shaft supported by to bearings 300mm apart and has two gears keyed to it. The first gear
having 20 teeth of 3mm module is located 20mm to the left of the right hand bearing and delivers
power horizontally to the right. The second gear having 60 teeth of 3mm module is located 50mm
to the right of the left hand bearing.
Diagrams:
Analysis
We know that the torque transmitted by the shaft.
T= = = 115N.m =115 103 N.mm
Assuming that the torque at C and D is same (i.e. 115 103N.mm) therefore tangential force on the
gear C, acting downward.
Ftc = = = 1277.78 N say Ftc = 1278N
16
And tangential force on the pinion D, acting horizontally.
FtD = = = 3833.3N say FtD = 3834 N
First of all, considering the vertical loading at C. let RAV and RBV be the reactions at bearings A
and B respectively.
RAV + RBV = 1278 N
Taking moments at A, we get
RBV 300 =1278 20
RBV =85.2 N
RAV =1192.8 N
We know that bending moment diagram at A and B
MAV = MBV =0
B.M at C, MCV = RAV 20 = 1192.8 20= 23856 N.mm
B.M at D, MDV = RBV 50 = 85.2 50 = 4260 N.mm
Now considering horizontal loading at D. let RAH and RBH be the reactions at the at the bearings A
and B respectively.
RAH + RBH = 3834N
Taking moments at A, we get
RBH 300= 3834(300-50)
RBH= 3195N
RAH= 639N
And we know that bending moment at A and B
MHA= MBH= 0
B.M at C, MCH= RAH 20=639*20=12780Nmm
17
B.M at D, MDH=RBH 50=3195*50=159750Nmm
We know that resultant B.M at C,
MC = = =27064 N.mm
And resultant B.M at D.
MD= = =159807N.mm
The resultant B.M diagram we see that the bending moment is maximum at D.
Therefore maximum bending moment
M = MD= 159807 N.mm
Let d is the diameter of the shaft
We know that the equivalent twisting moment.
Te = =
Te =196884 N.mm
We also know that equivalent twisting moment (Te),
196884= πτd3 / 16
d = 28.79 mm say d = 30mm
Chapter three
3. Design of speed reduction Gear box

The gear box is a one step speed reducing gear box. This used for reducing the speed that is
coming out of the engine to the appropriate speed for the drum revolution.
Design for the gear
Material selection
-steel
18
Grade ASTM 60-4510 Annealed
UTS=400Mpa
Yield strength=300Mpa
Elongations=10%
-In ductile iron carbon is present in the form of spheroids as against flakes of gray cast iron. This
form of carbon imparts such properties as merchantability, wear, resistance and toughness.
Further, the ductile cast iron also responds to heat treatment and hence it has now become an
important gear material. Nominal composition of ductile iron is,c-3.5%,Mn-0.35%,P-0.05%,S-
0.01%,Ni-1.25%,Mg-0.06%,Ir-rest.
Even if their could be a probability of using other types of gears we are going to design & use
spur gear. This can do the job properly. If we use helical it will not be economical, so we proceed
for the spur one.
Initial start-(assumption)
-We start by taking the no of teeth for the pinion to be medium profile, that is,
Zp=18 (Zp-Nº of teeth for the pinion)
Zp/Zw=Nout/Nin (Nout-for the wheel)
(Nin-for the pinion)
Nin-is the motor speed to be 3000rpm.
Nout-is the out put revolution.
18/Zw=3000/Nout.
Since the speed reduction is by 5
Nout=3000/5=600rpm.
18/Zw=3000/600.
Zw= (3000 18)/600 =90
19
Since pitting failure is more Sevier than bending Life, we design for pitting and then check for
bending,
Np, w-life cycle for pinion & wheel
Np=life time×60×Nin
=70Kh860×3000=1.26×1010
Nw =70Kh×60×600
=2.52×109
Life factor
For the pinion=2.466×Np10-0.056
=0.66
For the wheel=2.466×10-0.056
=0.726
Allowable stresses for the pinion and wheel
For the pinion
(B) BHN=350
Sb=350Mpa
Sc=1500Mpa
For the wheel
Sb=B (1.2-B/1150) +43
=356.6≈357Mpa
Sc=2.56B+186≈1634Mpa
(ScCl)I ---- (ScCl) p=990Mpa
20
---- (ScCl) w=259.182Mpa
Now our design depends on the wheel.
Next-we find the module
m³ = (KaKvKmKr²E*P) /((ScCl) ²i (π²BNp/60) ZpI)
E*-if identical material is used for both take 113Mpa.
Kr-(reliable factor) =1 for 99%survival less than one failure in 100.
Ka= (application factor)
-for mixer (variable density)
-medium shocks,
-combustion engine light shocks
Ka=1.5
Kv-first we find speed
Vt =wr= ((2πn)/60)*(mz/2)—(since d=mz)
But we don’t know m so we guess Kv to be 1.8.
Km=1+Cpf+Cma
Cma=A+ (f/B)-(f/C)² ;leaving f/B & (f/C)²=0,because they are very small.
Cma =0.127(commercial), so Km=1.27(adding some value).Pitting resistance geometry factor;
I ≈ (0.0404+0.1127P)/(1+0.7P)---P=Zw/Zp≥1=90/18=5
I≈0.1342.For more economical let’s take B=12
M3 = (Ka*Kv*Km*Kr²*E*P) / ((ScCl)² i(π²BNp/60)ZpI)
M=3.77 taking to standard≈4,
Pitch diameter for the pinion (Dp) = mZp
21
=4×18=72mm
V=πDpNp
=π (0.072) (3000/60) =13.6m/s
The general purpose of reduction gears the advisable degree of accuracy is from 6-9.So let’s take
8 to be more economical.
Kv = (1+ ) E0.63
=1.84 (is very god approximation)
Km=1+Cpf+Cma
Cpf=0.1 max (0.5,f/Dp)+max(0,f 0.025 --A
To be more economical take 9≤B≤15, B=9
F=mB
F=4 , substituting in to equation (A)
Cpf=0.035,
Cma=
Km
Good approximation with the previous one.
22
F=
Checking for failure by bending
For the pinion
For the wheel
23
Since both are ( & ) less than 0.8 they are safe.
3.1Design of the shaft

This shaft contains the second pulley and the gear pinion.
Material selection
Tall = (13-22) Mpa
Yield strength=400Mpa
Torque = =
The tangential fore on the gear
Ft= =
And the normal load acting on the of the gear,
(The pressure angle to be taken as 20
Since the gear is mounted at the middle of the shaft, therefore maximum bending moment at the center of
the shaft.
24
Let d= the diameter of the shaft.
We know that equivalent twisting moment
Teq =
Km & Kt for steady load applied and rotating shaft.
Km=1.5,Kt=1
Teq =
=77.82E3 N.mm
But we also know that
Ts-permissible shear streets.
We choose the smaller
Since there is key way it will be redused by 25%.so they became,
Ts1=74.433 Mpa Ts2=60.5Mpa,so we choose 60.5Mpa
25
For the second shaft,
But here we assume the power transmission to be 99%.so
Standard sizes of commercial shafting (dia.)
-Up to 25mm in increment of 0.5mm
-25 to 50mm in increment of 1.0mm
-50 to 100mm in increment of 2.0mm
26
-100 to 200mm in increment of 5.0mmsource machine design (Muber)
3.2 Design of Keys

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect these
together in order to prevent relative motion between them. It is always inserted parallel to the axis of
the shaft .Thier are many types of keys available like sunk key, saddle key, tangential etc.
Let-
T-torque transmitted by the shaft
Ft-tangential force acting at the circumference of the shaft
d- Diameter of the shaft
l=length of the key
T=thickness of key
Material selection
We used the same material as the shaft
We choose the square one because It is more stronger than the rectangular one in shearing &crushing.
W=T,W=D/4=19/5 .
Max.torque transmitted by the shaft and the key
27
1st let’s consider the failure of key due to sharing
Now considering the failure of key due to crushing,
Max-torque transmitted by the shaft & Key,
1st let’s consider the failure of key due to shearing
28
Now considering the failure of key due to crushing
3.3 Bearing selection

Since the bearing is subjected to radial load we selected the ball bearing. We selected the bearing
depending up on the load rating on the bearing. The load on the bearing is due to the load of the
gear, tangential load, and the shaft load
For the 1st bearings
Load of the gears
Mass (gear 1) =
Mass (gear 2) =
Total load=13Kg=130N
Mass of shaft 1
Mass of shaft 2
29
Total load of the shaft=1.272Kg 2Kg
Tangential load
T (load)1=850 N (from shaft 1 design)
T (load)2=1050N (from shaft 2 design)
For the 1st bearing-
Total rating load=850N+4.42N+20N
=874.42N
For the 2nd bearing-
Total rating load=1050N+8.3N+110N
=1168.3N 1170N
By using these values this we select the bearing (ball bearing) which can resist a load above the
mentioned value. Since bearings are standard we may not get the perfect size for the bore
diameter so we have to step down the shaft.
Bearing No Bore(mm) Outside diameter Width(mm)

203 17 40 12
205 25 52 15
30
Chapter four
4. Design of belt
The use of belt drives is to transmit power. Even there are many types of material used for making
belt we used rubber type, because cost is the main criteria in designing machines. It has been found that
for the efficient transmission of power the best speed is from 20m/s to 22.5m/s may be used .A little
consideration will show that when the speed of belt increases, the centrifugal forces also increase which
tries to pull the belt away from the pulley. Their are alternative power transmission like chain belt and flat
belts. The reason that we did not choose them is,
Advantages of V-belt drives
1-It has a very compact layout .The center distance will be very small.
2-They can be used for high velocity ratio.
3-Operation is noiseless and smooth because of absence of joints.
4-The drive can take up shocks, especially at starting.
5-Variable speed ratio drive can be made
6-The angle of inclination of center line does not affect power transmission.
7-The V-belt are normally impervious to heat moisture and dust.
The disadvantages of chain belt
-maintenance is hard
-noisy
-high cost,even if it is good in transferring power.
The flat belt is less cost but power transferring &life time in not as good as V-belt so we choose
V-belt.
31
4.1 Design of V-belt
Fig. Cross sectional area of v-belt
The inclination of the V-belt is usually from 30 -40 .
The Analysis
For the power (7.5-75) Kw
The recommended values are
W=22mm
Min pitch diameter of pulley (d) mm=200mm
T=14mm, Weight/meter length=3.43n
Cross-sectional area
32
For the best result the belt speed should be 20m/s. let the center distance be 400mm.But in our
assumptions,
Now the length of the belt can be calculated as
33
4.2 Selection of Pulley

The kind of pulley we selected depends of the dimension of the v-belt
-type of pulley (V-grooved pulley)
-Nº of grooved on the pulley
Material
-alloy steel or cast iron
34
-Manufacturing of pulley-by machining (ductile)
-Cast techniques (for brittle material)
Fig. Cross sectional view of the pulley
The pulley for the shaft of the reversing clutch
Do=212mm B=38mm
D=200mm r=8.75mm
Di=170mm d=21mm
S=17mm Do-D=2f=12mm
P=26mm f=6m
(Do+D1)/2=191 Di = (4oo-212)mm=170mm
The pulley for the shaft of the gear box
Do=398mm B=38mm
D=392mm r=8.75mm
Di=356mm d=21mm
S=17mm Do-D=2f=12mm
35
P=26mm f=6m
Chapter five
5. Design of the Drum

The drum is the main component of the mixer in which the mixing process of the concrete is
done.
Material selection
-steel370r alloy steel of quality available at MIE
Here in the design of the drum we can take the maximum force or torque, induced on the
drum of the engine drive or that of electrical motor. Speed in the drum=20rpm
Weight of the mixture for c-25 with the box of size
V= , 3times sand, 4times aggregate, 100Kg cement & 45litter water.
Mass Volume Density

(Kg) (m³) (Kg/m³)
Sand 151.2 0.108 1400
Aggregate 201.6 0.144 1400
cement 100 0.067 1500
water 45 0.045 1000
Stress on the drum
-Tensile stress on the circumference of the drum due to centrifugal force of the mixture on the
internal surface
-Tearing stress on the drum body by the bolts connecting the drum and the ring.
36
-Stress along the drum due to weight of the mixture.
Centrifugal force
While the drum is rotating the mixture inside the drum will be forced to the wall of the drum.It is
applied mostly in the cylindrical part. Take elemental mass,
W= (2 60=(2 *20)/60=2.094rad/sec.
37
We have w=2.09rad/sec =7800Kg/m³,h=1.38m,R=1380/2=0.69m,
M=500Kg
=1609.37N
Allowable tensile strength of the drum will be
Know considering the bolts effect,
Let’s take factor of safety F.S=2
38
And also taking a consideration for
-corrosion of the drum
-Due to friction affect between the concrete and the drum material and consideration other factors,
5.1 Design of blades

Mixing blades are used to distribute and agitate the ingredient uniformly by carrying up
solid parts and dropping it down to the bottom in to the liquid part.
Assumption
Number of blade=2
Length of the blades=250mm.The stress on the blades are
-Bending stress
-Shear stress around weld joint. Hear the blade is acting like a cantilever beam and the weight if
the mixture is to be distributed along the blade.
Material selection
-steel of type 45 c8
Let F.S=3.Then let’s take the blade cross section
39
Fig. Blade of mixing drum
Fig. cross section of the blade
Let the width(x) be =50mm
Assuming uniform load distribution.
-maximum bending moment,
The bending stress is,
40
Or we can check for shearing,
= 0.9 .so very small so the thickness will be 19mm.
For easy & nice distribution of the mixer the blade is tilted at angle of 45 .The same material and
dimension is used for the other blade.
Design for the second type of blade
There are another type of blade mainly used to discharging, but they are also used for mixing for
some exiting.
Material used is the same as before.
Assumption let’s take x=200 y=1952
41
But there are mixing facilitators that are welded at the inlet of the mixing part so the length should
be reduced to,
Checking for shearing
The orientation is 45 in opposite to the former one so that while rotating in reverse direction it
helps to remove the mixed concrete.
5.2 Design of the weld for the blade

Weld
A weld joint is a permanent joint which is obtained by the fusion of the edge of the two parts to be
joined together, with or with out the application of pressure and a filler material. The heat
required for the fission of the material may be obtained by burning of gas in case of a gas welding
or by an electric arc incase of electric arc welding. The Latter method is extensively used because
42
of greater speed of welding. Welding is extensively used in fabrication as an alternative method

forecasting or forging and as a replacement for bolted and riveted joints. It is also used as a repair
medium .Eg.to reunite metal at a crack, to build up a small part has broken off such as a bearing
surface.
The main considerations involved in the selection of weld type are;
1-The shape of the welded component required.
2-The thickness of the plate to be welded.
3-The direction of the force applied
Thickness
of the 3-5 6-8 10-16 18-24 26-55 Over 55
plate(mm)
Minimum
size of the 3 5 6 10 14 20
weld(mm)
thickness 1.5mm-5mm
thickness 6mm-10mm for
thickness 10mm-15mm
43
thickness 16mm-35mm for =80 -90

β
Fig. Relation between Welding & thickness
Fig. Blade weld
Assumption to taken weld width to be b=60mm,h=65mm.we know L=250mm.fillet weld around
the blade. The force that is applied on the weld is shear force,
For the blade,
Primary shear stress in the weld
44
Moment of inertia about x-axis for the four welds
Ixx=Ixx(full rectangle)-Ixx (the hallow)
Since t is very small compared to b & h t² and variables which has degrees above will be
neglected, so it will be simplified as
Ixx=
b=65mm,h=60mm,so the value will be Ixx=t(17.2*E4)
Bending moment, M=F(Shear)*L=
The maximum or result shear stress in the weld is given by,
45
make allowance for friction & corrosions so weld size will be 4mm.
Volume of the drum
Fig. Drum
Volume 1
Volume 2
D=1380mm
D1=1375mm
d=480mm
d1=475mm
t=5mm
46
h=690mm
V (conical) =
Volume 3
D=1380mm
D1=1375mm
D=480mm
D1=475mm
H=345mm
Volume (conical)=
The total volume is,
V Total=V1+V2+V3
=0.015m³+0.001625m³+0.000812m³
=0.01744m³
Mass of the drum=
47
Chapter six
6. Design of ring gear and the pinion

Known specifications are-Ni=600rpm, No (the drum)=20rpm
Material used-
-cast iron ring gear using class 40 cast iron.
Initial start Zp=20, Zw=(Np Zp)/N(ring)=
Since pitting failure if more Sevier than bending life, we design for pitting and then check
for bending.
Np,w -life cycle for pinion & wheel
Np=life time×60×Nin
=70Kh860×600=2.52×109
Nw =70Kh×60×20
=8.4×107
Life factor
For the pinion=2.466×Np10-0.056
=0.7337
For the wheel=2.466×E-0.056
=0.8876
Allowable stresses for the pinion and wheel-
For the pinion (B)
BHN=350
Sb=350Mpa
48
Sc=1500Mpa
For the wheel
Sb=B(1.2-B/1150)+43
=356.6≈357Mpa
Sc=2.56B+186≈1634Mpa
(ScCl)i ---- (ScCl)p=990Mpa
---- (ScCl)w=259.182Mpa
Now our design depends on the wheel.
Next-we find the module
m³ = (KaKvKmKr²EP)
(ScCl)²i(π²BNp/60)ZpI
E*-if identical material is used for both take 113Mpa.
Kr-(reliable factor) =1 for 99%survival fewer than one failure in 100.
Ka= (application factor)
-for mixer (variable density)
-medium shocks,
-combustion engine light shocks
Ka=1.5
Kv-first we find speed
Vt =wr= ((2πn)/60)×(mz/2) ---- (since d=mz)
But we don’t know m so we guess Kv to be 1.8.
Km=1+Cpf+Cma
Cma=A+ (f/B)-(f/C)² ;leaving f/B & (f/C)²=0,because they are very small.
49
Cma =0.127(commercial), so Km=1.26(adding some value).
Pitting resistance geometry factor;
I ≈ (0.0404+0.1127P)/(1+0.7P)---P=Zw/Zp≥1=90/18=5
I≈0.1342.For more economical let’s take B=12
m³ = (KaKvKmKr²EP)
(ScCl)²i(π²BNp/60)ZpI
M=2.9 taking to standard≈3,
Pitch diameter for the pinion (Dp) =mZp
=3×20=60mm
V=πDpNp
=π× (0.072) × (3000/60)=1.885m/s
The advisable degree of accuracy is from 6-9.So let’s take 8 to be more economical.
B=0.25× (12-Q) e(2/3)=1.84
Kv = (1+ ) 101.84
=1.5 (is very god approximation)
Km=1+Cpf+Cma
Cpf=0.1max (0.5, f/Dp)+max(0,f 0.025 ----------------A
To be more economical take 9≤B≤15, B=9
F=mB
50
F= , substituting in to equation (A)
Cpf=0.026
Cma
Km
Good approximation with the previous one.
F=
6.1 Design of the bolt

There are bolts that are used to connect the ring gear and the drum. The Nº of bolts to be used is assumed
to be 6.The challenge that they can face is tangential force.
The allowable shear stress for the bolts material is,
51
Pitch dmm-0.7
,minor or core diameter,
Bolt Nut
3.141 3.242
Depth of thread bolt (mm)=0.429,stress area=8.78.
Chapter seven
7. Design of hydraulic cylinder

The known values which needed to design the hydraulic cylinder:-
 Total load to be moved =

=Mass of sand + mass of aggregate + mass of cement + mass of bucket
=151.2kg + 201.06kg + 100kg + 90kg
= 542.26 kg
W= 542.26 9.81
= 1335.16 N
By considering some factor let W= 1340 N
 Coefficient of static (or breakaway) friction = 0.16

 Coefficient of sliding friction = 0.14
For cylinder with normal size and used at normal speed, it is desirable if the piston attains steady
state velocity with in 0.5 sec to 1sec or 10-15 mm.
52
From this a speed says, 0.5m/s has to be reached in 1.5cm of cylinder travel or with in a certain
time, say with in 0.5sec from the start of the cylinder.
Since it is generally safe to assume linear acceleration we can find by the formulae:
a = v2/ (2 s)
= = 8.3 m/s2
Breakaway load = W μs
= 1340 0.16
= 214.4 N
Load to keep it moving = W μd
= 1340 0.14
= 187.6 N
F= load which the cylinder encounters
F= a+w
= 8.3 + 1340
= 2473.74 N
Theoretically in determining the total load, the acceleration of the oil column should also be
considered. This calculated by:
P=h a Where h- Height of oil column in m
a- Acceleration
- Density of oil, kg/m3
53
But from practical point of view this is insignificant and hence it can be ignored for the low flow
rate system.
Stoppage load
Stoppage load may create large pressure. Here to calculate force F, we can use the formula:
F= a + w ms
F= 8.3 + 1340 0.16
F= 1348.14 N
The given cylinder diameter = 90 mm
Effective area of cylinder =
= 6361.73 mm2
Pressure =
= 1348.14/6361.73
= 0.212 Mpa
Hence it is found the pressure of (2.12 bar) can provide the necessary force.
If the value is closed to stop the motion while still under acceleration, the pressure (2.12 bar)
must be absorbed together with deceleration force.
F= 1348.14 – 1340 0.16
F= 1133.74 N
54
P=
= 0.178 Mpa = 1.78 bar
A surge pressure of 2.12 + 1.78 =3.9 bar
By considering some factor we take P= 5 bar.
Results for which the cylinder has to be designed.
Sizing of cylinder tubes
A good design of a cylinder starts with proper selection of geometric size of piston and rod
diameter, wall thickness, stroke length, etc.
While calculating the size, a designer should not depend only on the calculated value but he has to
consider the feasibility aspect of the values to be sure how much these are commercially
available.
Calculation of tube thickness
Tube thickness of a cylinder barrel is a very important factor.
For thin cylinders (diameter to thickness ratio greater than 10:1) thickness t may be calculated
from the normal Barlow formula as shown below
S= hoop stress= where; S=hoop stress
p= oil pressure
do= outer diameter of cylinder
55
di= inner diameter of cylinder
Fig. cylinder tube thickness
The cylinder must be of such material and the wall thickness to be such as to safely resist the
hoop stress produced by the hydraulic pressure.
Analysis
Dimensions given:-
 Cylinder bore =90mm

 System pressure = 5 bar
 Cold drawn carbon steel used for the cylinder has a tensile strength of 7350 N/cm2 (73.5
N/mm2).
 For continuous severe application safety factor = 4
S= working stress =
=18.4 N/mm2
From the formula:
S=
18.4=
56
do =92.48 mm
Therefore tube thickness =
7.1 Piston Rod Design

The piston rod of a hydraulic cylinder is highly stressed and therefore it should be able to resist
the bending, tensile and compressive forces that it may encounter during its operation without
buckling. Mostly piston rods are made of high tensile material finished and hardened with
chromium plating to provide resistance to corrosion. Stainless steel is also used as a rod material
due to its excellent anti-corrosive property.
Dimensions given:
d=40mm
Piston extension (stroke length) =775mm
As the thumb rule if the length of the rod exceeds ten times its diameter, one can consider it as a
column under compressive load and may buckle under the pressure of the load. If the piston rod is
stressed as a rod, the rod cross sectional area can be calculated from the formula
F=a s
Where F is compressive or tensile load
a is rod cross section
s is material stress
Critical load as per Euler’s formulae
Fc= where Fc is critical buckling load
57
Lk is free buckling length
E is modulus of elasticity (2.1*1010 *9.80665 Pa for steel)
I is moment of inertia
S is factor of safety=2-10
The moment of inertia and therefore the maximum permissible stress in order to avoid buckling is
dependent on the type of end fixing of the cylinder. The maximum load on the piston is
F=Fc/S
S=5 for general cylinders
Determine the safe load for a double acting hydraulic cylinder with two ends pivoted. According
to the four cases of Euler’s rule for these type of end fixing formulae for crippling or buckling
load
Fc=pi2EI/Lc2 =
Therefore the thrust load on the rod is = =
The thrust load is greater than the load which the cylinder encounter 2473.74N this shows the
design of the piston rod is safe.
58
Fig. Assembly fitting of double acting cylinder
7.3 Flow control

When the flow coming from the pump at the time of the cylinder extending, the needle valve is
being by passed through the check valve. When the cylinder is retracting the flow coming from
the cylinder can not pass through the check valve and forced to go through the mating orifice. The
net result is that the flow control valve is controlling the retracting speed, while the extended
speed is of the cylinder is uncontrolled.
Fig. Ace lender flow control the retract and extend stroke
59
Chapter eight
8. Design of frames
The frames are used for the supporting of the whole mixer components. The type of structural
tubing we used is square type because it can with stand higher load.
Fig. Sectional view of the frame
Material selection
ASTM A242 Type 1, UNS designation K 11510.
Nominal size= 4 4
Wall thickness =0.1875inch²
Area =2.77 inch²
I =6.59 inch³
( all units’ is in inch) -1inch=25.4mm
We take
Intended uses are structural members in welded bolted or riveted construction.
60
F.s=3 (since it is imposed to many loads)
Since
Chapter nine
9. Design of the axel

The axel is the one that supports the wheels. The type of the axel is circular.
Material selection
The same material as the frame but .
I=
61
We add this much because when the mixer is dragged the whole weight will be on the axel.
The amount of force which is applied on the axel is the summation focuses (F)
F (total) =F (drum) +F (Bucket) +some factor
Force of the drum=Force (ring gear) +Force (drum)
=3680N+1360N
= 5040N
Force of bucket=
= 900N
F (total) =5040N+900N=5940N, then load on each tire is
F/2=5940N/2 = 2970N
Shear force
Allowable shear force is
62
Fig.forceson the axel
Fig. Shear force diagram
Fig. Bending moment diagram
63
Fig. Deflection diagram
Since 8.4 Mpa<379 Mpa it is safe
Chapter ten
10. Details of casing Dimension

The casing of gear reducers are generally cast in cast iron, but some times the casting may be
done in steel or casing made by fabrication. The casting is made in two halves the upper parte
generally called cover can be lifted when desired and has a machined flange surface to contact
with the lower part. The bearing is supported in booes produced in the lower parts as well as in
the cover.
No Dimension symbol Empirical relation value

1 Thickness of casing ∂ 0.03A+5mm 18.5
wall
2 Thickness of cover ∂’ (0.8-0.85) ∂ 14.8
wall
3 Width of top flange of K (2.5-3.2) ∂ 55.5
casing
4 Thickness of top b 1.5∂ 27.75
flange of casing
5 Thickness of the rib c (0.8-1.0) ∂ 16.65
of body
6 Diameter of the d (1.5-2.0) ∂ 33.3
foundation bolt
64
7 Minimum clearance a ≥∂ 20
b/n gear and inner
wall of the cover
8 Diameter of bolts d’ 0.75d 25
near bearing
9 Diameter of the d’’ 0.75d’ 18.75
flange bolts
10 Thickness of the t (92.25-2.5) ∂ 44.4
foundation
11 Width of foundation K’ (92.2-2.5)d 80
flange
12 Distance b/n flange e (150-180)mm 170
bolt
13 Thickness of the b’ (1.5-1.75) ∂’ 25
cover flange
14 Thickness of the c’ (0.8-0.85) ∂’ 12.4
cover rib
A=center distance
= (360+90) mm
=450mm
Service and repair
Immediately after its successive operation, the mixer has to be cleaned of any dirt and residual
concrete scratches. Since steel materials are highly susceptible to corrosion due to air and
moisture the parts of the mixer especially the drum have to be kept carefully to avoid this effect.
-at the end of the mixing process ,after removing the product, admit fresh water in to the mixer
while the drum is rotating empty, after some rotation of the drum ,remove the water replace it
with another and clean it at the same process.
-pour anti-corrosions, normally thick oils or oils already used for other lubrication purpose on
the outside surface of the drum and fill it all around its surface.
-put the mixer as much as possible at moisture free place.
65
-fill lubricating grease oil the bearing using grease gun.
Chapter Eleven
11. Cost analysis

A-Consumable 1-Drilling machine
Scope of work-fabricating reversing concrete 4hr*15Birr/hr

mixer of two wheels.
=60 Birr
1-D=2.5mm=2set 60Birr=120 Birr 2-Binding machine
=4hr*27Birr/hr
D=3.5mm=2set 85Birr=170Birr
=108 Birr
2-Painting
3-Shearing machine
Anti rust =4Killo*34Birr=136 Birr
=10hr*25Birr/hr
Yellow =2Killo*95Birr=190 Birr
=250 Birr
Stucco=2Killo*85Birr=170 Birr
4-Power hack saw
Thinner=1Killo*24Birr=24 Birr
=10hr*27Birr/hr
Sheet metal =1500 birr

B-labor Cost
5-Skilled labor
=270 Birr
5-days (welding)
5-Grider
1-days (painting); per/day=200 Birr
=10hr*15Birr/hr
Sub total=5 Person*150 Birr/day*20 day
=150 birr
=15000 Birr
6-Welding machine
C-Machining
=10day*5hr*20birr/hr
66
=1000 Birr =10hr*37Birr/hr
7-lathe machine =370Birr
Material cost
Frame (squer-channal)
2 PCS of 2600*101.6*5mm=2*300=600
5 PCS of
1870*101.1*101.1*5mm=5*270=1350
Axel= 2000
Wheel bearing 4*70=280 Birr
Belt=2*40Birr=80Birr
Motor=20000Birr
Reducing gear box=3000 Birr
Reversing gear box=2000 Birr
Cylinder =3000 birr
Ring gear=3500Birr
Pump=5000Birr
Bearing=80Birr*9=720 Birr
67
Material cost (In birr)
Sheet metal (for the drum ,bucket ,casing for 1500
the ring gear)
Welding material 290
Ring gear 3500
Belt 80
Frame 1950
Tire 1000
Gear box 3000
Painting 520
Reversing gear box 2000
Pump 5000
Motor 20000
Operating cost 15000
Power cost to run the machine 2268
cylinder 3000
Taper bearing 200

wheel 1000
Ball bearing 630
Contingency (10%) 6455
TATOL=71,005 Birr
profit 110,000-71,005=38,995 Birr
In the local market the price of the mixer including the tax, the price is 110,000birr.But in this
project the total price of the mixer is 71,005 Birr. This shows the project is profitable .
11.2 Manufacturing process required

PARTS PROCESS REQUIRED
-Drum -cutting to the developed size,rolling,butt and
fillet welding type, drilling for bolts holes and
finishing (grinding and painting)
-Ring gear -casting and finishing process
-Shaft -Turning, milling for key ways and necking for
o-ring.
-Mixing blade -Pantograph cutting ,or milling operation and
fillet welding processes.
-Frames -shearing or cutting to size, bending, welding,
and grinding.
-Drum holding pin -Turning, necking and finishing.
-Bolts and nuts -Turning, milling .thread cutting (lathe), or
internal threads can be cut with dies.
-Keys -cutting and milling operations
11.3 Assembly procedure
1-Errect the frame on level surface by welding and bolting the components of frame to form the
complete frame assembly
2-fit the roller pin on to the frame.
3-Tightend the ring gears on to the center of mass of the drum by using bolts.
4-Put the assembled drum on the roller pulley.
5-Cuver the ring gear with the curve. And bolted them on the frame.
6-On the gear box fit the gear on shaft and put the key between them, then put the assembled shaft
in the bearing which is also fitted on the casing.
7-insert the pulley in t o the shaft of reversing gear box out put and the input shaft of reduction
gear box .Also use the key between the pulley and shaft.
8-Mount the gear box on the frame.
9-Mesh the pinion and the ring gear.
10-Mount the reversing gear box in the box then tightened the box on the frame.
11-put the belt on the smaller and larger pulleys, adjust the belt tension by moving motor from its
seat and move it on the seat.
12-cupple the reversing gears box and the motor.
13-tightened the motor and the gear box on the frame.
14-Insert a bearing on the frame so that the bucket shaft can role.
.15-fit the piston on the frame and on the bucket.
16-Insert the two wheels on the axel.

Recommendation
While we are intending to use a machine their should be a rule which has to be followed. If
we want to use this machine the parts of the mixer should be used for their life time, but if we
intended to use them for longer time, damages could occur and also proper attention should be
given during manufacturing & work time. The other thing is the components of the machine
should be oiled & greased for a proper function and longer life time the last .The last thing but not
the least is when we finished the mixing process we have to clean in and oil it not to be rusted .If
not the concrete will be attached to the blade and destroyed the blade profile. This will make the
concrete at the out put to be not well mixed, which is dangers for construction of a building .to
finalize the mixer should be given a good care
Bibliography
1-Frank Kreith, the CRC Hand book of Mechanical Engineering.
2-Joseph E.shigly, standard hand book of machine design 2nd edition.
3-Robert C.Juvinal fundamental of machine components design.
4-A Text book of machine Design by R.S Khurmi, J.K Gubta.
5-Machine design by p.c Sharma.
6-Machine design by Mubeen.

Specification for a 500 litter capacity concrete mixer
-Medium capacity mixer with the following specification
 Capacity
 Out put
-Water tank capacity 50liter
Application for concrete mixer

1-Diesel engine with a pumping unit
-RPM-3000
-Power 10-15 Kw
2-Reduction gear box
-Reduction ratio 5
3-Reversing gear (clutch)
4-with hydraulic jack

Design of Revesing Concrete Mixer

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Design of Revesing Concrete Mixer

Uploaded by

Copyright:

Available Formats

Design of Reversing concrete mixer MU/FST/MED

Table of content page

5.1 Design of blades.....................................................................................................................38

The material shall be placed in to the mixer in the following order,

-Half the volume of water

-the rest of the water

1.2 Mixer efficiency

Performance attributed as indictors of efficiency are the following points,

-workability of the concrete as defined by the slump.

-Density of the concrete

-distribution of cement, fine aggregates and coarse aggregates in the mixer

-variation in compressive strength and

1.3 Wear and tear and cleanness

-cost and difficulty of replacing the blades or parts

-sensitive of the mixer to wear and tear of the blade

1. 4 Hardware: the Mixers

1.4.1 Batch Mixers

1.4.2 Drum Mixers

1.5 Pan Mixers

1.6 Continuous Mixers

2. Design of reverse gear box

2.1Working mechanism (operation) of reverse gear box

2.1.1 Forward rotation

2.1.2 Reverse rotation

2.2 Synchronizing mechanism

Fig Synchronizer meshing mechanism

 Motor speed 3000rpm

 The motor shaft transmits 12kw of power at 3000 rpm

 Assume a factor of safety 5

 Ultimate shear strength for shaft 300N/mm2

 Ultimate shear strength for key 200N/mm2

 Ultimate shear strength for muff 50N/mm2

 Ultimate compressive strength for key 500N/mm2

=2π 3000/ 60 = 314.2 rad/sec

The torque transmitted by shaft is related to diameter, d of the shaft as

Where τs is the permissible shearing stress in the shaft.

Assuming the width of the key to be 0.25d

If F is tangential force on the shaft, causing shearing of the key, then

F= T / d = 38.2 103 / 16.3

And 2343.5 = 4.1 L 200 /5

2343.5= (h/2) 14.3 (500/5)

After the design of coupling we design the reversing gear box:

For 52 HRC steel (pinion)

1. Allowable bending stress Sb=380Mpa.

For pinion =70×103×60×3000

For wheel =70 103 60 1000

For pinion Scp =1320Mpa

For wheel Scw=made from 360BHM and grade 2

=2.51 360+186 =1089.6Mpa

Sbw=B (1.2-B 1150) +43=362.3Mpa.

From this the minimum one is selected.

m3= (Ka Kv Km KR2 E P) (Sc Cl)2 π2 B N2 z22 I

KR reliability factor 99 % survival (KR =1)

Dynamic factor Kv =1.7 it is guess

Load distribution factor Km

Cpf = 0.1max (0.5, f/D1) + max

For commercial A = 0.127, B= 1600, C= 2400

Km = 1+0.127 =1.127 by adding some value say Km = 1.2

Pitting resistance geometry factor

I = (0.0404 + 0.1127ρ) (1 + 0.7 ρ)

m3= (Ka Kv Km KR2 E P) (Sc Cl)2 π2 B N2 z22 I

m= 2.35 mm from standard table the appropriate value m = 3 mm