EQUIPMENT DESIGN AND DRAWING

BY
J.P.SRIVASTAVA
 DESIGN OF MILL ROLLER SHAFT
DESIGN CONSIDERATIONS
 Loading conditions on shaft and Journals
a. Bagasse load
b. Hydraulic load on Journals
c. Axial thrust
d. Eventual load due to foreign materials
Stresses developed on shaft
a. Torsional stress
b. Bending stress
c. Shear stress
d. Heat stress
e. Corrosion stress
Failure Criteria – Cyclic loading /Continuous loading
with strain hardening

Selection of material for shaft and shell

Testing of shaft during off season

 4 mills tandem
Hot water

F. Bagasse

I II III IV
Secondary Juice Juice

Primary juice
MILLROLLER SHAFT& SHELL
CI SHELL

HY.LOAD HY.LOAD

RRO

JOURNAL

BAGASSE LOAD
 STRESS CONSIDERATION
Mill roller shaft is failed due to
‘fatigue ‘
Fatigue is due to following stresses
1. Bending stress
2. Torsion stress
3. Corrosion stress
4. Heat stress
 MILL ROLLER DESIGN
 MATERIAL SPECIFICATIONS
A. ROLLER SHAFT
B. C.I. SHELL
 STRESS CONSIDERATION
 ROLLER SHAFT DESIGN
 JOURNAL DESIGN
 C.I.SHELL DESIGN
MATERIAL SPECIFICATIONS

ROLLER SHAFT

AS PER BIS CODE – IS: 1570 ( PART-2) 1979

 The shaft shall be made out of forged steel,

normalized steel confirming to the grade 35C8 or40C8
 Minimum tensile strength –55 Kg/mm²
 Elongation- 20%
CAST IRON SHELL
 AS PER BIS CODE – IS: 7754-1975
Surface Hardness - 180 to 210 BHN
Total Carbon - 3.2 to 3.6 %
Sulphur - 0.15%
Phosphorous – 0.5%
Maganese - 2.2 to 3.2 %
Silicon - 1.2 to 2.2%
 OTHER SPECIFICATIONS
 A fillet radius of 8mm shall be provided
 The shaft shall be ultrasonically tested as per IS: 8791-
1978
‘ Code of practice for ultrasonic flow detection of
steel forging ‘
MILLROLLER SHAFT& CI SHELL
CI SHELL

HY.LOAD HY.LOAD

RRO

JOURNAL

BAGASSE LOAD
 STRESS CONSIDERATION
Mill roller shaft is failed due to
‘fatigue ‘
Fatigue is due to following stresses
1. Bending stress
2. Torsion stress
3. Corrosion stress
4. Heat stress
Fatigue is due to cyclic or continuous stresses
Stresses are concentrated at certain spots like on
locus of inner fillet radius , notches and cracks
It changes the molecular structure of materials
causing crystallization and surface brittleness by
loosing its ductility
After considerable period of time a microscopic crack
is develops and start propagating causes eventual
failure of shaft
 MILL ROLLER SHAFT DESIGN
 Allowable tensile stress (Ft) - 1833kg/cm²
( 5500 kg/cm²/3 = 1833 )
 Bagasse load (w ) = 200,000kg/m length
Bearing pressure ( p ) = 84- 112 kg/cm²
Type of loads
1. Torsion
2. Bending
TORSION
Max. Torque transmitted:
Tmax = HPx 4500 kg -m
2πN
Where HP = Power to be transmitted
N = rpm of mill roller
BENDING
Max. Bending Moment :
Mmax = WL/ 8 kg -m
where W = Total bagasse load in kg ( w x L )
L = Length of roller in m
Equivalent Twisting Moment (Te) :

Te = √ Tmax² + Mmax²
Te max = Tex k
where k = Factor to takes into
consideration shock
loading & fatigue
= 4
 Te max = π d³ x Ft /16
where Te max = Maximum twisting moment
d = Diameter of roller shaft
Ft = Allowable tensile stress

Find ‘d ‘ from above equation

 ROLLER JOURNAL DESIGN

Type of loads
1. Compression ( Bearing pressure )
2. Torsion
3. Direct shear

1.Bearing pressure:

2 x L x d x Bearing Pressure = Bagasse load

where L/d = 1.25 ; L = length of journal

d = diameter of journal

Find the value of ’d ‘

 2. Torsion
T max = HP x 4500 kg -m
2πN
Te = T max x k
Te = π d³ x ft /16
where Te = Max. Torque
d = Diameter of roller journal
ft = Allowable stress
Calculate ‘d ‘ from above equation
 3. Direct shear
2 x π/4 d²x Fs = Bagasse load
where Fs = allowable stress
d = diameter of journal

Calculate ‘d’ from above equation

Take highest value of ‘d ‘ as diameter of journal
 DESIGN OF C.I. SHELL
Type of loads
1. Torsion
2. Bending
Te max = π/16 [ ( D₀⁴ _ Di⁴)/Di ] x ft
where D₀ = outside dia. of C.I. shell
Di = inside dia. Of C.I. shell
ft = allowable stress for C.I.
400 Kg/cm2
Calculate D₀ from above equation
THANKS