Solid Shaft Research Articles

RANCANG BANGUN MESIN PULPER KOPI MENGGUNAKAN PENGGERAK MOTOR LISTRIK

Design and manufacture of coffee pulper machines have been carried out with the aim of completing the needs of the coffee farmer groups when harvesting in the Kayu Aro area, Kerinci. The steps in designing and manufacturing a coffee pulper begins with a literature study, design and calculation, the process of making the tool and ends with testing the tool. Engineering drawing design is done by modeling in SolidWorks software. Coffee peeler machine with a capacity of 4 kg/min, with a machine size of 730 mm x 320 mm x 1040 mm, using an electric motor 1 HP 1420 rpm, with a frame using an elbow profile 40 mm x 40 mm x 3 mm. The transmission system uses an electric motor with an initial rotation of 1420 rpm to 364.6 rpm. In the 2 pulley component D = 74.6 mm and 290.5 mm, V-belt type B No.52, 1 solid shaft D = 25 mm. Initial test results using 2–5 kg of wet coffee beans take 30.07–77.20 seconds, and the skin has separated from the beans cleanly. These results show that the engine capacity is 235.62 kg/h, so that the desired target is met with relatively low operating costs. The existence of this tool will be able to help the process of separating the skin and coffee beans, so that the quality of coffee production will increase. Keywords: coffee, coffee machine, design and construction, farmer groups

Analytical Modelling of Interference Fit Joints with Power Law Strain-Hardening Behavior

Interference fit is a simple technique of connecting two parts together. Although attractive from both economic and technical viewpoints, its behavior beyond the elastic range is yet to be predicted analytically using the simple theory of plasticity. A cylinder shrunk into a solid shaft can provide a solid and reliable connection both statically and dynamically if the strength and stiffness are adequately selected to support the high torque and stresses. This article analyses the stresses and strains in a shrink fit composed of a solid shaft and a cylindrical hub operating in the plastic range. Using the Von Mises yield criterion and assuming the hub to have a power law strain-hardening behavior, the distributions of stresses and strain as functions of the interference are given. The developed analytical model shows that the contact pressure depends on the interference and the plasticity curve of the material, including the strain hardening exponent. To validate the analytical model, the results are compared with those obtained by finite element modelling.

Force–Displacement Characteristics of Helical Soil Nail under Monotonic Pullout Loading: Experimental and Theoretical Study

This study investigates the shear stress–displacement behavior of helical soil nails (HSN) under different overburden pressure and monotonic pullout loading. Two types of individual HSN (ribbed solid and hollow plain) and a group of nine ribbed solid shafts HSN installed with uniform spacing are experimentally investigated. The study also examines vertical stresses and axial stresses developed along with HSNs. Further, theoretical modeling of the obtained experimental stress–displacement behavior has also been carried out. The results depict mobilization of nonlinear stresses under monotonic pullout for both individual and group HSN. The stress–displacement behavior is vividly marked by a pre-peak and post-peak stage. Higher shear stress mobilization is found for solid HSN as compared to hollow ones. A close agreement with a low coefficient of variance between measured and predicted values for overburden pressure between 5 and 50 kPa depicts the efficacy of the developed theoretical model. The results of axial strain for both shaft types HSN reveal strain softening during post-peak, which diminishes in case of group behavior. It is concluded that truncated cone rupture failure during group behavior significantly governs the stress–displacement response majorly by bearing than interface shearing resistance of soil plugging in hollow shafts.

Dynamic Analysis and Experimental Research on the Cantilever High Speed Rotor of Turbofan Engine

Taking a simulated low-pressure rotor of a turbofan engine as the research object, the dynamic characteristic calculation model of the simulated low-pressure rotor with hollow shaft and solid shaft was established respectively by using the finite element method. The first three order critical speeds and mode shapes of the rotor were calculated systematically. The dynamic balance test of the simulated low-pressure rotor and the research on the damping effect of the squeeze film damper were carried out on the high-speed rotating test rig, and the dynamic characteristic test was completed in the full speed range. The results show that the finite element results agree well with the experimental results. The rationality of the rotor’s hollow shaft structure and rotor dynamic design was verified. The research provides reference and technical support for structural design, dynamic design and experimental research of real low-pressure rotor in engine.

Computation of the Release Force in a Gear Shrink-Fitted over a Solid Shaft

Computation of the Release Force in a Gear Shrink-Fitted over a Solid Shaft

Modification and performance improvement of chopper palm frond (AE03-Type)

A chopper machine has been developed to chop oil palm frond (OPF) for cattle feed in Aceh province. This paper reports the results of the modification of the third generation chopper machine named AE03-type. The purpose of this study is to improve the performance of the chopper machine for OPF through the process of modifying the chopper blade. Modifications made are designing a chopper blade with a plate thickness of 6 mm, a length of 15.5 cm and a width of 4 cm arranged in a spiral around a solid shaft with a diameter of 1 inch with a length of 100 cm, as many as 36 pieces. The parameters measured to show the performance of the chopper machine are dimension average of chopped, the percentage of chopped OPF, chopping efficiency, and capacity of the machine. Three variations of rotation speed are tested on the engine, which is 800 rpm, 1200 rpm, and 1600 rpm, respectively. The results show that modifying the chopper knife can improve the performance of the chopper machine. The best rotation speed for this chopper machine is 1200 rpm with length and width of chopped, OPF percentage of chopped, chopping efficiency, and capacity of the machines are 27.5 mm, 1.5 mm, 86.45%, 98.37%, and 147.85 kg/h, respectively. The size of the chopped is following the dimensions of feed for cattle feed needs, especially those in Aceh Province.

Dynamic analysis of rotor system with slant cracked shaft

Abstract The anisotropy, plane action and operating time of revolving machinery depend on the performances that identify the signs of faults. Crack is one of the peaks unreliable and insecure faults that reduction working life of component or machine systems, thereby most important to impending injury to person if it is invisible. Crack or cracks existent in a machine or system brings a modification in the mass, damping, and stiffness of the rotor, and subsequently measureable changes seem in the modal things (natural frequencies, modal damping, and mode shapes). Many methods and models have been settled to detect a crack (or cracks) in stationary and rotating systems. Identification of cracks is usually visual inspection; techniques and models are based on vibration-based methods such as destructive method. Optical examination is a time overwhelming method and determining of mode shape as well as structural deflection is tough rather than calculating frequency. Finite Element Analysis of solid shaft such as slant cracked shaft at various rpm is done in this work. Healthy and slant cracked shaft is modeled and analyzed with numerical method. FFT analyzer is used to record the results of vibration, which are used to analyze the vibration characteristics of slant cracks. From the comparison of ANSYS & FFT results 23.03% maximum variations were saw for healthy Shaft & 8.36% to 26.96% increasing variation were saw for 45° to 60° Orientation for 100 mm Crack for Defected Shaft. The investigational results openly exhibit the ability of the recommended methodology for the credentials and position of cracks in fixed and revolving shafts.

Analytical Modeling of a Material Efficient Hollow Shaft Design

This paper discusses the optimal distribution of material across the cross-section of a shaft under pure uniform torsional loads such that the factor of safety and thereby the shear stresses generated at any point in the cross-section remain largely the same irrespective of their radial distance from the centre of the shaft. An analytical mathematical relationship is deduced to relate the material distribution as a function of the radial distance. The relationship is then used to plot the corresponding variation in MATLAB. Finally, several CAD models of the proposed cross-sectional shapes are prepared in SolidWorks, and then simulated in ANSYS simulation software by employing the Static Structural analysis platform. The graphical and statistical results of the shear stress distributions are then compared with a solid shaft of the exact same radial and axial dimensions. It is found that the proposed 3-Branched model is about 25% more efficient in material utilization than the conventionally employed solid shaft of similar dimensions.

Laboratory investigation of pullout behavior of hollow and solid shaft helical nail in frictional soil

Helical soil nails are passive elements installed in the soil which attains its bond strength through skin friction and bearing from helices. The present study examines the behavior of helical soil nail installed in cohesionless soil subjected to pullout force under varying parameters such as helical nail configuration (shaft diameter, helical diameter, helical pitch, number of helices), nail shaft types (roughness and stiffness), installation torque, and overburden pressure. The installation torque and corresponding nail pullout capacity can be established using a torque correlation factor (Kt). Kt value decreases with increasing embedded nail area and is inversely proportional to the nail shaft diameter. From pullout tests result, it is found that pitch in the range of 24.5–35.5 mm shows better pullout capacity. Also, results show that additional helices will only contribute to pullout capacity if located outside the region of soil mobilized in the failure mechanism of lower helix. Moreover, higher axial strains are found for hollow shaft nail, which alters with the increase in number of helices. Test results also indicate that various hollow shaft helical nails have nearly equal interaction friction angle to solid shaft helical soil nails with lesser shaft diameter. Therefore, it is concluded that solid shaft helical nails can be replaced by hollow nails without compromising on pullout capacity adding to reduction in construction cost. Tests results show linear correlation between maximum pullout shear stress and overburden pressure following a Mohr–Coulomb failure for different helical nail types.

Behaviour of M60 grade concrete by partial replacement of cement with fly ash, rice husk ash and silica fume

Presently a-days with a quick populace development and a more appeal for lodging and foundation, joined by late advancements in structural designing, for example, elevated structures and long-range spans, higher compressive quality cement was required. As the foremost crude material in concrete is concrete which radiates CO2 during its creation some customary materials are utilized to decrease the utilization of concrete. In this examination, impacts of mineral admixtures on flexural quality and compressive quality of cements containing silica smolder (SF), fly debris (FA) and rice husk ash (RHA) were tentatively explored. The current work centers around M60 grade concrete with halfway substitution of concrete utilizing fly debris, rice husk debris and silica seethe (FA + RHA + SF = 30%) for three unique proportions i.e., FA:RHA:SF = 20:05:05, FA:RHA:SF = 18:06:06, FA:RHA:SF = 16:07:07. The real water concrete proportion utilized in blend structure for M60 grade concrete is 0.29 for 50 mm to 75 mm droop. The solid shapes and shafts are casted and tried for compressive quality and flexural quality separately at 7 years old days and 28 days.

Repair and Rehabilitation of RCC Beam using Synthetic Fiber Material

Retrofitting is the alteration of existing structures to make them continuously impenetrable to seismic development, ground development, etc. A large number of the current strengthened solid structures all through the world are in pressing need of recovery, fix or reproduction in light of crumbling because of different factors like consumption, absence of itemizing, disappointment of holding between pillar segment joints and so on. Fiber Reinforced Polymer (FRP) composite has been acknowledged in the development business as a promising substitute for fixing and in augmenting the quality of Reinforced concrete structures. This paper exhibits a test study on fortified solid shafts retrofitted with different kinds of filaments remotely. The goal of this examination is to explore the conduct of shafts in the wake of retrofitting utilizing different normal and engineered filaments including steel strands, polypropylene strands, glass filaments, Basalt filaments, carbon filaments and so forth.

알루미늄 IMS의 튜블러 & 솔리드 샤프트 요크의 직경이 하중 분포 특성에 미치는 영향

The objective of this numerical study is to investigate the effect of shaft part’s diameter on the load distribution, under-fill, and metal-flow line characteristics in tubular & solid shaft yoke of Al-IMS. The outer diameter of tubular shaft yoke was changed from 30mm to 35mm, and the shaft diameter of solid shaft yoke was varied from 20mm to 25mm. In this results, the required load for production was linearly increased with increasing the tubular shaft yoke outer diameter. In the solid shaft yoke, the loads for the shaft part extending process were almost constant by 10,000kg, however, the loads for generating the yoke process, which were needed a lot of strain, were increased by 4,000kg with increasing the diameter of shaft part. The under-fill regions according to diameter of the shaft part were not observed in both products, and the metal-flow lines were also straight without folding phenomena.

승용차용 알루미늄 IMS의 응력 분포 특성

The objective of this numerical study is to investigate the effect of aluminium material on the weight reduction in tubular shaft yoke and solid shaft yoke. The tubular shaft and the solid shaft were designed by 6 stage processes and the results were analyzed by using a finite element analysis method. The coefficient of friction was set to Oil_cold as referred to the analysis library. It was found that the weight was reduced as 65% with applying the aluminium alloy due to lower density than carbon steel. Von-mises stress values of applying aluminium alloy to the tubular shaft yoke and solid shaft yoke were lower than those of carbon steel because of the low yield stress of aluminium alloy. The folding and underfill phenomenon were not observed on the aluminium alloy in tubular shaft yoke and solid shaft yoke. From these results, the weight reduction of products and the extend life of dies can be expected when aluminium alloy is applied.

Quasi-static study of thin aluminium frusta with linearly varying wall-thickness

Energy absorbing structures are very important for safety reasons in automotive industries. Large portion of energy absorption depends on plastic deformation. Metallic frusta are extensively studied as plastic deformable energy absorbers. In this study, the experimental as well as numerical simulation are presented for metallic frusta with linearly varying wall thickness. Specimens are prepared from 6063 extruded solid aluminium shaft, annealed and tested under quasi-static compression. Two semi-apical angles viz. 5° and 10° along with thickness variation manner, resulting in four configurations of frusta are tested and analysed. Increasing the semi-apical angle increases the deformed mass efficiency within the studied range of angles. This also increases the compactness of the deformed material that leads to slight improvement of the specific energy absorption. Simulations are performed using Abaqus 6.14 commercial software. S4, S4R, C3D8R elements are used for modelling the frusta. Detailed analysis is done and results are presented. Among them the element S4R exhibits best simulation features. The simulation results are compared with the experimental results, and both are in good agreement. The best agreement between them is found to be when the frustum diverging and the thinning slope collaborate to initiate the collapse from the same side.

Mechanism and force-energy parameters of a hollow shaft’s multi-wedge synchrostep cross-wedge rolling

First, the rotation condition of a hollow shaft’s multi-wedge synchrostep cross-wedge rolling (MSCWR) is determined and the relevant influencing rule is illustrated based on a mechanical model of the hollow shaft and the theory of solid shaft’s rotation condition. The influence rule states that the increasing number of wedges increases the shrinkage rate of the hollow shaft and diminishes the rotation conditions, which can be improved by increasing μ on the forming surface of the hollow rolling mold, setting the stretching β, and forming α angles at approximately 4°–12° and 15°–35°, respectively. Second, a rigid-plastic finite element model is established for the hollow shaft with MSCWR by using the DEFORM-3D software, and the deformation mechanism of the hollow shaft is illustrated. The deformation degree of the rolling piece at the stretching stage decreases gradually from the surface to the interior of the hollow shaft, and radial compressive and transverse tensile strains interact with each other, thus resulting in an elliptic cross section of the hollow shaft. Stress field is mainly distributed in the exterior margin and then permeates into the inner part along the direction of the wall thickness, gradually transforming from compressive stress into tensile stress. Third, the influence of mechanical parameters on hollow shaft rolling is analyzed. The increased stretching angle increases the radial force, transverse force, and rolling torque and decreases the axial force. Moreover, the enlarged forming angle reduces the radial and transverse forces, while the decreased rolling torque increases the axial force. Finally, the 1:5 MSCWR experiment on the hollow shaft verifies the proposed finite element model’s accuracy. Results of the research provide a theoretical basis for the MSCWR of a precise hollow shaft.

Elastic-Plastic Stresses in Shrink Fit with A Solid Shaft

Shrink fit joining a solid shaft and a cylinder requires an accurate estimate of the residual contact pressure to transmit high powers, as in the case of gas turbines. Such torques require deformations of materials beyond their elastic limits. This paper presents an analytical model that analyses the stresses in a shrink fit assembly consisting of a solid shaft and a cylindrical hub operating in the elastic-plastic range. Assuming the hub to have a nonlinear work-hardening material behavior, the distribution of stresses as functions of the interference, and the effect of geometry on contact pressure and on interference are exhibited. To validate the analytic method, Finite Element Method was used.

Modified Strut Effectiveness Factor for FRP-Reinforced Concrete Deep Beams

A few examinations have endeavored to assess a definitive shear quality of a fiber fortified polymer (FRP)- strengthened solid shallow shafts. Be that as it may, need data announced for examining the solid profound pillars strengthened with FRP bars. The majority of these investigations don't think about the blend of the rigidity of both FRP support and cement. This examination builds up a basic swagger adequacy factor model to evaluate the referenced issue. Two sorts of disappointment modes; concrete part and pulverizing disappointment modes were examined. Protection from corner to corner part is chiefly given by the longitudinal FRP support, steel shear fortification, and cement rigidity. The proposed model has been confirmed utilizing an aggregate of 45 databases gathered from writing. Results show that the proposed model can evaluate a definitive shear quality. Structure of trial (DOE) programming was used to examine the impact of different parameter esteems on a definitive shear quality limit. The outcomes demonstrate that the shear range to powerful profundity proportion has the most astounding impact contrasted and alternate parameters.

Design and Construction of a Motorized Citrus Juice Extractor

This paper presents the design, construction and performance evaluation of a locally fabricated motorized citrus juice extractor for small and medium scale industry. The fabrication materials for the machine comprises of stainless steel aluminum alloy which is used for the construction of the hopper, compression chamber and collector or receiver. The presser and perforated cylindrical sieve was formed using stainless steel sheet. The power shaft was machined from stainless steel solid shaft; mild steel angle bar was used for the main frame while the transmission pulleys were machined from mild steel material. In selection of materials for the machine critical properties such as toxicity, corrosion and pitting resistance were considered. For power transmission, 4 HP electric motor, V-belt and cast iron ball bearings were used. The performance evaluation of the machine shows that the machine extraction capacity and extraction efficiency are significantly affected by the prime mover speed in revolution per minutes (rpm). The machine efficiency is found to be 84.54 %, average juice extraction capacity is 10.92 cm3/sec or 39.312 lit/h at 600 rpm and the machine capacity is 38.89 kg/h. The production cost of the machine is about N117,800.00 (326 USD) this cost compared with the imported GG-0.5 model of similar capacity which cost about 3150 USD makes the machine considerably acquirable for use by both small and medium scale citrus juice processing plants in Nigeria. Keywords— Design, Extraction efficiency, Fabrication, Juice extractor, Performance evaluation.

Fatigue crack growth in wheelset axles under bending and torsional loading

In the past, unexpected failures in wheelset axles lead to catastrophic consequences. To avoid those failures inspection intervals must be defined. The definition of the inspection intervals is based on fracture mechanical approaches. In the present work, the railway axle steel 34CrNiMo6 is investigated. For this material fatigue crack growth data have been experimentally determined for a range of different negative and positive stress ratios. Furthermore, the FORMAN/METTU parameters for different probabilities of survival are identified. In wheelset axles different geometry factors influence the crack growth behaviour. Therefore, different shouldered solid shafts with transition radii and a press fit seat are designed and tested under rotating bending. Moreover, the load situation also has an influence on the crack growth. The main bending load is overlapped with torsional loading at special wheel-rail-situations. With the developed mixed mode test rig, the influence of different load situations on wheelset axles are examined.

Effects of splined shaft bending rigidity on cylinder tilt behaviour for high-speed electro-hydrostatic actuator pumps

High-speed axial piston pumps are hydraulic power supplies for electro-hydrostatic actuators (EHAs). The efficiency of a pump directly affects the operating performance of an EHA, and an understanding of the physical phenomena occurring in the cylinder/valve plate interface is essential to investigate energy dissipation. The effects of the splined shaft bending rigidity on the cylinder tilt behaviour in an EHA pump need to be considered, because the deflection and radial expansion of a steel shaft rotating at a high speed cannot be ignored. This paper proposes a new mathematical model to predict the cylinder tilt behaviour by establishing a quantitative relationship between the splined shaft deflection, the cylinder tilt angle, and the tilt azimuth angle. The moments exerted by the splined shaft are included in the equilibrium equation of the cylinder. The effects of solid and hollow splined shafts equipped in an EHA pump prototype are compared at variable speeds of 5000–10,000 r/min. With a weight saving of 29.7%, the hollow shaft is experimentally found to have almost no influence on the volumetric efficiency, but to reduce the mechanical efficiency by 0.6–2.4%. The results agree with the trivial differences of the simulated central gap heights of the interface between the two shafts and the enlargement of the simulated tilt angles by the hollow shaft. The findings could guide designs of the cylinder/valve plate interface and the splined shaft to improve both the efficiency and power density of an EHA pump.