ENGINEERING DESIGN PROCESS

AGITATOR DESIGN

Presented by:
........
Mathematical Engineer in geology (deep under ground)
Mechanical Engineer
Senior Analyst (Structural/Mechanical Engineer)
PhD. Medical (Biomechanical) Engineering
BSc (Honours) in Applied Mathematics
BSc in Physics and Applied Mathematics
Importance of Design

Claims by causes

Source: Engineers Australia Magazine (January 2012 Edition)

Design Principle
Engineering Design in machinery industry
1. Define Problem & 8. Break down 9. Check health and safety
required from client
components for 3D in design (go to step 7 if
(include required
detailed model issues)
standard)

7. Based on information
2. Identify the needed and loads to assembly 3D 10. Correct loads (go back
information and model/ Architecture to step 7 if issue)
methodologies to solve design using CAD/CAE
the problem (resulted in contract
acceptance from client)
11. Design joints/links/pins

6. Summarise all
3. Brainstorm proposal
collected and required 12. Review design using
solutions
information for design & CAD/CAE as FEA for
Estimated loads on the analysis to predict
machine/structure mechanism of the
machine /structure (go
back to which step that
4. Discuss and sign exist issue)
contract to client
5. Search and study to
clear understand the Check results then Export
operational principles of CAD Drawings with
the machine, structures double checks, reports
including approached cost
Example of Identify Problems & Define
needed machines & Equipments

Example in bulk handling materials

 Example of Study & Clearly understand
Operational Principle of Equipments

(1) - Bucket wheel reclaims material from product coal stockpile

(2) - Material is transferred to the boom conveyor
(3) - From boom conveyor material is transferred to the reclaim conveyor
Example of General Calculations for
Designed Information

Height & Length of machine

Capacity
Rotational Angle
Rational & moving Speeds
Required Power
Detailed Loads on machines (based on
required standards)
 Example of 3D Assembly model

Design capacity 6000 t/h Travel Speeds:

Maximum capacity 7390 t/h Operating speed 5 m/min
Total weight 1450 t Positioning speed 30 m/min
Distance between rail centres 12m
Break down components
 3D Detailed Assembly of Components based on
calculated Detailed Loads
Bucket Wheel Boom

Equipment:

(1) - Bucket wheel

(2) - Bucket wheel chutes
(3) - Bucket wheel drive
(4) - Bucket wheel head
(5) - BW boom middle part
(6) - BW boom rear part
(7) - Boom suspensions
(8) - Mast BW boom
(9) - Connection CW boom
(10) - Connection superstructure
(11) - Boom belt conveyor
(12) - Walkway BW boom
(13) - Walkway BW drive
(14) - Access (2x)
(15) - Guards
 3D Detailed Assembly of Components
based on calculated Detailed Loads
Equipment:

(1) - Counter weight

(2) - Connection rods
(3) - Suspensions
(4) - Connection superstructure
(5) - Connection bucket wheel boom
(6) - Access superstructure
(7) - Walkway
(8) - Pedestal hydraulic cylinder
(9) - Connection cylinders

Counterweight Boom
Slide 11
Heath and safety
During detailing components:
 Familiar with relevant government
safety acts and regulations, specific site
safety requirements and procedures
 Be aware of safety signs, they also identify
hazard areas and special PPE requirements
 During operation it is prohibited to touch or
reach over any kind of fence, guards, into
chute areas or other moving parts!
 For any reason it is necessary to reach
areas near moving parts, correct isolations
are required
 Inspections while the machine is operating
should be kept to a minimum
 If an inspection of the machine during
operation is necessary, watch the long travel
gear accessing the machine, it could move,
start up or stop
Drawings (based on 3D Model)
 Presenting Drawings must comply with required standard codes
 Drawings includes:

◦ General drawings indicating components’ drawing addresses

for details
◦ Clear drawing views
◦ Clear standard materials, welds, connections & assembly
◦ All selected components should be tested using both hand
calculation and software checks.
◦ All selected sections/components should be existed in
catalogue on the markets.
◦ Explain weld process if necessary for quality
◦ List of ordered component and fabricated member masses
(Bill of materials (BOM)) in each drawing sheet & all.
Correct Loads and load cases
 ListMass and its Centre of components (called Mass
Take Off (MTO))
 Recalculate all loads and combination loads for each
case complying with standard codes based on MTP
 Check stability of the machines
 Check members’ buckling
Design Review Process

MESHING
FINITE ELEMENT
MODELLING
3D
2D AutoCAD /
3D Microstation 3D Mathematical
Microstation Drawings
Model (*.iges file) Model (Patran)

INTERPRETATION of
RESULTS

ANALYSIS
(Nastran)
Material Properties
Buckling Analysis Stress Analysis
& Loads Applied
(Patran)
Useful issues for analysis
Predict mechanism of the machine using FEA for
analysis in different cases. The useful FEA results for
analysis include:
◦ Deformation/ Deflection
◦ Stress
◦ Buckling
◦ Fatigue (working life)
◦ Frequency modes (for vibration)
Checks correct constraints, loads, theoretical
behaviours. Logically explain the differences in your
thought and FEA results before report the results.
Example: Agitator Design
1. Define problem:

◦ Mixer tank of 80t

◦ Liquid of 1.1 t/m3
◦ Two baffle plates
◦ A platform is located on top at the tank,
supported off the tank wall
◦ Using Australian Standard for design
◦ Working outside
2. Identify the needed information and
methodologies to solve the problem
Dimension and thickness of tank
The agitator consists of a motor, a shaft
and a propeller
Viscosity of liquid
Tank design standard
Wind load standard
Earthquake standard
3. Brainstorm proposal solutions
Principles of agitator

D/T= 0.2 to 0.6

Z/T is closed to 1.2
Off bottom = D
Axial and radial flow
Estimated needed information & loads on
the Agitator tank
Dimension of tank
Liquid pressure
Mass of tank
Mass of agitator
Mass of platform that support agitator
Wind load
Earthquake load
Load produced by agitator
Dimension of tank
 V=M/d=80/1.1=72.7m3
 Take h = 1.35 D (h= liquid height)
 V=3.14xR2xH=3.14xR2x2.7xR

R=(V/8.5)1/3=2.05m
 Take D =4.1m, h=1.35 D= 5.54m,
 H of tank, H=1.1h = 6.1m
Liquid Pressure
Pressure depends on liquid height
P=rgZ (z=the depth from surface)
Pressure at bottom:

p=rgh=1.1x9.81x5.54=59.8kPa
Hoop stress at bottom:

s= PR/t=122.6/t, (kPa)
t= tank thickness (m)
Mass
 Mass of tank (Exclude bottom face)
◦ Surface area = pDH+pD2/4=84.56m2
◦ Mass of this surface: 84.56tx7.85=663.8t (tonnes)
◦ Factor of 2 for others
 Mass of agitator: Assumed 2tonnes
 Mass of platform: Assumed 1tonne
 Mass of others: assumed 1tone
 Total mass on the bottom = 663.8t+5
 Vertical Stress

s= g(2x663.8t+4)/(pDt)=(1011.1+3.05/t)kPa
Tank Thickness
 Maximum principle stress:
Tension: s1=122.6/t
 Minimum principle stress:
Compression: s2=-(1011+3.05/t)
 Trescacriterion for 2 dimension:
s=0.5(s1-s2)=0.5(1011+126.05/t)
 Assume select steel of sy=235MPa & SF=15
 sy/31/3=SFxs

235/1.732 =7.5(1011+126.05/t)/1000, t=7.4mm

 Tank thickness: t =8mm
 Baffle width = 1/10 T
Power
Number
Select D=0.4 T=1.6

NP=0.5
Nq=0.65
Approximation for agitator selection

 Impeller tip speed: select V=440m/min (normal 120-

420)
 Impeller diameter: select D=0.4 T=1.6m
 Length of shaft is about 5m
 Speed of shaft: N=V/(0.5D)=88 RPM
 Gear ratio for 3 phase motor 1500/88=17.05
 Motor Power: P= (NpD5N3r/3.821376E7)
 Search catalogue to select correct motor, gear and
agitator system. Record all information and drawings
from manufacturing for design.
Recalculate load on platform
Recalculate total loads on platform that
support agitator
Design calculation for platform structure
and select other equipments and
arrangement
3D modelling
3D modelling
Drawings
 3 D modelling for analysis
Geometry
Meshing
3 D modelling for analysis
Geometry
Meshing
Property
 Load Calculation
 Dead load
 Material load
 Dynamic load from agitator
specification
Dynamic load application
Dynamic Load application
Material load

Apply on wall & bottom for normal

operation:
P P=rg(z-ho)
ho

 Apply on wall & bottom for

a Earthquake case:
g h  Tan(b)=a/g
 h= ho+Rtanb= ho+Ra/g
 Apply pressure:
 P=rg(z-(ho+Ra/g cosa))
Wind load

Base on standard code of wind load to calculate pressure

of wind for:
• Normal wind
• Storm wind
 Earth quake load
Location;
Annual probability factor; kp = 1.0; (AS 1170.4, Table 3.1)
Hazard factor; Zh = 0.1; (AS 1170.4, Figure 3.2)
Soil class; Ee; (AS 1170.4, Cl. 4.1.1)
Nominal ground acceleration coefficient (kpZ); kpZ = kp ´ Zh = 0.100;
Structure height (in m); hns = 6.0;
Type of structure (earthquake design category); II; (AS 1170.4, Table 2.1)

Static Analysis:
Moment –resisting steel frames; kt = 0.11; (AS 1170.4, Cl.6.2.3)
Natural priod of structure; T1 = 1.25´kt´(hns)0.75 = 1.6;
Spectral shape factor; ChT = 1.825; (AS 1170.4, Table 6.4)
Steel structure factors; ms = 3; Sp = 0.67; (AS 1170.4, Table 6.5A)
Earthquake base shear; Vsh = (kpZ ´ ChT ´ Sp /ms )´g = 0.400 m/s2;
Seismic distribution factor; kfeq = 1+0.5´(T1 -0.5) = 1.6;
Horizontal equivalent static load; EQ = kfeq ´ Vsh = 0.625 m/s2; (0.064g)
Earthquake Application on tank wall
 On the cylindrical wall (as shown on
the diagram):
dFx=(rdV)a
 Fx: total force in x-direction (assumed
direction of earthquake load)
 dFx=ar(2Rcosa dy)dz=2aRrcos2a.dl.dz
 dFr=dFx cosa = 2aRrcos3a.dl.dz
 Applied pressure:
 P=dFr/(dldz)= 2aRrcos3a
 The pressure applied on the half wall (-90o
to 90o),
Combine load cases

Dead load: weight only

Operational load
Operational load with normal wind
Abnormal load with normal wind
Operational load with Earthquake
Fatigue load
Review design structure from FEA Results
Meshing
Review design structure from FEA Results
Thickness
Review design structure from FEA Results
Displacement analysis – checking permit deflection
complying with the standard code
Review design structure from FEA Results
Stress analysis – Tresca stress or Von Mises
Review design structure from FEA Results
Buckling analysis
checking permit buckling complying with the standard code
Vibration Frequency Analysis
Theory of vibration

M d2X/dt2 +kX= F(t)

w=(k/M)0.5

w=(g/L)0.5
 Natural Frequency Analysis
Speed = 88RPM
Frequency =88/60=14.7Hz

2nd modal Frequency =15.1Hz

1st modal Frequency =14.6Hz

3rd modal Natural frequency (f=16.7Hz)
Fatigue Analysis
Fatigue Results from Analysis
Fatigue Results from Analysis
Fatigue Results from Analysis