International Journal of Engineering and Management Research, Volume-3, Issue-2, April 2013 ISSN No.

: 2250-0758 Pages: 22-30 www.ijemr.net

Design and Analysis of Rotor Shaft Assembly of Hammer Mill Crusher

E.Vijaya Kumar
Assistant Professor, Department of Mechanical Engineering, Siddhartha Institute of Technology & Sciences, Ghatkesar, Hyderabad, INDIA

ABSTRACT
The paper deals with the Design and analysis of shaft and rotor assembly for hammer mill crusher of capacity 0.1 (100kg/hr) tones per hour transmitting 20 B.H.P and a speed of 750 rpm. The design is based on the standard design procedure. In the present work by using the standard design procedure, diameter of rotor shaft of hammer mill crusher has been designed. The design should be safe when the values obtained from the present design procedure were compared with the values and results obtained from the analysis using Ansys package. When the shaft is rotated at rated speed (rpm) and the loads applied to the shaft it should not bend during rotation. When the shaft is rotated under free conditions, deflections will be created due to the critical speed of the shaft. To compare this deflection shaft was designed such that the natural frequency and speed is under limits. In this project the shaft and rotor assembly of hammer mill crusher was modeled using Pro-e modeling package and the FEM model of the shaft was developed using Ansys package. Meshing of the shaft model was done and the loads, stresses that were applied for the shaft to be checked out that the design should be safe one.

I. INTRODUCTION
A crusher is a machine designed to reduce large solid material objects into a smaller volume, or smaller pieces. Crushers may be used to reduce the size, or change the form, of waste materials so they can be more easily disposed of or recycled, or to reduce the size of a solid mix of raw materials (as in rock ore), so that pieces of different composition can be differentiated. Crushing is the process of transferring a force amplified by mechanical advantage through a material made of molecules that bond together more strongly, and resist deformation more, than those in the material being crushed do. Crushing devices hold material between two parallel or tangent solid surfaces, and apply sufficient force to bring the surfaces together to generate enough energy within the material being crushed so that its molecules separate from (fracturing), or change alignment in relation to (deformation), each other. The earliest crushers were hand-held stones, where the weight of the stone provided a boost to muscle power, used against a stone anvil. Querns and mortars are types of these crushing devices.

II. WORKING OF MACHINE

When coal is delivered to the hammer mill crusher, it is prepared for cyclone furnace firing

by being crushed into 1/4 inch or smaller size coal. Coal enters from the top and is violently thrown against the breaker blocks by the hammers. The final crushing is done between the hammer faces and the screen bars. Then the crushed coal goes to the conveyors below and is carried to the storage bunker. Tramp iron or material that will not go out between the screen bars is dropped into the iron pocket and is later removed. The final crushing is done between the hammer faces and the screen bars. Then the crushed coal goes to the conveyors below and is carried to the storage bunker. Tramp iron or material that will not go out between the screen bars is dropped into the iron pocket and is later removed. Hammer mill features: Material is reduced by impact from free-swinging bar hammers Finished Product size controlled by grates or crusher sizes Materials can be reduced to granular powder at high rate. Heavy-duty cast-iron or carbon steel construction Right-hand or left-hand machine available Easy access for maintenance and crusher/grate change Applications of Hammer mill crushers:

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Material used for Shafts: Recycling glass Feed industry Stone crushing Size reduction of waste materials Electronics recycling Ceramics Pulverization of sea shells Minerals Wood particles for fuel wood Limestone The material used for shafts should have the following properties: 1. It should have high strength 2. It should have good machinability. 3. It should have low notch sensitivity. 4. It should have good heat treatment property. 5. It should have high wear resistant property. Depending on the requirement, the shafts can be made of plain carbon steel or alloy steel. Designing of Shafts: The shafts may be designed on the basis of 1) Strength and 2) rigidity and stiffness In designing shafts on the basis of strength, the following cases may be considered: 1) Shafts subjected to twisting moment or torque only. 2) Shafts subjected to bending moment only. 3) Shafts subjected to combined twisting and bending moment 4) Shafts subjected to axial loads in addition to combined torsion & bending loads Shafts subjected to twisting moment or torque only: When the shaft is subjected to twisting moment (or torque) only, then the diameter of the shaft may be obtained by using the torsion equation. We know that

III.

DESIGN OF SHAFT

A shaft is a rotating machine element, which is used to transmit power from one place to another. The power is delivered to the shaft by some tangential force and the resultant torque (or twisting moment) set up within the shaft permits the power to be transferred to various machine linked up to the shaft. The following stresses are induced in the shafts: 1. Shear stresses due to the transmission of torque (i.e. due to torsional load). 2. Bending stresses (tensile or compressive) due to the forces acting upon machine element like gears, pulleys etc. 3. Stresses due to combined torsional and bending loads.

IV.

CLASSIFICATION OF SHAFTS

Shafts involved in power transmission may be classified as 1) Transmission shafts are used to transmit power between source and the machines using the power. They include line shafts, jackshafts and counter shafts. i) Line shaft is a long continuous shaft, which receives power from the source and distribute to different machines. ii) Jackshaft is directly connected to the source of power and from which other shafts are driven. iii) Counter shafts receive power from line shaft and transmit to a machine. 2) Machine Shafts are incorporated within the machine, such as crank shaft

Where, T=Twisting moment acting on the shaft, J=Polar moment of inertia of the shaft about the axis of rotation, F s =Torsional shear stress, and r=Distance from neutral axis to the outer most fiber =d/2 where We know for round solid shaft, polar moment of inertia,

The equation may be written as T/d4= 2f s /32d T = f s d3/ 16 Twisting moment (T) may be obtain by the following relation:

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In S.I units, power transmitted (in watts) by the shaft, P=2NT/60 or T=(P 60)/2N Where, T=Twisting moment in N-m N=Speed of the shaft in RPM In M.K.S units, horse power transmitted by the shaft, P=2NT/4500 T=P 4500/2N Where, T=Twisting moment in N-m and N=Speed of the shaft in rpm Shafts subjected to bending moment only: When the shaft is subjected to a bending moment only, then the maximum stress (tensile or compressive) is given by the bending equation. We know that

1) Guests Theory: According to maximum shear stress theory the maximum shear stress due to combined load is Let f s = Shear stress induced to twisting moment f b = bending stress (tensile or compressive) induced to Bending moment According to Maximum shear stress theory, the maximum shear stress in the shaft f s ( max) =[( f b )2 + 4(f s )2] Substituting the values of f b & f s as per above equations d3 f s = 16 (M2+T2) f s = (32M/ d3)2+4(16T/ d3) 3) Rankines Theory: According to maximum normal stress theory, the maximum normal stress in the shaft f b (max) = (f b /2) + [( f b )2 +4(f s )2] f b = (16/ d3) (M+ (M2+T2)) Shafts subjected to fluctuating loads: In above equations shafts are subjected to constant twisting moment & bending moment but in actual practice shafts are subjected to fluctuating torque & bending moments. In order to design such shafts like line shaft &counter shaft combined shock & fatigue factor to be considered for calculating33 twisting moment and bending moment Substituting these factors in above equations For maximum shear stress theory (d3/16) f s = [(K m M)2+ (K t T)2] =T e For maximum normal (tensile or compressive) theory (d3/16) f s = [(K m M) /2] + [(K m M) 2 + (K t T) 2] =M e Where: M= Bending Moment f b = Bending stress T = Twisting moment (Torque) upon the shaft f s = Tensional shear stress K m = Combined shock & fatigue factor for bending K t -= Combined shock & fatigue factor for twisting d = diameter of the shaft Shaft calculations:

Where, M=Bending moment, N-mm I=Moment of inertia of cross-sectional area of the shaft about the Axis of rotation, mm4 F b =Bending stress, N/mm2 and Y=Distance from neutral axis to the outer-most fiber, mm We know that, Moment of Inertia, for a round solid shaft and I = d4 /64 y = d/2 Substituting these values in the above equation Bending Moment M= (d3 /32) fb Shafts subjected to combined twisting and bending moment: When the shaft is subjected to combined twisting and bending moment then the shaft must be designed on the basis of the two moments simultaneously. The maximum induced stress can be obtained by considering the following theories. 1) Maximum shear stress theory or Guests theory. It is used for ductile materials such as mild steel. 2) Maximum normal stress theory or Rankins theory. It is used for brittle materials such as cast iron.

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Given Data: Power transmitted by the shaft=75kw or 100hp Speed of the shaft =750 rpm Weight of the rotor shaft =2000kg Beam length =165cm Arm length =27cm Shear stress =650 kg/cm Bending stress =300 kg/cm

We know /16 f s d = [(K m M)+(K t T)] /16 650 d =[(2x54000)+(2x9549) ] d=9.5cm (or) 95mm Deflection of Shaft: Actual deflection = (Wl/384) E I = 2000/384x2.1x10^6x1198.4 = 0.009246cm

Twisting Moment: Power p=2NT/4500 100= (2 750 T)/4500 T=95.49 kg-m (or) 9549 kg-cm We know T= (/16) f s d 9549= /16 650 d d=4.21 cm (or) 42.1mm Bending Moment: M =Weight of Screen Arm Length = 4500 27 =54000 kg-cm We know M = ( /32) f b d 54000= /32 300 d d=12.2cm (or) 122.3mm Combined Bending and Twisting Moment: We know that /32 f b d= [M+M+T]/2 /32 300 d = [54000 + (54000+9549)]/2 d=12.2cm (or) 122.7 m Fluctuating Loads: Allowable deflection = L/1500 = 0.11cm Factor of safety = Allowable deflection / Actual deflection = 0.11/0.009246 = 11 Selected diameter of shaft =122.7mm 125mm

V.

DESIGN OF BEARINGS

A bearing is a machine element, which supports another moving machine element, knows as journal. It permits a relative motion between the contact surfaces of the member, while carrying the load. The efficiency of the mechanical system depends to a great extent on the efficiency of its bearings. A necessity for the efficient working of the bearings is that the running surface should be adequately supplied with lubricant. For this purpose the oil is supplied through a lubricating ring firmly clamped on the shaft at the after end and a wiper device fitted in the upper part. This device, together with correctly formed oil grooves in the bearing shells ensure that in bearings the oil supply is maintained in all circumstances even at low revolutions.

VI.

SPHERICAL ROLLER BEARING

A spherical bearing is a bearing that permits angular rotation about a central point in

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two orthogonal directions within a specified angular limit based on the bearing geometry. Typically these bearings support a rotating shaft in the [bore] of the inner ring that must move not only rotationally, but also at an angle. Construction of spherical bearings can be hydrostatic or strictly mechanical. A spherical bearing by itself can consist of an outer ring and an inner ring and a locking feature that makes the inner ring captive within the outer ring in the

axial direction only. The outer surface of the inner ring and the inner surface of the outer ring are collectively considered the raceway and they slide against each other, either with a lubricant or a maintenance-free based liner. Some spherical bearings incorporate a rolling element such as a race of ball bearings, allowing lower friction. The design of this bearing permits radial load and heavy thrust load in either direction.

Fig. Spherical Roller Bearing

VII.

BEARING LIFE CALCULATION

Type of bearings used: spherical roller bearings Selected diameter of the shaft=125mm N=speed of the shaft=750 r.p.m L h =nominal/rated speed in hours =10000 hrs, 10hrs per a day heavy shock load Then life of bearing in millions of revolutions L=60NL h /106 L= (60 750 10000)/106 L=4500 millions of revolutions Where L is life that 90% of a group of apparently identical group of bearings will complete

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Fig Rotor Assembly with Bearings

VIII. ELEMENT USED FOR ANALYSIS

BEAM3 is a uni-axial element with tension, compression, and bending capabilities. The element has three degrees of freedom at each node: translations in the nodal x and y directions and rotation about the nodal z-axis. Other 2-D beam elements are the plastic beam.

2D Beam Analysis:

Fig Deformed Shape

Fig Von Mises Stress 3D Shaft Analysis:

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Fig Deformed Shape

Fig: Rotor Shaft Assembly Mesh in Ansys

Fig: Deformations in Ansys

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Fig. Von Mises Stress Now we can see the stresses in shaft. Maximum stress developed in shaft is 36.15 N/mm2 which is far less than the yield strength of the material, which is 45 N/mm2. So that shaft will not fail under these conditions 10.As per analysis of shaft and rotor assembly done in Ansys, deflection values of the shaft and rotor assembly are 0.008637 and 0.006404.

REFERENCES IX. CONCLUSIONS

Scham Tickoo, Pro-Engineer2001, 2nd edition. 2. J.N.Reddy, An Introduction to Finite Element Method, 3rd edition. 3. R.K.Allan,Rolling Bearing , 3rd edition 4. S.S.Rao, Mechanical Vibrations, 4th edition. 5. Richard G.Budynas Jata, Advanced Strength and Applied Stress Analysis, 2nd edition . 6. V.B. Bhandari, Introduction to Machine Design. 7. Robert L.Norton, Machine Design, 2nd edition. 8. Hall, Holowenko Laughlin, Theory and Problem of Machine Design, Schanms series. 9. PERRY, r.h., and d.w.Green, Perrys Chemical Engineers handbook, 7th ed. 10. F.D.Bond, Crushing Calculations. 11. Pennsylvania, Crushing Technologies. 12. P.C.Hayes, Construction of Hammer Mill Crusher. 1. As per drawings and information provided by Bevcon, 3D models are developed in Pro-e and the shaft of crusher is analyzed in Ansys package. 1. Based on calculations and analysis reports the safe diameter is selected as 125mm, which is safe. 2. Factor safety for selected diameter is 11. This factor of safety chosen for crusher to address sudden impact and shock loads created by the material. 3. Deflection of shaft as per theoretical calculations is 0.009mm. 4. Deflection of shaft in Ansys analysis is 0.007mm (load applied on shaft only). 5. Deflection of total rotor assembly in Ansys is 0.006mm. 6. Selected bearing for this application based on shaft diameter 125mm is heavy-duty spherical roller bearings on adapter sleeve. 7. 3D models developed in pro-e & analyzed reports have been submitted to Bevcon for their consideration in their designs 8. We suggested to consider this analysis report to reduce the bearing diameter metal for optimizing the rotor design of the hammer mill crusher. 9. Bearing life for selected bearings is 450 Millions of revolutions.

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