“DESIGN, ANALYSIS AND OPTIMIZATION OF DRAG CHAIN CONVEYOR FOR COAL

APPICATIONS”

PRESENTED BY

PRIYANKA VALMIK OGALE [F15322003]

ANKITA SAHADU DAPHAL[F16322020]
RUCHITA HEMANT SONAWANI [F16322018]
POOJA CHANDRAKANT DURGE [F16322007]
GUIDED BY
PROF. S.P. PATIL

SPONSORD BY
Mr. ANAND BHISE
MECHATOL ENGINEERING SOLUTION .

Department Of Mechanical Engineering

Modern Education Society’s College of Engineering
Pune – 411001
[2018-19]

 
 CONTENTS:
Sr. no Topic Page no.
1 Title 1

2 Introduction 3

3 Objective 6
4 Scope 7
5 Problem statement 8

6 Literature review 9-15

7 calculation 16-30
8 Models of parts 31-32
9 Final assembly 33
modeling
10 Project result 34

11 reference 35-36
 INTRODUCTION:
 1) A conveyor system is a material handling equipment.
 2) Application .
 3) In Drag chain coveyor the material transport time is less.
1) The profile of conveyor is horizontal.
  2) Drag Chain Conveyor system can convey the material horizontal
direction.
  3) The material is displaced by 25 m.
4 ) The material is transport with high efficiency.
5) Material handling is the combination of art and science of
moving, storing, protecting, controlling the material.
6) The demand of material handelling equipment is correlated with
the growth of Infrastructure sector, India needs to improve it in a big way.
7) A big scale application, (Roads, Steel, Coal, Cement, Power etc.)
CONVEYOR IMAGE :
Drag chain conveyor
for coal application
:
HYPERLINK DOCU
MENTS\VID-2018122
1-WA0035.mp4
 OBJECTIVE :

1)To reduce vibration of conveyor chassis by following design

changes: .[1,3,4,7]
a)Material selection as per Ashby Chart
b)Changing Section sizes and Types (ISMC,H Beam) .

 2)Increasing fatigue strength and Reducing deflection of drive

shaft.[1,3,5,6]

3) Improve performance and reduce the weight of chain link flight
assembly.[1,5]
 SCOPE :
1)Creating GA layout with all details along technical
specifications.

2)Creating product calculations.

3)Designing all parts of conveyor.

4)Performing product failure analysis on solidwork.

5)Creating production drawing.

6)Detailed costing and estimation of product.

7)Creating dispatch level bill of material.

 
 PROBLEM STATEMENT :

 Design and analysis of Drag Chain Conveyor and

optimizing Fatigue Cycles of Drive Shaft

 Designing Chain link

 Designing Bottom Chassis based on Vibrations

and reduce the weight of overall chassis

 Redesigning of conveyor based on optimization

 LITERATURE REVIEW :

Title:- Design and Experimental Analysis of Flight of Drag Chain Conveyor Belt with
respect to its Breaking Strength by Varying Materials.
Year:- 2015
Authors:- Mr. Harishchndra A. Shire , Prof. S. G. Ganiger
Publications:- International Engineering Research Journal Page No 856-863
Aim:- The main concept in this paper is to vary the material of Flights to increase
the breaking strength. Design and Analysis is carried out with Flight Materials such
as Mild Steel, Aluminum Alloy and Composite Material (Glass Fiber).
Outcomes:- From the analysis result it is clear that design for drop forged chain
flight system for all three material i.e. Mild steel, Aluminum alloy and Glass fiber is
safe. Hence they are concluded that among three materials, Glass Fiber is best
suited material for drop forged chain flight assembly.
Title –Design and analysis of shaft and sprocket for power transmission assembly.
Year- 2016
Author- Ramnath yadav ,Nithesh kumar Varshney , Manish mavi.
Publication- International journal of innovative science,engineering and technology.
Aim- The present research paper emphasizes upon design and analysis of shaft and
sprocket for power transmission assembly of vehicle for parking purpose.
Outcome- In this paper they concluded that, the stresses found out by analytical method.
The shaft and sprocket of a vehicle designed is safe for load and torque

Title – Design and analysis of chain outer link by using composite material.
Year - 2015
Author- Tushar s. shahane, Prof. Ameeth m. Umbajkaar.
Publication- ISOR journal of machanical and civil engineering
Aim-In this paper is to review the appications in the industry and explore the design
consideration that go into the design of the assembly. The use composite material for a
chain outlink to minimize the weight of link.

Outcome- They concluded that with increasing glass fiber link thickness, the stess is
reduced to great extent. The reduction in weight and maximum stress is obtained by using
glass fibers as comapre to original outer link chain.
Title :- A Review of a Fundamental Shaft Failure Analysis
Year :- 2016
Author :- Hariom, Prof. Vijoy Kumar, Dr. Chandrababu D.
Publication :- International Research Journal Of Engineering and Technology (IRJET)
Aim :- In this Research paper to study various shafts failure analysis and select the best
method to find out the root cause failure of heavy nip roller shaft.
Outcome :- They concluded that, the heavy nip roller shaft failure analysis is to done by
following methodologies are Design standards of the shaft considering maximum bending
and torsional theory and Analyzing stress concentration at major step down.

Title :- Conveyor Pulley Failure Analysis

Year :- 2014
Author :- Tapan R Patel, Mr.Ronak R Patel, Prof. Shashank P Joshi
Publication :- International Journal Of Engineering Development and Research (IJEDR)
Aim :- In this paper different component of conveyor pulley (shell, end disk, hub, and
shaft) failure and the stresses
generated on them
Outcome :- This paper mainly focused on the improvement in the design and dimension of
conveyor pulley which helpful for computational level.
Title:- Transfer Coal Conveyor Shaft Optimization Analysis and Modification in Sprocket
Structure.
Year:- 2018
Author:- Mr. Ganesh S. Khandare, Prof. Ravindra S. Shelke.
Publication:- IJARIIE-ISSN(O)-2395-4396
Aim:- In this paper research is done on optimization analysis of transfer coal conveyor shaft
and modification in sprocket structure.
Outcome:- They concluded that the optimization of shaft was carried out by selecting
better material for weight reduction and better strength.

Title :- Experimental Analysis Of Failure of Drive Shafts.

Year:- 2016
Author:- Mr. Shubham Basu, Prof. Gaurav Chaure
Publication:- International Journal Of Innovations in Engineering and Technology,
ISSN:2319-1058
Aim:- In this paper research is done on the failure analysis of shaft which are used for
transmissions of power between two moving element.
Outcome:- The whole motive behind this paper is to study and explain the causes of failure
of shaft and discussed about the factor which is responsible for a failure of shaft.
 Title:- Design optimization of Chain Sprocket Using Finite Element Analysis.
Year:- 2016
Authors:- Parag Nikam, Rahul Tanpure.
Publication:- International Journal of Engineering Research and Application Vol 6, Issue 9,
Part 5,September, 2016, pp.6669
Aim:- Chain Sprocket is designed & analysis for reducing it’s weight & design the sprocket
for safety & reliability.
Outcomes:- Design the Chain Sprocket using Finite Element Analysis software. Ansys
software is used for static & fatigue analysis of sprocket design.

Title:- Design and Analysis Of Modified Idler In Drag Chain Conveyor.

Authors:- B.Radha Krishnan, M.Ramesh, R.Giridharan and R.Sanjeevi

Publications:- International Journal of Mechanical Engineering and Technology, Vol 9, Issue 1,

January 2018, pp.378387, IJMET_09_01_041.
Aim:- The main concept in this research paper is to design the conveyor for mass production
requires high quality of products transfer from one place to another place. Effective
methodologies are use to solve several problems in conveyor.

Outcomes:- The Idler should be modified in conveyor to eliminate failures, breakdown and
various errors because anti friction bearing in conveyor.
Title:- Design Improvement for Enhancing the Performance of drag Conveyor Chain and its Cost Reduction.

Year:- 2015
Authors:- Vishal Wankhade, Prof. Suman Sharma.
Publication:- International Journal of Engineering Research and General Science Volume 3, Issue 2, Part 2, March-
April, 2015, ISSN 2091-2730
Aim:-In this research they are emphasis on failure of drag conveyor chain and trying to modify the design of pin and
fasteners for enhancing performance and meet the cost reduction by reducing the material and operations.

Outcomes:- By proposed design of chain they can achieve goal of productivity by saving material and operations.
They can also enhance the performance of chain by implementation suggested in the designing.

Title:- Failure analysis and weight optimization of chain conveyor system.

Authors:- Hrishikesh Kishor Kulkarni, Prof.Dr.R.J.Patil

Publications:- International Journal of Advanced Engineering Research and Studies, E-ISSN2249–8974

Aim:- The main concept in this research paper is to design chain link thoroughly and analyzed by varying different
material for weight optimization.

Outcomes:- In this research paper result obtained is compared with existing design and modified to a greater
strength which will result in more reliable and durable chains which will result in decrease losses.
Title:- Design and Weight optimization of Fin of Drag Chain Conveyor

Year:- 2017

Authors:- Mr. Jadhav P.A.1, Prof. Kulkarni R.D.2, Prof. Ghalke A.B.3, Prof. Patel A.Z.

Publication:- International Research Journal of Engineering and Technology (IRJET), e-ISSN: 2395 -0056, Vol: 04 Issue: 04

Aim:- The main concept in this paper is to design the fins of chain conveyor system for easily intricate and disintricate
assembly and also changing the material with aluminum alloy for weight reduction and performance improvement.

Outcome:- from this research it can be concluded that, aluminum alloy fins is a best suited with the replacement of
existing fins in term of cost, weight and performance.

Title:- Design of chain link for drag chain conveyor to increase breaking strength
Year:- 2015
Author:- Shruti S Kulkarni , Anirban C Mitra , Sameer Nandikar , Kedar Damle
Publication:- International Journal Of Advanced Research And Innovative Ideas In Education, ISSN(O)-2395-4396, Vol-1.
Aim:- In this research paper work has been done to increase chain link breaking strength for higher models, to achieve
target critical sections of a chain link in term of stress are found out and design is modified in those critical sections.

Outcome:- from this research paper it can be concluded that, to increase the breaking strength of chain link two options
are applied, resolved and validated and best suited option is selected for implementation.
CAPACITY CALCULATION
• CHECK THE CAPACITY

RESISTANCE

RESISTANCE A TO B

MATERIAL SIDE RUBBING

RESISTANCE

CHAIN TENSION

POWER
 INITIAL DESIGN FOR SHAFT :
 1. Material : 1045 Steel

 2. Fatigue Cycles : 510000 Cycles

 3. Deflection : 0.38mm
 DESIGN PROCESS :
Material • As per Ashby Chart
Selection
• Density
• Cost
Material • Fatigue Cycles
• FEA
Filter • FOS

• Using
Mechanica ASME’s
l Sizing Rule

Bearing
Selection
SHAFT DESIGN WORKING PLAN :

Objective :
1)To Increase Working Cycles of Drive Shaft
Failure Mode : Torsion, Shear, Bending, Stiffness
Constrain : Length of Shaft
Free Variable :Shaft OD,Material
MATERIAL SELECTION AS PER
ASHBY CHART
ASHBY CHART MATERIAL SELECTION :

M.S 1020
C45
IS:2062
SS:304
 FATIGUE CALCULATION :
MS 1020 C45 IS:2062 SS:304
Edurance limit 325 MPA
Edurance limit 413.5 MPA Edurance limit 350 MPA Edurance limit 450 MPA
Ultimate tensile
Ultimate tensile stress 650 MPA Ultimate tensile stress 700 MPA
stress 827 MPA Ultimate tensile stress 900 MPA
surface finish surface finish factor 1.2  
surface finish factor 1.2   factor 1.2   surface finish factor 1.2  
load correction factor 0.8  
load correction load correction load correction factor 0.8  
factor 0.8   factor 0.8   size factor 1  
size factor 1   size factor 1   size factor 1  
Edurance limit for 396.9 Edurance limit for Edurance limit for
variable axial stress 6 MPA Edurance limit for variable axial stress 336 MPA variable axial stress 432 MPA
variable axial
321.2 stress 312 MPA 287.72 481.967
Stress life Method 01876 MPA Stress life Method 242 MPA Stress life Method 213 MPA
159.5
Yeild Stress 625 MPA Stress life Method 1586 MPA Yeild Stress 550 MPA Yeild Stress 840 MPA
Edurance Stress 375 MPA Yeild Stress 350 MPA Edurance Stress 330 MPA Edurance Stress 504 MPA
Edurance Stress 210 MPA
Mean Stress 80 MPA Mean Stress 80 MPA Mean Stress 80 MPA
Mean Stress 80 MPA
Variable Stress 70 MPA Variable Stress 70 MPA Variable Stress 70 MPA
Variable Stress 70 MPA
3.177 1.779 2.7966 4.27118
Factor of Safety 9661   Factor of Safety 66102   Factor of Safety 1017   Factor of Safety 644  
850 x 410x 623 x 110 x
10^3 10^3 10^3 10^3
N Cycles   N Cycles   N Cycles   N Cycles  
 MATERIAL FILTER :
Material Cost FOS Fatigue Cycles

1020 M.S 80/- Kg 2.6 850000

C45 60/- Kg 2.7 623000

IS:2062 35/ Kg 1.7 410000

SS:304 165/- Kg 4.2 1100000

 DESIGN PROCESS FOR SHAFT :
EXTERNAL LOAD

REACTION CALCULATION

LOAD DIAGRAM AND

SFD,BMD DIAGRAM

If Nfs<FOS
CALCULATIONTORQUE
TOTAL MOMENT

CALCULAE d &D
BY USING GOODMAN CRITERIA

ENDURANCE LIMIT AND

BENDING STRESS
Fos comparison
CALCULATION
FOS CALCULATION

CALCULATION --
 SHAFT MODEL &ANALYSIS :
SHAFT MODEL :

VON MISSES STRESS : DISPLACEMENT RESULT :

Name Type Min Max
Name Type Min Max
Stress1 VON: von Mises 0.000 14.766
Displacement1 URES: Resultant 0.000 mm 0.003 mm
Stress N/mm^2 (MPa) N/mm^2
Displacement Node: 6 Node: 54
Node: 2105 (MPa)
Node: 15338

630-507-1002-1-Static 1-Displacement-Displacement1
630-507-1002-1-Static 1-Stress-Stress1
 BEARING CALCULATON :
STUDID DIFF. TYPES OF BEARING

SELECTION OF PROPER BEARING

FINDING (L10 )

SELECTED AVAILABLE BEARING FOR DEFINED DAIMETER ON THE BASIS OF (d, D, e,Y, C &
DESIGNATION OF BEARING)
REVERSE CALCULATION

FINDING DYNAMIC LOAD CAPACITY (C)

IF NO IF YES
IF C<Cgiven SELECTED BEARING IS SAFE
 DESIGN OF SPROCKET :
DESIGN OF SPROCKET

PITCH CIRCLE DIAMETER CALCULATION (d)

ROOT DIAMETER (df) CALCULATION

TIP DIAMETER CALCULATION (da)

DATA FROM COMPANY
1) CHAIN PITCH TOOTH HEIGHT CALCULATION
2) CHAIN DIAMETER
3) NUMBER OF TEETH
ROLLER SITTING RADIUS CALCULATION

ROLLER ANGLE DESIGN

CALCULATION-
TOOTH FLANK RADIUS HYPERLINK DOCU
MENTS\SPROCKET
WORD DOCUMEN
DONE WITH DESIGN
T.docx
SPROCKET MODEL:
 DESIGN FLOW CHART FOR CHAIN :

MATERIAL SELECTION
MILD STEEL & ALLUMINIUM ALLOY

MASS ,LOAD CALCULATION OF

CONVEYING MATERIAL CALCULATION -
HYPERLINK DOCU
R MENTS\chain calculat
E iuon.docx
V MOMENT &REACTION
E CALCULATION
R
D
E
S
I
BENDING STRESS & SHEAR STRESS MAXIMUM DISPLACEMENT
G
& TENSILE STRESS CALCULATION CALCULATION
N

ALL STRESSES CHECK

SAFE OR NOT

IF NO IF YES DESIGN DONE

 CHASSIS CALCULATION
MATERIAL SELECTION

THEORITICAL CALCULATION

C- SECTION
I-SECTION
(FOR ISMC 75)

BENDING MOMENT CALCULATION

MOMENT OF INERTIA OF BEAM

MOMENT OF INERTIA FOR C

SECTION

DESIGN STRESS

DESIGN STRESS < ALLOWABLE

STRESS

SO, DESIGN IS SAFE

 CHASSIS MODEL

VON MISSES STRESS DISPLACEMENT

Name Type Min Max Name Type Min Max

Stress1 VON: von Mises Stress 0.000 N/mm^2 24.523 Displacement1 URES: Resultant 0.000 mm 0.298 mm
(MPa) N/mm^2 (MPa) Displacement Node: 18728 Node: 13473
Node: 13473 Node: 267

630-507-2002-AssemFinal-Static 1-Stress-Stress1
630-507-2002-AssemFinal-Static 1-Displacement-Displacement1
 INTERMEDIATE CASING MODEL

VON MISSES STRESS DISPLACEMENT

Name Type Min Max Name Type Min Max
Stress1 VON: von Mises 0.003 59.711 Displacement1 URES: Resultant 0.000 mm 1.752 mm
Stress N/mm^2 N/mm^2 Displacement Node: 55 Node: 484
(MPa) (MPa)
Node: 19768 Node: 63

S630-507-3002-Assem4-Static 1-Displacement-Displacement1

630-507-3002-Assem4-Static 1-Stress-Stress1
FINAL ASSEMBLY MODELLING
 RESULT:

INITIAL DESIGN IMPROVED / FINAL

SPECIFICATION DESIGN CALCULATION

SHAFT CYCLE 510000 cycles 850000 cycles

(30 % increase )

OVERALL WEIGHT OF 3.71 TON 3.15 TON

CONVEYOR (15 % reduced)

DEFLECTION 0.38mm 0.28 mm

 REFERENCES :
 [1] Mr. Harishchndra A. Shire, Prof. S. G. Ganiger, “Design and Experimental Analysis of Flight of Drag Chain Conveyor Belt with respect
to its Breaking Strength by Varying Material” IJSETR, Volume 5, Issue 3, March 2016.
 [2] Vishal Wankhade, Prof. Suman Sharma, “ Design Improvement for Enhancing the performance of Drag Conveyor Chain and its Cost
Reduction” International Journal of Engineering Research and General Science Volume 3, Issue 2, Part 2, March-April, 2015.
 [3] Hrishikesh Kishor Kulkarni, Prof Dr. R. J. Patil, “ Failure Analysis and Weight Optimization of Chain Conveyor System” International
Jounrnal of Advanced Engineering Research and Studies, E-ISSN2249-8974
 [4 ] Mr. Jadhav P. A. , Prof. Kulkarni R. D. , Prof. Ghalke A. B. , Prof. Patel A. Z. , “Design and Weight Optimization of Fin of Drag Chain
Conveyor” IRJET- Volume 4, Issue 4, April-2017
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Breaking Strength” IJARIIE(O)-2395-4396, Issue-3-201
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Loading” ISSN-2250-1991, Volume 4, Issue 4, April-2015.
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