MECHANICAL TechEd 16 PDF

Sr.
No Name Page
1 Aditya R. Pandhare & Ritesh D. Banpurkar 1
2 Ankush M. Hatwar & Abhijit Misal 5
3 Dushant G. Waghamare & Ritesh D. Banpurkar 9
4 Vipin Mankar, Prof. Swapnil Thanekar & Prof. Neeraj Wayzode 14
5 Prof. Sachin Naik & Prof. Dr. A.R. Bapat 18
6 Prof. Swapnil Thanekar, Mr. Shailendra Ukirde & Prof. Vipin Mankar 23
7 Swapnil A.Mahajan 27
8 Rahul Mathankar, Asif Sheikh, Shubham Girde & Swapnil Thanekar 37
9 Pawan R. Giri, Ravindra R Gandhe & Ajay A. Mahawadiwar 41
10 Piyush A.Dalke & Prof.AbhijeetA.Raut 44
11 S. B. Bakal& P.J.Nikam 53
12 S. B. Bakal, G. P. Sharma & P. J. Nikam 58
13 Syed Irfan Ali, Deepak Kapgate, Sunita Parihar & Syed Akbar Ali 63
14 Harshal S. Jumade, Prashant P. Bansod & Ajay A. Mahawadiwar 67
15 Mr. Lokesh G. Dandekar, Prof.Ritesh Banpurkar & Prof. Ajay Mahawadiwar 71
16 Nikhil Ekotkhane, Prashant Bansod & Ajay Mahawadiwar 75
17 Ritesh V. Bhawarkar, Prof.Abhijit Misal & Prof.Ajay Mahawadiwar 77
18 Vinod B. Hiwase & Prof. Ritesh Banapurkar 80
19 Yogesh A. Mangaonkar, Prof.Ravindra Gandhe & Prof.Ajay Mahawadiwar 83
20 Chhaya Ladhi & Prof.Ajay Mahawadiwar 85
21 Pravin Meshram, Subham Shende & Mr.Vishwjeet Ambade 88
22 Mr.Vishwjeet Ambade, Deepak Bhure& Mr.Vishwjeet Ambade 91
23 A.B.Lanjewar, N.S.Wakchaure, P.R.Tete & S.S.Joshi 94
24 Piyush A.Dalke & Prof.AbhijeetA.Raut 98
25 Prasanna Gaikwad, Aditya Nakat, Vansh Devhare & Jayesh Nandankar 106
Mr.Akshay Shende, Mr.Nitin Gokhe, Mr.Avinash Ramteke & Prof. Harshwardhan
26 111
Mahawadiwar
Mr. Ajay Rathod, Mr.Arun Chavan, Mr.Dhiraj Bramhane & prof. Harshwardhan
27 114
Mahawadiwar
28 Mrs.Anjali Kadam & Dr.G.K.Awari 117
29 Nikhil H. Patil & Sharad S. Chaudhari 121
30 Vinay L. Jiwtode, Rahul K. Bhoyar & Sandeep M. Pimpalgaokar 127
31 Salman Khan 132
32 Aswad A Sagdeo & Prof V.P. Kshrisagar 134
33 Suhas V. Kale, Prof. S.G.Ghugal & Prof A.B.Ganorkar 137
34 Sumit yadav, Sumit Roy & Sumit Yadav 141
35 Rahul Singh, Anoop Chauhan, Aditya Dhawale & AkshayBalkhande 145
Shubham Thakre, Shubham Sarde, Shrikant Kothari, Nitin Mirge &
36 150
Mr.Vishwjeet.V.Ambade
A.S Puttewar, Krishna Yadav, Ketan Warjurkar, Latikesh Khedkar, Ashwin Gajbhiye &
37 155
Bhimrao Devtale
38 Sachin Khobragade, Mohankhangar & Akshay Dhanorkar 159
39 Anil H. Ingle & Krunali R. Charpe 163
40 Gaurav Puri, Lankesh Jadhav & Milind Palandurkar 169
41 Prof.S.V.Borkar, Mr.KunalI Mahajan, Mr.Sanket V Bure & Mr.PrashantN Khadatkar 174
42 Shubhangi Gondane, Dr.P. N. Belkhode & Manisha Joshi 178
43 MrsArtiMathur, DrA.B.Singh & Dr A subbarao 185
44 Aditi Pandey 191
Review on Analysis of Steam Turbine Blade
Aditya R. Pandhare Ritesh D. Banpurkar
M.Tech M.E.D., Department of Mechanical Asst. Prof., Department of Mechanical Engineering
Engineering Abha Gaikwad-Patil College of Engineering
Abha Gaikwad-Patil College of Engineering Nagpur, India
Nagpur, India [email protected]
[email protected]
Abstract— Steam turbine blades are one of the most critical Ever since the evolution of FEA, there has been a continuous
components in power plants Blade is a major component of the and growing need for a powerful design analysis tool in the
turbine, which receives the impulse directly from the steam jet power generation industry. In general, turbines represent a
and converts this force into the driving force. Statistics has shown class of challenging mechanical prime movers where steady
that LP blades are usually more predisposed to failure compared
and transient stresses (mechanical and thermal), turbine blade
to blades in HP or IP turbines. The present research work
analyses the effects of thermal and structural load on a steam vibrations, and the start/stop cycling of the machines present
turbine blade under the operating conditions. Stresses due to interesting design challenges to produce a highly reliable
thermal and dynamic loads of low Pressure Steam Turbine blade machine with long design lives. Particular interest is the
of 210 MW power stations analyzed in two stages. In first stage a analysis of turbine blades, as these rotating components, if the
three dimensional model of turbine blade was prepared in CREO separated from their attachment to the rotor, have the potential
2.0. for causing a tremendous amount of consequential damage,
both in the form of human life and property damage.
This model will import in ANSYS-14.5 for Finite Element
Analysis. Maximum stress and stress distribution is compute
using Finite Element Analysis (FEA) at the corresponding A. Problem definition
section.
All mordern steam power plants use impluse-reaction turbines
Keywords— Low pressure Blade, Steam Turbine, Stress as their blading efficiency is higher than that of impluse
Distribution, and Finite Element Analysis by ANSYS software. turbines. Last stage of steam turbine impluse-reaction blade
are very much directly affect efficiency of plant.With the
I. INTRODUCTION information that an understanding of the forces and stresses
acting on the turbine blades is vital importance, in this work
Steam turbines are major prime movers in thermal power we will compute such a force acting on a last stage Low
stations. The main parts of simple impulse steam turbine are Pressure (LP) blade of a large steam turbine rotating at 3000
rotor, blades and nozzles. Turbine blade is exposed to various rpm in order to estimate the material stresses at the blade root.
loads such as thermal, inertia, and bending and may fail due to One such LP steam turbine blade is show in Figure 1. We
different factors like Stress-Corrosion Cracking, High-Cycle studied structural and thermal analysis of blade using FEA for
Fatigue, Corrosion-Fatigue Cracking, Temperature Creep this work and by use of the operational data have performed
Rupture, Low-Cycle Fatigue, corrosion, etc. by using FEA (ANSYS) and This study work involved the
analyze bldde and check FEA data of std. blade with various
The software offers a comprehensive range of stress analysis material
and other capabilities in an integrated package for such large-
scale, complex problems. An integrated infrastructure, B. Objective
ANSYS Parametric Design Language customization
capabilities and nonlinear simulation with contact plasticity The main objectives of the study were
work together to provide powerful simulation capabilities for
this type of application. Key dimensions of the blade root were 1) To study effect of stress distribution on steam turbine blade
modified using ANSYS Parametric Design Language (APDL)
capabilities, with ANSYS Mechanical software analyzing the 2) Structural and thermal analysis of steam turbine blade
various combinations of parameters.
ISSN NO: 2454-1958 Special Issue Tech-Ed 2016 (International Conference) Page 1
3) Calculating stresses through advanced computer modelling picture of structural characteristics, which can utilized for the
techniques and simulation improvement in the design and optimization of the operating
conditions.
4) To study effect of pressure and get the response of the blade
Subramanyam Pavuluri, Dr. A. Siva Kumar was investigated
on design of high pressure steam turbine blade addresses the
II. RESEARCH METHODOLOGY
issue of steam turbine efficiency. A specific focus on airfoil
The following methodology used for carrying out Finite profile for high-pressure turbine blade, and it evaluates the
Element Analysis of 210 MW low-pressure blade of Steam effectiveness of certain Chromium and Nickel in resisting
turbine. creep and fracture in turbine blades. The efficiency of the
steam turbine is a key factor in both the environmental and
1) Formulation of the problem – the success of any experiment economic impact of any coal-fired power station. Based on the
is dependent on a full understanding of the nature of the research presented modifications to high-pressure steam
problem. turbine blades can made to increase turbine efficiency of the
turbine. The results and conclusions are presented for a
2) Validation of FEM method for finding maximum stress. concerning the durability problems experienced with steam
turbine blades. The maximum operational Von Mises Stresses
3) Modeling of the steam turbine blade will done using CAD are within the yield strength of the material but the
software CREO 2.0. deformation is comparatively better for material CA-6 NM
(Chromium Nickel). Modified solutions for Steam turbine
4) Stress distribution on turbine blade and root. blade values to machines to maximize their reduce life cycle
costs, efficiency, and improve reliability
5) Software ANSYS 14.5 using for Finite Element Modeling.
Sanjay Kumar was investgated on creep life of turbine blade.
Validation of fem method for finding stress A. Inertia load is the constant load that will cause creep failure.
Creep is a rate dependent material nonlinearity in which
Steps of validation of fem method for finding Stress: material continues to deform in nonlinear fashion even under
constant load. This phenomenon is predominant in
1) Prepare a three dimensional model in CREO 2.0.
components, which exposed to high temperatures. By studying
2) Import the CREO2.0 model in ANSYS software. the creep phenomenon and predicting the creep life of the
component, we can estimate its design life. The main objective
3) Mesh the ANSYS model. is to predict the creep life of the simple impulse steam turbine
blade, and to give the FEM approach for creep analysis. The
4) Apply boundary conditions and find out stress distribution analysis of turbine blade for different loads, which shows that
in the component. the maximum stresses, induced in each case. These stresses
are within yield limit of the material and will not undergo
5) Validate that maximum stress in component with operating plastic deformation during operationresult is found that, creep
condition. life decreases as the stress value increases. Hence, by
decreasing the stress value in the component we can increase
its creep life. This was be achieved by modifying the blade
III. LITERATURE REVIEW
design.
Many investigators have suggested various methods to explain Avinash V. Sarlashkar, MARK L. Redding investigated on the
the effect of stress and loading on turbine blade, roter and architecture and capabilities of Blade Pro. An ANSYS based
analysis the various parameters: turbine blade analysis system with extensive automation for
solid model and F.E. model generation, boundary condition
John. V, T. Ramakrishna was investigated on design and
application, file handling and job submission tasks for a
analysis of Gas turbine blade, CATIA is used for design of
solid model and ANSYS software for analysis for F.E. model variety of complex analyses; the program also includes turbo
generated, by applying boundary condition, this paper also machinery specific post-processing and life assessment
includes specific post processing and life assessment of blade. modules. Blade Pro is a cutting-edge example for vertical
applications built on the core ANSYS engine using ANSYS
How the program makes effective use of the ANSYS pre-
APDL. Examples of how the program makes effective use of
processor to mesh complex geometries of turbine blade and
apply boundary conditions. The principal aim of this paper is the ANSYS preprocessor to mesh complex geometries of
to get the natural frequencies and mode shape of the turbine turbine blade and apply boundary conditions are presented
blade. In this paper we have analyzed previous designs and using specific examples. A real world application is used to
generals of turbine blade to do further optimization, Finite demonstrate the pre-processing capabilities, static and
dynamic stress analyses results, generation of Campbell and
element results for free standing blades give a complete
Interference diagrams and life assessment. The principal blade root. The root modified due to the difficulty in
advantage of Blade Pro is its ability to generate accurate manufacturing the butting surface of the tang that grips the
results in a short amount of time, thus reducing the design blade to the disk crowns
cycle time. The good correlation achieved is a testament to the
accuracy of the ANSYS solvers and validity of the modeling having small contact area. Verify the same using Finite
techniques adopted in Blade Pro. Element Analysis for two cases with and without the tang in
the blade. Firstly, to study the fillet stresses with tang and then
DR.SHANTHARAJA.M, DR. Kumar. K., was work on the Petersons chart is used to reduce the peak stresses with the
large variety of turbo-machinery blade root geometries used in modification to the butting area and reducing the fillet radius.
industry prompted the question if an optimum geometry could To conduct the sensitivity analysis for the fillet stresses in
be found. An optimum blade root was defined, as a root with blade and disk using FEA.
practical geometry which, when loaded returns the minimum
fillet stress concentration factor. The present paper outlines the In the work, the first stage rotor blade off the gas turbine has
design modification for fillet stresses and a special attention analyzed using ANSYS 9.0 for the mechanical and radial
made on SCF of the blade root (T-root) which fails and to elongations resulting from the tangential, axial and centrifugal
guarantee for safe and reliable operation under all possible forces. The gas forces namely tangential, axial were
service conditions. Finite Element Analysis is used to determined by constructing velocity triangles at inlet and exist
determine the fillet stresses and Peterson’s Stress of rotor blades. The material of the blade was specified as
Concentration Factor chart is effectively utilized to modify the N155. This material is an iron based super alloy and structural
blade root. The root modified due to the difficulty in and thermal properties at gas room and room temperatures the
manufacturing the butting surface of the tang that grips the turbine blade along with the groove blade is modeled with the
blade to the disk crowns. 3D-Solid Brick element. The geometric model of the blade
profile is generated with splines and extruded to get a solid
Avinash V. Sarlashkar, MARK L. Redding investigated on the model in CATIA. The first stage rotor blade of a two-stage gas
architecture and capabilities of Blade Pro. An ANSYS based turbine has been analyzed for structural, thermal and modal
turbine blade analysis system with extensive automation for analysis using ANSYS 9.0 Finite Element Analysis software.
solid model and F.E. model generation, boundary condition The gas turbine rotor blade model meshed in HYPERMESH
application, file handling and job submission tasks for a 7.0, meshing software. The thermal boundary condition is
variety of complex analyses; the program also includes turbo such as convection and operating temperatures on the rotor
machinery specific post-processing and life assessment blade obtained by theoretical modeling. Analytical approach
modules. Blade Pro is a cutting-edge example for vertical used to estimate the tangential, radial and centrifugal forces.
applications built on the core ANSYS engine using ANSYS
APDL. Examples of how the program makes effective use of In this work the failure of a second stage blade in a gas turbine
the ANSYS preprocessor to mesh complex geometries of was investigated by metallurgical and mechanical
turbine blade and apply boundary conditions are presented examinations of the failed blade. The blade was made of a
using specific examples. A real world application is used to nickel-base alloy Inconel 738LC. The turbine engine has been
demonstrate the pre-processing capabilities, static and in service for about 73,500 hrs. Before blade has failure. Due
dynamic stress analyses results, generation of Campbell and to the blade failure, the turbine engine was damaged severely.
Interference diagrams and life assessment. The principal The investigation started with a thorough visual inspection of
advantage of Blade Pro is its ability to generate accurate the turbine and the blades surfaces, followed by the
results in a short amount of time, thus reducing the design fractography of the fracture surfaces, micro structural
cycle time. The good correlation achieved is a testament to the investigations, chemical analysis and hardness measurement.
accuracy of the ANSYS solvers and validity of the modeling The observation showed that a serious pitting occurred on the
techniques adopted in Blade Pro. blade surfaces and there were evidences of fatigue marks in
the fracture surface. The micro structural changes were not
DR.SHANTHARAJA.M, DR. Kumar. K., was work on the critical changes due to blade operation at high temperature. It
large variety of turbo-machinery blade root geometries used in found that the crack initiated by the hot corrosion from the
industry prompted the question if an optimum geometry could leading edge and propagated by fatigue and finally, because of
be found. An optimum blade root was defined, as a root with the reduction in cross-section area, fracture was completed.
practical geometry which, when loaded returns the minimum An analytical calculation parallel to the finite element method
fillet stress concentration factor. The present paper outlines the utilized to determine the static stresses due to huge centrifugal
design modification for fillet stresses and a special attention force. The dynamic characteristics of the turbine blade
made on SCF of the blade root (T-root) which fails and to evaluated by the finite element mode and harmonic analysis.
guarantee for safe and reliable operation under all possible Finally according to the log sheet records and by using a
service conditions. Finite Element Analysis is used to Campbell diagram there was a good agreement between the
determine the fillet stresses and Peterson’s Stress failure signs and FEM results which showed the broken blade
Concentration Factor chart is effectively utilized to modify the
has been resonated by the third vibration mode occasionally The authors would like to thank the anonymous reviewers
before the failure occurred for their comments which were very helpful in improving the
quality and presentation of this paper.
. Conclusion
From above literature, review it is indicated that References

[1] John. V, T. Ramakrishna,‟‟The Design And Analysis Of Gas Turbine
1) There are many researches done on turbine blade in high- Blade”, International Journal of Advanced Engineering Research and Studies,
pressure stage or rotor section and work also done in steam VOL,2., ISSUE I,OCT.-DEC.,2012 , page no . 53-55
and gas based power plant. But I found that are very few
researches done work on last stage tangent-twisted blade of [2] Subramanyam PAVULURI, DR. A. Siva KUMAR,„‟ Experimental
Investigation On Design Of High Pressure Steam Turbine Blade‟‟,
LP stage of turbine so we want to do research on this section. International Journal of Innovative Research in Science, Engineering and
We like to use FEA for analysis. Technology,VOL. 2, ISSUE 5, MAY 2013, ISSN: 2319-8753
2) Turbine blade tupe,flow of steam through impluse or [3] S. M. Sanjay Kumar, ―Creep Life Prediction of Steam Turbine Blade
rection blade,geomeatry of blade,helix angle,force on the Using Finite Element Method.” International Journal of Advanced
Engineering Research and Studies, VOL. I, NO.2, PP. 95-98
blade,material properties of the blade,speed of the turbine and
etc. are various parameter important for the turbine blade [4] Avinash V. Sarlashkar ,MARK L. Redding,“ An Ansys-Based Turbine
condition. Blade Analysis System‟‟ Impact Technologies, LLC, ROCHESTER, NY
14623, U.S.A
3) They affect the blade life and efficiency of the plant in
[5] DR.SHANTHARAJA.M, DR. Kumar. K .‟‟Design Modification For
terms of mechanical properties and working codition. Fillet Stresses In Steam Turbine Blade‟‟, IJAE International Journal of
Advanced Engineering Research and Technology, VOL III,ISSUE I 2012
4) The complex Design of blade will done in CREO 2.0
parametric software with coordinate point of tip and root [6] G.NARENDRANATH, S.SURESH,‟‟THERMAL Analysis Of A Gas
section of blade Turbine Rotor Blade By Using Ansys‟‟, International Journal of Engineering
Research and Applications, VOL. 2, ISSUE 5, SEPTEMBER- OCTOBER
2012, PP.2021-2027, ISSN: 2248-9622
5) To perform analysis with appropriate set of parameters is
done in ANSYS14.5 software (FEA). [7] Patil A.A.,SHIRSAT U.M,.‟‟Study Of Failure Analysis Of Gas Turbine
Blade‟‟, IOSR Journal of Engineering, ISSN: 2250-3021, ISBN: 2878-8719,
PP 37-43
Acknowledgment
Design of Single Fork of Folding Bicycle
Ankush M. Hatwar Abhijit Misal

Mechanical engineering department Mechanical engineering department
Abha Gaikwad Patil College of engineering, Nagpur Abha Gaikwad Patil College of engineering, Nagpur
Maharashtra, India Maharashtra, India
[email protected]
Abstract—In today’s life the bicycle can play the very important public transport facility and in many cases the destination will
role for daily transportation purpose in human life. The reason be far from the main roads where the public transport might
behind increase in the importance is because of increased not be able to reach due to the small roads, to avoid which
pollution due to automobiles and cost of fuel which is most people use vehicles of their own, which in turn leads to
continuously increasing now a day. Also the transport has been
issues with parking, traffic, etc. But not all can opt for having
one of the most important issues to be deal with in the present
day situation as commuting from place to place within the city own vehicles as it is expensive. With such issues in health,
has become a tedious and an expensive task. It is very difficult to transport, space for parking, etc. one solution that comes to
reach the nearest public transport facility and in many cases the mind is bicycle. Bicycles are being promoted in the corporate
destination will be very far from the main roads where the public and educational sectors. But how convenient is it to use a
transport might not be able to commute or it might be very conventional bicycle? In many cases there is no special facility
expensive. To overcome a common problem faced by the society, provided for locking the bicycles and even if one is present, it
an idea is conceptualized to design a single fork foldable bicycle. is probable to theft, which is one of the fears that obstruct use
The aim of our paper is to design and analysis of single fork of of bicycle. Conventional bicycles occupy sufficient space and
foldable bicycle which fold in compact form which facilitating
hence providing one at work place or at home are quite
easy transport and easily park. We already have seen many
foldable bicycles in the global market but the main idea of this difficult. They are probable to be exposed to the weather
paper is to provide only one side fork to a foldable bicycle which outside and do require frequent maintenance. With all such
is light & safe, easy to handle, easy to fold and easy to maintain. issues in the conventional bicycles, the next possible solution
Unlike the conventional cycles, this bicycle will occupy very less is the usage of foldable bicycle. With foldable bicycles, there
space and also is very easy to be carried around. is no issue since the bicycle can be folded and carried around
to the work place or even it can be used to reach the nearest
Keywords—conventional, conventional bicycles, fork, foldable public transport facility and then folded and carried along.
bicycle, transport Since the bicycle is being folded, it occupies very less space
and doesn’t require any special parking space. They are not
I. INTRODUCTION exposed to the weather since they can be carried inside
buildings with ease and hence prone to less maintenance. The
The Currently available bicycles are made up of heavy usage of foldable bicycle helps combine the different modes of
materials which make them difficult to carry. The prices of the transport as mentioned above, which helps in cutting down
bicycles are also not affordable to the common man. Many of some cost involved in travelling.
them are not foldable in a configurable geometrical order,
because of which their transportation becomes very difficult. It
II. COMPONENT OF FOLDING BICYCLE
also leads to a lot of difficulty, when it is to be stored for
future use. To propose a compact foldable bicycle this is
weightless and overcomes all the limitations in the currently A. Folding Body Frame
available bicycles. The proposed bicycle is designed in such a
way that it is foldable by providing fasteners at the joints. The It is a main supporting part of the bicycle. On which wheels
design structure imparts stable bicycle geometry. and other components are fitted. The modern and most
common frame design for an upright bicycle is based on the
Transport has been one of the major issues in developing cities safety bicycle, and consists of two triangles, a main triangle
such as Bangalore since commuting from one place to another and a paired rear triangle. This is known as the diamond frame.
has become tedious and expensive. With the petrol and diesel Frames are required to be strong, stiff and light, which they do
prices increasing day by day, almost all the modes of transport by combining different materials and shapes. At the time of
are becoming expensive. It is difficult to reach the nearest folding the folding bicycle the main frame or folding body of
the folding bicycle is folded in such manner that the horizontal
axis of the front wheel and the horizontal axis of the back
wheel are come in a same axis As the folding of the main
frame or folding body of the folding bicycle is completed. The
front wheel holder and back wheel holder are fixed with each
other with the help of Velcro.
B. Compact joint
It is a joint which provides on the frame so that front and rear
portion can be overlap.
C. Handle Fig 1: Component of folding bicycle

It is the front portion of bicycle which uses to control the
direction of bicycle. Bicycle handlebar or often bicycle III. MATERIAL SELECTION FOR FRAME
handlebars refer to the steering mechanism for bicycles; the
The selection of suitable material for the frame was most
equivalent of a steering wheel. Besides steering, handlebars
important to make the frame study, yet light. After long
also often support a portion of the rider's weight, depending on
sessions of discussion it was finalized to use the standard
their riding position, and provide a convenient mounting place
material used in conventional bicycles i.e. Mild steel.
for brake levers, shift levers, cycle computers, bells, etc.
Mild steel is easily available in the required diameter and
Handlebars are attached to a bike's stem which in turn attaches
length and is also not expensive. One main advantage of using
to the fork.
mild steel is that it is easy to fabricate with it as welding of
D. Transmission mechanism mild steel is by arc welding process which is cheap compared
to other welding methods. Use of other materials like alloys of
It is the mechanism which transmits the power from pedal to aluminum was not selected as the availability is less and also
rear wheel. A bicycle chain is a roller chain that transfers the fabrication cost is high.
power from the pedals to the drive-wheel of a bicycle, thus Mild steel tubes of 1”, 1.5”, and 0.5” are easily available in the
propelling it. Most bicycle chains are made from plain carbon market and are the ones used for conventional bicycle
or alloy steel, but some are nickel-plated to prevent rust, or manufacturing. The hinge found in the market is also made of
simply for aesthetic. Before the safety bicycle, bicycles did not mild steel which eases the process of joining the frame to the
have chains and the pedals were typically attached directly to hinges.
the drive-wheel, thus limiting top speed by the diameter of the The following are the chemical composition and mechanical
wheel and resulting in designs with front wheels as large as properties of mild steel.
possible. Various linkage mechanisms were invented to raise
the effective gear ratio, but with limited success. Using chain Chemical composition
drive allowed the mechanical advantage between the drive and Carbon 0.16-0.18%
driven sprockets to determine the maximum speed.
Silicon 0.40% max
E. Adjustable Seat Manganese 0.70-0.90%
It is the setting arrangement in the bicycle. The Saddle, Undo Sulphur 0.040% Max
the lever, push the saddle right down, and re-clamp the lever. Phosphours 0.040% Max
During this action, it is because of this that the rear frame
remains folded, in turn retaining the front wheel in its folded IV. TESTING FOR BENDING AND COMPRESSION
position. So if you do not push the saddle fully down, it is LOADS
possible for the folded package to come apart when you pick
the bike up. Folding pedal, it is best to fold this with the left
hand crank as high as possible i.e. with the cranks turned so A. BENDING TEST:
that the right hand pedal touches the front wheel also, the
ridged side of the nylon latch plate on the pedal should face The tube used to fabricate the bicycle was subjected to
upwards. This is the arrangement used in the bicycle which is bending test. A tube of outer diameter 1 inch, 16 gauge and
use for the carrying the bags or any kind of things on carriage length 10 inches was used as the test specimen. The specimen
we have to fixed it first on the carriage. was mounted on the UTM with necessary arrangements to
perform bending test. The specimen was supported by two v-
blocks and then the bending test was done. It was observed that
the tube does not show much deflection till a load of 4 KN, but
the since the tube is hollow first the outer surface of the tube
was bent then the whole tube started bending. The bending test
was carried out till a deflection of 8.5 mm was observed. The analysis.
variation of the deflection with respect to the load is as shown
in the graph below.
Fig 2: Graph of Deflection v/s Load for bending test Fig 4: Single fork design
B. COMPRESSION TEST:
The mild steel tube was cut and welded to the angle as in the
frame design and tested on the UTM till fracture. The mild
steel tube of outer diameter 1 inch and 16 gauges was used to
build the specimen as per the required dimensions.
Compressive load was applied on the specimen. It is observed
that there is very less deflection up to a load of 4 KN and then
the joint shows plastic deformation at 5KN and then fractures
at a load of 6.5 KN. The result of the test is plotted as a graph
of deflection versus load and is as shown in the below figure.
Fig 5: Design of various components
VI. 3D MODELLING OF SINGLE FORK

For modeling and analysis of our proposed folding bicycle we
use the softwares Pro-E and Ansys.
A. Pro/ENGINEER
Fig 3: Graph of Deflection v/s Load for compression test
It is basically the 3D modeling tool software in which
modeling and drawing and drafting is taking place also it gives
V. DESIGN OF SINGLE FORK the tutorial-based introduction to creating parts, assemblies and
drawings in Pro/ENGINEER. If you follow the complete series
Fork is the portion of bicycle that holds the front wheel allows of procedures, you will learn how Pro/ENGINEER passes 3D
the rider to steer and balance the bicycle. Forks have several design information to and from every design
key dimensions which include: offset length, width, steerer
tube length, and steerer tube diameter. B. ANSYS
We use the simple design of fork for our bicycle; we selected ANSYS is a Workbench application that can be use to perform
the size 25 mm diameters of tube and 300 mm length as shown a variety of engineering simulations, including stress, thermal,
in the figure. A normal mild steel fork was to be converted into vibration, thermo-electric, and magneto static simulations. A
a member that can lock after the bicycle was unfolded. This typical simulation consists of setting up the model and the
was a challenging task. Once the required data was gathered loads applied to it, solving for the model's response to the
regarding the dimensions of the fork and frame, the fork was loads, examining the details of the response with a variety of
modeled using 3D tools. tools.
We analyze the mechanical properties on the single side fork Analysis is used to evaluate the fatigue failure of the proposed
by FEA using various materials and investigate optimum and bicycle design. The failure locations and the cycles to failure
effective material based on results obtained by proposed are determined by analysis. The foldable bicycle frame is
modeled and simulated in the CAD/CAE environment. The REFERENCES
developed 3D cad model of foldable bicycle frame is show in
fig. The tetrahedral element type has been used in this study for [1] Shishir. S, Manjunath. P, Pavanasudan. R, Ravi Sathyajith, Abhijith
the bicycle analysis. Gowda A. R. “Study Of Design And Fabrication Of Foldable Bicycle
Hinge Mechanism” International Journal of Informative & Futuristic
Research /June 2015/ISSN: 2347-1697
[2] Arunachalam M, Arun Prakash R. and Rjesh Rao, “foldable bicycle
evaluation ofexisting design and novel design proposal” ARPNA
Journal of Engineering and Applied sciencevol. 9, NO.5 May 2014
[3] A.K. Singh, A.S. Bobade, A.K. Ghodmare, B.C. Bisen, H.H. Walmik,
P.C. Padole “Concept of User Friendly Modified Folding Bicycle”
European Journal of Applied Engineering and Scientific Research, 2014,
3 (1):16-20
[4] M.A. Maleque1, a, M S Hossain2, b and S. Dyuti3, c “Material
Properties and Design Aspects of Folding Bicycle Frame” Advanced
Materials Research
[5] Herder, “foldable bicycle frame”,United State patent,
Australia,3\2000,6032971
[6] P.A Rodgers, G. Green and A. Mc Gown.2013. Using concept sketches
Fig 6: 3D modeling of frame with single fork to tack design progress.CIRP Annals Manufacturing technology.58:543-
565.5
[7] Shih-Wen Hasio, Jyh-Rong chou, “A creativity-based design process for
CONCLUSION innovative bicycle design”, International Journal Of Industrial
Ergonomic 34 (2004) 421-443
From the proposed concept we can conclude that single fork
[8] Derek Covill, Steven Begga, Eddy Eltona. “Parametric finite element
used in folding bicycle can be effectively employed in new analysi of bicycle frame geometries” 2014 conference of the
upcoming bicycle for optimum design, flexibility in International Sports Engineering Association
maintenance, good aesthetics and best design for improved
structure of folding bicycle.
Review of disc brake squeal analysis
Dushant G. Waghamare Ritesh D. Banpurkar
M.Tech M.E.D., Department of Mechanical Asst. Prof., Department of Mechanical Engineering
Engineering Abha Gaikwad-Patil College of Engineering
Abha Gaikwad-Patil College of Engineering Nagpur, India
Nagpur, India [email protected]
[email protected]
Abstract— It has been observed that brake squeal noise is locking of brake corner components. Modal locking is the
faced as a major issue by automotive manufactures for many coupling of two or more modes of various structures
years due to consistent customer complaints, high warranty costs producing optimum conditions for brake squeal. High-
and accidents caused by misbalancing due to crash braking. An frequency brake squeal is defined as a noise which is produced
automobile survey has revealed that the brake noise is being one
by friction induced excitation imparted by coupled resonances
of the most critical vehicle quality measurements. From early of
the last century and till date disc brake squeal is being a complex (closed spaced modes) of the rotor itself as well as other brake
problem in the automobiles. Many researchers have investigated components. It is typically classified as squeal noise occurring
the problem by means of experimental, analytical and at frequency range 3-12 kHz. Since it is a range of frequency
computational methods. This paper provides review of which affects a region of high sensitivity in the human ear,
investigations carried out in context with disc brake squeal high-frequency brake squeal is considered the most annoying
analysis. It also includes review on characteristic of brake squeal. type of noise.
A reviews of the analytical, experimental and numerical methods
used for the investigation of brake squeal is given. Brake squeal is a concern in the automotive industry that
has challenged many researchers and engineers for years.
Keywords— Disc Brake Squeal, Brake squeal noise, Brake squeal
Considerable analytical, numerical and experimental efforts
analysis, automotive, analytical, experimental.
have been spent on this subject, and much physical insight has
I. INTRODUCTION been gained on how disc brakes may generate squeal, although
all the mechanisms have not been completely understood. No
Brake squeal is the unusual sound which occurs in precise definition of brake squeal has gained complete
the frequency range between 1 and 12 kHz, has been one of acceptance, but it is generally agreed that squeal is a sustained,
the most difficult concerns associated with vehicle brake high frequency greater than 1 kHz vibration of brake system
systems. In most cases, this type of noise has little or no effect components during a braking action resulting in noise audible
on the performance of brake system. However, most to vehicle occupants or passers-by. There exists no general
customers perceive this noise as a problem and demand that means for completely eliminating brake squeal. Brakes that
their dealers fix it. Thus automotive industry is thus looking squeal do not, in general, squeal during every braking action.
for new ways to solve this problem. Rather, the occurrence of squeal is intermittent or perhaps
even random. Many different factors on both the micro- and
In general, brake noise has been divided into three categories, macroscopic levels appear to affect squeal, and some of these
in relation to the frequency of noise occurrence. The three factors (especially on the microscopic level) are not well
categories presented are low frequency noise, low-frequency understood. As different brake squeal experiments produce
squeal and high-frequency squeal. Low-frequency disc brake widely different and even conflicting results. Generally, a
noise typically occurs in the frequency range between 100 and central difficulty in modeling brake squeal is one of scales.
1 kHz. Typical noises that reside in this category are grunt, Effects on very small scales in length and time (i.e.,
groan, grind and moan. This type of noise is caused by friction microscopic contact phenomena and high-frequency
material excitation at the rotor and lining interface. The energy vibrations) interact in important ways with effects on large
is transmitted as a vibratory response through the brake corner scales (such as wear over the life of the brake and dynamics of
and couples with other chassis components. The failure mode large vehicle substructures). A number of theories have been
for this category of squeal can be associated with frictional formulated to explain the mechanisms of brake squeal, and
excitation coupled with a phenomenon referred to as modal
numerous studies have tried with varied success to apply them non-repeatable. There are many potential squeal frequencies
to the dynamics of disc brakes. (unstable modes) for a brake system. Each individual
component has its own natural modes. The modal frequencies
II.CHARACTERISTICS AND MECHANISM OF DISC BRAKE and modal shapes of the rotor, caliper, anchor and pad will
SQUEAL change once these parts are installed. During a brake
application, these parts are dynamically coupled together
A. Brake noise squeal mechanisms resulting in a series of coupled vibration modes, which are
different from the component free vibration modes. The
The Disc brake squeal occurs when a system experiences addition of the friction coupling forces at the friction interface
vibrations with very large mechanical amplitude. There are results in the stiffness matrix for the system containing un-
two theories that attempt to explain why this phenomenon symmetric off-diagonal coupling terms. From the stability
occurs. The first theory states that brake squeal is a result of a point of view, this coupling is considered to be the root cause
stick–slip mechanism. Second theory is mode coupling theory. of the brake squeal. A brake system may not always squeal
It states that high levels of vibration result from geometric given the „„same‟‟ conditions. Alternatively, small variations
instabilities of the brake system assembly. Both theories, in operating temperature, brake pressure, rotor velocity or
however, attribute the brake system vibration and the coefficient of friction may result in differing squeal
accompanying audible noise to variable friction forces at the propensities or frequencies. Figs.1and 2 show the percentage
pad–rotor interface. According to the first hypothesis, the occurrence of brake squeal obtained at PBR Automotive Pty
stick–slip theory, a variable friction coefficient with respect to Ltdusing a Rubore drag type noise dynamometer and an AK
sliding velocity between pads and rotor, provides the energy noise matrix for various brake pressures and the temperatures
source for the brake squeal. Several studies based on this respectively. It can be seen from Fig.1that there is no simple
theory were conducted when disc brakes were first used on relationship between the percentage occurrence and frequency
automobiles. Squeal noise was found to be more likely when of the brake squeal and the brake pad pressure. Similarly, the
the decreasing relationship between the friction coefficient and influence of temperature on both the occurrence and frequency
the sliding velocity become pronounced. An increase in the of the brake squeal is quite complex (Fig. 2). Due to the
negative slope did not always increase the occurrence of above-mentioned difficulties in designing a noise free brake
squeal, however, the need for an alternative or accompanying system, efforts to eliminate brake squeal have largely been
theory was revealed. In the case of geometric instability, the empirical, with problematic brake systems treated in a case by
second theory, the variable friction forces are caused by case manner. The success of these empirical fixes depends on
variable normal forces. Even if the coefficient of friction is the mechanism that is responsible for causing the squeal
constant, variable friction forces are still possible. problem. The most fundamental method of eliminating brake
Investigations based on this hypothesis began with Spurr and squeal is to reduce the coefficient of friction of the pad
were advanced by Earles and Soar. In this case, two system material. However, this obviously reduces braking
modes that are geometrically matched move closer in performance and is not a preferable method to employ. The
frequency as the friction coefficient increases. These two use of viscoelastic material (damping material) on the back of
modes eventually couple at the same frequency and become back plate can be effective when there is significant pad
unstable bending vibration. Changing the coupling between the pad and
rotor by modifying the shape of the brake pad has also been
B. Characteristics of brake squeal
found effective. Other geometrical modifications that have
One of the biggest contributors to a brake squeal is the been successful include modifying caliper stiffness, the caliper
friction material, since Squeal excitation occurs at the friction mounting bracket, pad attachment method and rotor geometry.
interface, and it normally takes approximately 12 months to
finalize a friction material selection. This certainly makes it
very difficult to predict a priori the propensity of a brake
system to squeal. Also, often in the design of a brake system,
priority is given to requirements such as braking performance,
cost and ease of manufacture. The common practice for the
different components of a brake system to be manufactured by
different suppliers further complicates matters. The large
number of vehicles produced means that even a low squeal
propensity found during initial testing of a brake system can
become a major concern once a vehicle is in production due to
a much larger population size. Modifications towards the end
of development phase will have two potential risks: [1] Fig.1 Variation of occurrence of brake squeal with frequency
leading to production delays and increased costs to both the and brake pad pressure
brake and vehicle manufacturers and [2] leading to products
not fully validated with potential field warranty concern. The
most significant complication in brake research is the fugitive
nature of brake squeal; that is, brake squeal can sometimes be
modulus of pad material, and the mass and stiffness of caliper.
Squeal propensity was found to increase steeply with the
coefficient of friction, but squeal would not occur below a cut
off value of 0.28. He found that for a constant friction value,
the occurrence of squeal and squeal frequency depends on the
stiffness of pad material (Young‟s modulus). Caliper mass and
stiffness also displayed distinct narrow regions where squeal
propensity was high. The common conclusions of these
models are that brake squeal can be caused by geometrically
induced instabilities that do not require variations in the
coefficient of friction. Since these closed form theoretical
Fig.2 Variation of occurrence of squeal with frequency and approaches cannot adequately model the complex interactions
temperature between components found in practical brake systems, their
applicability has been limited. However, they do provide some
III. ANALYSIS OF BRAKE SQUEAL good insight into the mechanism of brake squeal by
highlighting the physical phenomena that occur when a brake
A. Analytical Methods system squeals.
The earliest research into brake squeal suggested that the Experimental methods are expensive mainly due to hardware
variation in the friction coefficient with sliding velocity was cost and long turnaround time for design iterations. Frequently
the cause. Not only is there a difference between the static and discoveries made on a particular type of brakes or on a
dynamic coefficient of friction, but it was thought the drop in particular type of vehicles are not transferable to other types of
kinetic friction with increased sliding velocity could lead to a brakes or vehicles. Product development is frequently carried
stick-slip condition and produce self-excited vibration. out on a trial-and-error basis. There is also a limitation on the
However, squeal has been shown to occur in brake systems feasibility of the hardware implementation of ideas. A stability
where the coefficient of kinetic friction is constant and has led margin is usually not found experimentally. Unfortunately,
to analysis of the geometrical aspects of a brake system. Spurr this produces designs that could be only marginally stable.
proposed an early sprag-slip model that describes a geometric
coupling hypothesis in 1961. Consider a strut inclined at an
angle θ to a sliding surface as shown in Fig.3 (a). The
magnitude of the friction force is given by
F = (µL) / (1 - tan θ)
Where, μ is the coefficient of friction and L is the load. It can

be seen that the friction force will approach infinity as μ
approaches cot θ. When μ=cot θ the strut „sprags‟ or locks
and the surface can move no further. Spurr‟s sprag-slip model
consisted of a double cantilever as shown in Fig. 3(b). Here,
the arm O’P is inclined at an angle θ’ to a moving surface. The
arm will rotate about an elastic pivot O’ as P moves under the
influence of the friction force F once the spragging angle has
been reached. Eventually the moment opposing the rotation Fig 3 (a) Single strut rubbing against moving surface; (b)
about O’ becomes so large that O”P replaces O’P, and the Sprag slip system
inclination angle is reduced to θ”. The elastic energy stored in
O’ can now be released and the O’Pswings in the opposite B. Experimental Methods
direction to the moving surface. The cycle can now
recommence resulting in oscillatory behaviour. Others The frequencies of a squealing brake are highly dependent on
extended this idea in an attempt to model a brake system more the natural frequencies of the brake rotor. Consequently it is of
completely. Jarvis and Mills used a cantilever rubbing against fundamental importance to be able to determine the vibration
a rotating disc in 1963, Earles and Soar used a pin-disc model modes of the rotor. Not only will an understanding of the
in 1971, and North introduced his eight-degree of freedom vibration modes of the rotor help predict how a brake system
model in 1972. The culmination of these efforts was a model may vibrate, but it is also necessary in developing
published by Millner in 1978. Millner modelled the disc, pad countermeasures to eliminate the problem. The existence of
and caliper as a 6 degree of freedom, lumped parameter model in-plane modes in addition to the bending modes is a further
and found good agreement between predicted and observed complication, and there is evidence that the in-plane modes
squeal. Complex eigenvalue analysis was used to determine can be the cause of some type of brake squeals as well as the
which configurations would be unstable. Parameters bending modes. Accelerometers provide an effective tool for
investigated included the coefficient of pad friction, Young‟s determining the vibration mode shapes and the forced
response of a system. Fig. 4(a) shows a bending mode shape Fig. 4 (a) Experimental bending mode shape (b) FEA bending
of a typical brake rotor that has been determined mode shape
experimentally. A model was created using STAR MODAL
software that consisted of 384 grid points over the surface of a C. Numerical Methods
brake rotor. Frequency response measurements were made
with a B&K 2032 FFT analyser using a B&K 4374 uni-axial Finite element analysis (FEA) has been used in the analysis of
accelerometer and a B&K 8001 impedance head. The brake squeal. CAE simulation and analysis methods play an
excitation was introduced with a B&K 4810 shaker driven by important role in understanding brake squeal mechanism.
a random noise signal. Unfortunately, the contact mounting Numerical modeling, on the other hand, can simulate different
required for accelerometers limits their usage on rotating structures, material compositions and operating conditions of a
brake components. They can only be used for analysis of disc brake or of different brakes or of even different vehicles,
stationary brake components making it almost impossible to when used rightly. With these methods, noise improvement
determine the mode shapes of a squealing brake rotor. Optical measures can be examined conceptually before a prototype is
techniques have been used more recently. In particular, double made and tested. Theoretical results can also provide guidance
pulsed laser holographic interferometry has been successfully to an experimental set-up and help interpret experimental
applied to squealing brake systems. This has allowed the findings. It can also be used to interpret test results, prepare
coupled mode shapes of a complete brake system to be for upfront DoE (design of experiment), simulate structural
determined while it is squealing. A holographic image is modifications and explore innovative ideas.
produced by triggering a laser at the maximum and minimum
amplitude of a vibrating object. The difference in optical path Ansys 14.5 solves the brake squeal problems effectively. To
length, caused by the deformed shape of the vibrating object, predict the onset of instability a modal analysis is performed
creates an interference fringe pattern on a holographic plate. on the prestressed structure. An unsymmetric stiffness matrix
The mode shape can then be determined by interpreting the is a result of the friction coupling between the brake pad and
fringe pattern. The advantage of holographic interferometry is disc; this may lead to complex eigenfrequencies. If the real
that the mode shapes of a brake rotor can be determined while part of the complex frequency is positive, then the system is
it is squealing. Included in the holographic image can be the unstable as the vibrations grow exponentially over time. Three
rotor as well as the pads, anchor bracket and caliper. The different methods to perform a brake squeal analysis are
technique can be applied to a brake system mounted on a present in Ansys 14.5.
brake dynamometer. Suspension components, such as the
1) Full Nonlinear Perturbed Modal Analysis.
spindle, spring and damper, can also be included to simulate
the on car performance of the brake system. An example of 2) Partial Nonlinear Perturbed Modal Analysis.
the value of double pulsed holography in investigating a
squealing brake was work done by Nishiwaki et al. in 1989. In 3) Linear Non-prestressed Modal Analysis.
the brake system that was being investigated it was apparent
that the mode shape of the vibrating brake rotor was stationary A full nonlinear perturbed modal analysis is the most accurate
with respect to the brake caliper. Hence, the mode shape is method for modeling the brake squeal problem. This method
also stationary with respect to the area of excitation. The rotor uses nonlinear static solutions to both establish the initial
was modified by changing the symmetry of the rotor about its contact and compute the sliding contact. A partial nonlinear
axis of rotation. The mode shapes of the modified rotor must perturbed modal analysis is used when a nonlinear solution is
now rotate with respect to the area of excitation, preventing required to establish contact but a linear analysis can be used
the rotor from vibrating in the original vibration mode. to compute the sliding contact.
A linear non-prestressed modal analysis is effective when the

stress-stiffening effects are not critical. This method requires
less run time than the other two methods, as no nonlinear base
solution is required. The contact-stiffness matrix is based on
the initial contact status.
IV. CONCLUSION
Presently, research into brake squeal is focused on specific

brake systems. The challenge for the future is to be able to
develop general techniques and guidelines to eliminate brake
squeal during the design stage. Given the complexity of the
mechanisms that generate brake squeal, it appears that general
guidelines are some way off in the future. For the present, the
reduction of squeal noise for specific brake systems is
achievable, with the additional knowledge acquired in each
case adding to the overall understanding of brake squeal.
Theoretical analysis of brake systems is difficult given the [2] N.M. Kinkaid, O.M. O‟Reilly, P. Papadopoulos. “Review Automotive
disc brake squeal”. Journal of Sound and Vibration 267 (2003) 105–166.
complexity of the mechanisms and the lack of an adequate
model for the friction interface that causes brake squeal. [3] Ouyang, H., Nack, W, Yuan, Y. and Chen, F. (2005) “Numerical analysis
However, this should not limit the development of simplified of automotive disc brake squeal: a review”, Int. J. Vehicle Noise and
models as valuable insight can be gained. Understanding Vibration, Vol. 1, Nos. 3/4, pp.207–231.
obtained by studying simplified models can assist in the
[4] Antti Papinniemi, Joseph C.S. Lai, Jiye Zhao, Lyndon Loader. “Brake
interpretation of experimental results and the development of squeal: a literature review”. Applied Acoustics 63 (2002) 391–400.
improved computational tools
[5] Utz von Wagner, Daniel Hochlenert, Peter Hagedorn, “Minimal models
Acknowledgment for disk brake squeal” Journal of Sound and Vibration 302 (2007) 527–539.
The authors would like to thank the anonymous reviewers [6] P. Liu, H. Zheng, C. Cai, Y.Y. Wang, C. Lu, K.H. Ang, G.R. Liu.
“Analysis of disc brake squeal using the complex eigenvalue method” Applied
for their comments which were very helpful in improving the Acoustics 68 (2007) 603–615.
quality and presentation of this paper.
[7] H. Hetzler, K.Willner. “On the influence of contact tribology on brake
References squeal” Tribology International 46 (2012) 23
[1] Ma´rio Tricheˆs Ju´ nior, Samir N.Y. Gerges , Roberto Jordan. “Analysis
of brake squeal noise using the finite element method: A parametric study”.
Applied Acoustics 69 (2008) 147–162.
Boiler Performance Optimization
Vipin Mankar Prof. Swapnil Thanekar Prof. Neeraj Wayzode
Department of Mechanical Engineering Department of Mechanical Engineering, Department of Mechanical Engineering,
Nagpur, India Tulsiramji Gaikwad-Patil College of Tulsiramji Gaikwad-Patil College of
Email: [email protected] Engineering and Technology, Nagpur, Engineering and Technology, Nagpur,
India India
Email: [email protected] Email: [email protected]
Abstract- Survival market is not only based on the quality of the does not include the blowdown loss in the efficiency
product but also the cost of the product. Today we are in era of determination process.
competition where performance of products, its production time
and production cost are considered as integral parts of quality.
Any enterprise ignoring to optimize cost will eventually be PARAMETERS AFFECTING THE BOILER PERFORMANCE:
perished by others who strive to achieve cost reduction by
maintaining or enhancing the quality of the product. So, we begin
this paper by quoting the definition of the energy efficiency in
context to the above discussion. Energy efficiency is "using less
energy to provide the same service". Here we have chosen the
most common utility i.e. Boiler and discussed about various
parameters that impact boiler efficiency and possible energy
conservation measures. The main purpose served by boilers is to
convey heat for process applications. Boilers are therefore
essentially operated to generate the required quantity and quality
of steam with least possible fuel consumption and thus at
minimum cost.
INTRODUCTION
Performance of the boilers, like efficiency and evaporation

ratio reduces with time, due to various reasons which include
poor combustion, heat transfer fouling, deterioration of fuel 1. Loss due to dry flue gas (Sensible heat): It represents
quality, water quality, poor operation and maintenance, high the % heat carried out by the flue gases. The stack
flue gas temperature, excess air supply to boilers etc. The
temperature should be as low as possible. However, it
boiler efficiency test helps to indentify the existing should not be so low that water vapor in the exhaust
performance level of the boiler and identify the necessary condenses on the stack walls. This is important in
corrective actions to bring the boiler performance to the fuels containing significant sulphur as low
optimized leading to conservation of energy. The British
temperature can lead to sulphur dew point corrosion.
Standard BS845: 1987 describes the methods and conditions
Stack temperatures greater than 200°C indicates
for the boiler testing. In India we are utilizing IS 8753: Indian potential for recovery of waste heat. It also indicates
Standard for Boiler Efficiency Testing. The boiler the scaling of heat transfer/recovery equipment and
performance are tested based on hence the urgency of taking an early shut down for
water / flue side cleaning. Controlling excess air to
i. The Direct Method: This is also known as input-output an optimum level always results in reduction in flue
method due to the fact that it need only the useful output gas losses; for every 1% reduction in excess air
(steam) and the heat input (i.e. fuel) for evaluating the there is approximately 0.6% rise in efficiency.
efficiency.
THEORETICAL COMBUSTION DATA – COMMON BOILER FUELS
ii. The Indirect Method: The indirect method is also called as
heat loss method. The efficiency is arrived at by Fuel kg of air req./kg of fuel CO 2% in flue gas achieved in
practice
subtracting the heat loss fractions from 100. The standard
Moisture entering the boiler with the fuel leaves as a
Solid Fuels
Bagasse 3.3 10-12 superheated vapour. This moisture loss is made up of the
Coal (bituminous) 10.7 10-13 sensible heat to bring the moisture to boiling point, the
Lignite 8.5 9 -13 latent heat of evaporation of the moisture, and the
Paddy Husk 4.5 14-15 superheat required to bring this steam to the temperature
Wood 5.7 11.13 of the exhaust gas
4. Heat loss due to moisture present in air:
Liquid Fuels
Furnace Oil 13.8 9-14 Vapour in the form of humidity in the incoming air,
LSHS 14.1 is superheated as it passes through the boiler. Since
this heat passes up the stack, it must be included as a
boiler loss.
TYPICAL VALUES OF EXCESS AIR LEVELS FOR DIFFERENT To relate this loss to the mass of coal burnt, the
FUELS moisture content of the combustion air and the
amount of air supplied per unit mass of coal burnt
Fuel Type of Furnace or Burners Excess must be known.
Air(% by 5. Heat loss due to incomplete combustion:
wt)
Products formed by incomplete combustion could be
mixed with oxygen and burned again with a further
Pulverized Completely water-cooled furnace for 15-20 release of energy. Such products include CO, H2, and
coal slag-tap or dry-ash removal various hydrocarbons and are generally found in the
flue gas of the boilers. CO is the only gas whose
Partially water-cooled furnace for dry- 15-40 concentration can be determined conveniently in a
ash removal boiler plant test.
6. Heat loss due to radiation and convection:
Coal Spreader stoker 30-60 The other heat losses from a boiler consist of the loss
of heat by radiation and convection from the boiler
casting into the surrounding boiler house. Normally
Water-cooler vibrating-grate stokers 30-60 surface loss and other unaccounted losses is assumed
based on the type and size of the boiler as given
Chain-grate and traveling-grate stokers 15-50 below:
 For industrial fire tube / packaged boiler =
Underfeed stoker 20-50 1.5 to 2.5%
 For industrial water tube boiler = 2 to 3%
Fuel oil Oil burners, register type 15-20  For power station boiler = 0.4 to 1%
7. Heat loss due to unburnt carbon in fly ash and

Multi-fuel burners and flat-flame 20-30 bottom ash:
Small amounts of carbon will be left in the ash and
Natural gas High pressure burner 5-7 this constitutes a loss of potential heat in the fuel. To
assess these heat losses, samples of ash must be
Wood Dutch over (10-23% through grates) 20-25 analyzed for carbon content. The quantity of ash
and Hofft type produced per unit of fuel must also be known.
Case Study: Onsite Observation for Multifuel

Bagasse All furnaces 25-35
travelling grate boiler
Black Recovery furnaces for draft and soda- 30-40 Particular Onsite Observed Data
liquor pulping processes o
Ambient air Temperature ( C) 31
BEE Chapter 2, Book 02
Gross calorific value (GCV) adjusted 4489
based on moisture present in as on
2. Heat loss due to evaporation of water formed due toH2
received coal sample (kCal/kg)
in fuel (%): The combustion of hydrogen causes a heat
Gross calorific value (GCV) as on 1055
loss because the product of combustion is water. This
received ash sample (kCal/kg)
water is converted to steam and this carries away heat in
the form of its latent heat. This loss thus varies as per the Average Steam Pressure (kg/cm2) 15.5
% H2 is the fuel. Average Steam Temperature (oC) 60.5
3. Heat loss due to moisture present in fuel:
o
Steam Temperature ( C) 520
Steam extraction no 1 7 TPH (P = 5 kg/cm2) De super heater 1 Temperature (oC) 210
Steam extraction no 2 9.4 TPH (P = 21 De super heater 2 Temperature (oC) 208

kg/cm2) De-super heater 3 Temperature (oC) 253.5
Percentage of boiler loading (%) 91.11
Average Wind Velocity (m/s) 3
Feed water Temperature (oC) – inlet 85
to economizer Fuel Analysis (%)
Feed water Temperature (oC) – outlet 213 Moisture 39.89
from economizer Ash 11.89
Power generation (kW) 400
Carbon 41.80
Air flow rate at FD fan– inlet to air 35
Hydrogen 1.38
preheater (m3/sec)
BOILER SURFACE Temperature 142.6 Nitrogen 1.15
(oC) Oxygen 3.89
37.6 and 39.9
 Boiler front side near coal 92.5
feeder 97.5
38.1 and 41.2 Results and Recommendations for Efficiency
 Boiler bagasse side
89.2 Improvement:
 Below travelling grate
(bagasse side)
Input/ Output Parameter kCal / kg of fuel %
 Boiler rare side, below
travelling gate Heat Input in fuel 4489 100
 Boiler road side Various Heat losses in boiler
 Below travelling
gate road side 1. Dry flue gas loss 6.43%
CO2 in exhaust gas (%) 7.5 2. Loss due to hydrogen in fuel 1.74%
O2 in exhaust gas (%) 9.5 3. Loss due to moisture in fuel 5.57%
Air Temperature (oC)– inlet to air 26 4. Loss due to moisture in air 0.24%
preheater 5. Partial combustion of C to
0.00%
Air Temperature (oC)– outlet fromair 103.5 CO
preheater 6. Surface heat losses and blow
5.00%
Furnace Temperature (oC) 677.3 down loss
7. Loss due to Unburnt in fly 2.81 %
Flue gasTemperature (oC) – inlet of 383.3
ash and
economizer
8. Loss due to Unburnt in
Flue gas Temperature (oC) – outlet 167.6
bottom ash
of economizer
Flue gas Temperature (oC) – outlet 131 Total Losses = 21.78 %
of air preheater
Boiler efficiency = 100 – (1+2+3+4+5+6+7+8) = 78.2%
Flue gas Temperature (oC)– ESP 109.8
outlet i.e. supply to chimney via ID
fan
Feed water tank Temperature (oC) 64.6 RECOMMENDATION:
o
Deaerator tank Temperature ( C) 81.9
AREAS OF IMPROVEMENT
o
Feed water line Temperature ( C) 70.6
Combustion of coal: -
Water Temperature (oC) - Inlet of 84.7
economizer Efficient combustion of fuel requires availability of oxygen at
Water Temperature (oC) – outlet of 213.3 reactive condition of fuel. Spreader stoker is suitable for 30%
eco Oversize, 30% Size, 40% undersize.
Outlet of pre-super heater header 328 It is essential that at operating firing rate of around 4 tons per
Temperature (oC) hour, 1.3 tons per hour should fall on last 30% length, 1.3 tons
Outlet of super heater header 388 per hour in the middle zone and rest in last 30% or in
Temperature (oC)
suspension. Such distribution can be verified only in cold in length, carrying saturated steam at 8kg/cm2 would
condition. waste 25 kl of furnace oil in a year.
Effect of the above on Air to fuel ratio: - CONCLUSION:

The reduction of heat losses due to dry flue gases, moisture
Air follows least resistance path. Zone where coal bed height present in fuel and air, incomplete combustion force the major
is less, air tends to flow more in that zone. Therefore unless impact on the performance of boiler. In the case study to
height of coal bed is uniform, air flow cannot be adjusted. improve the efficiency of the boiler the requirements for air
combustion of coal is recommended. Also some energy
At present to maintain the desired unburnt Carbon, air to fuel conservation methods also discussed.
ratio is 11.66 kg/kg. Theoretical requirement of air is 5.16
Kg/Kg. Thus, about 126% excess air is being used.
REFERENCES:
Normally 50% excess air is recommended, provided  International Journal for Scientific Research and Development,
vol. 1, Issue 3, 2013
distribution of coal is uniform on grate.
 Power plant engineering by A. K. Raja, Amit P. Srivastava,
Reduction of air can result into savings of Manish Dwivedi, 2006
 Energy performance assessment of boiler”, Bureau of Energy
Efficiency, PP 1-22.
 Energy Hand Book, Second Edition, Von Norstand Reinhold
Savings potential: Company- Robert L. Loftness
 Pawan Kumar, Training manual on energy efficiency for small and
Increase in efficiency- reduction in heat losses by stack medium enterprises, Asian Productivity Organization, 2010.
 Heat Rate Improvement Reference Manual, EPRI Palo Alto, CA:
= (126%- 50%) x 5.16 kg/kg x0.24kcal/kg-oC x (130- 1998. TR-109546
 Mircea, Malvina Baica, Application of the methodology to
30)oC/4489 kcal/kg estimate the energyecologic efficiency of fluidized bed boilers.
Elsevier Science Ltd 2000.
= 2.01%
Fuel savings
= 2.01% x (2.16 x 1000) kg/hr x 24hrs/day x 300 days per year
=313 tonnes of coal
Savings in INR
= 313 tones X INR 3700/ton
= 11.58 lakh per year
Energy Conservation/ Monitoring Parameters for Boilers:
 Remove soot deposits when flue gas temperature

raises 40°C above the normal. A coating of 3mm
thick soot on the heat transfer surface can cause an
increase in fuel consumption of as much as 2.5%.
 Recover heat from steam condense. For every 6°C
rise in boiler feed water temperature through
condense return, there is 1% saving in fuel.
 Improve boiler efficiency. Boilers should be
monitored for flue gas losses, radiation losses,
incomplete combustion, blow down losses, excess air
etc. Proper control can decrease the consumption
upto 20%.
 Use only treated water in boilers. A scale formation
of 1mm thickness on the waterside would increase
fuel consumption by 5-8%.
 Stop steam leakage. Steam leakage from a 3 mm-
diameter hole on a pipeline carrying steam at 7kg/cm 2
would waste 32 kl of fuel oil per year.
 Maintain steam pipe insulation. It has been estimated
that a bare steam pipe, 150 mm in diameter and 100m
DESIGN OF AN ALTERNATIVE
ARRANGEMENT FOR STACKING OF
BARE WELDING RODS
Prof. Sachin Naik, 2, Dean, Mechanical Department, Tulsiramji
1, Asst. Prof., Mechanical Department, Cummins Gaikwad- Patil college of Engg,
College of Engineering for women, Nagpur. [email protected]
1
[email protected] Pradeep Sargaonkar
Prof. Dr. A.R. Bapat 3, HOD, Mechanical Department, Cummins College
of Engineering for women, Nagpur.
[email protected]
Abstract: Automation in production is need of enable them to stack the rods directly in the rack
today’s industry. Automation enhances the production, without any human intervention. This paper focuses on
increases accuracy, improves quality and reduces the the basic steps involved in the welding rod manufacting
chances of accidents. Keeping this in mind we have and the design of new system for stacking of rods.
taken problem from ‘Weld Well Industries Pvt. Ltd’,
the manufacturers of welding rods. In industry, the wire Keywords: Stacking of rods, welding electrode process,
rods are being cut by the cutting machine and are automation for collection of bare electrodes
collected in a pot. Then the cut rods are collected in a
rack manually. The company needs a system which will
1.0 INTRODUCTION Weldwell Electrodes Pvt. Ltd was
established in the year 1985, the company got
In fabrication of various equipments and reputation in the field of electrode making from last
constructions works generally we need welding 30 years, and hence are one of the trustworthy
electrodes made up of Mild steel & its alloys. M.S. manufacturers and suppliers of a gigantic compilation
Welding Electrode is the most widely used core wire. of Welding Electrodes & Mig Wire. Main product of
the company consists of Mild Steel Electrodes, Low
Welding electrodes consists of steel core Hydrogen Electrodes and Creep Resistant Electrode
wire and flux Besides mild steel, nickel, Nickel- that are manufactured as per the preset IS, AWS,
copper, Nickel irons are also used in MIG & TIG LRS, DNV, BV, IRS, ABS, BIS and DIN standards.
welding.
years, they have gained immense trust from their
To improve the product Quality Company customers and consumers.
frequently does third party inspection, R & D on the
existing and for new components. Company has 3.0 STEPS INVOLVED IN ELECTRODE
marked its presence in business, and proved MANUFACTURING
themselves as an example for their peers. In these
3.1 Step I: Wire Drawing
A 5 mm diameter wire is drawn through the
rollers by two step reduction process. In Each step
0.5mm dia. is reduced.
Figure 3.4: Powder formed for flux coat preparation
3.4 Step IV: Flux Coating
Figure 3.1: Wire Drawing Process When a flux-coated electrode is heated up,
part of the flux burns and forms a gaseous shield
which keeps the oxygen away from the weld. This
prevents the formation of a poor weld which occurs
when iron burns in oxygen. Another part of the flux
melts and mixes with the weld pool, the impurities of
which float and are easily removed when the weld
joint cools down.
Figure 3.2: Dry Drawing Lubricant used by Weld Flux coating on the electrodes ensures a
well company weld with good mechanical properties, chemical
3.2 Step II: Wire Cutting composition and weld metal cleanliness
The wire drawn from the Step-I is

then cut into the required lengths by cutting machine
as is collected in the container as shown.
Figure 3.5: Flux coating by extrusion
3.5 Step V: Flux Drying (De-moisturizing)
Figure 3.3: Cut wire collected in container

Electrodes must be kept dry. Moisture
3.3 Step III: Flux Coat Preparation
destroys the desirable characteristics of the coating
and may cause excessive spattering and lead to Weight of electrodes is measured and
porosity and cracks in the formation of the welded checked. Also core wire diameter, length and flux
area. Electrodes exposed to damp air for more than coating thickness, moisture is inspected. [1]
two or three hours should be dried by heating in a
suitable oven for two hours at 500°F (260°C).
Figure 3.8: Inspection of electrode

4.0 SPRING DESIGN
Let Dm/d = c (Spring Index)

Figure 3.6: Flux de-moisturizing in oven The spring will be subjected to direct shear
load and a torque T.
3.6 Step VI: Finishing [1] The resultant shear stress on the section will be
τmax = T/Zp + F/A…….(1)
The flux at end of the welding rod is removed by For Round Wire
brush and other end is chamfered by means of Zp = π/16 x d3
grinder. It is done so that one end must be properly A = π/4 x d2
gripped to the welding holder and proper arc T = F.Dm/ 2
formation at other end. Both these process are done at τmax = 8FDm/πd3 + 4F/πd2
a time. = 8FDm/πd3 [1+ 0.5d/Dm]
= 8FDm/πd3 [1+ 0.5/c]
= K1 8FDm/πd3
The quantity [ 1+ 0.5/c] is called shear stress
multiplication factor and is denoted by K1.
The deflection of the helical spring having n,
effective turns is given by
δ = 8FDm3n/ Gd4
The equation for the spring stiffness (Ks) is given by,
Figure 3.7: Finishing of electrodes Ks = F/δ
= Gd / 8c3n
3.7 Step VII: Quality Checking & inspection
As per our design consideration, we need the Ball Bearing of size 6205 (i.e. Dia =25mm bore) is
spring which will get compressed by 5mm under the used for the wheels of the trolley
action of 50 N Force.
5.0 ALTERNATIVE ARRANGEMENT FOR
It means the spring should have a stiffness
of Ks= 10N/mm. COLLECTION OF BARE RODS
i.e Fmax = 50N

Ks = 10N/mm
Free Length =40mm
Material Cr- Vanadium Steel (Cr-V Steel)
From Table VIII-9

Sys = 770MPa,
G = 85 GPa
Di =Dm-d+d(c-1) Figure 5.1: Conceptual model of system
=10 (assumed)
d = 10/(c-1)
No. of effective turns,
n = Gd/ 8c3Ks
= 85x 103 x 10
80 c3(c-1)
= 10625/ c3(c-1)
Figure 5.2: Electrode exit arrangement
Total no. of turns

n1 = n+1.75
Minimum free length
= n1 X d + δmax
40 = [10625/ c3(c-1) +1.75] 10/(c-1) +
50/10
After solving this equation we get
Figure 5.3: Spring stopper having weight sensor
C = 4.5 (Spring index)
d =2.85mm
= 3mm (Wire Diameter)
Dm = 12.5mm (Mean Diameter)
3. Harald Strolimeier and Gottlieb Pernkopf, Kapfenberg,,
“Apparatus for Stacking and packing cylindrical or rod-
shaped work pieces-patent.” United States Patent
Office, 2012.
4. Bob Romig, “Stacking Lumber for Drying.”, The OHIO
State University US. School Natural Resources, 2021
Coffey Road, Columbus, Ohio 43210.
5. Vincent m. Altamuro, “Materials Handling Systems”,
Columbus McKinnon Corp
6. Nimmo Jr., Philip E. (Wayne, NJ) , Townsend, Richard
A. (Rockaway, NJ), “Ribbon package and process for
production thereof US 3735862 A”, Sun Chemical
Corporation (New York, NY).
Figure 5.4: Drafting of the trolley prepared 7. Haley, “Magnetic material feed control US 2962150
A”, United States Patent Office
8. Hoar, “Counting and packaging apparatus US 2632588
6.0 CONCLUSION
A”, United States Patent Office
9. Roland W. Wagner, William K. Switzer, “Apparatus
After the cutting of wire, the bare rods are
for and method of accumulating and thereafter
collected in container which is further stacked in a releasing, en masse, a pre-determined number of
trolley manually. Two operators were engaged for the individual, elongated, cylindrical articles”, United
collection and stacking of wire rods in the trolley. States Patent Office
10. Design Data Book by B.D. Shiwalkar.
The time needed for collection and stacking

of 100 bare rods was around 4.5 to 5 mins with
existing system.
The proposed system eliminates the one of

the operators. Also the time required for the
collection of 100 bare rods is reduced to around 2.5
to 3 mins. Hence adopted by the company for the
future work.
7.0 REFERENCE
1. Company website for details:

http://www.weldwellelectrodes.com
2. Yrd. Doç. Dr. Oguzhan Yılmaz, “Electrode Materials
and electrode selection”, Department of Mechanical
Engineering, University of Gaziantep, Welding
Technology, pp 1-30.
Experimental Investigation of Solar Air Heater
Prof. Swapnil Thanekar Mr. Shailendra Ukirde Prof. Vipin Mankar
Department of Mechanical Engineering, KSB Pumps, Pune, India Department of Mechanical Engineering,
Tulsiramji Gaikwad-Patil College of Email: shailendra.ukirde@ksbtech,com Tulsiramji Gaikwad-Patil College of
Engineering and Technology, Nagpur, Engineering and Technology, Nagpur,
India India
Email: [email protected] Email: [email protected]
Abstract: In the current scenario the whole world is

looking for solar energy because of its abundant availability, The
solar energy has found good response in heating applications and
thus air heater is most commonly used solar application. It is
advantageous and its main features are its cost-effectiveness. In
this paper we are focused on how to improve the performance of
glass covered solar air heater with help of experimental
investigation of interrelationship of various parameters to
understand its behavior and further opportunities to optimize
and predict its performance under variable environmental as
well as working conditions. Our main motive is to improve the
Air outlet temperature, which is the function of inlet air, plate
and glass temperature. To optimize productivity we are Figure No.1
segregating the performance efficiency of air heater in 3 factors
as follows, to proper utilize the solar flux and to raise the air Ub=ki/δb=0.05/0.075=0.67W/m2K
outlet temperature.
Us= (L1+L2) L3 ki/L1L2δs=0.163W/m2K
The efficiencies are categorized as follows:
1) Efficiency when solar radiations are absorbed by air as well
Experimental approach
as oil and there is no fall in oil temperature. Velocity measured with Anemometer of air through duct of
2) Efficiency when heat to the air is supplied by solar radiation diameter 6cm = 6.5m/s
as well as oil. Density of air at average intake air temperature
3) Efficiency when air is being heated only due to the heat 430C=1.08kg/m3
released by oil. This term will not exist because the Mass flow rate m’= ρ A v
calculated efficiency in this case will always come as infinity = 0.0198 kg/s
since S=0 W/m2. Measure mV with the help of pyranometer
INTRODUCTION Convert it into incident solar flux (W/m2)
S = mV*1000/13.27
Burned engine oil is filled in the inner bed as shown in the Useful heat gain for air quair= mairCpair(Toair-Tiair)
figure 1. In this case the incident solar radiations are utilized Useful heat gain for oil quoil = moil Cpoil (Tfinal-Tinitial)/3600
for raising the temperature of air as well as the temperature of Useful heat gain for oil quoil = moil Cpoil (Tfinal-Tinitial)/3600
oil. Hence the useful heat gain will be the addition of heat Net Total useful heat gain qu = quair + quoil
gained by air as well as heat gained by oil. Useful heat gain is Solar air heater efficiency = qu/S*A
calculated by both the cases, viz. by theoretical and Thus efficiency of solar air heater is calculated for the day and
experimental approach, and on the basis of it their efficiencies Graph of solar air heater efficiency vs. time is plotted.
are calculated and compared. Analysis:
Air outlet temperature Tfo = 58oC
Mean film temperature = (Tp+Tg)/2 = 351 K
Properties at 351 K
ρ = 0.995 Kg/m3 , Cp = 1010J/KgK ,  = 20.80 *10-6 Ns/m2 , k

= 0.03 W/mK
Equivalent diameter = 4*0.9*0.08/2(0.9+0.08) =0.1469m

Average velocity = 0.0198/(0.995*0.9*0.08) =0.2763 m/s
Re = 0.995 *0.2763* 0.1469/(20.80*10-6)
S dA = hfp(Tp-Tf)dA + ho(Tp-To)dA + dA(Tp4-Tg4) Re = 1941.61
(1/p+1/g-1)
dA(Tp4-Tg4) = hr(Tp-Tg)dA
(1/p+1/g-1)
S dA = hfp(Tp-Tf)dA + ho(Tp-To)dA + hr(Tp-Tg)dA
For Fluid
m’CpfdTf = hfp(Tp-Tf)dA + hfg(T g-Tf)dA
For Glass
hr(Tp-Tg)dA = hw(Tg-Ta)dA + hfg(T g-Tf)dA
For Oil
ho(Tp-To) A = Cpoovo(dTo/dt) + Ub(To-Ta) A
m’CpfdTf = hfp(Tp-Tf) dA + hfg(T g-Tf) dA

Nu = 0.0158 * ( 1941.61 )0.8
m’CpfdTf / dA= hfp(Tp-Tf) + hfg(T g-T f) Nu = 6.74
= hfp Tp- hfp Tf + hfg T g- hfg Tf hfp = 6.74 * 0.03/0.1469 =1.378W/m2K
substituting this value in equation(a)
m’CpfdTf / dA= hfp Tp + hfg Tg-Tf(hfp + hfg) we get Tfo = 54.00C
put (hfp Tp + hfg T g) = a % error =(58-54)/58 =0.0689 =6.89%
(hfp + hfg) = b Inlet air Plate Glass Measure Outlet Air % Error
m’CpfdTf / dA = a-Tf*b temperat Temperat Tempera d Outlet Temperature By
1 dTf = dA ure(oC) ure (oC) tu-re Air Tfo = Tfi +
a-Tf*b m’Cpf Tfi Tp (oC)Tg Tempera ((Tg+Tp-2Tfi )/2 *
A = - 1 ln 1- (Tfo-Tfi) b tu- (1-exp{-2hfpA
m’Cpf b a-Tfi b re(oC) /m’Cpf}))
49 80.0 65.0 58.0 54.0 7%
51 100.0 85.0 63.8 59.8 6%
(Tfo-Tfi) = a-Tfib 1 - exp - b A 50 105.0 88.0 63.8 59.8 6%
b m’Cpf 52 95.0 78.0 63.3 59.3 6%
Substituting (hfp Tp + hfg T g) = a 52 104.0 87.0 65.2 61.2 6%
(hfp + hfg) = b 53 103.0 86.0 65.8 61.8 6%
52 94.0 77.0 63.1 59.1 6%
for simplicity let us assume h fp = hfg
54 90.0 73.0 63.8 59.8 6%
now a=hfp(Tp+Tg) 52 72.0 55.0 58.4 54.4 7%
and b=2 hfp 45 54.0 37.0 49.1 45.1 8%
Tfo-Tfi = (Tg+Tp-2Tfi)/2 * (1-exp{-2hfpA /m’Cpf}) 45 49.0 32.0 48.0 44.0 8%
Tfo = Tfi + ((Tg+Tp-2Tfi)/2 * (1-exp{-2hfpA /m’Cpf})) ----------- 44 46.0 29.0 46.6 42.6 9%
----------------------------(a) TABLE NO. 1
If T fi , T g , Tp are known at any instant then Tfo can be
calculated for that particular instant.
This table shows that the outlet air temperatures obtained by
Sample calculation the derived formula are nearly equal to the measured outlet air
temperatures.
Time: 9 a .m.
Plate temperature Tp = 80oC

Conclusion:
Glass Temperature Tg = 76oC
Air inlet temperatureTfi = 49oC
The governing equation for the relation between incident solar
flux and plate temperature for oil based glass covered solar air
heater is found out to be exponential. The relation is y = -3E-
06x2 + 0.0792x + 47.018 with regression value R2 =0.9998.
Here in this equation y= Plate temperature in oC and
x= Incident Solar flux in W/m2. This equation is quite
satisfactory over a large span of incident solar flux ,because
the maximum % error in the plate temperature found by using
this equation could be not more than 3% and It is obtained
only in single case.
Graph No.1 Solar Flux Vs Time
Let us divide the performance efficiency of this air heater in 2) Incident Solar Flux Vs Oil Temperature
following 3 zones
efficiency when solar radiation are absorbed by air as well as GRAPH NO. 4 SOLAR FLUX VS. OIL TEMPRATURE
oil and there is no fall in oil temperature. Incident Oil oil temperature (oC) %Error
efficiency when heat to the air is supplied by solar radiation as Solar temperature y = 60.073e0.0003x
well as oil. Flux(W/m2) (oC) R2 = 0.9047
Efficiency when air is being heated only due to the heat 666.9 70 73.38 -5%
released by oil. This term will not exist because the calculated 896.8 73 78.62 -8%
efficiency in this case will always come as infinity since S=0 957.0 75 80.05 -7%
W/m2 859.1 76 77.73 -2%
Graph No.2 % Efficiency Vs Time 979.7 79 80.60 -2%
911.8 79 78.97 0%
Mathematical Modeling for glass covered oil based flow
663.1 74 73.30 1%
over absorber plate solar air heater
557.6 70 71.01 -1%
1) Incident Solar Flux Vs Plate Temperature
346.6 65 66.66 -3%
52.8 61 61.03 0%
TABLE NO. 3
Zone II
GRAPH NO. 3 INCIDENT SOLAR FLUX VS OIL TEMPERATURE
Solar Plate Plate temperature measured %

Flux Temperatur by y = -3E-06x2 + 0.0792x Error
(w/m2) e oC + 47.01 8 R2 = 0.9998 The governing equation for the relation between incident
666.9 98.08 99.84 -2% solar flux and oil temperature for oil based glass covered
896.8 115.18 118.04 -2% solar air heater is found out to be exponential. The
957.0 119.67 122.82 -3% relation is y = 60.073e0.0003x with regression value
859.1 112.38 115.06 -2% R2 =0.9047. Here in this equation y= oil temperature in
o
979.7 121.35 124.61 -3% C and x= Incident Solar flux in W/m2. This equation is
911.8 116.30 119.24 -3% quite satisfactory over a large span of incident solar flux
663.1 97.80 99.54 -2% ,because the maximum % error in the plate temperature
557.6 89.95 91.18 -1% found by using this equation could be not more than 8%
346.6 74.25 74.47 0% and It is obtained only in single case.
52.8 52.39 51.20 2% Solar Flux Vs air outlet Temperature
Table No. 2
Graph No. 4 Solar Flux Vs Air Outlet Temperature Solar air heaters are significantly saves the household
emission; reducing the amount of air pollution and greenhouse
Solar Measured Air Air Outlet Temperature % Error gases that created from the use of fossil fuels. The cost of
Flux Outlet by y= installing a solar air heater can be rather expensive, however
(W/m2) Temperature(oC) 32.586x0.0985 there are many local utility companies or state agencies
R2 = 0.9032 offering rebates for solar systems. To make the solar air
666.9 58.0 61.830 -7% heaters more effective we enhance the efficiency of the solar
896.8 65.3 63.660 2% air heater by dividing ino the following ways.
957.0 62.8 64.070 -2% 1 Efficiency when solar radiation are absorbed by air as
859.1 63.3 63.392 0% well as oil and there is no fall in oil temperature.
979.7 64.1 64.217 0%
911.8 64.5 63.765 1% 2 Efficiency when heat to the air is supplied by solar
663.1 63.3 61.796 2% radiation as well as oil.
557.6 63.0 60.750 4%
3 Efficiency when air is being heated only due to the
346.6 57.2 57.971 -1%
52.8 48.3 48.158 0% heat released by oil. This term will not exist because
Table No. 4
the calculated efficiency in this case will always
The governing equation for the relation between incident solar
flux and air outlet temperature for oil based glass covered
solar air heater is found out to be power. The relation is y =
32.586x0.0985 with regression value R2 =0.9032. Here in this
equation y= air outlet temperature in oC and x= Incident Solar
flux in W/m2. This equation is quite satisfactory over a large
span of incident solar flux, because the maximum % error in
the plate temperature found by using this equation could be
not more than 7% and It is obtained only in single case.
Glass Covered Solar Air Heater with Flow over Absorber
Plate
(Without Oil Bed)
Equation (a) for finding out air outlet temperatures which is
the function of inlet air, plate and glass temperature can be
used for finding out outlet air temperature for the same solar ir
heater. Here we will use the relation derived in chapter 7for
finding out plate temperature and glass temperature.
Time Solar Inlet Plate Glass Outlet air Useful Heat %
Flux air Temperatu Tempe temperature Gain (W) Efficie
(W/m2) temper re(oC) by rature by Tfo = Tfi -ncy come as infinity since S=0 W/m2
ature(o y=48.738 (oC) + ((Tg+Tp-
C) e0.001x 2Tfi)/2 * (1-
exp{-2hfpA REFRENCES:
/m’Cpf}))
9 715.9 49 99.719 82.7 57.9 178.2121 14.6%
 Bhushan B, Singh, A review on methodology of artificial
10 896.8 50 119.488 102.5 63.7 273.1654 17.8%
roughness used in duct of solar air heaters. Energy 2010;35:202–1
11 957.0 50 126.913 109.9 64.5 288.78 17.6%  Yeh HM, Ho CD. Solar air heaters with external recycle. Applied
12 859.1 52 115.070 98.1 63.5 230.3451 15.7% Thermal
1 979.7 52 129.815 112.8 66.7 292.5868 17.5%  Engineering 2009;29:1694–701.
2 911.8 53 121.303 104.3 65.7 252.4339 16.2%  Singh D, Bansal NK. Analysis of a glass solar air heater. Energy
3 663.1 52 94.595 77.6 59.2 143.9202 12.7% Conversion
4 557.6 54 85.124 68.1 58.8 95.4978 10.0%  And Management 1983;23(4):231–6
5 346.6 52 68.931 51.9 53.8 35.58799 6.0%  Hasan A. Phase change material energy storage system employing
6 52.8 44 51.378 34.4 44.6 10.99121 12.2% palmitic acid. Solar Energy 1994;52:143–54.
Table No. 5  Mohamad AA. High efficiency solar air heater. Solar Energy
1997;60(2):71–6.
 Naphon P, Kongtragool B. Theoretical study on heat transfer
Graph No.5 Comparison of Efficiencies for Solar Air characteristics and performance of the flat-plate solar air heaters.
Heater With And Without Inclusion Of Oil. International Communication of Heat Mass Transfer
2003;30:1125–36
CONCLUSION  Naphon P. On the performance and entropy generation of the
double-pass solar air heater with longitudinal fins. Renewable
Energy 2005;30:1345–57.
Parametric Optimization of GMAW Welding
Process
Swapnil A.Mahajan
Department of Mechanical Engineering
Bhonsla College of Engineering and Research
Akola, India
[email protected]
Abstract— The study aimed at the investigation of the effect The quality of the welded material can be evaluated by
of preheating, shielding gas flow rate and heat input on the many characteristics, such as bead geometric parameters
hardness of weldment. In this study, 304 stainless steel was (penetration, width and height), hardness, residual stresses and
bonded by MIG welding with Argon as a shielding gas and deposition efficiency (ratio of weight of metal deposited to the
hardness properties of the welded samples at different points
from the weld center line was investigated. For that purpose
weight of electrode consumed). These characteristics are
welding was done with different level of preheat, shielding gas controlled by a number of welding parameters, and, therefore,
flow rate and heat input. Welding samples were characterized by to attain good quality, is important to set up the proper
means of hardness test on optical Brinell hardness tester. welding process parameters. Out of these properties hardness
Hardness test revealed that for all welding parameters hardness is important property because hardness determines the impact
in HAZ and weld metal was higher than parent metal. strength, toughness and crack susceptibility of welded joint.
With application of design of experiment (DOE) Unfortunately, an underlying mechanism connecting
mathematical relationship between the welding process input welding parameters and quality characteristics is usually not
parameters and output variable like hardness of welded joint in known. Traditionally, it has been necessary to determine the
order to determine the welding input parameters that lead to
desired weld hardness. Preheat, shielding gas flow rate, and heat
weld input parameters for every new welded product to obtain
input are selected as input parameter and hardness as output a welded joint with the required specifications. To do so,
parameter. By application of response surface methodology and requires a time-consuming trial and error development effort,
Tanguchi method of DOE, relationship between these parameters with weld input parameters chosen by the skill of the engineer
and Hardness was developed. or machine operator. Then welds are examined to determine
whether they meet the specification or not. Finally the weld
The experiment result show that the heat input has greatest
effect. Gas flow rate has second largest effect on hardness and parameters can be chosen to produce a welded joint that
preheat has very little effect on hardness of weldment. closely meets the joint requirements. Also, what is not
achieved or often considered is an optimized welding
parameters combination, since welds can often be produced
with very different parameters. In other words, there is often a
Keywords— MIG, SS 304, Preheat Gas flow rate, Heat input; more ideal welding parameters combination, which can be
Hardness.
used if it can only determined.
In order to overcome this problem, various optimization
methods can be applied to define the desired output variables
I. Introduction through developing mathematical models to specify the
relationship between the input parameters and output
The GMAW welding process is easily found in any variables. In the last two decades, design of experiment (DoE)
industry whose products require metal joining in a large scale. techniques has been used to carry out such optimization.
It establishes an electric arc between a continuous filler metal
The Taguchi method is a systematic application of design
electrode and the weld pool, with shielding from an externally and analysis of experiments for the purpose of designing and
supplied gas, which may be an inert gas, an active gas or a improving product quality. In recent years, the Taguchi
mixture. The heat of the arc melts the surface of the base metal method has become a powerful tool for improving
and the end of the electrode. The electrode molten metal is productivity during research and development so that high
transferred through the arc to the work where it becomes the quality products can be produced quickly and at low cost.
deposited weld metal (weld bead).
One of the most widely used methods to solve this
problem is the response surface methodology (RSM), in which
the experimenter tries to approximate the unknown The Taguchi‟s parameter design approach has been used to
mechanism with an appropriate empirical model, being the obtain the above objective.
function that represents it called a response surface model
Identifying and fitting from experimental data a good response
surface model requires some knowledge of statistical III.SYSTEM DEVELOPMENT
experimental design fundamentals, regression modeling
techniques and elementary optimization methods To study the effect of Welding Process parameter on
weld Penetration in TIG Welding a heat source is required.
Heat source produce an electric arc to generate heat to melt the
GAS METAL ARC WELDING
II. metal and form a weld for this purpose continuous supply of
either direct or alternating electric current. The experiments
(GMAW) OF AISI 304 were carried out on INARC400-i series IGBT Inverter based
arc welding power source with soft switching technology
Gas Metal Arc Welding (GMAW) is a welding process
This TIG welding machine has fallowing technical
which joins metals by heating the metals to their melting point
specifications
with an electric arc. The arc is between a continuous,
consumable electrode wire and the metal being welded. The Input power 18.4 KVA
arc is shielded from contaminants in the atmosphere by a Current range 20A-400 A
shielding gas.
Duty cycle 60%
A. Objective solution to be used Weight 43 Kg
There remains a continuing requirement in the art of TIG Input supply 380-440 V
welding to achieve even greater penetration levels of welding
Efficiency at full load 89%
involving penetration activating fluxes without affecting the
quality of the weld to end use and applications and also to Power factor 0.95
improve upon the productivity for welding by greater
Ambient Temperature 40 degree C
penetration of weld without degrading the microstructure and
mechanical properties. Hence need of optimization rises. A. Details of Test Specimens
1. Comparative study of coated uncoated sample. AISI304 Steel material plate is used, as it has a very large
2. Find out the most effective parameter by Taguchi Method. scale application in the process industry. Sample of
3 .Enhancement of weld Penetration. 100mm×70mm×5mm size has been used as a work piece
4. Study the effect on tensile strength on welded sample. material and bead on welding is done for present
experiments.
The SS304 sheet is converted in the desired work pieces
B. Different Phase of size by using shearing operation. After shearing the work
Experimentation pieces are straighten by holding them in a press. The burr
from the cut edges of the work pieces is removed by
Phase-I manual filing.
1. Development of experimental setup providing varying Table I- Chemical Composition of Test specimens
range of input parameters in ATIG Welding and measuring the Chem
various responses.
ical
2. Investigation of the working range and the level of ATIG C Si Mn P S Cr Ni
Analy
Welding parameter (pilot run) affecting the selected quality
characteristics, by using one factor at a time approach. sis
Phase-II 0.03
% 0.066 1.57 0.017 <0.03 18.05 8.57
6
1 .Investigation of the effect of the ATIG process parameter
on quality characteristics that is welding penetration.
2. Optimization of quality characteristics of ATIG Welding.
C. Activated Flux Powder
a) Prediction of optimal sets of ATIG Welding process Activated flux can increase the joint penetration, mainly
parameter because the surfactant (surface-active element) in the molten
b)Prediction of optimal value of quality characteristics pool switches the surface tension gradient, and consequently
reverses the Marangoni convection pattern, resulting in a
welding penetration.
deep-penetration weld. To clarify this uncertainty, this study
c)Determination of confidence interval (95%). used following flux powder.
3. Experimental verification of optimized quality
characteristics.
3 250 4.1
4 300 5.0
Table II- Activated Flux Powder Used
Sr. No 1 2 3 4 5
Activated
Flux Cr2o Tio2 Al2o3 Cao Sio2
Powder 3
c. Preparation of Specimens
The SS304 sheet is converted in to the desired

100mm×70mm×5mm size by using shearing operation. After
shearing the work pieces are straighten by holding them in a
press. The burr from the cut edges of the work pieces is
removed by manual filing the plate surface was ground using FIG-I Graph Effect of Welding Current on Weld Penetration
400 grit (silicon carbide) flexible abrasive paper to remove
impurities, and then cleaned with acetone .The Thirty number E. Effect of gas flow rate on
of SS304 plate of are prepared. The various flux powders were weld penetration
mixed with acetone to make a paint-like consistency. A brush
was used to apply the mixture on the joint surface to be
welded. The mean coating density of flux powder was 4.3 In the second case Shielding gases are used in GTAW in
mg/cm2.The four set of plates are made from thirty plates. order to prevent atmospheric contamination of the weld metal.
This contamination can produce porosity, weld cracking,
Table III- Chemical Composition of Test specimens scaling and even change in the chemical composition of
Sr.No melted material. Besides shielding
1 2 3 4 5 6
Gas also has a large influence on the stability of the

TiO2 Cr2O3 Al2O3 Uncoated CaO
electric arc. Gases with low ionization potential facilitate the
Sample SiO2
Coated Coated
Coated
ignition of the electric arc and those with low thermal
Coated Coated
conductivity tend to increase the arc stability. Argon is the
most used GTAW shielding gas. It has low ionization
potential and is heavier than air, providing an excellent
D. Effect of current on weld shielding of the molten weld pool.
penetration
To study the effect of gas flow rate on weld penetration
with following parameter constant Current 200 A, Welding
speed 1.6 mm/s and torch angle 60 degree. Following result
Welding current is the most influential parameter because are observed for various Gas flow rate.
it affects bead shape, controls the rate at which electrode is
melted and therefore also controls the deposition rate, heat Table V: Effect of Welding Current on Weld Penetration
affected zone, the depth of penetration, and the amount of base
metal melted. For studying the effect of current on weld
penetration with following parameter constant. Sr.N Gas flow Weld penetration
o rate(LPM) in mm
1 5 3
Gas flow rate 10 LPM, Welding speed 1.6 mm/s and torch 2 10 3.5
angle 60 degree. Following result are observed for various
3 15 5.0
current.
Table IV: Effect of Welding Current on Weld Penetration
Sr.N Weld penetration

o Welding current A in mm
1 150 2.5
2 200 3.1
align itself along the axis of the electrode, the weld
pool shape is different in each case, and so is the shape of the
weld bead. To study the effect of torch angle on weld
penetration with following parameter constant Current 200 A,
Gas flow rate 10 LPM, 1.6 mm/s and torch angle 60 degree.
Following result are observed for various torch angles on weld
penetration.
Table VI: Effect of Torch Angle on Weld Penetration
Sr.N Torch Angle Weld
o in degree penetration in mm
1 60 5
2 75 3
3 90 1.6
Fig II: Graph Effect of Welding Gas Flow Rate on Weld
Penetration
F. Effect of welding speed on

weld penetration
In the third case, the effect of time on undercut Welding
speed is the linear rate at which an arc is moved along the
weld joint. With any combination of welding voltage and
welding current, the effect of changing 106 the welding speed
confirms to a general pattern. To study the effect of Welding
speed on weld penetration with following parameter constant
Current 200 A, Gas flow rate 10 LPM and torch angle 60
degree. Following result are observed for various Welding
speed.
Table VI: Effect of Welding Speed on Weld Penetration
Sr.N Welding speed Weld penetration
o in mm
FIG IV: Graph Effect of Torch angle on Weld Penetration
1 6.66 3
III. Taguchi’s Experimental Design and Analysis
2 3.33 3.5
3 1.66 5.0
Taguchi‟s comprehensive system of quality engineering is
one of the greatest engineering achievements of the 20th
century. His methods focus on the effective application of
engineering strategies rather than advanced statistical
techniques. It includes both upstream and shop-floor quality
engineering. Upstream methods efficiently use small-scale
experiments to reduce variability and remain cost-effective,
and robust design for large –scale production and market
place. Shop-floor techniques provide cost based real time
methods for monitoring and maintaining quality in production.
The farther upstream a quality method is applied, the greater
leverage it produces on the improvement, and the more it
reduces the cost and time. Taguchi‟s philosophy is founded on
the following three very simple and fundamental concepts
(Ross, 1988; Roy 1990):
1. Quality should be design into the product and not inspected
FIG III. Graph Effect of Welding speed on Weld Penetration into it.
2. Quality is best achieved by minimizing the deviations from
G. Effect of torch angle on weld penetration the target. The product or process should be so designed that it
In the third case, the effect of the torch may be held is immune to uncontrollable environmental variables.
perpendicular to the work piece or, tilted forward or backward
with respect to the weld pool. As the arc stream tends to
3. The cost of quality should be measured as a function of A. Average loss-function for product population
deviation from the standard and the losses should be measured
system-wide. In a mass production process, the average loss per unit is
expressed as (Roy, 1990):
Taguchi proposes an “off-line” strategy for quality
improvement as an alternative to an attempt to inspect quality L(y) = (1/n)*{k (y1-m) ² +k (y2-m) ² +……+k (yn-m) ²} (2)
into a product on the production line. He observed that poor Where,
quality cannot be improved by the process of inspection,
screening and salvaging. No amount of inspection can put y1, y2, yn = Actual value of the characteristic for unit 1, 2,
quality back into the product. Taguchi‟s recommends a three 3…….n respectively.
stage process: system design, parameter design and tolerance n = Number of units in a given sample
design. In the present work Taguchi‟s parameter design
approach is used to study the effect of process parameters on k = Constant depending on the magnitude of the
the depth of penetration of the Metal Inert Gas Welding characteristic and the monetary units involved.
process. m = Target value at which the characteristic should be set.
A. Loss function The eq n can be simplified as,
The Taguchi loss function recognizes the customer‟s desire L(y) =k (MSDNB) (3)
to have products that are more consistent, part to part, and a
producer‟s desire to make a low-cost product. The loss to Where,
society is composed of the costs incurred in the production MSDNB =Mean squared deviation or the average of
process as well as the costs encountered during use by the squares of all deviation from the target or nominal value
customer (repair, lost business, etc.). To minimize the loss to
society is the strategy that will encourage uniform products NB = “Nominal is Best”
and reduce cost at the point of production and at the point of B. Signal to noise ratio
consumption.
The loss function discussed above is an effective figure of
The heart of Taguchi method is his definition of the
merit for making engineering design decision. However, to
nebulous and elusive term „quality‟ as the characteristic that
establish an appropriate loss-function with its k value to use as
avoid loss to the society from the time the product is shipped a figure of merit is not always cost-effective and easy.
(Braker, 1986). Loss is measured in terms of monetary units Recognizing the dilemma, Taguchi created a transform
and is related to quantifiable product characteristic.
function for the loss-function which is named as signal-to-
Taguchi defines quality loss via his „loss function‟. He noise ratio(S/N ratio) (Barker, 1990).
unites the financial loss with the function specification The S/N ratio, as stated earlier, is a concurrent statistic. A
through a quadratic relationship that comes from a Taylor concurrent statistics is able to look at two characteristics of a
series expansion. The quadratic function takes the form of a
distribution and roll these characteristics into a single number
parabola. Taguchi defines the loss function as a quality
or figure of merits. The S/N ratio combines both the
proportional to the deviation from the nominal quality parameters (the mean level of the quality characteristics and
characteristic (Roy, 1990). He has found the following
variance around this mean) into a single metric (Barker, 1990).
quadratic form to a useful workable function (Roy, 1990):
The S/N ratio consolidate several repetition (at least two
L(y) = k(y-m) ² (1)
data point are required) into one value. The equation for
Where, calculating S/N ratios for „smaller is better‟ (LB), „large is
better‟ (HB) and „nominal is best‟ (NB) type of characteristics
L = Loss in monetary units are as follows (Ross, 1998):
M = value at which the characteristics should be set 1) Larger the Better: (S/N) HB = -10 log (MSDHB) (4)
Y = actual value of the characteristic Where, MSDHB = (1/R) Σ (1/y²j)
K =constant depending on the magnitude of the 2) Smaller the Better: (S/N) LB = -10 log (MSDLB) (5)
characteristics and the monitory unit involved
Where, MSDLB = (1/R) Σ (y²j)
The characteristics of loss function represented as below:
3) Nominal the Best: (S/N) NB = -10 log (MSDNB) (6)
1. The farther the product‟s characteristic varies from the
target value, the greater is the loss. The loss must be zero Where, MSDNB = (1/R) Σ (yj-y0)²
when the quality characteristic of a product meets its target R= Number of repetitions. The mean square deviation
value.
(MSD) is a statistical quality that reflects the deviation from
2. The loss is a continuous function and not a sudden step as in the target value. The expressions for MSD are different for
the case of traditional (goal post) approach. This consequence different quality characteristics. For the „nominal is best‟
of the continuous loss function illustrates the point that merely characteristics, the standard definition of MSD is used. For the
makes a product within the specification limits does not other two characteristics the definition is slightly modified.
necessary mean that product is of good quality. For „smaller is better‟, the unstated target value is zero. For
„larger is better‟ the inverse of each large value becomes a Depending on the number of level of the parameters and
small value and again, the unstated target value is zero. Thus total DOF required for the experiment, a suitable OA is
for all three expression, the smallest magnitude of MSD is selected.
being sought.
D) Assignment of Parameters and interaction to the OA
C. Steps in experimental design and analysis
The OA‟s have several columns available for assignment
I) Selection of orthogonal array (OA) of parameters and some columns subsequently can estimate
the effect of interaction of these parameters.
In the selecting an appropriate OA, the pre-requisites are
(Roy1990, Ross, 1988): Taguchi has provided two tools to aid in the assignment of
parameters and interactions to arrays (Ross, 1988; Roy, 1990):
a) Selection of process parameters and/or interactions to be
evaluated 1. Linear graphs
B)Selection of number of levels for the selected parameters 2. Triangular tables
The determination of which parameter to investigate is depend Each OA has a particular set of linear graphs and a
upon the product or process performance characteristics or triangular table associated with it. The linear graph indicates
response of interest (Ross, 1988). Several methods are various columns to which parameters may be assigned and the
suggested by Taguchi for determining which parameters to columns subsequently evaluate the interaction of these
include in an experiment. These are (Ross, 1988): parameters. The triangular table contains all the possible
interaction between parameters (columns). Using the linear
1. Brainstorming graphs and or the triangular table of the selected OA, the
2. Flow charting parameters and interactions are assigned to the columns of the
OA. The linear graph of L09 OA is given in Table.
3. Cause effect diagrams
E. Selection of outer array
The total Degree of Freedom (DOF) of an experiment is a
direct function of total number of trial. If the number of levels Taguchi separates factors (parameters) into two main
of a parameter increases, the DOF of the parameter also group: controllable factors and uncontrollable factor (noise
increases because the DOF of a parameter is the number of factors). Controllable factors are factors that can easily be
level minus one. Thus, increase the number of levels for a controlled. Noise factors, on the other hand, are nuisance
parameter increases the total degree of freedom in the variable that are difficult, impossible, or expensive to control
experiment which in turn increases the total number of trials. (Byrne and Taguchi, 1987). The noise factors are responsible
Thus, two levels for each parameter are recommended to for the performance variation of a process. Taguchi
minimize the size of the experiment (Ross, 1988). If curved or recommends the use of outer array for the noise factor and
higher order polynomial relationship between the parameter inner array for controllable factors. If an outer array is used,
under study and the response is expected, at least three level of the noise variation is forced into the experiment. However,
each parameter should be considered (Barker, 1990). experiments against the trial condition of the inner array (The
OA used for the controllable factors) may be repeated and in
The standard two levels and three level arrays (Taguchi this case the noise variation is unforced into the experiment
and Wu, 1979) are: (Byrne and Taguchi, 1987). The outer array, if used, will have
1. Two level array: L4, L8, L12, L16, and L32. same assignment considerations. However, the outer array
should not be complex as the inner array because the outer
2. Three level array: L9, L18, and L27. array is noise only which is controlled only in the experiment
The number as subscript in the array designation indicates (Ross, 1988).
the number of trial in that array. The total degrees of freedom E.Selection of orthogonal array
(DOF) available in an OA are equal to the number of trial
minus one (Ross, 1988): Taguchi orthogonal design uses a special set of predefined
fLN = N-1 (7) arrays called orthogonal arrays (OAs) to design the plan of
experiment. These standard arrays stipulate the way of full
Where, information of all the factors that affects the process
performance. The corresponding OA is selected from the set
fLN = Total degree of freedom of an OA of predefined OAs according to the number of factors and
LN = OA designation their levels that will be used in the experiment. For the present
experimental work, three factors with their three levels are
N = Number of trial used for which the corresponding orthogonal array is L9
When a particular OA is selected for an experiment, the which is shown in Table.
following inequality must be satisfied (Ross, 1988):
fLN ≥Total degree of freedom required for parameters and
interaction
Table 4.2: L-9 Orthogonal Array
Process Parameter Table 4.3: Experimental Results
Exp Sr Welding Gasflow Welding Weld
No No Current(Amp) rate(LPM) speed(mm/s) Penetration(mm)
Welding Gas flow Welding Speed
Current rate 1 150 10 6.66 1.6
1 1 1 1 2 150 12.5 3.33 2.5
2 1 2 2 3 150 15 1.66 2.7
3 1 3 3 4 175 10 3.33 3.0
4 2 1 2 5 175 12.5 1.66 5.0
5 2 2 3 6 175 15 6.66 3.0
6 2 3 1 7 200 10 1.66 2.5
7 3 1 3 8 200 12.5 6.66 2.5
8 3 2 1 9 200 15 3.33 2.0
9 3 3 2
G. Analysis of S/N ratio

F.. Conduction of experiments
In the Taguchi Method the term Signal represents the
By putting the values of three levels of three desirable value (mean) for the output characteristic and the
parameters in L9 Orthogonal array , the nine set of term Noise represents the undesirable value (standard
experiments with different values of parameters are deviation) for the output characteristic. Therefore, the S/N
obtained as fallows ratio to the mean to S.D.S/N ratio used to measure the quality
Experiment No.1 Current=150Amp. characteristic deviating from the desired value.
Gas flow rate=10.0 LPM. Welding speed = 6.66 mm/s. The S/N ratio is defined as n=10log (M.S.D.) Where,
M.S.D is the mean square deviation for the output
Experiment No.2 Current=150Amp. characteristic. To obtain optimal welding performance, higher
Gas flow rate =12.5 LPM. Welding speed = 3.33 mm/s. the better quality characteristic can be taken and S/N ratio is
calculated for each experiment.
Experiment No.3 Current=150Amp. Table 4.4: Analysis of S/N Ratio
Gas flow rate =15.0 LPM. Welding speed = 1.66 mm/s. Sr No Welding Gas flow Welding Weld S/N
Experiment No.4 Current=175Amp. Current(A rate(LPM speed{mm/s Penetration(mm Ratio
mp) ) ) )
Gas flow rate=10.0 LPM. Welding speed = 3.33 mm/s.
1 150 10.0 6.66 1.6 4.08
Experiment No.5 Current=175Amp.
Gas flow rate =12.5 LPM. Welding speed = 1.66 mm/s. 2 150 12.5 3.33 2.5 7.95
Gas flow rate =15.0 LPM. Welding speed = 6.66 mm/s. 3 150 15.0 1.66 2.7 8.62

4 175 10.0 3.33 3.0 9.54
Gas flow rate=10.0 LPM. Welding speed = 1.66 mm/s.
Experiment No.8 Current=200Amp. 5 175 12.5 1.66 5.0 13.97
Gas flow rate =12.5 LPM. Welding speed = 6.66 mm/s.
Experiment No.9 Current=200Amp. 6 175 15.0 6.66 3.0 9.54
Gas flow rate =15.0 LPM. Welding speed = 3.33 mm/s.

7 200 10.0 1.66 2.5 7.95
8 200 12.5 6.66 2.5 7.95
9 200 15.0 3.33 2.0 6.02
Maximum penetration = 3.66+3.33+3.4-2x2.75
= 10.39 – 5.5
H. S/N Response analysis = 4.89 mm
The S/N Response is calculated for each level of each
parameter as fallows
I. Confirmation experiment
[1]Welding Current
Once the optimal level of process parameters has been
Level 1=[4.08240+7.95880+8.62728]/3=6.8894 selected, the final step is to carry out the confirmation
experiment by taking the optimal values of process parameter
Level 2=[9.54243+13.9794+9.54243]/3=11.0214 which are as fallows
Level 3=[7.95880+7.95880+6.02060]/3=7.3127
Current =A 2 = 175Amp
[2] Gas flow rate Gas flow rate =B 2 = 12.5 LPM
Level 1=[4.08240+9.54243+7.95880]/3=7.1945 Welding speed =C3 = 1.6 mm/s.
Level 2 =[7.95880+13.9794+7.95880]/3=9.9656 The above set of optimal process parameters are not
Level 3=[8.62728+9.54243+6.02060]/3=8.0634 found in orthogonal array so we have to carry out
confirmation experiment. After carrying out confirmation
[3] Welding speed experiment the actual penetration obtained is 5.00 mm.
Level1=[4.08240+9.54243+7.95880]/3=7.1954
Level 2 =[7.95880+9.54243+6.02060]/3=7.84601 Main Effects Plot for SN ratios
Data Means
Level 3 =[8.62728+13.9794+7.95880]/3=10.1884
Welding current Gas flow rate
Table 4.5: S/N Response Table for Weld Penetration
11
S Mean S/N Ratio
ymbo 10
l Input Parameter Level Level 2 Level 3
1 9
Mean of SN ratios
A Welding Current 6.889 11.021 7.313 8
B Gas flow rate 7.195 9.966 8.063 7

C Welding speed 7.195 7.841 10.188 1 2 3 1 2 3
Welding speed
11
J. Finding the optimal process parameters 10
Regardless of the category of the quality 9
characteristic, a greater S/N ratio corresponds to better quality 8
characteristics. Therefore, the optimal level with the greatest
S/N ratio. The optimal levels of process are 7
1 2 3
Current =A 2 = 175Amp
Signal-to-noise: Larger is better
Gas flow rate =B 2 = 12.5 LPM
Welding speed =C3 = 1.6 mm/s. Graph 4.1: Main Effects Plot for S/N Ratio
Maximum Penetration = T + (A2-T) + (B2-T) + (C3-T)
=A2+B2+C3-2T (8)
A2=Average value of penetration at the second level of
current=[3.0+5.0+3.0]/3=3.66
B2=Average value of penetration at the second level of gas
flow rate=[2.5+5.0+2.5]/3=3.33
C3=Average value of penetration at the third level of
welding speed=[2.7+5.0+2.5]/3=3.4
T=Overall mean of penetration
=[1.6+2.5+2.7+3.0+5.0+3.0+2.5+2.5+2.0]/9=2.75
By putting the respective values, we get
5) Sum of Squares due to speed (SS speed) = ∑y
Main Effects Plot for Means speed² - C.F. (13)
Data Means 6) Sum of Squares due to Error (SS E) = SST - (SS cur
Welding current Gas flow rate + SS gas flow rate + SS speed) (14)
11 In order to statistically analyze the result, ANOVA was
10 performed. Process variables having p-value<0.05 are
considered significant terms for the requisite response
9 characteristics. The insignificant parameters were having p
value larger than 0.05.
8
Mean of Means
The ANOVA.
7
1 2 3 1 2 3
Table 4.6 Analysis of Variance for SNRA1, using
Welding speed
Adjusted SS for Tests
11 Source D Seq SS Adj SS Adj
10
F MS
9
Welding current 2 3.7422 3.7422 1.8711
Gas flow rate 2 1.5622 1.5622 0.7811
8
7
Welding speed 2 1.8956 1.8956 0.9478
1 2 3 Error 2 0.0622 0.0622 0.0311

Total 8 7.2622
Graph 4.2: Main Effect plot for Means
K. Analysis of Variance S = 0.176383 R-Sq = 99.14% R-Sq (adj) = 96.57%
Analysis of variance (ANOVA) is the statistical IV. CONCLUSION
treatment most commonly applied to the results of the
experiments to determine the percentage contribution of each The optimum response for welding penetration by Taguchi
parameter against a stated level of confidence. Analysis of Method is given as below
Variance (ANOVA) is a statistically based objective decision
making tool for detecting any difference in average 1. According to Taguchi methods, an attempt is made to
performance of groups of items tested. The decision rather determine set of values of process variable at their selected
than pure judgments, take variation in to account. The levels
experimental design and subsequent analysis like ANOVA are 2. To have predicted optimum value of welding
intrinsically tied to each other. Analysis of Variance penetration 4.89 mm but actual value of welding penetration is
(ANOVA) breaks total variation down into accountable source 5.00 mm at conditions of confidence interval as in table
and total variations is decomposed into its appropriate Conclusion according to Taguchi method.
components.
Table 5.1: Predicted Vs Actual Value of Welding Penetration
The P-value approach is widely adopted in practice risks Response Predicted Value Actual Value
implied by specific value or level of significance. The P- value Welding Penetration Set of optimum
is probability that the tests statistics will take on a value that is value of process parameter are as
at least extreme as the observed value of the statistic when the follows
null hypothesis Ho is true. Thus, the P- values convey much  Welding Current 175 Amp
4.89 mm 5.0 mm
information about the weight of evidence against the Ho and  Gas flow rate 12.5 LPM
so a decision maker can draw a conclusion at any specified  Welding Speed 1.66 mm/sec
level of significance. The P- value is therefore the smallest
level of significance that would lead to rejection of the null
hypothesis Ho. Detail step for ANOVA are given below for In addition to welding Penetration one additional test is
weld penetration in (mm). Calculation of correction factor: performed to analyze what happened to tensile strength. The
standard value of tensile strength for 5mm AISI304 Plate is in
1. Correction Factor (C.F.) = (Total) ²/ T.C. (9) the range of 540 to 750 N/mm2 and when the Specimen is
2. Total Sum of Square (SS T) = ∑ y² - C.F. (10) welded with Cr2O3 Coating and at the level of optimum
Parameter in addition to full Weld Penetration the tensile
3. Sum of Squares due to Current (SS cur) = ∑ y cur² - C.F. strength found to be 707 N/mm2 which is within Standard
(11) range of Tensile strength.
4.Sum of Squares due to gas flow rate = ∑ y gas flow tate² -
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Performance and Evaluation of Solar
Powered Bicycle: A Review
Rahul Mathankar Shubham Girde3
Student, Tulsiramji Gaikwad- Patil College of Students, Tulsiramji Gaikwad- Patil College of
Engineering and Technology, Nagpur, Engineering and Technology, Nagpur
Asif Sheikh Swapnil Thanekar
Student, Tulsiramji Gaikwad- Patil College of HOD (MECH), Tulsiramji Gaikwad- Patil College of
Engineering and Technology, Nagpur, Engineering and Technology, Nagpur
(Email: [email protected])
ABSTRACT: This paper gives the details about the chain sprocket, chain & gear shifting arrangement of
research papers related to the solar power bicycle a conventional bicycle being used by most common
project and includes the methods and considerations man. As a part of dissertation work, the solar assisted
regarding the proper working of the bicycle. The main bicycle is fitted with a dc hub motor on front axle of
components of this project is Solar PV panel, Brushless
a bicycle with power rating of 250W and with a
motor, Charge controller and battery. This paper will
deals with the main idea of the component and here we travelling speed of around 25-30 kmph. It is provided
compare the different component of solar bicycle. with a pair of lead acid batteries of 35 Ah each, a
photovoltaic solar panel with capacity of 20 watt, a
Solar energy is one of the renewable energy which can voltage regulator of 24v 10 Amp, accelerator and
be a feasible and can be used as alternative fossil fuels. motor controller of 24v 25Amp. There is also a
In this work, a solar powered bicycle is fabricated by
provision for charging of the battery with 220-240V,
modifying allcomponents of existing geared bicycle.
AC wall outlet supply, in case of poor solar supply
This paper deals with the design, assembly and
performance evaluation of the bicycle. This paper due to cloudy weather.
highlights the advantages of dual mode of charging and
B. ABDULKADIR BABA HASSAN, present a
economic feasibility of the bicycle.
paper on „„DESIGN AND FABRICATION OF A
Keywords:Solar PV panel, Brushless motor, Charge MOTORIZED D.PROTOTYPE TRICYCLE FOR
controller. THE DISABLE PERSONS‟‟:
LITERATURE REVIEW This project design is embodied on a
motorized tricycle for disabled Persons. The tricycle
A. M. REDDI SANKAR, T. PUSHPAVENI,
was specifically designed to suit wheelchair
V. BHANU PRAKASH REDDY, present a paper on
occupants of healthy Upper torso with pelvic to foot
“DESIGN AND DEVELOPMENT OF SOLAR
ASSISTED BICYCLE” Process. restraint. It is also designed to suit a commonly
available Wheel chair. The level of relationship
The solar assisted bicycle developed is driven between the disabled people in the society has highly
by DC motor fitted in front or rear axle housing & being jeopardized; therefore this project was
operated by solar energy. The solar panels mounted designed to correct the difficulties in mobility of the
on the carriage will charge the battery & which in wheelchair users. The main aim of the project design
turn drive the hub motor. When the bicycle is idle, is to ease mobility for the physically challenged and
the solar panel will charge the battery. This also provide adequate comfort they desire. Existing
arrangement will replace the petrol engine, the gear tricycles for the disables requires the disabled person
box & the fuel tank in case of a two wheeler or a to dismount from the wheelchair onto the tricycle.
The motorized tricycle in this project is designed to WHEEL CHAIR: MOBILITY FOR PHYSICALLY
overcome this problem by allowing the disabled CHALLENGED”.
person to wheel up or down his wheelchair onto or
down the tricycle. This is achieved using a specially Personal mobility means freedom for the
designed platform that allows the wheel chair to be physically challenged. One of the best inventions in
wheeled up or down. The prototype of this tricycle the medical field that helped both the elderly and the
has been fabricated. The anthropometrics data that handicapped is the mobility vehicle. The fact that
need to be considered in the design of the platform they are no longer depending on someone else to
and frame of the tricycle have been taken into perform daily duties is a big step forward. On the
consideration at the design stage of the tricycle. journey to mobility and freedom, motorized scooters
and wheelchairs are the tools to finish that journey.
C. N.SASIKUMAR, With scooters and wheelchairs, there is a small
DR.P.JAYASUBRAMANIAM, present a paper on inconvenience to mobility independence. The
“SOLAR ENERGY SYSTEM IN INDIA”. addition of some devices enables persons with
physical disabilities a comfortable travel beyond their
Conventional energy sources like coal, oil, own homes. The present work involves in design and
natural gas, etc., are limited in quantity, and if these fabrication of solar powered wheel chair. A
continue to be depleted at the present rate, these will motorized wheelchair, power chair, electric
be exhausted in the coming decades. Energy demand wheelchair or electric powered wheelchair (EPW) is
is resulting in the creation of fossil fuel based power propelled by means of an electric motor rather than
plants leading to substantial greenhouse gas manual power.
emissions having an adverse impact on global
warming and climate change Solar energy offers a F. TILAKISWARAN A/L
clean, climate-friendly, abundant and inexhaustible SAMURGAM, Present a paper on
generation in tropical countries Solar photovoltaic “DEVELOPMENT OF BATTERY POWERED
(SPV) cells convert solar radiation (sunlight) into TRICYCLE”.
electricity. A solar cell is a semiconducting device
made of Silicon materials, which, when exposed to The main purpose of this project is to develop a
sunlight, generates electricity. Solar cells are battery powered electric motor tricycle which can be
connected in series and parallel combinations to form used as a simple transportation and for economy
modules that provide the required power. reasons, to develop a battery powered electric motor
tricycle which can be used as a simple transportation
D.RAJENDRA BEEDU, presents a paper on and for economy reasons. A motorized tricycle is a
“DESIGN, DEVELOPMENT AND three wheeled bicycle with an attached motor used to
PERFORMANCE EVALUATION OF SOLAR assist with pedaling. Generally considered as a
POWER ASSISTED BICYCLE’’. vehicle, tricycles are usually powered by electric
motors or small internal combustion engines and
The fast depletion of fossil fuels due to exponential have function as electric bicycles. Some can be
increase in demand and global warming due to the propelled by the motor alone if the rider chooses not
emission of CO2 made engineers and scientists to to pedal; while in others the motor will only run if the
look for an alternative source of energy which is rider pedals. Electric bicycles are generally powered
renewable, eco-friendly, affordable and available. by rechargeable batteries. These are normally
Among the renewable sources like wind, tidal , charged from the utility supply (mains), with perhaps
geothermal and solar energy, solar power is the option of using the motor to effect regenerative
promising in nations like India which is in the braking or charging while being pedaled or rolling
tropical region. India spends large amount of foreign downhill. Electric motorized bicycles are either
exchange to import crude oil,with the use of solar power-on-demand, where the motor is activated by a
power assisted vehicles, the dependency on the handlebar mounted throttle, or pedelec (from pedal
import of crude oil can be reduced and reasonable electric), where the electric motor is regulated by
amount of foreign exchange can be saved. pedaling.
E. ARUN MANOHAR GURRAM, P.S.V
RAMANA RAO, RAGHUVEER DONTIKURTI,
presents a paper on “SOLAR G. POWERED
I. T. PUSHPAVENI, V. BHANU PRAKASH
REDDY,presents a paper on “DESIGN AND
DEVELOPMENT OF SOLAR ASSISTED
BICYCLE’’.
G. YOGESH SUNIL WAMBORIKAR, As we all know the fuel prices especially the petrol is
ABHAY SINHA, Presents a paper on “SOLAR rising steadily day by day. Again the pollution due to
POWERED VEHICLE”. vehicles in metro cities & urban areas is increasing
continuously. To overcome these problems, an effort
The renewable energy is vital for today‟s world is being made to search some other alternative
as in near future the nonrenewable sources that we sources of energy for the vehicles. Again, it is also
are using are going to get exhausted. The solar not affordable to purchase vehicles (mopeds, scooters
vehicle is a step in saving these nonrenewable or motorcycles) for all the class of society. Keeping
sources of energy. The basic principle of solar car is this in mind, a search for some way to cater these
to use energy that is stored in a battery during and economically poor people as well as to provide a
after charging it from a solar panel. The charged solution for the environmental pollution was in
batteries are used to drive the motor which serves progress. The solar assisted bicycle developed is
here as an engine and moves the vehicle in reverse or driven by DC motor fitted in front or rear axle
forward direction. The electrical tapping rheostat is housing & operated by solar energy. The solar panels
provided so as to control the motor speed. This mounted on the carriage will charge the battery &
avoids excess flow of current when the vehicle is which in turn drive the hub motor. When the bicycle
supposed to be stopped suddenly as it is in normal is idle, the solar panel will charge the battery. This
cars with regards to fuel. This idea, in future, may arrangement will replace the petrol engine, the gear
help protect our fuels from getting extinguished. box & the fuel tank in case of a two wheeler or a
chain sprocket, chain & gear shifting arrangement of
H. CHETAN MAHADIK, SUMIT
a conventional bicycle being used by most common
MAHINDRAKAR, PROF. JAYASHREE DEKA,
man.
presents a paper on “AN IMPROVED & EFFICIENT
ELECTRIC BICYCLE SYSTEM WITH THE CONCLUSION
POWER OF REAL-TIME INFORMATION
SHARING”. It can be concluded from paper that the overall
efficiency of the bike will definitely be improved by
This paper presents the development of an working on the parameters discussed earlier. Also, a
associate degree "Electric Bicycle System‟ with an completely new dimension of the bike will be
innovative approach. The aim of this paper is to show designed with enhanced features. If the venture
that the normal bi-cycle can be upgraded to electric proves to be successful then an enhanced solar bike
one by some means– that including the development can be available at a much cheaper price. The design
of a regenerative braking system and innovative of the solar bike can also be improved further in
BLDC motor control. The main components of the terms of its appearance in view of the 21st century
electric bicycle are brushless DC motor, motor people. The bike can prove to be an ideal for
controller, photo-voltaic, dry cell battery and solar promoting the concept of “GO GREEN AND
panel. Also throttle and extra features such as horn, CLEAN”.
speedometer, and LED signal etc. The power source
for this system is given by dry cell battery. The
output of dry cell battery is 48V. There are multiple
forms of charging source is used such as AC voltage
through an outlet, solar energy and mechanical pedal
charging system. The source of battery charging is
photovoltaic solar panel and it is light weight. The
solar panel output is 12V and 20 watt. Also they use
mechanical pedal charging system, so dynamo is use
for this charging system.
www.inpressco.com/wp-content/uploads/2012/03/Paper11211-
214.pdf
REFRENCES [6] Daniel Dourte, David Sandberg, Tolu Ogundipe, PRESENT a

PAPER ON “ELECTRIC TRICYCLE: APPROPRIATE
[1] M. Reddi Sankar, T. Pushpaveni, V. Bhanu Prakash Reddy,
MOBILITY”: International Journal of Engineering Science
“DESIGN AND DEVELOPMENT OF SOLAR ASSISTED
Invention, ISSN (Online): 2319 – 6734, ISSN (Print): 2319 – 6726
BICYCLE”,International Journal of Scientific and Research
April 2014 Volume-3 (PageNo.29-32)
Publications, (Volume 3, Issue 3), (March 2013) ISSN 2250-3153,
www.ijesi.org/papers/Vol(3)a/Version-3/E0343029032.pdf
( Page No. 781-786).
www.ijeit.com/vol%202/Issue%206/IJEIT1412201212_79.pdf [7] Tilakiswaran A/L Samurgam, Present a
Paper On “DEVELOPMENT OF BATTERY POWERED
[2] Abdulkadir Baba Hassan (Department of Mechanical
TRICYCLE”.International Journal of Research in Engineering and
Engineering, Federal University of Technology, Minna, Niger
Science (IJRES) ISSN (Online): 2320-9364, ISSN (Print): 2320-
State, Nigeria) “DESIGN AND FABRICATION OF A
935 Volume 2 Issue 5 May. 2014 (Page No. 21-28)
MOTORIZED PROTOTYPE TRICYCLE FOR THE DISABLE
www.ijres.org/papers/Volume%202/v2-i5(i)/D0252128.pdf
PERSONS” IOSR Journal of Engineering , (Vol. 2(5 )), May 2012
(Page No. 1071- 1074). [8] Yogesh Sunil Wamborikar, Abhay Sinha, Presents a paper on
www.iosrjen.org/Papers/vol2_issue5/Z02510711074.pdf “SOLAR POWERED VEHICLE”. International Journal of
Renewable Energy Research Volume 2, No.3 Received:
[3] N.Sasikumar (Ph.D (Part – Time) Research Scholar, Kamban
05.06.2012 Accepted:01.07.2012 (Page No.457-462)
Arts & Science College, Coimbatore),
www.ijrer.org/index.php/ijrer/article/download/260/pdf
Dr.P.Jayasubramaniam(Head & Asst.Prof in Professional
Accounting, Dr.N.G.P. Arts & Science College, Coimbatore), [9]T. Pushpaveni, V. Bhanu Prakash Reddy, presents a paper on
“SOLAR ENERGY SYSTEM IN INDIA” IOSR Journal of “DESIGN AND DEVELOPMENT OF SOLAR ASSISTED
Business and Management (IOSR-JBM) ISSN: 2278-487X. BICYCLE’’.International Journal of Scientific and Research
Volume 7, Issue 1 (Jan. - Feb. 2013), (Page No. 61-68) Publications, Volume 3, Issue 3, March 2013 ISSN 2250-
www.iosrjournals.org/papers/Vol-2%20Issue=6/D0262730,pdfJ. 3153(Page No.1-6)
Clerk Maxwell, A Treatise on Electricity and Magnetism, 3rd ed.,
vol. 2. Oxford: Clarendon, 1892, pp.68–73.
[4] Rajendra Beedu, presents a paper on “DESIGN,

DEVELOPMENT AND PERFORMANCE EVALUATION OF
SOLAR POWER ASSISTED BICYCLE’’ International Journal of
Research in Engineering and Technology eISSN: 2319-1163 |
pISSN: 2321-7308 (Vol-4), (Page No. 513-517)
[5] Arun Manohar Gurram, P.S.V Ramana Rao, Raghuveer

Dontikurti “SOLAR POWERED WHEEL CHAIR: MOBILITY
FOR PHYSICALLY CHALLENGED” International Journal of
Current Engineering and Technology Volume 2, No.1 (March
2012) ISSN 2277 – 4106 (Page No. 211-214)
DESIGN AND FEBRICATION OF MULTI-
PORPOSE AGRICULTURAL MACHINE
Pawan R. Giri Ravindra R Gandhe
nd
Student MED II year Mechanical Engg. Dept. Assistant Professor Mechanical Engg. Dept.
Abha Gaikwad Patil College of Engg. Abha Gaikwad Patil College of Engg.
Nagpur, India Nagpur, India
[email protected] [email protected]
Ajay A. Mahawadiwar
Head of department Mechanical Engg. Dept.
Abha Gaikwad Patil College of Engg.
Nagpur, India
[email protected]
Abstract- The farming sector in India primarily consists of small technologies in the form of more intelligent machines to
scale farmers. These small scale farmers cannot afford equipment reduce and target energy inputs in more effective ways than in
like tractors, paddy processing machine s, thereby restricting the past. Precision farming has shown benefits of this
their output .The present work involves designing and approach but we can now move towards a new generation of
fabricating simple and economical farming equipment to
equipment. The advent of autonomous system architectures
perform multiple farming operations like crop cutting,
cultivating, towing loads, seed sowing etc. This vehicle was built gives us the opportunity to develop a complete new range of
keeping in mind the need of small scale farmer. agricultural equipment based on small smart machines that can
Initially various concept were explored and calculated .The final do the right thing, in the right place, at the right time in the
design was selected with these calculations and specifications. right way.
This equipment can be used for cutting crop, cultivator and also The final design was selected with these calculations
for sowing seed. It is easily operated by unskilled person. It and specifications. This equipment can be used for cutting
can reduce labor cost due to the only one person can be handle. crop, cultivator and also for sowing seed. It is easily operated
Crop cutter machine does not required high maintenance. by unskilled person. It can reduce labour cost due to the only
one person can be handle. Machine does not required high
Keywords— Farmer, Crop, Cultivator, Sowing etc
maintenance. On the basis of this large number of farming
equipment are in use at today’s date, which are available at
I.INTROSUCTION different shape and size and on different power supply. Since
Agriculture forms the backbone of our country economy; they are costlier keeping in to consideration the economic
about 55% of citizen is depending on agriculture. Thus ability of our farmer it is required that is should be simple and
developing our country means providing our farmers with should fulfil the same intention which are achieved by
more “Sophisticated” and “Advanced Tool” which would “DESIGN AND FEBRICATION OF MULTI-PORPOSE
decreases overall time required for the task and the task will AGRICULTURAL MACHINE”.
become more easy and convenient. In agriculture have done
more process
Developed agriculture needs to find new ways to improve II.LITERATURE REVIEW
efficiency. One approach is to utilize available information
Agro-Technology is the process of applying the agricultural equipment based on small smart machines that can
technology innovation occurring in daily life and applying that do the right thing, in the right place, at the right time in the
to the agriculture sector which improves the efficiency of the right way.
crop produced and also to develop a better mechanical
machine to help the agriculture field which reduces the 3 A.Kannan , K. Esakkiraja, S. Thimmarayan et al “Design
amount and time of work spent on one crop. Hence in this Modifications in Multipurpose Sowing Machine” IJRAME.
work of project we decided to design a better mechanical Volume 2, Issue 1, 2014
machine which is available to the farmers at a cheaper rate and
also which can sow and seed the crop at the same time. This A multipurpose sowing machine is
project consists of the better design of the machine which can designed for small farmers to improve their productivity. In
be used specifically for rice, wheat crops etc.Sectional this machine a common seed storage place is introduced to
Committee as detailed below: reduce the cost of the machine. The existing sowing machine
had the individual storage place and separate seed metering
1. Adarsh J Jain, Shashank Karne1, Srinivas Ratod , Vinay mechanism which leads to more cost. The drawbacks in the
Thotad and Kiran et al “Design and Fabrication of small scale existing sowing machine are rectified successfully in our
Sugarcane harvesting machine” IJMERS, Vol. 3, No 3, APRIL machine. It will be more useful for small farmers and the
2013 agricultural society. The cost of the machine comes around Rs
6000/-.
In today’s competitive world there is a
need for faster rate of production of agricultural products.
Agriculture is the backbone of India. In India almost all 4 Anant J. Ghadi and Arunkumar et al “Design, development
farmers facing problems of labour shortage. Day by day labour and fabrication of a low cost corn deseeding machine”,
wages are increasing and in the same way demand of IJRET. Volume: 03 Issue: 08 | Aug-2014
agriculture products are also increasing and today’s world
need faster rate of production of agriculture products. This This paper present work is carried out on the de-
project aims to design and fabricate small scale sugarcane seeding machine has been designed, developed and fabricated
harvesting machine for sugarcane harvesting to reduce keeping in mind the constraints and requirements of the Indian
farmer’s effort and to increase production of agricultural farmers. The deseeding machine was tested in the machine
products. Machine consists of petrol engine and different shop and later taken to the field. It worked well in the field
mechanisms are used in this machine. When compare to conditions and gave an output of 45 Kg/hour. The
manual harvesting by using this machine has a capacity to cut maneuverability of the device is quite good and the handling is
canes in faster rate and it is economical. The machine is quite simple. The seed discharging mechanism is effective and
helpful for both whom having small or big farms. corn seeds can be discharged off very easily. For commercial
purpose one can improve the efficiency of the device
effectively by increasing the size of the device and providing it
2 P.Vijay, K.V.N.Rakesh, B.Varun, et al “Design of a Multi- with multiple heads. Additionally, the de-seeder is a
Purpose Seed Sower Cum Plougher”, IJETAE, Volume 3, multifunctional machine that can de-seed various types of food
Issue 4, April 2013 item such as rice, chilly powering, potato past, corn de-
husking etc. This can be done by changing the drum and teeth.
This paper deal with Agro-Technology is the
process of applying the technology innovation occurring in
daily life and applying that to the agriculture sector which III PROBLEM DEFINITION
improves the efficiency of the crop produced and also to The research project aims to accumulate all possible design &
develop a better mechanical machine to help the agriculture fabrication of multipurpose agriculture machine. When a
field which reduces the amount and time of work spent on one farmer doing work in the farm they required more equipment
crop. Hence in this work of project we decided to design a or machinery, and this machines are available in more cost
better mechanical machine which is available to the farmers at sometime it’s not affordable to the farmer. There for these
a cheaper rate and also which can sow and seed the crop at the machine is design and fabricate for small scale farmer and it is
same time. This project consists of the better design of the available in low cost in future.
machine which can be used specifically for rice, wheat crops
etc. Developed agriculture needs to find new ways to improve
efficiency. One approach is to utilize available information IV.CONCLUSION
technologies in the form of more intelligent machines to
The multipurpose agriculture machine has been
reduce and target energy inputs in more effective ways than in
designed, developed and fabricated keeping in mind the
the past. Precision farming has shown benefits of this
constraints and requirements of the Indian small scale farmers
approach but we can now move towards a new generation of
and to improve their productivity. In this machine try to
equipment. The advent of autonomous system architectures
reducing the cost and affordable to farmer.
gives us the opportunity to develop a complete new range of
We are reduce time in farming and also reduce cost
of labour. This machine fuel consumption is covered. The
manoeuvrability of the machine is quite good and the handling
is quite simple the mode of operation is very simple even to
the lay man. It is more efficient than the present existing
machines of this category and range. The maintenance cost of
this equipment is very less as there is no delicate part
involved.
.
REFERENCES
[1] “Design and Fabrication of Multipurpose Robust Cutting Machine for
Agriculture” (2011-12ject Report) (Retrieved on April 17, 2013).
[2] Adarsh J Jain, Shashank Karne1, Srinivas Ratod , Vinay Thotad and Kiran
et al “Design and Fabrication of small scale Sugarcane harvesting
machine” IJMERS, Vol. 3, No 3, APRIL 2013
[3] P.Vijay, K.V.N.Rakesh, B.Varun, et al “Design of a Multi-Purpose Seed

Sower cum Plougher”, IJETAE, Volume 3, Issue 4, April 2013
[4] A.Kannan, K. Esakkiraja, S. Thimmarayan et al “Design Modifications in

Multipurpose Sowing Machine” IJRAME. Volume 2, Issue 1, 2014
[5] Anant J. Ghadi and Arunkumar et al “Design, development and fabrication

of a low cost corn deseeding machine”, IJRET. Volume: 03 Issue: 08 |
Aug-2014
[6] V.K CHANDEGARA “design and developing of bullock drawn

multi‐purpose implement for Sandy loam soil”, Journal of agricultural
engineering, Vol, 40(4): October December, 2003
[7] R.S. Khurmi & J.K Gupta (2003), “A textbook of machine design”,S.
Chand & company
DESIGN AND DEVELOPMENT OF
HYBRID MOPED USING ELCTRICAL
AND PETROL OPERATING
ARRANGEMENT
Piyush A.Dalke1 Prof.AbhijeetA.Raut2

Mechanical Engineering Department Mechanical Engineering Department
G.H.Raisoni College of Engineering, Nagpur G.H.Raisoni College of Engineering Nagpur
NOx, 64% of NMHC and 30% of PM were emitted

ABSTRACT from motorcycles and scooters alone.
Rapid depletion of fossil fuels has forced the Internal combustion engines are relatively
necessity of an alternate energy vehicle. Electric less efficient in converting the on-board fuel energy
vehicles serve as promising technology for the future to propulsion as most of the energy is wasted as
world transportation arena Due to minor drawbacks heat. On the other hand, electric motors are
the electric vehicles cannot match up with the fossil efficient in converting the stored energy in driving
fuel powered vehicle which made the invention of
a vehicle, and electric drive vehicles do not
hybrid technology. Concentrated efforts are mainly
towards implementing a concept called as hybrid consume power while coasting. Some of the energy
system by which one system will be charged while the loss in braking is captured and reused by
other system provides propulsive power to the regenerative braking. With the help of regenerative
vehicle. When the s runs on the electric motor it is braking one fifth of the energy loss can be
almost nonpolluting. regenerated. Typically, petrol engines effectively
This project is deal with the development of use only 15% of its fuel content to move the
the as the only petrol vehicle or electrical vehicle is vehicle. Whereas an electric drive vehicle has an
not as sufficient as hybrid vehicle. This hybrid on-board efficiency of about 80%. But due to
technology can compensated the disadvantages of
reasons such as cost, inability to reach higher
both type of vehicle. There is various type of base on
the type of charging as it becomes plug-in type or speeds electric drive vehicles failed to capture
other. markets. Contrary to this petrol vehicle can cover
longer distances with higher speed but it cannot
I. INTRODUCTION cover shorter distance with slow speed (say in
Hybrid electric moped (HEM) have a traffic) in an efficient way. Two-wheeled vehicles,
great potential in lowering emissions and reducing especially motorcycles and scooters contribute to a
fuel demand as the ever growing problems of air major part of air pollution, especially in the Asia
pollution and global warming reached its critical region.
stage. Although various researches are carried out Thus a hybrid approach, which is to utilize
to reduce emissions and fuel dependencies for four- an internal combustion engine (ICE) and a battery,
wheeled vehicles, not much research is focused on is more feasible as a much higher range could be
two wheeled vehicles for example, motorcycles in achieved compare to pure electric scooters. The
Jakarta, Indonesia contributed to more than 20% in only trade-off is that emissions are not reduced to
both PM10 and CO and 40% of HC emissions zero. Thus two-wheeled hybrid research is as
during 1998. Whereas in Hanoi, Vietnam, equally as important
motorcycles contributes to about 54% of CO,HC
and Pb and 43% of dust Finally, in Taiwan where II. CONCEPT OF HYBRID
emissions reports indicate that 38% of CO, 3% of VEHICLE
B. Plug-in hybrid vehicle
A Plug-in hybrid electric vehicle(PHEV),
also called as Plug-in hybrid, is a hybrid electric
vehicle withrechargeable batteries that can be
restored to full charge just by connecting to an
external power source. A Plug-in hybrid electric
vehicle shares the characteristics of both
conventional hybrid electric vehicle having an
electric motor and an internal combustion Engine
Fig No. 1 Basic Concept diagram
and of an all-electric vehicle, having a plug to
connect to an electric grid.
It is basically a two-way source one of
which is rechargeable energy storage system. As
shown in diagram that the wheels are get power by III. CONSTRUCTION DETAIL:
the two sources P1 and P2 this are the two way
sources. While converting the ordinary moped into
Hybrid vehicle is an automobile which hybrid moped. We required following components.
combine more than one method of Propulsion  Electric motor preferably (Hub motor).
system. It cans anything from petrol with  Batteries (Dry lead acid battery).
combine’s more than one method of propulsion
system. It can be anything from petrol with a Moped (Kinetic kine).
hydraulic motor, diesel with electric or even solar This is main component of the . On the
power. In fact, we already see around us so many basis of availability and low cost We select this
hybrid cars and motorcycles running on CNG with component. The various detail of the following
petrol with electric motor, petrol with a hydraulic component is as below
motor diesel with electric or even solar power, In
Electric motor:
fact, we already see around us so many hybrid cars
and motorcycles with LPG. They are nothing but The BLDC motor is widely used in
form of a parallel Hybrid system. Hybrid applications including appliances, automotive,
technology is nothing but the solution to the aerospace, consumer, medical, automated industrial
problem of pollution by fuel and limited equipment and instrumentation.
availability of the storage. In future we have to The BLDC motor is electrically
think out any alternative source so why not from commutated by power switches instead of brushes.
now? That’s why we are dealing with this concept. Compared with a brushed DC motor or an
induction motor, the BLDC motor has many
TYPES OF HYBEID VEHICLE Advantages:
Higher efficiency and reliability Lower
Hybrid vehicle is mainly classified in two acoustic noise Smaller and lighter Greater dynamic
main types on the basis of power supplied to the response Better speed versus torque characteristics
vehicle. The types are as below, Higher speed range
 Parallel hybrid vehicle Longer life Motor fundamental concepts:
 Plug-in hybrid vehicle 1. General principle:
Motors convert electrical energy into
A. Parallel hybrid vehicle mechanical energy using electromagnetic
principles. The energy conversion method is
In parallel hybrid vehicle, the internal fundamentally the same in all electric motors.
combustion engine and the electric motor are
connected to mechanical transmission and can 2. Magnetic Force:
transmit power simultaneously to drive the vehicle. Magnetic poles generate invisible lines of
The commercialized parallel hybrid vehicles use a magnetic force flowing from the North Pole to the
single small electric motor and a small battery South Pole as shown in Figure. When magnetic
pack. Parallel hybrid vehicles are capable of poles of opposite polarity face each other, they
regenerative braking and the internal combustion generate an attractive force, while like poles
engine present in it is capable of supplemental generate a repulsive force.
charging of the battery.
IV. Working of motor:
Motor operation is based on the attraction

or repulsion between magnetic poles. Using the
three-phase motor shown in Figure, the process
starts when current flows through one of the three
stator windings and generates a magnetic pole that
attracts the closest permanent magnet of the
Fig No.2 Unlike-pole attraction & like-pole opposite pole. The rotor will move if the current
repulsion shifts to an adjacent winding. Sequentially charging
3. Construction of BLDC motor: each winding will cause the rotor to follow in a
I) Stator:There are three classifications of rotating field. The torque in this example depends
the BLDC motor: single-phase, two-phase and on the current amplitude and the number of turnson
three-phase, the stator for each type has the same the stator windings, the strength and the size of the
number of windings. The single-phase and three- permanent magnets, the air gap between the rotor
phase motors are the most widely used. Figure and the windings, and the length of the rotating
shows the simplified cross section of a single-phase arm.
and a three-phase BLDC motor. The rotor has
permanent magnets to form 2 magnetic pole pairs, ADVANTAGES OF BLDC MOTOR OVER
and surrounds the stator, which has the windings. OTHER MOTOR:
• Higher efficiency (75% vs. 40% of an AC
motor)
• Less heat generated
• Higher reliability (no brushes to wear
out)
• Safer to operate in a dangerous
environment (no brush dust generated as
is found with brushed motors).
Table No. 1
Fig no. 3 (a) & (b) Construction diagram
There are two types of stator windings:

trapezoidal and sinusoidal, which refers to the
shape of the back electromotive force (BEMF)
signal. The shape of the BEMF is determined by
different coil interconnections and the distance of
the air gap. In addition to the BEMF, the phase
current also follows a trapezoidal and sinusoidal
shape. A sinusoidal motor produces smoother
electromagnetic torque than a trapezoidal motor,
though at a higher cost due to their use of extra
copper windings. A BLDC motor uses a simplified
structure with trapezoidal stator windings.
II) Rotor:
A rotor consists of a shaft and a hub with Fig. 4: controller for BLDC hub motor
permanent magnets arranged to form between two
The controller connects the power source
to eight pole pairs that alternate between north and
to the motor. It controls speed, direction of rotation,
south poles. There are multiple magnet materials,
and optimizes energy conversion. While batteries
such as ferrous mixtures and rare-earth alloys.
produce constant voltages which decrease as
Ferrite magnets are traditional and relatively
theyare used up, some controllers require a DC to-
inexpensive, though rare-earth alloy magnets are
DC converter to step down this changeable voltage
becoming increasingly popular because of their
to the motors expected constant operating voltage,
high magnetic density. The higher density helps to
but other controllers incorporate a DC-to-DC
shrink rotors while maintaining high relative torque
converter and can accept a varying voltage.
when compared to similar ferrite magnets.
Converter efficiencies are typically greater than
90% [4]. The voltage control is achieved by
“chopping” the source current - the voltage is Wet charged:
switched on and off, with the ratio of on to off The lead –acid battery is filled with
determining the average voltage. Chopping is electrolyte and charged when it is built. During
performed by power electronic circuitry such as storage, a slow chemical reaction will cause self-
diodes and thrusters and silicon control rectifiers discharge. periodic charging is required. Most
(SCR). Controllers also effect regenerative braking, batteries sold today are wet charged.
by which the motor is acted as a generator to
recharge the batteries. Dry charged:
The battery is built, charged washed and
The controller which we used has dried, sealed, and shipped without electrolyte. It
following specification. can be stored for up to 18 months. When put into
use, electrolyte and charging are required Batteries
V. BATTERIES: of this type have a long shelf life. Motorcycle
batteries are typically dry charged batteries
A lead-acid storage battery is an
electrochemical device that produces voltage and VII. BATTERY CONSTRUCTION:
delivers electrical current. The battery is the
primary “source” of electrical energy used in An automobile battery contains a diluted
vehicles today. It’s important to remember that a sulfuric acid electrolyte and positive and negative
battery does not store electricity is produced. electrodes in the form of several plates. Since the
Basically, two different types of lead in acid plates are made of lead or lead-derived materials,
mixture react to produce an electrical pressure this type of battery is often called a lead acid
called voltage. This electrochemical reaction battery. A battery is separated into several cells
changes chemical energy to electrical energy and is (usually six in the case of automobile batteries),
the basis for all automotive batteries. and in each cell there are several battery elements,
The purpose of the battery: all bathed in the electrolyte solution.
The battery supplies electricity to the
BLDC motor while the engine is off. That is our
second alternative of moped operation. The motor
run the shaft of the rim through the coupling. the
battery can use to run the other accessories of the
moped.
The other battery in arrangement is to use
in self-staring of the moped.
VI. TYPES OF BATTERIES: Fig No.5: Basic Construction
 Primary cell VIII. CELL OPERATION:

 Secondary cell
 Wet charge Two dissimilar metals placed in an acid
 Dry charge bath produce electrical potential across the poles.
The cell produces voltage by a chemical reaction
Primary cell: between the plates and the electrolyte. The positive
This type of Batteries are such as plate is made of reddish-brown material such as
flashlight battery once used, throw it away because Lead Dioxide (PBO2). While the negative plate is
the chemical reaction totally destroys one of the made of grayish material called Sponge Lead (PB)
metals after a period of time, primary cells cannot the acid bath is a mixture of sulfuric acid and the
be recharge. Small batteries such as flashlight and water cell electrolyte. Together a cell element is
ratio batteries are primary cells. formed.
Secondary cell: CYCLING:
The metal plates and acid mixture change
as the battery supplies voltage. As the battery The battery stores electricity in form of
drains the metal plates become similar and the acid chemical energy. Through a chemical reaction
strength weakens. This process is called process the battery creates and releases electricity
discharging .by applying current to the battery in as needed by the electrical system or devices. Since
the reverse direction.the battery materials can be the battery losses its chemical energy in this
restored, thus recharging the battery. This process process, the battery must be recharged by the
is called charging. Automotive lead-acid batteries alternator. By reversing electrical current flow
are secondary cells and can be recharged. through the battery the chemical process is
reversed, thus charging the battery. The cycle of Vent caps cover the holes that are used for
discharging and charging is repeated continuously adding electrolyte. They are also designed to
and is called “battery”. separate the sulfuric acid mist and the hydrogen gas
that forms when the battery charges. The caps are
BATTERY CELL ELEMENT:
designed to the sulfuric acid mist to condense and
drop back into the battery and allow hydrogen gas
The key to the battery operation is the cell element. to escape through the vent holes to the atmosphere.
Positive plates and negative plates are each Vent caps can cover each individual cell as shown
connected together by separate plate straps. These below.
groups of positive and negative plates are then
placed alternately, separated by micro-porous
separators. Assembled together, the plates and
separators form a battery cell element. Grouping
the plates in this way serves to enlarge the surface
area between the active materials and the
electrolyte, thus allowing a greater amount of
electricity to be supplied. In other words, the
battery capacity is increased because of the
increase in the surface area. More plate surface area Fig no 7:Vent caps
means the battery can deliver more current.
PLATES: IX. SEVERAL BATTERY
MATERIAL AND THEIR
Battery plates are constructed of a lead ADVANTAGES:
alloy containing a percentage of either antimony or
calcium. The plates are designed as thin flat grid, Several variations of the lead-acid battery
grids crossing at right angles {shown below} or are used today. Variation to the battery plate
grids crossing diagonally at different angles which material and electrolyte solution provides different
reduce internal resistance. The grid provides the battery characteristics. Construction is basically the
necessary framework for active materials to be same; however, the materials used are slightly
pasted on the plate, making either a positive or different.
negative plate. The active material on a charge
positive plate is a reddish brown Lead Di Oxide 1. Lead Antimony:(Most commonly used)
[Pbo2] while the active material on a charge Is commonly used in conventional lead acid battery
negative plate is a grayish spongy lead. which uses lead antimony cell plates
ADVANTAGES
1. Longer service life than Calcium batteries.

2. Easier to recharge when completely
discharged.
3. Lower cost.
Fig no 6:Battery Case
2. Lead Calcium(AC Delco maintenance free
batteries). Is a maintenance free lead acid battery
The battery case holds the electrolyte and which uses lead calcium cell plates.
the individual battery cell elements. It is divided
into six compartment or cells. The plates are raised
up off the bottom of the case with ribs to prevent ADVANTAGES
them from shorting out if any of the active
materials (lead, etc) should happen to fall from the 1. Larger electrolyte reserve area above the
plates. The case is made of polypropylene, hard plates.
rubber, and plastic base materials. some battery 2. Higher Cold Cranking Amp ratings
manufactures use translucent plastic cases which 3. Little or No maintenance
allow checking electrolyte level without removing 4. Recombination (Gel Cell)
vent caps. These cases often have “upper” and
“lower” electrolyte level markers on the outside of Is a completely sealed lead acid battery
the case. which uses an electrolyte that in a gel (solid) rather
than a liquid.
VENT CAPS:
ADVANTAGES Overall Height 1076 mm
1. No liquid electrolyte to spill or leak. Wheel Base 1235 mm

2. Can be Deep Cycled several time without
damage. Kerb /wet
3. Totally corrosion and maintenance free. Weight 86 kg
4. Three to four times longer battery life than
regular batteries. Fuel Tank
5. More plate surface and closer plate spacing Capacity 4 liters
provides a compact case size.
Front Tyre 3.00×10 inches
X. FULL SPCIFICATION
OF KINE: Rear Tyre 3.00×10 inches
1. ENGINE, POWER AND TORQUE Head Light 12v 25w/25w

Table 2
VARIABLS VALUE This data is available from the manual of
Displacement 71.55cc this product.
Maximum XI. DESIGN CRITERIA:

power 4.2Bhp
Some part is necessary to design, on the
Maximum basis of the data available from the manual of the
Torque 5.7Nm moped and standard data book the value are taken
and their corresponding value is calculated.
Engine 2 Stroke Single
Displacement cylinder Following part which are necessary to design.
Cooling Air cooling

TRMISSION (1) Design Procedure for shaft
Table 3 Given Data
Torque on the Driving Shaft
PART TYPE =10N-m =10x103 N-mm
Gearbox Automatic
Total Load acting on the shaft
= 300 kg x 9.81
3. BRKAES
Table 4 =2943 N
TYPE SIZE
Total Length of driving shaft
Front Brake Drum 110 mm = 0.125m = 125 mm
Rear Brake Drum 110 mm Design Procedure for Flange

: ˑ d = 10.66 mm
Method (II)
4. DIMENSION ,WEIGHT, CAPACITY For Simply Supported Beam
=WL/4= 2943 x 0.125/4
Table 5
M=91.96 N-mm
PART SIZE M=91. 96N.m = 91.96 x103N-mm
M=𝜋 /32 × 6b × d3
Overall Length 1740 mm
91.96 × 10 3/32 =3.14 x42 x d3
d = 28.14 mm
Overall Weight 640 mm
Coupling
For stress
Given Data = π 𝐷1
T= 4 x 𝑑2 1 x τbx n x [ 2 ]
N = 5000 rpm motor π 42
T = 10 N-m 10x103=4 x 𝑑2 1 x 20x 4 x [ 2 ]
Actual Diameter of Engine shaft,
d = 14mm (given)
𝑑1 =2.75mm
(a) P = 2 x N x T / 60 N-m
Outer Diameter of Flange
P = 5.235 KW
T = π/16 x s xτs x d3
D2 = 4d = 4 X 14 = 56mm
10 x 103 = π /16
π
x= τs x 143
16 ‫ ·׃‬Thickness of the Protective Circumferential
τs=18.56 N/mm2 Flange
tp = 0.25 d
Outer diameter of Hub = 0.25 X 14 = 3.5mm
= 5 mm
D = 2d = 2 x 14 mm As our bolt actual diameter is 8 mm so our
design is safe.
= 28mm,30mm
(3) (1) Design Specification of Coupling
But Actual outer diameter of hub d =Diameter of Shaft = 14mm
D= outside Diameter of flange = 44mm
D = 122mm Thickness of flange = 4 mm
Allowable shear stress for shaft
So for given data our design is safe. =18.58 N/mm2
(1) Design specification for Bearing

(b) Hub is hollow shaft for that shear
stress Bearing No. 202
π 𝐷 4 −𝑑 4 Bore = 15mm
T = 16 x τs x [ 𝐷 ]
π 28 4 −14 4 Outer Diameter = 35mm
10 x 103=16 x τs x [
28
]
τs =2.47 N/mm2 Width = 11mm
For actual diameter of engine shaft Bearing 203
d = 14 mm Bore = 17mm
Outer diameter of hub
d = 122 mm Outer Diameter = 40mm
Ts= 0.23 N/mm2
Width = 12 mm
(4) Design Procedure for C- Clamp

Form above given data design is safe.
(c)Desing For Flange

Thickness of Flange = 0.5d
Tf= 0.5 x 14 = 7mm
3.14 ×𝐷
T= 𝜏𝑐 × 𝑡𝑓
2
3.14 ×28
10x103 = 2
𝜏𝑐 × 7
𝜏𝑐 = 1.16 𝑁/𝑚𝑚2
Cross Section at X – X
(c) Design for Bolt A=bxt
Given Data 40 x 5 = 200mm2
𝜏𝑏 = 20 𝑁/𝑚𝑚2
No. Of bolts n=4 Consideration (I) =
d1=Normal diameter of bolt . ‫ · ׃‬Direct tensile stress at x-x
D1 = Pitch circle diameter
D1= 3d= 3 x 14 = 42 mm
𝑃 2943
𝜎0 = = 4) Rim:
𝐴 200
𝜎0 = 14.71 N/mm2
Behind moment at X-X due to the load P

M=PXe 5) Rim disc:
= 2943 X 17.5
M = 51502.5 N-mm
Section Modulus
𝑡 ×𝑏 2 5 ×40 2
Z= = Coupling:
6 6
Z= 1333.33mm3
Behind stress at X-X I) Main Coupling
σb= M = 51502.5
Z 1333.33
σb = 38.62 N/mm2
Maximum tensile stress
= σ0 + σb II) Large Coupling:
= 14.17 + 38.62
= 53.33 N/mm2
Consideration (II)
Assembly: Explode View
XIII. ADVANTAGE’S:
Bending moment at X-X due to the load P  The range of an Electric bike increased.
M= P X e  The city traffic air and noise pollution is
= 2943 X 77.5 decreased to a greater extent.
 One third of energy is captured by
M = 228.08 X 103 N-mm regenerative braking, which would
otherwise go waste.
XII. CAD MODEL:  Decreased the dependency of fossil fuels.
1) Motor:
XIV. DISADVANTAGE’S:
 The initial cost of the vehicle is marginally
increased, compared to the conventionally
available.
 The disposal of battery is to be properly
2) Bearing:
handed to avoid pollution.
3) Clamp:
highway.Fuel efficiency is greatly increased
(twice).
 Emissions are greatly decreased.
 Dependency on fossils fuels can be decreased.
 Hybrids can be run on alternative fuels as well.
 Battery can be charge by the solar energy.
This is the main area where we need to be

Fig no. 8: Actual design and development of hybrid focused in future. All the above option will
moped. increase its efficiency. but the initial cost we need
XV. CONCLUSION: to be work on.
Finally, we conclude that canreduce
consumption of the fuel to the great extent. There is REFERENCES:
always an alternative source of fuel to the vehicle
as hybrid technology is the most promising
technology. Typically, petrol engines effectively [1] A. Raskin, S. Shah, The emerge of hybrid electric vehicles,
use only 15% of its fuel content to move the Alliance-Bernstein, 2006.
[2] M. Anderman., The challenge to fulfil electrical power
vehicle. Whereas an electric drive vehicle has an requirements ofadvanced vehicles, Journal of Power Sources,
on-board efficiency of about 80%. But electrical 127(2004).
vehicle cannot reach to the high speed as petrol [3] P. Denholm, W. Short, An Evaluation of Utility System
engine that’s why the hybrid technology is use. Impacts and Benefits of Optimally Dispatched Plug-In Hybrid
Electric Vehicles, Technical Report, October 2006.
[4] S. Logghe, B. Van Herbruggen, B. Van Zeebroeck,
This can efficiently work with the hub Emissions of road traffic in Belgium, Transport & Mobility
motor. And it supplies the power by the battery Leuven, January 2006.
[5] Clement K., Van Reusel K., Driesen J., The consumption of
(lead acid battery). the disadvantages of the both electrical energy of plug-in hybrid electric vehicles in Belgium,
electric moped and the petrol moped are EET-European Ele-Drive Transportation conference, Brussels,
compensated by the hybrid technology. and one Belgium, 30th May - 2nd June, 2007.
whole automobile industry catch this concept soon. [6] Commission Energy 2030, Belgium’s energy challenges
towards 2030,
preliminary report, November 2006.
[7] Clement K., Haesen E., Driesen J. The impact of
uncontrolled and
controlled charging of plug-in hybrid electric vehicles on the
distribution
grid, EET-2008 3rd European Ele-Drive Transportation
Conference,
Geneva, Switzerland, March 11-13, 2008.
XVI. RESULT: [8] Kersting W., Distribution System Modeling and Analysis,
Boca Raton,
2002.
The following are the result which are [9] Haesen E., Driesen J., Belmans R. Robust planning
obtain from during operation of the methodology for
vehicle.Charging Time of the battery – 6 hr. Max integration of stochastic generators in distribution grids, IET
Journal on
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[10] J. Linderoth, A. Shapiro and S. Wright, The em-pirical
behavior of
sampling methods for stochastic programming, Annals of
XVII. FUTURE SCOPE: Operations Research, Vol. 142, No. 1,
This modeled has a parallel hybrid

structure. The main propulsion units consist of a
two stroke internal combustion engine and a hub
motor attached to the Rear wheel of the moped.
The methodology used to optimize the energy and
fuel consumption of the hybrid electric scooter is
the multi-mode approach.
The hybrid vehicles have a wide scope in

the upcoming future. The main reasons of it are-
 Regenerative braking actually makes city

driving more economical than on the
Performance of Bullock Driven Tractors
S. B. Bakal P.J.Nikam
Assistant Professor, department of Agricultural Engineering, Associate Professor & Head, department of
Shri Shivaji Agriculture College, Amravati Agricultural Engineering, Shri Shivaji Agriculture
College, Amravati
[email protected]
Abstract- Animal power does not get proper attention on the other factors such as period available for cultivation, nature of soil,
hand; these days may be poses maintenance burden on the animal crops grown and timeliness requirement of each operations
based farmers. However, on the other hand, one of the serious and transportation work. It is pertinent to state that there is a
problems in Indian agriculture caused by increased cost of direct relation between energy inputs to crop production in
mechanical operations today is the extreme economic conditions
terms of output. The “tractorization” has grown at a rapid
which have been forcing farmers to commit suicides in thousands.
A study was conducted in sandy soil at village Kharmanja space and about 2.5 lack tractors are being added annually to
Kutubpur, Post Office – Lashkara, Dist – Haridwar (Uttaranchal), the Indian farms to help farmer to supply energy for
and in black soil at Gram Khajuria, Dist – Indore, Village - Ugrani conducting various farm operation and transport activities.
Dist – Bhopal for Kamdhenu and Brahmpuri Bullock Driven The tractors are suited for big size farms but farmers are not
Tractors. Both bullock driven tractors are used for cultivation, aware with the bad effect of tractorization.
ploughing, and harrowing, sowing and inter-cultivation operations. Regular use of tractor makes the soil hard and
The desired depth and width of cutting soil were found for various compact and also reduces fertility and moisture content of the
attachment of Plough, cultivator, ridger, Seed drill to bullock soil. Due to the compacted layer of the soil beneath the earth
driven tractor for black and sandy soil. For both types of the
infiltration and percolation properties of the soil goes on
tractors no difficulties were noticed and no stresses were found on
Bullock during operations. It is Easy to assemble and dissemble. decreasing and so sufficient soil moisture is not available for
Any farmer can do it easily. No vibration, no noise, no maintenance the depth of deep rooted crops and there is no rise in water
problems occurred. However, the two designs can learn from each table. For removing deep rooted weed and preparation of
other and there is enough scope for improvements. smooth seed bed multi-paired bullock drawn M.B. plough is
To make this technology more viable and popular among the used.
farmers it is necessary to adopt some improvements. The efficiency Considering these factors it was decided to undertake
of the BDT can be improved and can be made more acceptances in an experiment to evaluate the performance of multi-paired
the field. bullock drawn M.B. plough on the field over tractor drawn
Evaluating the two bullock drawn tractors on the basis of
M.B. plough.
their cost, working capacity, number of implements, it can be said
that the two types of tractor developed by Rajasthan Mechanical
Works Limited and Bhartiya Cattle Resource Development
Foundation are presently suitable for different conditions, may be MATERIALS AND METHODS
so designed and can become more promising by improving design
and learning from each other. The experiment trials were conducted in light soil at Anwi,
Sawalapur, Dabhadi for multi-paired and Dhaga for tractor
Keywords – Animal Power, cultivator, Plough, Ridger drawn M.B. plough on 2000 m2 area. The trials were
conducted according to RNAM test codes. The parameters like
INTRODUCTION depth of operation (cm), operating speed (Km/ha), field
efficiency (%), H.P., cost of ploughing (Rs/ha) were evaluated
According to the 1972 census, (1976) the working animal as per standard procedure mentioned below. The data was
population in India was 80 million and the total cropped area
used for comparing the performance of tractor operated M.B.
167 million hectares (www.indiastat.com). Thus on an average
plough and multi-paired bullock drawn M.B. plough.
one pair of working animals, i.e. bullock was available for
Table 1. General specification of tractor and bullocks used
4.16 hectares of land. Management studies have shown that a throughout experiment.
pair of bullocks can manage about 3 hectares farm. According
to Roy S.E. (1966) the maximum area of land which can be
cultivated by a pair of bullock, not only depends on the
efficiency of bullocks and the size of holding but also on
The selected two pairs were arranged in passion i.e. taller pair
should be at front and the other pair was behind it shown in
Fig 1. Previous work has shown (Adkine, Rapte & Acharya;
Particulars Specification
1977). Due to this reason maximum power of bullocks can be
harnessed, this method was followed generally in villages. The
Tractor used (HP) 35
two pairs were located just behind the plough.
No. of bullock pairs used 2 pairs
Size of M.B. plough for tractor drawn

(cm) 52.5
Size of M.B. plough for bullock drawn

(cm) 30
Average age of bullocks (years) 12
Breed of bullocks Jersey breed
Site Selection
The site was selected by considering the suitability of land

with uniform topography. The different sites were selected in
different villages during kharip season..
Neck method of harnessing animals:
This method is most commonly used with bullocks in India Figure 1. Ploughing operation by multi-paired bullock drawn
and other countries because the neck muscles of bullocks are MB plough at Sawalapur.
well developed and have sufficient strength against the
depression caused by the harness. There is no direct Harnessing with yoke
compression given to any bone or muscular structure of the
animal (Swamy Rao, 1966). The two labours, which were operators of each pair, put the
yoke on the neck of front and rear pair.
Procedure for Conducting the Trials
Arrangement of dynamometer
The trials were conducted as per the method generally
followed in the rural areas and the parameters were tested
Mechanical dynamometer was used for measuring draft (Fig
according to the RNAM Test Codes for testing the implement.
2). The details of dynamometer used while conducting trials is
given in Appendix-C. Mechanical dynamometer was tied in
Hitching
between yoke and implement body. As Mechanical
dynamometer was connected in the line of pull, the measured
Hitching of bullocks to the implement was done according to force represented the total pull (Ojha, 1958). For calculation of
the method generally followed in rural areas. In this method draft, the inclination of the line of pull from horizontal and
two yokes for two pairs were tied with the help of strong iron horizontal angle from the direction of travel was measured.
chain and it was connected to the ring of the plough with the Draft required by the formula. At the same time, depth and
help of peg.
width of tillage were measured. While conducting the trials,
angle of inclination were also measured
M.B. plough arrangement
The selected plough was cleaned before operation and

adjustment of horizontal and vertical clevis was done. The
specification of the mould board plough used for multi-pared
bullock and tractor drawn in different villages are given in
Appendix- A and Appendix- B respectively.
Standing of pair
θ2 = Angle between the rope of rear pair with
horizontal.
Unit Draft
It is the draft per unit cross sectional area of the furrow. The
cross sectional area of the furrow is computed by assuming the
furrow cross section triangular.
Therefore, Area of Trapezoidal section = ½ (Top width +
Bottom width) × Depth
Traveling speed
The traveling speed was computed with the help of stopwatch.

It is the distance covered by the bullocks and tractor in given
time.
Horse power
Draft in (kgf)  Speed (metre/sec)

Figure 2 Dynamometer during ploughing operation of multi- Metric hp 
paired bullock drawn M.B. plough. 75
Theoretical field capacity
Depth of ploughing
It is the of field coverage of the implement based on 100
While conducting the trials the depths of different locations percent of time at the rated speed and covering 100 percent of
were measured by removing the disturb soil from the furrow. its rated width.
Minimum five readings of depths were noted. width (cm)  speed (metre/sec)
Theoretical field capacity 
10000
Width of ploughing
The width of ploughing was recorded at the place from where Effective field capacity or Actual field capacity
depth was taken. The top widths and bottom widths were
measured by pushing the crown form on one side of It is the actual area covered by the implement based on total
ploughing. time consumed and its width.
Pull Field efficiency
It is the total force required to pull an implement. It is the ratio of effective field capacity and theoretical field
Dynamometer was used for measuring pull. capacity expressed in percentage.
Effective field capacity
Draft Field efficiency   100
Theoretical field capacity
It is the horizontal component of pull, parallel to the line of
motion. It is calculated by following way Soil Inversion Test
D  P Cos 
Where, Weed and stubble count method suggested by
D = Draft in (kgf) (Prasad & Misgara, 1981) was adopted to find out the soil
P = Pull in (kgf) inversion. Randomly three plots of size 60 X 60 cm were
θ = Angle between line of pull and horizontal. selected in the field. The no. of weed and stubble present in
each plot were measured before and after ploughing. The soil
The angle θ in calculated as the mean angle between the rope
inversion was then expressed on percentage basis.
of front pair and rope of rear pair with horizontal.
No. of weed before test - No. of weed after test
1   2 Soil inversion   100
Draft  P Cos No. of weeds before test
2
Where, Soil Moisture
θ1 = Angle between the rope of front pair with
horizontal.
Moisture content on dry weight basis was selected 4 Draft (Kg) 164.54 292.50 204.12
hp
for soil measurement. Core sample of wet three different
location of test plot random will be weighted the sample in Unit draft
balance and it was kept in oven for dry for 105 OC –110 OC for 5 (Kg/cm2)
0.65 1.54 0.97
at least 8 hours, cool in desiccators and weighted again.

Horse
6 Power (hp)
1.41 1.5 1.47 35
Results and Discussion
Experiments were conducted with the help of bullock and Traveling

7 speed 1.67 1.385 1.95 3.193
tractor drawn M B plough for draft analysis. It was observed (Km/h)
that the higher depth that is 17.50 cm was observed in case of
tractor drawn M.B. plough compared to bullock drawn M.B. Theoretical
8 field 0.0542 0.0378 0.057 0.144
plough that is 11.50 which is obvious. It indicates the capacity
deformation of soil at higher depth by tractor drawn M.B. Actual field
plough which is sometimes undesirable because soil capacity
9 (ha/hr)
0.0485 0.0345 0.038 0.144
manipulation below root zone depth is not required. Soil
manipulation at greater depth also requires higher energy Field
hence it is wastage of energy. Whenever deep ploughing is 10 efficiency 89.64 91.42 75 85.85
require, tractor drawn M.B. plough can be used. (%)
The speed of operation for tractor drawn M.B. plough Soil
was 3.19 Km/h and that of bullock drawn M.B. plough was 11 Inversion 90.1 93 85 87
1.5 Km/ha. Also the size of M.B. plough used with tractor was (%)
52.5 cm and that used bullocks was 30 cm. Hence the field
capacity of the tractor drawn M.B. plough was 0.12 ha/hr and Soil
12
moisture 11.52
9.692 15 10.20
that of bullock drawn M.B. plough was 0.03 ha/hr only. But
the field efficiency of bullock drawn M.B. plough was found content
Cost for
higher i.e. 91.42% compared to tractor drawn M.B. plough for 13 (%)
ploughing 1758.47 1820.25 1799.10 2535.95
which it was 85.85%. This was because of the fact that the (Rs/ha)
tractor takes higher turning time at the head lands compared to
bullocks. CONCLUSION
The cost of operation in case of bullock drawn M.B. 1. It is observed that harnessing of bullock is essential for
plough was found less than that of tractor drawn M.B. plough bullock drawn M.B. plough.
which is one more advantage of using bullock drawn M.B. 2. Speed of operation by tractor drawn M.B. plough was
plough. more as compared to multi-paired bullock drawn M.B. plough
Considering the time limits available for manipulation of soil 3. It is observed that average speed of ploughing was 1.5
and field capacity of tractor drawn M.B. plough it is advisable km/h for bullock drawn M.B. plough
to use it on large fields. But the task can be done more 4. It is found that, field efficiency was more in bullock as
efficiently by bullock drawn M.B. plough on small fields that compared to tractor drawn M.B. plough.
in turn saves cost of operation. More number of bullocks pairs 5. It was found, soil inversion test during all the trials was
if used on the field can compensate the time, but it will add to above 90%.
the operational cost. Average value of parameters for
comparing multi-paired bullock and tractor drawn M.B. REFERENCES
plough, shown in Table 2. 1. Adkine B.D. Rapte S. L. and Acharya H. S. 1977. Deoni red
Table 2. Average value of parameters for comparing multi- khandheri and holdeo bullock as draft animal. Paper
paired bullock and tractor drawn M.B. plough 2. presented at XV annual convention of ISAE, College of
Agriculture, Pune.
3. Agrawal J. P. 1983. Farm machinery testing in Iraq. Agricultural.
S. N. Parameters M.B. Plough Engineering. Today. Convention issue, ISAE 7(1): 11-12
Tractor
Bullock Drawn 4. Fischer R. C. 1982. A more efficient bufflow plough. A. M. A.
Drawn
Pub. Farm Machinery Industrial Research Crop, Tokyo
Sawalapur Anwi Dabhadi Dhaga 5. 13 (3): 11
6. Kepner R. A. Bainer R and Barger E. L. 1972. Principals of farm
machinery, 2nd Edn, A.V.I. Publication Company, New
1 Depth (cm) 14.49 11.50 13.48 17.51 7. Delhi.
8. Ojha T P. 1958. Design and construction of hydraulic drawbar
Width of cut dynamometer. Unpublished M. Tech. Thesis. Department of
2 (cm)
2.217 2.017 1.74 2.79
9. Agricultural Engineering, IIT., Kharagpur, W.B.
10. Prasad J. and Misgara S. K. 1981. Unit operation of chemical
3 Pull (Kg) 190 304.27 230.13 Use given engineering, 2nd edi. Pub. Mcgraw hill, London.
11. Sarkar R. I. and Mosharaf H. 1981. Research and development
need for improved utilization of animal draft power in
Bangladesh. A.M. A.Pub.Farm Machinery Industrial Research
Corp. Tokyo, 612 (4): 86
12. Roy S. E. 1966. Source and nature of available power in India.
Agricultural Yearbook published by I.C.A.R. New Delhi.
13. Swamy Rao A A. 1966. Report on bullock harness research
project; Allahabad Agricultural Institute,Allahabad,India.
MICROWAVE DRYING OF GARLIC
S. B. Bakal G. P. Sharma P. J. Nikam

Assistant Professor, department of Professor, Department of Processing & 3Associate Professor & Head,
Agricultural Engineering, Shri Shivaji Food Engineering, CTAE, MPUAT, department of Agricultural Engineering,
Agriculture College, Amravat Udaipur – 313001 (India) Shri Shivaji Agriculture College,
[email protected] Amravati.
Abstract- Microwave drying, application of microwaves, are to or better than those dehydrated by convective drying [4, 5,
relatively new addition in the existing drying techniques. Whole 6].
garlic cloves were subjected to microwave drying as well as
convective drying. The drying parameters for microwave drying
were 1 W, 2 W, 2.5 W and 500C, 600, 700C for convective drying.
For quality assessment garlic samples were dried to safe moisture
content. The quality of the products evaluated by the flavour II. MATERIALS AND METHODS
strength and color test. In both the test, microwave drying found
better in terms of uniformity, time and quality of the products. The microwave drying of garlic cloves were investigated in
The economics of microwave drying were evaluated and found microwave dryer installed in the Department of Processing
viable as cost benefit ratio is 3.77 for 3 years. and Food Engineering, College of Technology and
Engineering, MPUAT, Udaipur. A microwave dryer, having a
Index Terms- microwave drying, convective drying, garlic, flavor capacity of about 15 kg of garlic cloves /day is shown in
strength
Figure 1 and its specifications given in Table 1.
I. INTRODUCTION
Garlic (Allium sativum Linn.) is a bulbous perennial vegetable
spice. The world production of garlic in 2002 was 12.23 MT
from an area of 1.13 Mha, out of which 500,000 tones from an
area of 120,200 ha was produced by India [1]. Due to lack of
suitable storage and transportation facilities, about 30% of
fresh crop is wasted by respiration and microbial spoilage [2].
More recently, it has found uses in its dried form, as an
ingredient in precooked foods and instant convenience foods
including sauces, gravies and soups which has led to sharp
increase in the demand of dried garlic.
Drying of foods is aimed at producing high density product,

which when adequately packaged has long shelf life and after
which the food can be rapidly and simply reconstituted
Fig.1. Peeled garlic cloves being dried in microwave dryer
without substantional loss of flavor, taste, color and aroma.
Most of the cost of final product is dependent on the drying
Table:1 Specification of microwave dryer .
process. So it is necessary to dry the product in minimum cost,
energy and time for techno-econo-socio compatibility. Microwave Cavity
Garlic is a high-moisture commodity and microwave drying Dimention 700 X 700 X 550 mm
technique has attempted rarely. Microwave drying is relatively Thickness of the 16 gauges
a new addition in the existing drying techniques, viz. cavity
convective air drying (cabinet, fluidized bed, tunnel), spray, Material of the cavity S S 304 with mirror finish
vacuum, foam mat and freeze drying [3]. Published work in
the microwave drying domain have pointed out that this Microwave generator
technique leads to a greater reduction in drying time,
Magnetron 1 no.
increasing the production capacity. This is due to high thermal Type no 2M121A Hitachi Make
efficiency of the process increase quality attributes equivalent Power 2.5 kW
Pulsed operation Duty cycle 10 to 100%
Raw Garlic (64 % moisture)
Freqency 2450 MHz
Efficiency 60-70% Breaking in to cloves
Cooling of Magnetron Air (Air blower be provided)
Mode of operation Continuous & stepwise 0.25 kW variation. Peeling
Product Holder Circular type having diameter 600 mm, Microwave Drying;
height of rim 120 mm, made of Teflon & 6 % moisture (db)
rotating product at 360 degree.
Control and Interlocks An electronic control system, comprising of

relays, contractors and switches be provided
Packaging Grinding
on the control console. BSS 100 mesh
Storage
A. Principle of microwave dryer Polyethylene laminate
(27°C, 65% RH)
Microwaves are electromagnetic waves in the frequency range
of 300 MHz – 30000 MHz. It is the combination of electrical
and magnetic fields, with only the farmer being engaged in the D. Quality Assessment
conversion process when waves interact with the non-
magnetic materials. The conversion of Microwave Energy in Color measurement
to heat in the food is because of the presence of water. As the Color of fresh garlic and dried samples was evaluated by a
water molecules are bipolar and rotate in the rapidly changing Minolta Chroma Meter CR-200 Reflectance System shown in
electromagnetic field (billion times a second), heat is evolved fig. 2. The results were expressed as L* (whiteness–darkness),
within the food stuff due to friction between the water a* (red–green), and b* (yellow–blue) values. The
molecules. As waves can penetrate directly in to material, measurements of color were repeated three times.
heating is volumetric (from inside out) and provide fast and
uniform heating through the product. The quick absorption of Fig. 2 Pictorial view of colour measurement of Garlic Powder
energy by water molecules causes rapid evaporation of water, using Colorflex Colormeter
resulting into high drying rates of the food.
B. Specification of the raw material
According to Indian standard for Garlic, IS: 3240 – 1965, the

bulbs of garlic shall be mature, well cured, compact, that is,
the cloves shall not be spreading out but shall fit closely
together practical the entire length of individual of cloves and
enclosed in an outer sheath. Mature and well cured means
fully develop, fair, sufficiently dry and not soft and spongy.
The cloves shall be well filled and fairly plump.
Fresh garlic (Allium sativum) bulbs were used in the
investigation, which were procured in bulk from the local
market. The Garlic had moisture contents ranging between 60
– 65 % (w.b.) and moisture content reduce up to safe moisture
content of 6 % (w.b.). The vacuum oven method was used to
determine the initial moisture content of the garlic cloves. Flavour strength
Initial moisture content was determined with the help of The flavor strength in the dried cloves was determined by
vacuum oven with 70 °C with a gauge pressure of 85 kPa for Chloramine T method, a titration method. Garlic has
about 24 h [7]. charactorstic pungent flavor because of interaction of S –
substitutes, L- cystein sulfoxide derivatives and the enzyme
C. Process Parameters allinase. These sulfoxides are collectively called allins.
Flavour strength can be determined by measuring the amount
Conventionally peeled garlic cloves are dried immediately in of Chloromine – T solution consumed for allin oxidation. The
Microwave dryer applying 1 W, 2 W and 2.5 W through excess of Chloromine – T can be assessed by adding
experiment. For convective heating, tray dryer was used with potassium thiosulphate using starch as indicator.
operating temperature of 50oc to 70 c with air velocity 2 m/s
[8, 9]. A process flow chart of garlic cloves are furnish III RESULTS AND DISCUSSION
hereunder.
A amount of about 7.5 kg of peeled garlic cloves was loaded
in the microwave cavity and it took about 6 hours for 2.5 W,
6.3 h for 2 W and 7 h for 1 W to dry to the product of final Microwave Dried 4.86 73.42
moisture content of 6.0 % (w.b.). The drying time can be Convective Dried 3.28 64.31
greatly reduced by applying the microwave energy to the 60oC, 1 m/s
dried material [10, 11]. However, when the same load was
kept in a tray dryer, drying took place in about 12 – 13 hours
at 600C, in 16 h at 500C and 18 h at 400C. Increased drying 76
temperature entails higher costs and may cause biochemical 74
changes that degrade the dried product quality; whereas 72
subdividing the material is an additional process that results, 70
L Value
especially under industrial conditions, in mass losses and 68
lowering of the product quality [12]. Garlic cloves dried in 66
microwave dryer as shown in figure 3. respectively. 64
62
60
58
.
Microwave Convective
Drying Drying
Fig. 4 (a) Color (L - value) of garlic powder dried by two
methods.
Volatile oil (mg/g dry matter)

5
4
Fig. 3. Garlic cloves dried in microwave dryer
3
E. Quality of Dried Products
2
The dried garlic cloves were analyzed for quality with respect
to flavor strength and color, because these two parameters 1
become the basis of choice for acceptability by the consumers
as far as garlic powder is concerned. 0
Microwave
. drying
Color assessment Convective drying
It was found that microwave drying made the color brighter
(L = 73.42). Whereas drying slices with the convective
method lessened the color brightness (L = 64.31), shifting it Fig. 4 (b) Flavor strength of garlic powder dried by two
markedly towards red and yellow. Comparing the results methods.
presented with color assessment of garlic dried with the
microwave method only [11, 13]. F. Economics of the Microwave drying techniques
Flavour strength When garlic processing and dehydration plant considered from
Flavour strength for for microwave dried powder was found to a gross benefit steam the capital investment and operating
be. 4.86 and for convective drying was 3.28. L value and favor costs i.e. cost of microwave dryer, packaging machine, labour
strength are shown in Table 2 and Figure 4 (a), (b). This input, electricity charges are deducted.
showed that favor strength was more in Microwave drying Financial Aspects
powder as compared to convective drying powder because The following parameters have been considered for carrying
uniformity and less time period increase the quality of the out the economic analysis of the microwave dryer.
products. Same results were also be found, [11, 13]. a) Life of the MW dryer 20 years
b) Life of packaging machine 10 years
Table: 2 Color Values and Favor Strength of Dried Garlic c) Discount rate 8%
cloves d) Capacity of the dryer 15 kg of raw material and
processed product will be 6 kg per batch of 5
Drying Method Flavour L- hours and two batches per day.
Strength Value e) Number of days working for dryer = 300
(mg/g DM)
The details of the fixed and operating cost shown in Table 3 iii. Qualities of the microwave garlic cloves are found to
and results of economic analysis shown in Table 4. be better.
iv. Microwave drying are economically viable.
Table 3. The details of the fixed and operating cost. v. The microwave drying could be employed in the
drying of garlic cloves to produce dried cloves and
Fixed capital garlic powder.
Land and Building Amount
(Rs Lakh)
Land, 50 sq.m. 0.50
G. Future extension
Built up area, 25 sq. m. 1.50
Total cost of land and building 2.0 Combination of microwave drying with other mode of heating,
may give better results.
Machinery and equipment
It is necessary to designed microwave dryer for more fruits
Description 2.50
and vegetables drying.
Microwave dryer 0.40
Packaging unit 2.90
Total cost involved V. REFERENCES
Total fixed cost (1.1.1 + 1.1.2) 4.90
Recurring expenses per annum [1] FAO, FAP Production Yearbook, Food and
Labour, 2 salary 10,000 per month 1.20 Agricultural organization of the United Nations,
Rome, 2002.
Raw material including packaging [2] Anonymous, “Project Opportunities for Food
material 3.60 Industries”, Ministry of Food Processing Industries,
Peeled garlic cloves, 30 kg per day 0.50 GIO and CFTRI Mysore, India, 1993.
for 300 days @ Rs. 40 per kg [3] D.G. Prabhanjan, H.S. Ramaswamy and G.S.V.
Packaging material Raghavan, “Microwave-assisted convective air
Utilities drying of thin-layer carrots, J Food Eng, Vol. 25, pp.
Power, 2.5 kWh for 10 hour per 0.45 283–293, 1995.
day @ Rs. 5 per kWh for 365 days 0.15 [4] M. Bouraoui, P. Richard and T. Durance,
per year water. “Microwave and convective drying of potato slices”,
Other contingency Expenses J Food Process Eng, Vol. 17, pp. 353–363, 1994.
Repair & maintainance charges 0.30 [5] T.N. Tulasidas, G.S.V. Raghavan and A.S.
Total recurring expenditure Mujumdar, “Microwave drying of grapes in a single
(1.2.1 + 1.2.2+1.23+1.2.4) 6.20 mode cavity at 2450 MHz: drying kinetics”, Drying
Total Capital investment 11.10 Technology, Vol. 13, 8-9, pp. 1949–1972, 1995.
(Fixed capital + Recurring [6] H. Feng and J. Tang, “Microwave finish drying of
expenditure) diced apples in a spouted bed”, J Food Process Eng
Sale proceeds per year Vol. 63, 4, pp. 679–683, 1998.
Dehydrated cloves, 12 kg per day 25.20 [7] P.S. Madamba, R.H. Driscoll and K.A. Buckle,
for 300 days @ Rs. 700 per kg “Models for the specific heat and thermal
conductivity of Garlic”, Drying Technology, Vol. 13,
Table 4: Results of Economic Analysis 1-2 pp. 295–317, 1995.
[8] Z. Bobic, Baumani and Curic, D, “Rehydration ratio
Economic indicators of fluid bed dried vegetables”. Sadhana, Vol. 27, 365
B/C ratio 3.7752 – 374, 2002.
Pay back period Less than 3
years [9] P. Navarri and J. Andrieu, “High intensity infrared
drying study Part I. Case of capillary porous
The Table shows the economic indicators determined for the material”, Chemical Engineering & Processing, 32,
garlic dehydration unit. It can be seen that benefit-cost ratio of 319 -325, 1993.
the project is 3.77 and the payback period is less than 3 years. [10] G.P. Sharma and S. Prasad, “Effective moisture
This indicates that project is economically viable. diffusivity of garlic cloves undergoing microwave
convective drying”, Journal of Food Engineering
Vol. 65, pp. 609–617, 2004.
IV. CONCLUSION [11] A Figiel, “Drying kinetics and quality of vacuum-
microwave dehydrated garlic cloves and slices” ,
i. The drying time increased with increase microwave Journal of Food Engineering, Volume 94, 1, Pages
output power level. 98-104, September 2009.
ii. Microwave drying found better in terms of [12] A.E. Watada, N.P. Ko and D.A. Minott, “Factors
uniformity and reduce in time as compared to affecting quality of fresh-cut horticultural products”,
convective drying. Postharvest Biology and Technology, Vol. 9, pp.
115–125, 1996.
[13] G.P. Sharma and S. Prasad, “Drying of garlic
(Allium sativum) cloves by microwave-hot air
combination”, J Food Engineering, Vol 50, pp. 99–
105, 2001.
Diagnosis of Neuromuscular Disorder using EMG
Signal and neural network
Syed Irfan Ali Sunita Parihar
Department of Electronics and Communication Engg. Department of Electronics and Communication Engg.
PIET PIET
[email protected] and 9860492850 [email protected] and 9422506546
Syed Akbar Ali
Deepak Kapgate Department of Electronics and Telecomm. Engg.
Department of Electronics and Communication Engg. ACET
PIET Nagpur, India
Nagpur, India [email protected] and 8855093867
[email protected] and 9049996103
Abstract—EMG Signal classification has become the area of

interest for the researchers since past years. Electromyography is
a technique which plays an important role in diagnosing
neuromuscular disorders in the field of biomedical engineering.
Multiple methods have been proposed for the classification of
EMG signals. But the scholars are focusing on neural network
due to its classification accuracy and Motor Unit Action Potential
(MUAP) as a feature of classification to the neural network.
This paper explores an approach for processing

the EMG signal and its classification based on Artificial Neural
Network (ANN) whereas Discrete Wavelet Transform (DWT) as
a tool for classification of neuromuscular disorder. In this work a
multilayer feed forward neural network with back propagation
algorithm is used to train the Neural Network. For achieving
Fig 1.Nerve fiber taking the signal from skin or muscles to brain
maximum efficiency Back Propagation Algorithm (BPA) with
Discrete Wavelet Transform (DWT) is used to classify the
Neurological and Neuromuscular Disorders. This work explores muscle or skin and from muscle to brain, thereby control the
a comparison between k-Nearest Neighbours (kNN) classifier and muscle movements.
Feed Forward Neural Network (fNN).
Multiple types of electrodes are available for recording of
Keywords—Electromyography (EMG); Artificial neural EMG signal. Needle Electrode is used to read muscle EMG
network (ANN);Motor unit Action Potential (MUAP); Amyotrophic signal and Surface Electrode is used to read skin EMG signal.
Lateral Sclerosis (ALS); k-Nearest Neighbors (kNN);Discrete
wavelet transform (DWT); feed forward neural network (fNN)
I. INTRODUCTION
Human body generates a set of electrical signals as a
function of time. Electromyography evaluates and records Fig 2.Anatomical Model for recording of EMG Signal.
electrical variations of skeletal muscles with time. Our interest
is to make a tool for diagnosing neuromuscular disorders. The For this research, a 25 mm Needle Type Electrode is suitable
neurons that connect muscles and brain surface i.e. grey matter under hygienic clinical environment to read potential of motor
generates electrical signals to and fro ash shown in figure 1. nerve. This is called as Motor Unit Action Potential or MUAP.
These neuron fibers actually take the signal from brain to These signals are generated by muscles and goes to Central
Nervous System CNS through motor nerve. This is shown in HPF of EMG amplifier is set at 2 Hz while LPFis set at 10 kHz
figure 2. [5].
The Neurophysiologist usually decode the MUAPs
information from graphical patterns using oscilloscope [1]. As
a single needle electrode makes the contact with multiple
nerves, therefore receives a composite signal of different
shapes and sizes on graphical screen. To classify muscular
disorders visually from the received composite signal is very
difficult, thus various algorithms have been developed.
In this work,to classify between myopathy, ALS and
healthy patient signals we have used wavelet based
classification scheme. This has been accomplishedthrough
Feed Forward Neural Network using Back Propagation Neural
Network.
Here, features are extracted using DWT (discrete wavelet
transform). As we know that in practical case, EMG signal is a
continuous composite signal varying with time, thus,
decomposing it using wavelet transform is quite efficient. For Fig4.Back Propagation neural network
decomposing a software known as EMG-LODEC is specially
developed for recording multichannel long-term signals. The III. DWT FEATURE EXTRACTION
wavelet based algorithm distinguishes single MUAP by Any classification method can‟t be directly to the EMG
superposing the input signal [3]. samples, due to the large amount and the high dimension of the
II. METHODOLOGY examples are necessary to describe such a big variety of
clinical situations. A set of algorithms is usually adopted to
Classification of EMG signal needs following steps, which perform a quantitative description of the signal and a parameter
include (1)Reading EMG signal in wave format, (2) Feature extractionfrom the signal conditioning to the measurements of
extraction using wavelet, (3) Classification using NN. The average wave amplitudes, durations, and areas, [6].
block diagram of proposed work is shown in figure 3.
Discrete wavelet transform (DWT) in comparison with
discrete Fourier transform (DFT) is anefficient time-frequency
approach which has been used for processing multiple
biomedical engineering signals, viz. EMG. Thus, for EMG,
DWT provides the time and frequency information
simultaneously [7]. Equation (1) showswavelet function.
1 ∞ t−a
X a, b = x t Ψ dt 
b −∞ b
Where „a‟ and „b‟ are the dilation and the translation
parameters respectively. In this present work Db4(Wavelet
Daubechies-4) wavelet is used. For best result, the pre-
processed EMG signal is decomposed by using the discrete
wavelet transform up to the 10thlevel because only 262134
samples are available with this work. The feature set consists of
levels 1 to 10 and coefficients cd1 to cd10 and ca10. The
energy peak of the EMG signal lies between 0.5 Hz and 40 Hz.
This energy of the wavelet coefficients is muchintense in the
lower sub-bands ca10, cd10, and cd9. The levels 1 to 8 and
coefficients cd1 to cd8 areignored as they lack information and
intolerable noise is present in the frequency band of these
levels. Coefficients cd9 and cd10 shows the highest frequency
components and ca10 shows the lowest one. The obtained
Fig 3. Block Diagram for Classification of EMG signal. feature vectors form Db4 and wavelets decomposition is given
as an input to the Neural Network classifier.
A. Discrete wavelet algorithm
The EMG signal samples of a myopathy, ALS and a The EMG Signal information is passed through two
normalperson were collected from [4]. Signals from arm biceps convolutions functions (filters), each of which gives an output
of different persons are taken. The recording is done at low stream which is half in length to that of original input.One half
level but just above the threshold of constant contraction. The of the output is produced by the LPFgiven by equation (2).
𝑦1 𝑘 = 𝑛 𝑥 𝑛 ℎ0 [2𝑘 − 𝑛] (2) from ALS, Myopathy and Healthy person is shown in figure 5.
Decomposition to higher levels depends on the number of
While another half of it is produced by the HPF given by samples present in a given signal. To get clear information for
equation (3). a very large number of samples, it can be decomposed to a
level higher than tenth level.
𝑦2 𝑘 = 𝑛 𝑥 𝑛 ℎ1 [2𝑘 − 𝑛] (3)
Where y1 and y2 are the output of LPF & HPFrespectively,

which are known as an approximate and detail component.
These outputsare down sampled by a factor of 2, which is
known as 1-level decomposition. This process is repeated up to (a)
10 levels of decomposition, which results in a reduction of
samples from 262134 to 262. This issuitable for training of
neural network.
IV. NEURAL NETWORK AS A CLASSIFIER
(b)
The neural network is one of the efficient and accurate
classifier. It hasdense parallel structure& it learns from
previous experience. The accuracy of the classification is based
on trainingof the neural network.Here,Multilayer Feed Forward
Neural Network with Back Propagation Algorithm is used.
(c)
The informationobtainedfrom experience is stored in the
form of connection weights. The weighs updatesafter training, Fig 5. (a) Healthy (b) ALS (c) Myopathy
which runs in multiple iterations to get the desired level of
training.Since this algorithm is a supervised training After tenth level of db4, the Histograms of samples shown
algorithm,three issues need to be solved in designing an ANN in figure (6) distinguish the three classes, which are to be given
for a specific application. In this work, total 14 hidden neurons to neural network.
are used, simplified network is shown in figure 4.
V. K-NEAREST NEIGHBOR TECHNIQUE
The k-Nearest Neighbor is denoted by k-NN. If the cost of
error is same for each class, the estimated class of an unknown
sample is chosen to be the class, which is normally represented
in the collection of its K nearest neighbors. This technique does
not consider a priori assumptions about the distributions
wherefrom the training samples are taken. For classification of
a new sample, the distance to the nearest training case is
calculated then the sign (plus or minus) of this point classifies (a)
the sample. The k-NN classifier picks the k nearest points and
allot the sign of the majority. Large value of k reduces the
effects of noisy points within the training data set, andcross-
validationis used to choose the value of k. This way, its
Euclidean distance d is calculated. Equation (4) with all the
training samples classifies to the class of the minimal distance.
𝑛 2
𝑞 𝑥, 𝑦 = 𝑗 =1 𝑥𝑗 − 𝑦𝑗 (4)
(b)
Each training example with a class label is a vector in a
multidimensional feature space. The algorithm‟s training phase
includes only storing of the feature vectors and class labels of
the training samples. The algorithm‟s classification phase has
„k‟as a user-defined constant, and the unlabeled vector is
classified by assigning the label. Even if the Euclidean
distanceis only applicable to continuous variables, it is used as
the distance metric.
VI. RESULT AND DISCUSSION
In this method, features are extracted using wavelet for (c)
neural network. Decomposition up to 10 levels for the samples
Fig 6. Histogram of (a) Healthy (b) ALS (c) Myopathy
[3] Daniel Zennaro, Peter Wellig, Volker M. Koch, George S. Moschytz, “A
software package for the decomposition of long-term multichannel EMG
VII. CONCLUSION signals using wavelet coefficients,” IEEE TRANSACTIONS ON
BIOMEDICAL ENGINEERING, VOL. 50, NO. 1, JANUARY 2003.
The results of Decomposition and Histogram is clearly [4] Nikolic M. Detailed Analysis of Clinical Electromyography Signals
showing the difference between Healthy, ALS & Myopathy. EMG Decomposition, Findings and Firing Pattern Analysis of Patients
The kNN and fNN classifiers will be used to differentiate with Myopathy and Amyotrophic Lateral Sclerosis. PhD Thesis, Faculty
between Healthy, ALS and Myopathy.These classifiersare of Health Science, University of Copenhagen, 2001.
efficient to classify the data with a greater accuracy. This work [5] M. Sc. MikiNikolic,“Detailed analysis of clinical electromyography
will be an assistive contribution to doctors for a neuromuscular signals,” APh.D. dissertation submitted to the university of copenhagen
the faculty of health science August,2001.
disorder.
[6] Ali Hussein Ali Al-Timemy, Nebras Hussein Ghaeb, Taha Yassin
REFERENCES Khalaf , “Wavelet neural network based Emg signal classifier,” The
1stRegional Conference of Eng. Sci. NUCEJ Spatial ISSUE vol.11,
[1] Samaneh Kouchaki, Reze Boostani, Soona shabani, “A new feature No.1, 2008 pp 137-144
selection method for classification of EMG signals”, The 16th CSI [7] Akhila Devi B V, S.Suja Priyadharsini, “Diagnosis of neuromuscular
International Symposium on Artificial Intelligence and Signal disorders using softcomputing techniques,” International Journal of Soft
Processing (AISP 2012). Computing and Engineering (IJSCE) ISSN: 2231-2307, Volume-3,
[2] G. Eason, B. Noble, and I. N. Sneddon, “On certain integrals of Issue-5, November 2013.
Lipschitz-Hankel type involving products of Bessel functions,” Phil.
Trans. Roy. Soc. London, vol. A247, pp. 529–551, April 1955.
DESIGN OF MACHINE ROOMLESS ELEVATOR
Harshal S. Jumade Prashant P. Bansod
Student MED IInd year Mechanical Engg. Dept. Assistant Professor Mechanical Engg. Dept.
Abha Gaikwad Patil College of Engg. Abha Gaikwad Patil College of Engg.
Ajay A. Mahawadiwar
Head of department Mechanical Engg. Dept.
Abha Gaikwad Patil College of Engg.
Nagpur, India
[email protected]
Abstract- The present invention relates to an installation

structure for mounting an elevator traction machine at a rooftop I. INTRODUCTION
floor being capable not only to distribute a concentrated Elevators are vertical transport systems that are utilized for
operating load generated on the elevator traction machine during
efficient transport of passengers and goods between different
elevator operation over the guide rail to the bottom of a pit
through the installation structure members, but also to remove a efficient transport of passengers and goods between different
conventional machine room separately located at the upper end floors (landings). An elevator differs from other hoisting
of a shaft and to minimize an installation space of the elevator mechanisms in that it runs at least partially on guide rails. The
traction machine without altering an operating height of elevator. elevator is a mass transit system (conveyor) whose design has
Machine Room Less (MRL) elevator drives offer evolved rapidly from that of a simple drum and rope traction
advantages over conventional traction drives such as a higher system to traction less and machine room less systems.
energy efficiency, low weight and more design freedom and
better utilization of hoist-way space. MRL drives have emerged Elevator usage has grown exponentially in India but the
as the superior choice in most high rise applications. Currently a adoption of newer technologies such as the MRL drive or
majority of MRL drives are mounted on a guide rail spanning systems is lagging behind because of additional costs of
beam which forces safety and stabilization components to act as maintenance and inspection involved as convenience of
load bearing component and degrades ride quality. The MRL machine room diminishes. It becomes imperative to establish
drives are also difficult and costly to inspect and maintain if MRL elevators as a superior choice and provide additional
located in such a configuration. Alternate methods of mounting
future changes that provide advantage of MRL drive during
MRL drives on hoist-way spanning I beams if utilized can
eliminate eccentric hauling leading to better utilization of guide operation and the convenience of a machine room during
rails and an improved ride quality. A hoist-way spanning support inspection and maintenance. Such an elevator drive will
configuration also aids in decreasing inspection and maintenance provide least cost of maintenance and inspection for the
costs by improving ease of access and increasing safety. Thus a customer over the elevator lifetime. The present invention
properly located MRL drive can provide best possible operating relates to a machine-room-less installation structure for
parameters for a high rise application with lower costs of mounting an elevator traction machine at a rooftop. More
inspection and maintenance over the elevator lifetime. particularly, the installation structure for mounting the elevator
traction machine is capable not only to distribute a
Keywords—Machine roomless elevator
concentrated operating load being generated on the elevator
traction machine over the guide rail to the bottom of a pit
through the installation structure members, but also to remove
a conventional machine room being separately located at the
upper end of the shaft and installation space of elevator traction Section 3- Lift Car frame, Car, Counterweight and
machine without altering the traveling height of the elevator. Suspension
Section 4- Lift Safety Gears and Governors
This paper is organized as follows. Firstly, literature review
Section 5- Lift Retiring Cam
of IS: 14665 is discussed in section II. Problem and drawbacks
Section 6- Lift Doors and Locking Devices and
of machine room elevators and proposed system is explained in
Contacts
section III. Finally we conclude in section IV.
Section 7- Lift machines and Brakes
Section 8- Lift Wire Ropes
II. LITERATURE REVIEW Section 9- Controller and Operating Devices for Lifts
Indian Standard for Electric Traction Lifts provides
guidelines for outline dimensions of passenger, goods, service 5. IS 14665 (PART 5) - 1999 ELECTRIC TRACTION
and hospital lifts. This standard was adopted by the Bureau of LIFTS - SPECIFICATION (INSPECTION
Indian Standard. This was done with a view to align the Indian MANUAL)[5]:
Standards with the latest developments in the field of Lifts and 5.1 This standard (Part 5) applies to electric traction
also to align the standards with the European Norms on Lifts passengers/goods lifts erected at any place and
and Escalators EN 81. Moreover, these standards are published intended for use by passengers.
with a view to have a uniform code for electric traction lifts all 5.2 This standard does not apply to:
over the country, where presently different rules are being a) Service lifts(dumbwaiters)
followed by different states. This standard is one among the b) Hydraulic lifts
series of standards finalized by the Lifts and Escalators c) Escalators
Sectional Committee as detailed below: d) Cranes
5.3 This standard is concerned with inspection of lifts
1. IS 14665 (PART 1) - 2000 ELECTRIC TRACTION from safety point of view and does not cover
LIFTS (GUIDE LINES FOR OUTLINE DIMENSION performance requirements and corresponding tests.
OF PASSENGER, GOODS, SERVICE & HOSPITAL
LIFTS)[1]: Yeti et al. [6] provides comparative design of direct drive
This standard specifies outline dimensions of lift cars for PM synchronous motors in gearless elevator. In today’s world
passenger, goods, service and hospital lifts. The electrical machines becomes irreplaceable for human beings to
corresponding well sizes, pit depth, headroom, machine- continue daily routines. Due to the features such as high
room details and type of car and landing doors are also efficiency, high starting torque, and silent working, permanent
specified. magnet synchronous motors (PMSM) are becoming more
common in many applications. One of these applications is
2. IS 14665 (PART 2 - SEC 1 & 2) - 2000 - CODE OF gearless elevator system where PMSM seems to be the best
PRACTICE FOR INSTALLATION, OPERATION AND candidate so far. In this paper, comparative design of PMSM
MAINTENANCE[2]: for gearless elevator has been investigated. Maxwell 2D Finite
This standard (Part 2/Sec 1) covers the essential element analysis software has been used in this study. With
requirements, design considerations, testing and comparative design, the influence of pole count on the machine
precautions to be exercised during installation of performance is studied.
passenger and goods lifts operated by electric power, so
as to ensure safe and satisfactory performance. It also Kumar et al. [7] discusses about elevator control system
provides guidance for proper maintenance after which is one of the important aspects in infrastructure industry.
installation. This elevator control system is designed with the help of
hydraulic motor and programmable logic control (PLC) while
3. IS 14665 (PART 3-SEC 1 & 2)-2000 SAFETY RULES internal controlling is done through human machine
(SECTION 1 PASSENGER & GOODS LIFTS, interference (HMI). This research is divided into two Parts on
SECTION 2- SERVICE LIFTS)[3]: the basis of programming. Firstly the program is developed on
3.1 This standard (Part 3/ Sec 1) applies to the ladder logic and then simulated on software itself but for later
construction and safety of new passenger and goods testing and running the application a visualization is created on
lifts suspended by ropes and employing a guided lift Indraworks engineering Software and testing of hardware is
car. done. In the second level for controlling the internal commands
3.2 This standard does not apply to platform lifts, of the system and for floor recognition HMI is developed on
amusement devices, skip hoists, conveyors or similar Rexroth touch screen HMI and internal switch for floor
apparatus used for raising, piling. selection is done by HMI. The system consists of three floor
hardware and recognition of floors is done by inductive
4. IS 14665 (PART 4-SEC 1 TO 9) – 2001[4]: Components proximity sensors and limit switch. Hydraulic motor used for
Section 1- Lift Buffers UP-DOWN movement of the elevator is controlled through 4/3
Section 2- Lift Guide Rails and Guide Shoes Directional control valve (DCV).
Fig. 1 Machine room elevator
Lee et al. [8] discusses about structure design and
3.2 Proposed system and conceptual design
magnetic force analysis of a ropeless elevator model that
employs permanent magnet linear synchronous motors To overcome the drawbacks of old systems, traction
(PMLSMs) with the structure of a double-sided long-stator. To machine can be installed in shaft itself and control panel can be
obtain the optimal structure, the combination of response mounted near top floor landing door. Comparison between
surface methodology and 2-D finite element analysis, which elevator with machine room and machine roomless elevator is
can solve the problem effectively without consuming much as shown in Fig. 2.
time, is utilized to estimate the design parameters of PMLSM.
The numerical calculations and the experimental results are
reported to validate the applicability of this double-sided long-
stator type PMLSM for a ropeless elevator system.
Dae-Woong et al. [9] presents a new standardized type of

gearless traction machine drive system with a PM motor for
high-speed elevators. Some control functions which are
indispensable for improving the performance of elevator
systems have been addressed. Stringent evaluation,
environment and life tests ensure that the presented system is
not only high-performance but long-lasting and more reliable.
Wes et al. [10] discusses the overall importance and

benefits of a complete and efficient preventative maintenance
Fig. 2 Comparison between machine room elevator and
program. Implementing a strong program will have positive machine roomless elevator
impacts on safety, early detection, predictive maintenance, life
expectancy, and reducing operating costs. We will look at This reduces the cost of construction and increases
existing tools and new technologies; specifically the load efficiency and performance of elevators. Machine Room Less
measuring roller and analytical review. drives represent current pinnacle of elevator drive technology
and have made other traction drives obsolete. MRL drives offer
III. PROBLEM DEFINITION best operating parameters including costs, energy efficiency,
and ride quality. Elevation view and Plan view of Machine
3.1 Problem and drawbacks of machine room elevators Roomless Elevator are shown in Fig 3 and Fig. 4, respectively.
The separate room is required at the top of the shaft This shows conceptual layout/arrangement.
for mounting traction machine and controller as shown in
Fig. 1. It results in increase in construction cost as well as
Elevator cost. Also, due to increase in height, motor power
consumption also increases.
difficulty and increased costs of inspection and maintenance.
Most of these disadvantages occur due to older method of
Supporting MRL drives on a Beam spanning the Guide rails.
Use of alternate configurations with the drive housed in the
hoist way at top or bottom locations (use of pit floor may be
made when moving from hydraulic to traction drives)
eliminates majority of disadvantages associated with MRL
drives. Lower costs of inspection and maintenance over the
elevator lifetime will also encourage widespread use of the
highly efficient MRL drives.
REFERENCES
[1] IS 14665 (PART 1) - 2000 Electrical traction lifts (Guide lines for
dimension of passenger, goods, service & hospital lifts).
[2] IS 14665 (PART 2 - SEC 1 & 2) - 2000 - Code of practice for
installation, operation and maintenance.
[3] IS 14665 (PART 3-SEC 1 & 2) - 2000 Safety rules Section 1-Passenger
& goods lifts, Section 2-Service lifts.
[4] IS 14665 (PART 4-SEC 1 TO 9) - 2001 Components.
[5] IS 14665 (PART 5) – 1999 Electrical traction lifts – Specification
(Inspection manual).
[6] Hicret Yeti, Hande Boztepeli, YusufYaa, Erkan Mee, “Comparative
Design of Direct Drive PM Synchronous Motors in Gearless Elevator
Systems” in 3rd International Conference on Electric Power and Energy
Conversion Systems, October 2-4,2013, pp 978-981.
[7] Kumar, Roushan, et al. "Design and implementation of hydraulic motor
based elevator system." Power Electronics (IICPE), 2014 IEEE 6th India
International Conference on. IEEE, 2014. Chung,
[8] Lee, Sang-Geon, et al. "Optimal Structure Design for Minimizing Detent
Force of PMLSM for a Ropeless Elevator." Magnetics, IEEE
Fig. 3 Machine Roomless Elevator (Elevation view) Transactions on 50.1 (2014): 1-4.
[9] Dae-Woong, et al. "Drive systems for high-speed gearless elevators."
Industry Applications Magazine, IEEE 7.5 (2001): 52-56.
[10] Allen, Wes. "Preventative maintenance and root cause analysis for
critical process conveying equipment." Cement Industry Conference
(IAS/PCA CIC), 2015 IEEE-IAS/PCA. IEEE, 2015.
[11] Tetlow, Karin. "New Elevator Technology: The Machine Room-Less
Elevator." (2009): 169.
[12] Asvestopoulos L, Spyropoulos N, Hellas K (2010) Elevators Energy
Consumption Study, Elevator Report, Greece.
[13] Zarikas, Vasilios, et al. "Intelligent Decisions Modeling for Energy
Saving in Lifts: An Application for Kleemann Hellas Elevators." (2013).
[14] Sachs, Harvey M. "Opportunities for elevator energy efficiency
improvements." Washington, DC: American Council for an Energy-
Efficient Economy, 2005.
[15] Andrew, J. P., and Stefan Kaczmarczyk. Systems Engineering of
Elevators. Elevator World, 2011.
[16] Stephen, N. G. "Macaulay's method for a Timoshenko beam."
Fig. 4 Machine Roomless Elevator (Plan view) International Journal of Mechanical Engineering Education 35.4 (2007):
285-292.
IV. CONCLUSION
Machine Room Less drives represent current pinnacle
of elevator drive technology and have made other traction
drives obsolete. MRL drives offer best operating parameters
including costs, energy efficiency, and ride quality. When
compared to other types of drives for high rise applications and
are being preferred to hydraulic drives in low rise applications.
However MRL drives currently in use have few disadvantages
including less seismic safety, eccentric haulage of cabin,
Design and analysis of cutter drum for a cable
laying machine
1
Mr. Lokesh G. Dandekar 2Prof.Ritesh Banpurkar 3 Prof. Ajay
M-Tech (MED) IIIrdSem, Assistant Professor, Mahawadiwar
AGPCE, Nagpur Department of Mechanical Assistant Professor,
Engineering, Head of Department
AGPCE, Nagpur Mechanical Engineering,
AGPCE, Nagpur
Abstract: A cable laying machine for underground created in CREO-PARAMETRIC 2.0. Here
placement of cable incorporating a basic frame and dynamic mechanism will be made for calculating
power unit incorporating a rear warred attractive velocity, acceleration impact variation with respect
component with the front and rear components with to time. Design calculation in the reverse direction
the front and rear components being articulately
so that how much torque is required to dii up the
interconnected for steering control of the machine
and the rear component including cable laying plough soil. After that we design the whole system from
associated there with the rear component may be bottom to top. MD SOLID software will be used to
provided with cable reels and guide structures for calculate the SFD and BMD Diagrams as well as
guiding the cable the plough. The cable laying deflection in the shaft.in terms of robustness we
machine has a cutter drum at its front end which digs analyses the whole parts in the assembly which is
up the soil along linear channels rolls down the cable made in Design software. Different analysis will be
mounted on the roller behind. The proposed machine made such as structural analysis in ANSYS 16.0.
eliminates hazards faced by commuters solving three Keywords: Cable, Soil
purposes simultaneously of digging, Cable laying and
conditions,Creo,MDsolid,Ansys
then covering the soil. The simulation model will be
INTRODUCTION:
The cable laying machine is to lay a utility cable

underground and laying the cable at a uniform
depth.it has a Cutter drum mounted on the front
section, Cable drum along with cable on back
section. Accumulated soil is removed by the
flapper
BLOCK DIAGRAM OF CABLE LAYING

MACHINE
The machine is run by motor whichperforms 4

functions:-
• digs up the soil (with the help of cutter
drum)
• clears the channel (by means of flapper)
• lays the cable (through the cable roller
drum) Keywords: laser alignment, reduction gearbox, V-belt
• Refilling the channel. transmission, test rig.
LITERATURE SURVEY: 3.A DISCRETE ANALYSIS OF METAL-V

BELT DRIVE
1. Analysis of Power Transmission System A. KARAM and D. PLAY
for Ginning Machine with Feeding UniversitéLibanaise
Mechanism using FEA Faculté des sciences II
FANAR-MATEN B.P. 90656
Prof. P. S. Nerkar1, Dr. J. F. Agrawal2, Mr. P.D. Lebanon
Deshpande3 1 Assistant Professor, Department of
Mechanical Engineering, S.V.P.C.E.T, Nagpur, Abstract
Maharashtra, India. 2 Principal, Shri Sai College of The metal-V belt drive includes a large number of
parts which interact between them to transmit power
Engineering & Technology, Bhadravati,
from the input to the output pulleys. A compression
Maharashtra, India. 3Application Engineer, DCS. belt composed of a great number of struts is
PVT. Limited, Nagpur, Maharashtra, India. maintained by a tension flat belt. Power is them
shared into the two belts that moves generally in
ABSTRACT: In India, it was found that ginning opposite directions. Due to the particular geometry of
factories do not operate efficiently with regard to the the elements and to the great number of parts, a
labour force employed and the amount of capital numerical approach achieves the global equilibrium
invested. In order to make a more concrete evaluation of the mechanism from the elementary part
of the cotton ginning sector, it is necessary to equilibrium. Sliding arc on each pulley can be thus
determine the structural characteristics of the defined both for the compression and tension belts.
factories, costs and profitability, the level of technical Finally, power sharing can be calculated as
efficiency, and the most important, potential for differential motion between the belts, is defined. The
improvement in the industry. Irregular feeding of first part of the paper will present the different steps
Seed Cotton to ginning machine decreases the of the quasi-static mechanical analysis and their
production rate of seed and fiber. It also affects the numerical implementations. Load distributions, speed
quality of the fiber and seed. To overcome these profiles and sliding angle values will be discussed. The
difficulties feeding mechanism is developed. The second part of the paper will deal to a systematic use
primary function of feeding mechanism is to feed seed of the computer software. Speed ratio, transmitted
cotton uniformly to the ginning machine at torque, strut geometry and friction coefficients effect
controllable rates. Feed rollers, located at the bottom will be analysed with the output parameter
of the feeder, directly under the hopper, control the variations. Finally, the effect pulley deformable
feed rate of seed cotton to the ginning machine. Stress flanges will be discussed.
analysis carried out by using FEA software and the
results are compared with the calculated values. This 4.SPEED RATIO PREDICTION AND
paper illustrates how the chain drives are very PERFORMANCE ANALYSIS OF SINGLE
important to carry forwards the power. In this Paper
recommendations and suggestions to improve quality
BALL TRACTION DRIVE FOR CVT
of cotton fiber, suggestions for ginning factories are Kunal S. Marathe*, Vishnu D. Wakchaure**
highlighted. *(Amrutvahini College of Engineering, Department
of Mechanical Engineering, University of Pune,
2.ANALYSIS OF THERMAL GROWTH Sangamner-422605, Maharashtra State, India)
INFLUENCE ON V-BELT TRANSMISSION **(Amrutvahini College of Engineering,
ALIGNMENT PRECISION Department of Mechanical Engineering, University
AndrisPrizevaitis, DmitrijsLitvinovs, of Pune, Sangamner-422605, Maharashtra State,
EriksGerins India)
Riga Technical University, Latvia
[email protected], [email protected] ABSTRACT Drives are basically used to transmit
power and speed from the prime mover to the
Abstract. V-belt transmission alignment is a machine. The power transmission and speed
necessary criterion of its reliable and accident-free reduction between the prime-mover and the driven
work. Most exact and useful is an alignment by laser machine can be achieved by using conventional drives
equipment. However, during an alignment it is like Belt drive, Rope drive, Chain drive, Gears, etc.
necessary not only exactly and correctly to align the with their numerous advantages and disadvantages.
drive and led units, but also to take into account the There are many machines and mechanical units that
size of V-belt transmission component thermal under varying circumstances make it desirable to be
growth. In this article the principle of thermal growth able to drive at a barely perceptible speed, an
size determination will be considered, and also the intermediate speed or a high speed. Thus an infinitely
analysis of thermal growth influence on the V-belt variable (step less) speed variation in which it is
transmission alignment quality and precision will be possible to get any desirable speed. Some mechanical,
conducted. hydraulic, drives serve as such step less drives.
However the torque versus speed characteristics of compared for idling loss and power transmission
these drives do not match torque at low speeds. Hence efficiency. Data is documented for Vee, joined-V, V-
the need of a step less or infinitely variable speed ribbed, and synchronous belt types and for cogged,
drive came into existence. The drive presented by the plain, and laminated V-belt constructions. The level
end of this research work is single ball traction drive of energy savings achieved by the replacement of
for continuously variable transmission systems. plain-base wrapped V-belts with cogged V-belts is
Dissertation includes the brief history of existing emphasized. Belt efficiency, slip, and temperature
drives, speed prediction methodology and dependence on the basic drive parameters of torque,
performance analysis of the drive developed. sheave diameter, belt tension, and contact angle is
Keywords – Analysis, Ball, CVT, IVT, Traction reported
5. DYNAMICS MODELING FOR 7.THE BENEFITS OF A FINAL APPLIED

MECHANICAL FAULT DIAGNOSTICS AND DESIGN PROJECT THAT
PROGNOSTICS COMPREHENSIVELY INTEGRATES
Colin D. Begg, Terri Merdes, Carl Byington, and COURSE MATERIAL CONTENT &
Ken Maynard CONCEPTS
The Pennsylvania State University, Applied Mathew A. Kuttolamadom
Research Laboratory Texas A&M University
Condition-Based Maintenance Department College Station, TX, 77843
University Park, Pennsylvania 16804 [email protected]
ABSTRACT Abstract: The objective of this paper is to

While tremendous improvements have been made in explore the benefits of a final applied engineering
the performance of modern engineered systems due to design project, which serves to comprehensively
increased design cycle accuracy and testing integrate the content and concepts of a senior-level
capabilities, traditional time/use maintenance course. By integrating course content and concepts
practices have not changed much. While wear through an applied project, the benefits of a typical
longevity of many subsystem components has multi-semester capstone design project are translated
increased with a beneficial decrease in weight and size to a single course. For this, an upper-level mechanics-
the margins of safety have also decreased because of track course that is being offered to seniors in the
greater accuracy in design analysis and improved Manufacturing and Mechanical Engineering
testing techniques. In an effort to increase efficiency Technology (MMET) program at Texas A&M
in use of high performance and heavy-duty systems, University was chosen. The course, titled “Mechanical
especially in power generation and transmission Design Applications-II” involved the application of
subsystems, Condition-Based Maintenance (CBM) the principles of design to mechanical power
has emerged as an improvement over more costly transmission elements. The final assigned project was
time/use maintenance practices. CBM is being to complete the design of all the individual elements
enabled by the same technological (testing, modeling, constituting the power transmission system that was
analysis) improvements that have spawned increased intended to deliver power between two machines, and
system performance. As part of a combined to put them together (with certain requirements and
experimental-theoretical analysis investigation effort constraints). Periodic guidance was offered to the
related to CBM diagnostics and prognostics, an students on a need-basis for this open-ended project.
experimental gearbox failure test bed was On completion, it was observed that this interactive
constructed. The primary interest is the\ study of activity was very well received by the students, and
mechanical fault evolution in damaged rotating that it clearly exhibited many short-term and long-
components that involve mechanical power term benefits in the form of concept and content
transmission. As part of that same research effort a clarity, problem-based learning, metacognition, and
dynamics model of the system is being developed for higher-order thinking
response simulations and study of in situ mechanical skills.
dynamic fault models. Simulations of system
vibratory responses will allow physical insights to be 8.CALCULATION OF THE STARTING
gained in vibratory measurement sensor placement REGIME OF THE POWER TRANSMISSION
and specification, dynamic system response to a fault, SYSTEM WITH A HYDRODYNAMIC
and fault detection signal processing algorithms. In
this paper, the dynamics modelling of the gearbox
COUPLING AND A DRIVING MOTOR
drive rotor/bearing-foundation system using the UDC 621.817.032
Finite Element method is outlined and it’s relevance BožidarBogdanović, ŽivanSpasić,
to diagnostics and prognostics is highlighted. JasminaBogdanović-Jovanović
Faculty of Mechanical Engineering, A. Medvedeva
6.ENERGY LOSS AND EFFICIENCY OF 14, Niš, Serbia and Montenegro
POWER TRANSMISSION BELTS
Abstract. In this paper a graph-analytical procedure
ABSTRACT: A comprehensive selection of belt for calculating a starting regime of the power
type and construction from industrial and transmission with a hydrodynamic coupling and a
agricultural applications is extensively tested and driving motor is presented. The presented iterative
procedure for solving this problem provides for TECHNOLOGY AND ADVANCED ENGINEERING, VOL.02
obtaining the starting power transmission system , NO. 10, OCT 2012.
regime with accuracy determined in advance. The
number of iterative steps depends on the defined [3] OHTA Tsutomu et al “Route Design/Cable laying
accuracy. technologies for optical submarine cable”, NEC TECHNICAL
JOURNAL ,VOL. 05 , NO. 01/2010
Key Words: Hydrodynamic Coupling, Electromotor,
Starting Regime [4] Shaun Austine et al, “A Comparative analysis of
submarine cable installation method in northern Puget sound,
Washington ”, JOURNAL OF MARINE ENV. ENGG., Vol
CONCLUSION: .07,pp. 173-184.
After the completion of literature survey the cable [5] Chetan Samarth , A.K. Mahalle, “Design and
optimization of speed ratio for convetional chain drive used in
laying machine is boon to the mankind. The Tricycle”, IJITEE , Vol. 01, No. 01, JUNE 2012
machine is a first of its kind which digs up the soil, .
lays the cable and covers the channels [6] Victor D. Antonielo, “Underground power cable
simultaneously. The implementation of this consideration: Alternative to overhead ”, 47 th Minnesta power
system conference , Nov 2011.
machine would certainly reduce the time of cable
laying work and will also assist in greater precision [7] JunzhouHuo et al,,“Static and dynamic characteristics of
that manual cable laying work. The cable laying the chaine drive system of a heavy duty apron feeder ”,THE
machine reduces the labour cost associated with the OPEN MECHANICAL ENGG. JOURNAL , 2013 No.7, pp.
121-128
digging up the soil and covering the channels. It
also reduces the traffic snarls and hazards faces by [8] Gao Kui-Dong et al ,“Drum cutting specific energy
the commuters due to cable laying work. Having consumption model built by cutting curves analysis ”,
seen this machine working satisfactorily on a small TELKOMNIKA , Vol. 11 , No. 01 , July 2013.
scale, we can conclude that with the aid of high [9] A. Pillay, SAIE and B. S. Rigby, “Investigations into
transmission system, high capacity motors and the effect of inductor size on the performance of f Thyristor
cutter teeth of high harden ability; it can be used in Controlled Series Capacitor”, AFRICON, 7th AFRICON
the large small project undertaken by the Conference in Africa, (2004) September 1517.
government for cable laying work.
[10] Rahul urankar“ Study of Drive Mechanisms of Bicycle,
Tricycle or Like Vehicles to Optimize Operating Performance”,
IJERA , Vol. 4 , No. 1 , Jan 2014.
REFERENCES:
[11] Shaun Austine et al, “A Comparative analysis of
[1] Prashantkumar S. Patel1 “ Analysis Of Grading
submarine cable installation method in northern Puget sound,
Techniques In Xlpe Cable Insulation By
Washington ”, JOURNAL OF MARINE ENV. ENGG., Vol
Fem”,INTERNATIONAL JOURNAL OF RESEARCH IN
.07,pp. 173-184.
ENGINEERING AND TECHNOLOGY Vol. 3, No. 4, Apr-
2014
[12] Victor D. Antonielo, “Underground power cable
consideration: Alternative to overhead ”, 47 th Minnesta power
[2] Vigya et al “Comparisions of cables”,
system conference , Nov 2011
INTERNATIONAL JOURNAL OF EMERGING
DESIGN, ANALYSIS AND OPTIMIZATION OF
PRESS MACHINE USING FEA
Nikhil Ekotkhane, PrashantBansod,NagpurAssitant Professor (MED) Head Of
III Sem,M tech, Department Of MechanicalEngineering, MechanicalEngineeringDepartment
Department Of MechanicalEngineering AGPCE, Nagpur AGPCE, Nagpur
,AGPCE, Nagpur Ajay Mahawadiwar

Abstract—In hydraulic press, the force generation, transmission
and amplification are achieved using fluid under pressure. The
liquid system exhibits the characteristics of a solid and provides a
very positive and rigid medium of power transmission and
amplification. In a simple application, a smaller piston transfers
fluid under high pressure to a cylinder having a larger piston area,
thus amplifying the force. There is easy transmissibility of large
amount of energy with practically unlimited force amplification. It
has also a very low inertia effect. Main objective of project is to
modify major component of one cylinder four post hydraulic press
so that rigidity and strength of the components are increase by
using optimum material. The function of the major component like
frame, bottom plate, bed, top box are to absorb forces, to provide
precise slide guidance and to support the drive system and other
auxiliary units. The structural design of the component depends on
the pressing force this determines the required rigidity. The current
machine does not have high rigidity and needs to be redesigned.
Figure1: Existing Press machine
Keywords: hydraulic press, fluid,power transmission, cylinder.
II. LITERATURE REVIEW
I. INTRODUCTION
[1]Ankit H Parmar, Kinnarraj P Zala, Ankit R Patel Suggested
HYDRAULIC PRESS: In hydraulic press, the force
thatthe goal of structure optimization is to decrease total mass of
generation, transmission and amplification are achieved using
hydraulic press while assuring adequate stiffness. Structural
fluid under pressure. The liquid system exhibits the
optimization tools and computer simulations have gained the
characteristics of a solid and provides a very positive and rigid paramount importance in industrial applications as a result of
medium of power transmission and amplification. In a simple innovative designs, reduced weight and cost effective products.
application, a smaller piston transfers fluid under high pressure A method of structure optimization for hydraulic press is
to a cylinder having a larger piston area, thus amplifying the proposed in order to reduce mass while assuring adequate
force. There is easy transmissibility of large amount of energy stiffness. Key geometric parameters of plates which have
with practically unlimited force amplification. It has also a very relatively larger impacts on mass and stiffness are extracted as
low inertia effect. design variables. In order to research relationship between
stiffness, mass and design variables, common batch file is built
In these types of presses, press-body is of C Shaped. When
by CREO and analysis is done in ANSYS. Top plate, movable
free space required from three sides of press table to work for
loading and unloading of pressed component then this type of plate and column design and analysis done.
presses are designed. As main cylinder placed eccentric to [2]B.PARTHIBANP.EAZHUMALI, S.KARTHI.A hydraulic
central axis of press-body, it applies eccentric load on press-body press is a machine using a hydraulic cylinder to generate a
hence heavier press body is required as compared to same compressive force. Frame and cylinder are the main components
capacity of other type of press. These types of presses are also of the hydraulic press. In this project press frame and cylinder
called as single press. are designed by the design procedure. Press frame and cylinder
are analyzed to improve its performance and quality for press
working operation. Structural analysis has become an integral amplification are achieved using fluid under pressure. The liquid
part of the product design. The frame and cylinder are modeled system exhibits the characteristics of a solid and provides a very
by using modeling software CATIA. Structural analysis has been positive and rigid medium of power transmission and
applied on C frame hydraulic press structure and cylinder by amplification. In a simple application, a smaller piston transfers
using analyzing software ANSYS. An integrated approach has fluid under high pressure to a cylinder having a larger piston
been developed to verify the structural performance and stress area, thus amplifying the force. There is easy transmissibility of
strain distributions are plotted by using ANSYS software. large amount of energy with practically unlimited force
According to the structural values the dimensions of the frame amplification. It has also a very low inertia effect. Main objective
and cylinder are modified to perform the functions satisfactory. of project is to modify major component of one cylinder four
post hydraulic press so that rigidity and strength of the
[3]Muni Prabaharan and V.AmarnathStructural optimization components are increase by using optimum material. The
tools and computer simulations have gained the paramount function of the major component like frame, bottom plate, bed,
importance in industrial applications as a result of innovative top box are to absorb forces, to provide precise slide guidance
designs, reduced weight and cost effective products. Especially, and to support the drive system and other auxiliary units. The
in aircraft and automobile industries, topology optimization has structural design of the component depends on the pressing force
become an integral part of the product design process. In this this determines the required rigidity. The current machine does
project, topology optimization has been applied on various not have high rigidity and needs to be redesigned.
components of scrap baling press and 5Ton hydraulic press using
ANSYS WORKBENCH software. Suitable loads and constraints V CONCLUSIONS
are applied on the initial design space of the components. An
integrated approach has also been developed to verify the By undertaking this project, major component of one cylinder
structural performance by using ANSYS software. At the end, four post hydraulic press machines will be redesigned and
shape optimized design model is compared with the actual part optimized so that it has sufficient strength and stiffness.
that is being manufactured for the press. It is inferred that
topology optimization results in a better and innovative product REFERENCES
design. In this project, we showed 26.26 percent cost reduction
in scrap baling press. And we fabricated 5ton hydraulic press [1] Ankit H Parmar, Kinnarraj P Zala, Ankit R Patel, “Design and
Modification of Foremost Element of Hydraulic Press Machine”ISSN
with cost reduction of 24.54 percent. 2249-9954,Issue 4 volume 3, May-June 2014.
III. IDENTIFIED GAPS IN THE LITERATURE [2] B.Parthiban, P.Eazhumali, S.Karthi, P.Kalimuthu, “Design and
Analysis of c type Hydraulic Press Structure and Cylinder”issn (online):
Main objective of project is to modify major component of 2321-3051,Vol.2 Issue.3, March 2014,Pgs: 47-56.
one cylinder four post hydraulic press so that the rigidity and [3] Muni Prabaharan and V.Amarnath , “Structural Optimization of
strength of the components are increased. 5Ton Hydraulic Press and Scrap Baling Press for Cost Reduction by
Topology”International Journal of Modeling and Optimization, Vol. 1, No.
IV.PROBLEM FORMULATION 3, August 2011.
In hydraulic press, the force generation, transmission and
Design & CAD simulation of Right Side Dropping
Dumper
(For Small Vehicle)
Ritesh V. Bhawarkar[1] Prof.Abhijit Misal Prof.Ajay Mahawadiwar[3]

Student M Tech (MED) Department Student M Tech (MED) Department Head Of Department Of Mechanical
Of Mechanical Engineering Of Mechanical Engineering Engineering Abha Gaikwad Patil
Abha Gaikwad Patil College of Abha Gaikwad Patil College of College of Engineering Mohagaon,
Engineering Engineering Nagpur, India
Abstract—In this research work an improved way of unloading constructional site. One of the problem are cited with
material from dumper is design. Conventional Dumper dumper in the time and energy for setting the huge dumper
unloads material only at back side of dumper which may cause in the proper direction to dump the material it in carrying
problem of road blockage in limited space area. The right side and hence the need of the project work riser which is about
dropping dumper overcomes problem of unloading the
Design & CAD simulation of Right Side Dropping Dumper.
material by using hydraulic cylinder. Modern right side
dropping dumper has been conceived by observing difficulty in
unloading the material. Hence suitable arrangement has been
designed for small vehicle (TATA ace). The vehicles can be
unloading material from right side. The concept leads to 1. Design and Development of 3-Way Dropping Dumper,
efficient working. www.ijetae.com (ISSN 2250-2459, ISO 9001:2008
Certified Journal, Volume 4, Issue 9, September 2014)
Keywords—Dumper,dropping side,right side dropping.
A small scale model has developed using light weight
I. INTRODUCTION material i.e. plastic and hydraulically operated piston and
cylinder arrangement. This hydraulic arrangement actuates
A dumper is a vehicle designed for carrying bulk material, on motor driven which makes the prototype semi automatic.
often on building sites. Dumpers are distinguished from The trolley piston gets out and makes the trolley to tilt by
dump trucks by configuration: a dumper is usually an open operating various cylinders; the material can be dropped in 3
4-wheeled vehicle with the load skip in front of the driver, ways. Limitation- Increased complexity: It requires complex
while a dump truck has its cab in front of the load. The skip mechanism for getting desired
can tip to dump the load; this is where the name "dumper"
comes from. They are normally diesel powered. A towing 2. Development Of Three Axes Lifting Modern Trailer,
eye is fitted for secondary use as a site tractor. Dumpers Volume I, Issue 5, May 2015 (ISSN: 2394 – 6598)
with rubber tracks are used in special circumstances and are
popular in some countries. In this work the trailer is pulled up in three axis. The figure
1 shows ths working principle of hydraulic cylinder used in
Early dumpers had a payload of about a ton and were 2- this modern trailer. For the trailer action we are using
wheel drive, driving on the front axle and steered at the back hydraulic as a source. The 3/2 direction control valve is used
wheels. The single cylinder diesel engine (sometimes made to control the direction of the hydraulic. When the inlet port
by Lister) was started by hand cranking. is open the hydraulic is pumped from the sump using
hydraulic pump. The trailer is now pushed upward in the
The steering wheel turned the back wheels, not front. ―Y‖ axis direction and the outlet port is activated now, then
Having neither electrics nor hydraulics there was not much the trailer was pushdown in Y axis direction. Now the knee
to go wrong. The skip was secured by a catch by the driver's joint of the trailer is removed for trailer action in „Z‟ axis.
feet. When the catch is released, the skip tips under the Then again the inlet port is open. The trailer is now pushed
weight of its contents at pivot point below, and after being upward in the ―Z‖ axis direction and the outlet port is
emptied is raised by hand. activated now, then the trailer was pushdown in „Z‟ axis.
Again the knee joint is removed for the trailer action in „X‟
Modern dumpers have payloads of up to 10000kg and axis. Then again the inlet port is open. The trailer is now
usually steer by articulating at the middle of the chassis. A pushed upward in the ―X‖ axis direction and the outlet port
dumper is an integral part of any construction work and is activated now, then the trailer was pushdown in „X‟ axis.
hence its role is important for completion of any
we can dispatch the load in three axis in the trailer by using horizontal ground, the sudden change of weight and balance
the universal joint in the hydraulic cylinder. due to lifting of the skip and dumping of the material can
cause the truck to slide, or even—in some light dump
3.Design and Fabrication of Unidirectional Dumper, trucks—to turn over.
International Journal for Scientific Research &
Development| Vol. 3, Issue 02, 2015 | ISSN (online): 2321- 3) Back-up accidents:
061.
Because of their size and the difficulty of maintaining visual
An operating system consists of electric motor, worm & contact with on-foot workers, dump trucks in car parks can
worm gear mechanism to rotate the dumper horizontally in be a threat, especially when backing up. Mirrors and back-
required direction. Two Chassis (Frame) is provided on up alarms provide some level of protection, and having a
which trolley is mounted, where first frame of chassis is spotter working with the driver also decreases back-up
stationary & attached to the worm & worm gear to rotate the injuries and fatalities.
trolley horizontally in required direction.
4) Working condition:
Second frame of chassis consists, one end of Pneumatic
cylinder which is hinged with this frame of chassis and Because of constructional side road limitation it is difficult
other end of pneumatic cylinder is also hinged but to the one to drop material at proper location
end of trolley to give vertical movement
Also the problem are cited with dumper in the time and
Limitations: energy for setting the huge dumper in the proper direction to
dump the material it in carrying and hence the need of the
Increased Complexity: As, it requires complex mechanism project work riser which is about Right side dropping
to get desired output. dumper which can dump the material in side direction
except the back one. The main objective of this project work
Cost Increases. As more will be the complications to is to improve dropping side. So here right side is selected
perform the operation, more will be the cost encountered instead of any side because in Indian vehicle driver seat is
with it. located in right side so it is very easy to see obstacles in
dropping side.
Maintenance Increases: More parts in working leads to
more maintenance.
III CONCEPT
Problem and drawbacks of existing Dumpers

Trolley
Hydraulic
Cylinder
Hinge
Joint
Left Side Right Side

Side Side
Back Side
1) Collisions:
In proposed work, dumper dropping components will be
Dump trucks are normally built for some amount of road or designed manually for Right side dropping. Different
construction site driving; as the driver is protected by the components required in designing Right side dropping
chassis and height of the driver's seat, bumpers are either dumper are: Trolley, Hinge joints, Cylinder mounting
bracket, Chassis beams, Pins, Calculation of bending stress
placed high or omitted for added ground clearance. The
& deflection in trolley (dumper), Calculation for dia. of pin,
disadvantage is that in a collision with a standard car, the
entire motor section or luggage compartment goes under the Calculation Shear & Bending stress on cylinder mounting
truck. Thus the passengers in the car could be more severely bracket. Standard components will be selected as per
injured than would be common in a collision with another manufacturer catalogue.
car.
The proposed method has several advantages.
2) Tipping:
Can be used in very compact places: Where reversing &
Another safety consideration is the leveling of the truck turning of vehicle is difficult, Saves time & energy, Easy to
before unloading. If the truck is not parked on relatively unload material.
Hydraulic Cylinder REFERENCES
A hydraulic cylinder is placed below the body of truck [1] Design and Development of 3-Way Dropping Dumper,
longitudinally at one end of the truck, and the piston end of www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal,
Volume 4, Issue 9, September 2014)
the hydraulic cylinders is connected by the means of a pivot
joint to the chassis of truck. In the forward stroke of the [2] Design and Fabrication of Unidirectional Dumper, International
cylinder, it pushes the truck body upward thus gives Journal for Scientific Research & Development| Vol. 3, Issue 02,
necessary lift for tipping dumping. So, in the forward stroke 2015 | ISSN (online): 2321-061.
of the cylinder, the truck is unloaded. In the return stroke of [3] Development Of Three Axes Lifting Modern Trailer, Volume I, Issue
the cylinder the body of the truck comes to its original 5, May 2015 (ISSN: 2394 – 6598)
position.
[4] Linear Static & Impact Analysis Of EH 600 Dumper Body by R
Hinge Joint sandya Rani &Kanchan Bag
The other bottom end of the body of the truck is connected

by a hinged joint with the chassis.
Mounting Brackets
Cylinder mounting bracket is mounted in crossbeam

provided to chassis beam.
Pins
Pins are provided to joint trolley with chassis so that trolley

can tilt about fix plane.
Advantages
1) Can be efficiently used in very compact places where

turning of vehicle is difficult.
2) Reduction in amount of accidents on constructional site

or plant.
3) Increased moving ability as it does not become tiresome

to perform the job.
4) Reduces extra cost paid on unloading of material by labor

or machines like cranes or any other pick and placer.
5) Saves times and energy.
Applications:
1) At Constructions site.
2) At remote locations where floor space area is less.
IV CONCLUSION
As this concept saves time & energy as well this may leads
to efficient working, which helps constructional work or the
infrastructural work demands of efficient and user friendly
machinery will lead to more and more use of the project
work like Right side dropping dumper.
“DESIGN, ANALYSIS AND VALIDATION OF
CONCEPTUAL BRICK HANDLING TRAILER’’
Prof. Ritesh Banapurkar
Vinod B. Hiwase Department Of Mechanical Engineering
Department Of Mechanical Engineering Abha Gaikwad Patil College Of Engineering
Abha Gaikwad Patil College Of Engineering Mohagaon, Nagpur, India
Mohagaon, Nagpur, India
Abstract type and extent of use of materials handling should be

carefully designed to suit the application and which becomes
Nowadays, construction industry is on a boom. Almost cost effective.
everywhere one can find some kind of construction work in
progress. At every construction site bricks are required. For Overhead cranes are commonly employed in the transport
normal wall construction bricks are must have. Bricks are of
industry for the loading and unloading of freight, in the
vital importance in construction. To provide bricks in time at the
construction site and that too without damage is still a challenge construction industry for the movement of materials and in the
in India. But manually handling these bricks cause workers to manufacturing industry for the assembling of heavy
suffer from back injury and long-term pain if regularly equipment, because they can move loads far beyond the
lifting/carrying heavy or awkward objects. So, the palletizing and normal capability of a human. Thus in this project a detailed
mechanization of the bricks is suggested so as to reduce the design and analysis of the overhead hoist system is undertaken
human injury and to increase the productivity and profitability. to handle construction bricks.
Keywords: Bricks, construction side, palletizing, mechanization.
I. INTRODUCTION
Expressed in simple language, materials handling is loading,

moving and unloading of materials, i.e. raw material,
semi/finished good, etc. To do it safely and economically,
different types of tackles, gadgets and equipment are used, for
mechanical handling of materials. Since primitive times men
discovered the use of wheels and levers, they have been
moving materials mechanically. Any human activity involving
materials need materials handling. However, in the field of
engineering and technology, the term materials handling is
used with reference to industrial activity. In any industry, be it II. LITERATURE REVIEW
big or small, involving manufacturing or construction type
work, materials have to be handled as raw materials, A.D.Anjikar [1] Handling of raw material, semi finished,
intermediate goods or finished products from the point of finished product & other material is ever concern & cost in an
receipt and storage of raw materials, through production industry. With increasing cost of labour & its scare city the
processes and up to finished goods storage and dispatch manual work or operation in industries are now replaced by
points. A material handling as such is not a production process semi automatic or automatic system. These low cost systems
and hence does not add to the value of the product. It also are not only cost efficient but also enhance productivity &
costs money; therefore it should be eliminated or at least address the issues related to labour problem. Conventionally in
reduced as much as possible. However, the important point in micro or small scale industries which are labour intrinsic
favor of materials handling is that it helps production. transportation of raw material, semi finished product is always
Depending on the weight, volume and through put of an expensive & problematic issue. After visiting Waghmare
materials, mechanical handling of materials may become food products, Nagpur & after discussion with the concern the
unavoidable. In many cases, mechanical handling reduces the shifting of raw material from store to the work place was a
cost of manual handling of materials, where such materials costly labour activity. Presently it is done manually. The
handling are highly desirable. All these facts indicate that the industry was interested to identifying some optional material
handling system to encounter their problems After carefully brick handling process for a Heavy commercial vehicle,
survey of factory layout, discussing with management, following problem were identified,
concern exhaustively literature search it was preferred to
design & develop a overhead monorail for handling of rawA. Labor Force is More:
material The main aims to design cost efficient, overhead
monorail material handling system. The detailed drawings will In current material handling system the number of labor
also drawn using the software’s like CATIA/ PRO-E. The cost required for carrying material from intake zone to delivery
estimation along with economical feasibility and pay back will zone is more.
also be calculated.
B. Cost is More:
Du-Ming Tsai [2] Material handling pallets are the most
common tool used in warehousing industries. Nearly every Due to large labor force the cost of material handling
warehouse uses them to some extent. Pallets have become an is increases.
almost universal warehouse operations tool. They provide a
C. Efficiency is Less:
convenient, simple way to transport, stack, and store
materials.Traditional palletizing methods load only boxes of The input provided to the system in terms of labor
the same size on one pallet. For retail business such as grocery effort is more but output obtained interms of
distribution or manufacturers that produce many products of material delivered to the unloading zone is less.
small quantities, a wide product mix of different box sizes
must be loaded onto the same pallet. The traditional D. Flexibility in System is Less:
palletizing method may not optimize the utilization of the
pallet cube. Manual palletizing is an extremely tedious and There is no other option than the manual conveying
fatiguing task. Automatic palletization is, therefore, a system for conveying material which makes the
potentially attractive alternative. Commercially available system less flexible to suit changing atmosphere
palletizers handle only one box size at a time. They cannot within industry.
meet the requirements of palletizing applications with mixed
box sizes. Industrial robots have always been a viable solution E. Material Conveying Time is More:
to complex loading operations due to their flexibility and
programming capability. Due to manual conveying system time required to
deliver material is more as compare to other
Sourabh R. Dinde, Rajashekhar S. Talikoti [3] According conveying system
to the structural point of view Industrial Pallet rack structure
can be considered typical steel framed structure. This work F. Human Safety is Less:
presents a general analysis of an industrial pallet rack
structure, evaluating the influence of each of the components Instead of motor or other driving mechanism humans
on the global stability. An analytical study for the sensitivity are use to lift the bricks which create unsafe
of pallet rack configuration in linear static equivalent lateral environment for them, also it may cause back
loads. The aim is to braced/unbraced frames were design and injuries.
their analytical models are to be built in software. The finite
element analysis is used to determine axial forces in beam and IV. PROBLEM FORMULATION
column, maximum storey displacement and buckling loads on Design of conceptual trailer which would help in loading and
braced/unbraced pallet rack structure. Bracing systems are unloading of bricks with much ease with the assistance of
mostly provided to enhance the stiffness factor of the
mechanical machine mounted on the trailer. Design a frame
structures with the seismic loads. Unbraced systems have
with some mechanical movement which would assist in the
mostly translational modes of failure and are very flexible due
movement of the hoist mounted on it. The hoist can slide on
to excessive loads. the guide rail along the length of truck .It can also move
perpendicular to it on sliding rail. The hoist can be manually
III. IDENTIFIED GAPS IN THE LITERATURE
operated, electrically or pneumatically driven and may use
Bricks are of vital importance in construction. To provide chain, fiber or wire ropes as its lifting medium.
bricks in time at the construction site and that too without
damage is still a challenge in India. But manually handling V. CONCLUSIONS
these bricks cause workers to suffer from back injury and
To provide bricks in time at the construction site and that too
long-term pain if regularly lifting/carrying heavy or awkward without damage is still a challenge in India. But manually
objects. So, the palletizing and mechanization of the bricks is handling these bricks cause workers to suffer from back injury
suggested so as to reduce the human injury and to increase the
and long-term pain if regularly lifting/carrying heavy or
productivity and profitability. After closely monitoring the
awkward objects. So, the palletizing and mechanization of the
bricks is suggested so as to reduce the human injury and to
increase the productivity and profitability.
REFERENCES
[1] A.D.Anjikar, “Design, Development of Overhead Monorail for Material

Handling System For food Processing Industry” ISSN : 2249-5762, Vol. 3,
Issue 2, May - Oct 2013 .
[2] Du-Ming Tsai, “Modeling and analysis of three-dimensional robotic

palletizing systems for mixed carton sizes” .
[3] Sourabh R. Dinde, Rajashekhar S. Talikoti, “Structural Behavior Of

Industrial Pallet Rack With Braced And Unbraced Frames”
“Design & Fabrication of Self-Guided Chair system
for library book access’’
Yogesh A. Mangaonkar Prof.Ravindra Gandhe
Prof.Ajay Mahawadiwar
Department Of Mechanical Department Of Mechanical
Engineering Engineering Head of Department Of
Abha Gaikwad Patil College Of Abha Gaikwad Patil College Of Mechanical Engineering
Engineering, Mohagaon,Nagpur, Engineering Abha Gaikwad Patil College Of
India Mohagaon,Nagpur, India Engineering
Mohagaon,Nagpur, India
Abstract Often the two branches are used in conjunction with each
other, but unless the basic laws are studied separately, the
A library is a collection of sources of information. It is necessary result could be misleading. The study of pneumatics deals
to provide comfort to access a book specially while selecting with system operated with air or other gaseous media. The
books from shelf. So in order to access book comfortably from
shelf at height up to 4 ft and more, an innovative idea of auto
term “pneuma” is derived from the ancient Greek and means
guided smart chair system is implemented. Main motive behind breath or wind. The term “pneumatics” was derived from the
this concept is to allow person to sit on chair which will be auto word “pneuma”; pneumatics, literally, “pertaining to air”, has
guided and same chair can lift to access books from a heighted one set of fundamental laws governing the behavior of
shelf. Some ergonomic points are also considered to design chair. gaseous fluids. Pneumatics (Greek: which means "breath") is a
This paper discusses design and fabrication of smart library branch of physics applied to technology that makes use of gas
chair which will lift at a particular height and rotate at an angle or pressurized air. Pneumatic systems used extensively
of 45 degree. The operation of lifting and revolving of chair will in industry are commonly powered by compressed air or
done by pneumatic system and the base platform provided with compressed inert gases. A centrally located and electrically
wheels will turn and move by a battery operated system. This
concept is more beneficial for a handicapped person.
powered compressor powers cylinders, air motors, and other
pneumatic devices. A pneumatic system controlled through
Keywords: Pneumatic system, Library book issue, self-guided, manual or automatic solenoid valves is selected when it
human comfort. provides a lower cost, more flexible, or safer alternative to
electric and actuators. Pneumatic systems are cheaper and
I. INTRODUCTION light in weight and air is easily available compared to
hydraulic fluids.
A library is a collection of sources of information and similar
resources, made accessible to a defined community for
reference or borrowing. It provides physical or digital access
to material, and may be a physical building or room. There are
lots of issues while taking out books from heighted shelves.
Hereby, to overcome this issue we are implementing a new
system which will be pneumatic based.
There are two main branches of fluid power.
1. Pneumatics
2. Hydraulics
These two branches of fluid power are very different in

behavior and performance, and hence are treated separately.
Fig 1. Concept diagram of smart chair system
Jasmer Singh (1990) carried out research for doctorate degree

on the topic “College Libraries in Punjab: A Statistical
Analysis of the Problems” He conducted a survey to find the
problems being faced by college libraries of Punjab and
Chandigarh and also attempted to study the use of libraries.
Mr. S.R. Mujumdar have discussed on pneumatic system

working in which it has been explained, that in automation
technology pneumatic technology is one of advance part in
order to utilize a appropriate technology.
The aim of the project is to overcome the problems faced

while collecting books from heighted shelves which is a
problem discussed in library analysis literature and use of
pneumatic system compared to hydraulic system. Make use of
pneumatic system that is readily available and cheap.
IV. PROBLEM FORMULATION
Many problems observed in library like to select books from

big library shelves by manually effort. Problems face out to
when we take out the books from heighted shelves.To prepare
efficient and cost effective system.
V. CONCLUSIONS
We will fabricate such type of smart library chair that can

easily lift a person to provide human comfort level inside the
library while selection of books by the use of pneumatic
system that is readily available and cheap to prepare efficient
and cost effective system.
Lifting at a particular height and rotate at an angle of 45

degree.
Lifting and revolving of chair operation will be done by

pneumatic system and the base platform provided with wheels
will turn and move by battery operated system.
REFERENCES
[1] J. L. Shearer, "Study of Pneumatic Process in the Continuous Control of
Motion with Compressed Air," Transactions of the ASME, pp. 233-249, 1956.
[2] Davis, K. Kotowski, S., Sharma, B., Herrmann, D. and Krishnan, A. (2009).
Combating the Effects of Sedentary Work: Postural Variability Reduces
Musculoskeletal Discomfort, in Proceedings of the Human Factors and
Ergonomics Society.
[3] Du Jingmin, Fu Xiaoyun, Li Baoren. Experimental Research on High

Precision Real-time Control of Air Temperature[J]. Chinese Hydraulic and
Pneumatic, 2002,12: 19-20
Desing And Analysis Of Roller Mill Bearing Using
FEA
Chhaya Ladhi Prof.Ajay Mahawadiwar
department of mechanical engineering ,Nagpur India HOD of mechanical engineering department
[email protected]
Abstract: Tapered Cylindrical roller bearing is used in aircraft 1.1Rolling Contact Fatigue:
Rolling mill, machine tools, steel industries and other application
due to their precision and high load carrying capacity. In this The origin of RCF failure is understood to be stress
project tapered roller bearing which is use in rolling mill concentrations, which initiate and propagate fatigue crack
industry that will design and calculate the stress strain ,also under cyclic loading. These stress concentrations occur due to
design 4-Row tapered roller bearing and compare which is
surface or subsurface stress risers or to the geometry and
suitable. The theoretical value of stress and strain on bearing will
compare with software value after applying a particular load, kinematics of the contacting pair. Figure 4 summarizes a list
drafting file will generate in AutoCAD, 3-D model in pro-e and of these stress risers, which have been the subject of numerous
stress analysis in ansys. scientific investigations that have resulted in the improved life
of rolling-element bearings. With the introduction of cleaner
Keywords—Stress,strain steels and greater precision in the manufacture of bearings,
most of the surface and subsurface stress risers listed in Fig. 4
1. Introduction have been addressed. Nevertheless, the demand to operate
rolling element bearings in harsh tribolgical environments of
There are five types of rolling-elements that are used in rolling lubrication, load, contamination, and temperature push for
element bearings: balls, cylindrical rollers, spherical rollers, higher fatigue limits, and thus call for improved understanding
tapered rollers, and needle rollers. Most rolling-element of the RCF failure modes. Four distinct failure modes have
bearings feature cages. The cages reduce friction, wear, and been established in rolling-contact bearings[3]. These
bind by preventing the elements from rubbing against each classifications include wear-type failures, plastic flow, contact
other. Caged roller bearings were invented by John fatigue, and bulk failures.
Harrison in the mid-18th century as part of his work on
chronometers. Typical rolling-element bearings range in size
from 10 mm diameter to a few meters diameter, and have
load-carrying capacity from a few tens of grams to many
thousands of tones. Cylindrical roller bearings with Deep end-
cavity rollers are advantageous in applications where load and
speed are major considerations in the operations of the
bearings. An improvement in load distribution and thus load
capacity may be realized, as well as contact stress is also
reduced considerably by using a bearing with Deep end-cavity
rollers. This bearing is basically used in rolling mill where
heavy load is applied on bearing. Deep end-cavity roller is
proposed for rolling mill bearings with a view to reducing the
contact stress distribution for life improvement. Deep end-
cavity rollers are one of the advanced concept used to
eliminate the sharp edge-stresses at the apexes of the roller.
The main objective of this work is to enlighten the engineers
to make use of deep cavity rollers to increase load carrying
capacity and improvement of fatigue life.
Terminology of Tapered Cylindrical Roller bearing
Industrial bearing failure by rolling contact fatigue rolling performance of rolling-element bearings, the actual life of a
element bearings are widely used in industrial machinery to given bearing can significantly vary from the predicted life. It
allow relative motion and shaft load RCF fatigue occurs due to was reported that only 10% of all bearing replacements in the
the result of cyclic stresses developed at bearing contact field can be attributed to classic RCF failure, whereas the
surface during operation. Rolling contact fatigue includes tri- remaining 90% are made for reasons and conditions not even
axial stress state, high hydrostatic stress component, non- closely related to RCF. Although this highlights the
proportional loading, and during loading cycles changing improvements achieved in designing and manufacturing
planes of maximum shear stress, that leads to sub-surface better-quality bearings[9], it also indicates that other factors in
cracks. Sliding forces can cause failure to originate at the addition to RCF need to be considered to predict the life of a
subsurface that propagate parallel to the surface and it may bearing. Even under the controlled conditions of load,
significantly reduce bearing life. Rolling contact fatigue may lubrication, and alignment in a dust-, corrosion-, and moisture-
divide into two categories [4], i.e. surface and sub-surface free environment, there is generally large scatter in the RCF
initiated. Further classification of RCF may do by location and performance for a given bearing. Bearing manufacturers thus
appearance of the fatigue, and factor that leads to crack provide a statistical probability of the life of a bearing on the
initiation which causes bearing failure. These factors may basis of experimental results conducted at a given load, speed,
relate to lubrication, materials, operation and mountings. and lubrication regime. Weibull analysis can then be used to
Fractography [4] plays a vital role to identify this defects.3.1. estimate the life expectancy of the bearing. Bearing life is
Wear mechanism RCF wear mechanism involves fretting. generally referred to as L10, L50 or L90 and indicate the
Fretting wear may be of two types, i.e. contact corrosion and probability of failure (e.g., L10 indicates that 10% of the
brine ling. Contact corrosion takes place between the of the bearings in a given population will fail before a fixed number
bearing and the shaft. Fretting occurs within the contact area of stress cycles are reached). Lundberg and Palmgren
of the bearing, developed a theory that indicates the life of a roller or ball
bearing at a given load (P) can be approximated using the
2. Objective: Bearing used for roller mill is very important relationL10=(C/P where L is the fatigue life in a million
bearing for that selection of proper bearing much important as revolutions, C is the load that gives an L10 life of 1 million
well as maintain the life of bearing To increase the life of revolutions, and n is a constant for a bearing type (e.g., n _ 3
bearing by reducing the failure causes of bearing of it also to for ball bearings and 10/3 for roller bearings). A detailed list
decrease the cost of bearing, sometimes cause of failure is of various values of n for different bearing types can be seen
contact fatigue between the rollers, if we improve the design elsewhere. The use of a specific value of n is critical for a
of tapered roller to avoid the failure then we can improve the given bearing type, and the product law of probability is in
life of bearing which very beneficial to rolling mill industry. effect (e.g., as the design changes from single-row to double
row bearings). Hence, the life of a double-row bearing under
similar conditions to that of a single- row bearing of identical
3. FAILURE ANALYSIS OF HCRB design will be less than that of a single-row bearing.
In the present work failure analysis of Hollow Cylindrical 3.2 Vibration response due to local defecton bearing
Roller Bearing (HCRB) made from material AISI 52100 is element.
carried out to understand the type and mode of failure. This
bearing is basically used in earthmoving equipments where
heavy load is applied on bearing. The photograph of this The vibration signal generated by the faulty bearing can be
bearing is shown in Fig. 5 with hollow roller in breakage analyzed in time domain or frequency domain. The time
condition. The objective of this work is to identify the type of domain vibration analysis is depend on the estimation of
failure by using material oriented investigations. Also Fig. 6 statistical parameters like crest factor, skewness, kurtosis,
shows the cross section of hollow roller with its dimensions. probability density curve, etc. Among this kurtosis is the most
The hollowness of this roller is 42%. effective parameter in a time domain which is calculated using
following expression (1). For the healthy bearing the kurtosis
is closer to 3 and for defective bearing it is more than 3.
Much work has been devoted to characterizing alterations of Another way of defect consideration adopted by the
the micro-structure, hardness and residual stress distribution researchers is addition of extra displacement in total
occurring in rolling bearing components during bearing deflection. Initially a simple dynamic model was proposed by
operations. The results of this work provide a technological McFadden and Smith [14-15]. In their theoretical and
experimental studies they have considered single point defect
3.1 Rolling Bearing Life : and multiple point defects on the inner race. The impulses
generated by interaction of defect with inner race has been
generated by delta function while, variations in the load
Life prediction of a roller or ball bearing is based on the around the bearing has been computed by Stribeck equation
statistical treatment of full-scale bearing tests conducted under under radial load. Su and Lin [16] have extended the original
controlled environments, for example, full-film lubrication
work of McFadden to characterize the vibrations measured
regime, dust-free environment, and so on. Although these
from bearings subject to various loading conditions and with
controlled environments are useful indicators of the RCF
defects located on any bearing components. They have [6.]Dr. D. P. Vakharia Prof. P. H Darji “Fatigue Failure Analysis of Hollow
Cylindrical Roller Bearing”at International Journal of Advances in
determined the periodic characteristics of various loading, Engineering Sciences Vol.1, Issue 2, April, 2011
transmission path and their influence on the vibration
amplitude. Su et al. [17] have obtained a reliable model to [7]Pratik Patadia1, Dr. Pranav Darji2 “A Review Paper On Fatigue Life
predict the possible bearing frequencies, harmonics and Analysis And Its Improvement Of 4-Row Cylindrical Roller Bearing Used In
sidebands for the various types of localized fatigue damage, Hot Rolling Mill” IJREAT International Journal of Research in Engineering &
Advanced Technology, Volume 3, Issue 2, April-May, 2015 ISSN: 2320 –
the pattern of expected frequencies can be searched for as part 8791
of routine bearing condition monitoring. The information
regarding frequency at any particular time is difficult to [8]WaltersC T. Dynamics of ball bearing. ASME Journal of Lubrication
achieve either from frequency domain or time domain. The Technology 1971; 93(1): 1-10.
wavelets provide time-scale information of a signal, enabling
[9]HarrisT A,Mindel M H. Rolling element bearing dynamics. Wear 1973,
the extraction of features that vary in time. The discrete 23(3): 311-37.
wavelet transform (DWT) is derived from the discretization of
continuous wavelet transform (CWT). The wavelet transform [10] Boesiger EA, Donley AD, LoewenthalS.An analytical and experimental
has proved its significance in bearing fault detection [20-24]. investigation of ball bearing retainer instabilities. ASME Transactions
onTribology 1992; 114:530-39.
However, the effectiveness of the analysis depends on the
selected mother wavelet. The defective frequencies of locally [11] Tomovic R, Miltenovic V, Banic M, Aleksandar M. Vibration response
defective bearing were analyzed more accurately through of rigid rotor in unloaded rolling element bearing. International Journal
DWT by Prabhakar etal.[20]. Rubini and Meneghetti [21] of Mechanical Sciences 2010; 52: 1176-85.
have proposed the method of envelope analysis and wavelet
[12] Kim PY.A review of rolling element bearing health monitoring (II):
transform for the diagnosis of incipient bearing fault under preliminary test results on current technologies. In: Machinery vibration
very low radial load. The researchers of references [22-23] monitoring and analysis meeting.LA: Vibration Institute, New Orleans; 1984.
have used the Laplace wavelet transform for the defect p. 127–37.
detection. Hong and Liang [24] have proposed a new version
[13] Tandon N. A comparison of some vibration parameters for the condition
of the Lempel–Ziv complexity as a bearing fault (single point) monitoring of rolling element bearings. Measurement 1994; 12: 285-9.
severity measure based on the continuous wavelet transform [14] McFadden PD, Smith JD.Model for the vibration produced by a single
(CWT). The researchers [20] have proposed the method of point defect in a rolling element bearing.Journal of Sound and
singularity analysis using continuous wavelet transform for Vibration1984;96(1):69-82.
bearing fault diagnosis. [15] McFadden PD, Smith JD.The vibration produced by multiple point
defects in a rolling element bearing.Journal of sound and vibration 1985;
98(2):263–73.
4. Conclusion:
[16] Su YT, Lin S J. On initial fault detection of a tapered roller bearing:
On basis of this study it can be concluded that it is aimed at Frequency domain analysis. Journal of Sound and Vibration 1992;
155(1):75-84.
presenting the taperd Cylindrical roller bearing with Deep end
cavity roller in various fields and the research and [17] Su YT, Lin MH, Lee M S. The effects of surface irregularities on roller
development conducted to improve technologies that will bearing vibrations.Journal of Sound and Vibration1993; 163(3):455-66.
directly benefit the Rolling mill industries and other industries. [18] Choudhury A, Tandon N.Vibration response of rolling element bearings
in a rotorbearing system to a local defect under radial load. ASME
Transactions on Tribology2006;128:252-61.
References
[19]Arslan H, Aktürk N.An investigationof rolling element vibrations caused
by local defects. ASME Transactions on Tribology2008;130: 041101-1-9.
[1]Zhang Yongqi, TanQingchang, Zhang Kuo, LiJiangang on “Analysis of
Stress and Strain of the Rolling Bearing by FEA Method” at 2012
[20] Lijia Xu. Study on fault detection of rolling element bearing based on
International Conference on Applied Physics and Industrial Engineering
translation-invariant denoising and Hilbert-Huang Transform. Journal of
Computers 2012;7(5): 1142-46.
[2] R.K. Upadhyay*, L.A. Kumaraswamidhas, Md.SikandarAzam “Rolling
element bearing failure analysis”atCase Studies in Engineering Failure
[21] Prabhakar S, Mohanty AR, Sekhar AS.Application of discrete wavelet
Analysis 1 (2013) 15–17
transform for detection of ball bearing race faults. Tribology
International 2002; 35:793–800. [22] Rubini R, Meneghetti U. Application of
[3]Dipen S. Shaha* Vinod N. Patelb on “A Review of Dynamic Modeling and
the envelope and waveletTransform analyses for the diagnosisof incipient
Fault Identifications Methods for Rolling Element Bearing” at 2nd
faults in ball bearings. Mechanical systems and signal processing2001;
International Conference on Innovations in Automation and Mechatronics
15(2): 287-302. [23] Khalid F, Raheem A, Asok R, Ramachandran K. P,
Engineering,ICIAME 2014
Harrison D. K, Grainger S.Rolling element bearing fault diagnosis
usingLaplace waveletenvelope power spectrum. EURASIP Journal on
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Roller Bearing Surface Defect Detection” at Procedia Engineering 15 (2011)
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Dual Purpose Refrigeration System: A Review
Pravin Meshram1, Subham Shende2, Mr.Vishwjeet Ambade 3
Students, Tulsiramji Gaikwad- Students, Tulsiramji Gaikwad- Assistant Professor,Tulsiramji
Patil College of Engineering, Patil College of Engineering, Gaikwad- Patil College of
Buttibori Buttibori Engineering, Buttibori
Nagpur,441108(MS)India Nagpur,441108(MS)India Nagpur,441108(MS)India
superheated vapour and it is at a temperature and pressure at

which it can be Condensed with typically available cooling
ABSTRACT: water or cooling air. That hot vapour is routed through a
condenser where it is cooled and condensed into liquid by
A refrigerator is a common household appliance that flowing through a coil or tubes with cool water or cool air
consists of a thermally insulated compartment and a heat flowing across the coil or tubes. This is where the
pump that transfers heat from the inside of the fridge to its
circulating refrigerant rejects heat from the system and the
external environment so that the inside of the fridge is cooled
to a temperature below the ambient temperature of the room.
rejected heat is carried away by the air. The condensed
Cooling is a popular food storage technique in developed liquid refrigerant, in the thermodynamic state known as a
countries. Lower temperature in a confined volume lowers the saturated liquid, is next routed through an expansion valve
reproduction rate of bacteria, so the refrigerator reduces the where it undergoes an abrupt reduction in pressure. That
rate of spoilage. pressure reduction results in the adiabatic flash evaporation
of a part of the liquid refrigerant. The auto-refrigeration
The Multipurpose refrigeration system is making use effect of the adiabatic flash evaporation lower the
of both the temperature below the atmosphere and above the temperature of the liquid and vapour refrigerant mixture to
atmosphere is to be achieved in freezer section and the
where it is colder than the temperature of the enclosed space
temperature above the atmosphere is maintained in hot
section. The temperature will below the atmosphere can be to be refrigerated. The cold mixture is then routed through
used as a food preservative, because it prevents the bacteria the coil or tubes in the evaporator. A fan circulates the warm
which can spoil the food. Also this temperature can be used to air in the enclosed space across the coil or tubes carrying the
make ice cubes and to cool water for drinking purpose. cold refrigerant liquid and vapour mixture. That warm air
Heating chamber is the heart of this project. It is used for evaporates the liquid part of the cold refrigerant mixture. At
heating purpose which is the need of new era. No extra amount the same time, the circulating air is cooled and thus lowers
of energy is consumed during the working of heating chamber. the temperature of the enclosed space to the desired
temperature. The evaporator is where the circulating
Keywords: Heat Transfer, Heating Chamber, Thermal
Insulation.
refrigerant absorbs and removes heat which is subsequently
rejected in the condenser and transferred elsewhere by the
INTRODUCTION water or air used in the condenser. To complete the
refrigeration cycle, the refrigerant vapour from the
A refrigerator is a common household appliance that evaporator is again a saturation vapour and is routed back
consists of a thermally Insulated compartment and which into the compressor. And cycle is continued.
when works, transfer heat from the inside of the
compartment to its external environment. Generally it works In the project, the condenser tube is cut in two
on the vapour compression cycle that uses a circulating sections: one is for cooling purpose while other is for
liquid refrigerant which absorbs heat from the space to be heating purpose. The waste heat from the compressor is
cooled and subsequently rejects that heat elsewhere. All delivered to the hot box and the hot temperature is
such systems have four components: - a compressor, a maintained inside the heating chamber. The hot box is made
condenser, evaporator and expansion valve. up of steel box on which copper tubes are wound. Glass
wool is used as insulation for this hot box so that the
Circulating refrigerant enters the temperature inside the hot box is more than that of ambient
compressor in the thermodynamic state known as a temperature.
saturated vapour and is compressed to a higher pressure,
resulting in a higher temperature. The hot, compressed
vapour is then in the thermodynamic state as a known
LITERATURE REVIEWS welded with stainless steel flat plate (Cond.2). Pressures and
temperatures measurements of each point in the
A. MOHD FAIZANRAJA QASIMRAJA SHEIKH, refrigeration cycle are collected in order to evaluate the
PROF. P. P. MANWATKAR, presented a paper on refrigerator performance. The results showed that the
“MULTIPURPOSE REFRIGERATION SYSTEM” average COP of Cond.1 and Cond.2 are increased up to 20
% and 14% respectively more than regular condenser design
The Multipurpose refrigeration system is making under no load. The evaporator load effects on the machine
use of both the temperature below the atmosphere and above performance, where the COP of the machine increases with
the atmosphere is to be achieved in freezer section and the the increase of the evaporator load.
temperature above the atmosphere is maintained in hot
section. The temperature will below the atmosphere can be D. G.G. MOMIN, S.R.DESHMUKH, M.T. DESHMUKH,
used as a food preservative, because it prevents the bacteria P.T.CHAVAN, P.P.CHOUDHARI, presented a paper on
and other type of formation which can spoil the food article. “COP ENHANCEMENT OF DOMESTIC
Also this temperature can be used to make ice cubes and to REFRIGERATOR BY RECOVERING HEAT FROM THE
cool water for drinking purpose. Heating chamber is the CONDENSER”
heart of this project. It is used for heating purpose which is
the need of new era. No extra amount of energy is consumed Refrigerator has become an essential commodity
during the working of heating chamber. Total cost rather than luxury item. The heat absorbed in refrigerated
estimation of the project is near about Rs. 3300/-. After space and the compressor work added to refrigerant is too
doing the analysis, COP of the system is increased, because rejected to ambient through a condenser. Our aim is to
of replacement of refrigerant from R-12 to hydrocarbon. recover waste heat from condenser unit of a household
refrigerator to improve the performance of the system. The
B. S. C. WALAWADE, B.R. BARVE, P. R. heat recovery from the household refrigerator is by thermo
KULKARNI, presented a paper on “DESIGN AND siphon. From the experimentation it was found that after
DEVELOPMENT OF WASTE HEAT RECOVERY recovering heat from the condenser of the conventional
SYSTEM FOR DOMESTIC REFRIGERATOR” refrigerator its performance get improved than conventional
refrigerator.
Heat is energy, so energy saving is one of the key
matters from view point of fuel consumption and for the E. P.SANTOSH KUMAR, P.SITARAMA RAJU,
protection of global environment. So it is necessary that a S.SURESH KUMAR, P. V. V. SATYANARAYANA, T.
significant and concrete effort should be made for ARJUN, G. S. D. K SRAVANI, presented a paper on
conserving energy through waste heat recovery too. The “REFRIGERANT RECOVERY UNIT”
main objective of this paper is to study “Waste Heat
recovery system for domestic refrigerator”. An attempt has This project is made with preplanning, that it
been made to utilize waste heat from condenser of provides flexibility in operation. This innovation has made
refrigerator. This heat can be used for number of domestic the more desirable and economical. This project
and industrial purposes. In minimum constructional, “REFRIGERANT RECOVERY UNIT SYSTEM” is
maintenance and running cost, this system is much useful designed with the hope that it is very much economical to
for domestic purpose. It is valuable alternative approach to recover the refrigerants and useful to small and large
improve overall efficiency and reuse the waste heat. The industrial applications.
study has shown that such a system is technically feasible
and economically viable. With the use of refrigerant recovery unit, we can
C. ENG. NASER R. M. AL-AJMI, presented a paper recover the refrigerant from Any Repair or service
on “COEFFICIENT OF PERFORMANCE
ENHANCEMENT OF REFRIGERATION CYCLES” or leakage systems (central AC systems).It is very
Refrigerator is one of the home appliances costly but we fabricate it as very low cost. It is very useful
utilizing mechanical vapour compression cycle in its to recover the refrigerants in central „AC‟ Plants because in
process. Performance of the systems becomes the main issue that they use 50-3000 tons. By the using of refrigerant
and many researches are still on going to evaluate and recovery unit, we protect
improve the efficiency of any used system. Therefore, this
paper presents an experimental investigation of the the ozone layer from the choro-fora carbons present in the
performance of the refrigeration cycles. A small refrigerator refrigerants when they exposed to atmosphere. We can also
is used as the test rig. The Coefficient of Performance protect the atmosphere from global warming temperature.
(COP) is studied by using different condenser designs and These systems are used for most of air conditioning and
under varying evaporator loads. Three condenser designs are refrigeration applications such as comfort air conditioning
used in present work. These condensers are regular industrial applications. It is very useful in future to recover
condenser of domestic refrigerator, condenser with copper the banned refrigerants. It is very useful in every house.
plain tubes (Cond.1) and condenser with copper tubes
F] Y. A. PATIL, H. M. DANGE, presented a paper on water heating in minimum constructional maintenance and
“IMPROVING THE PERFORMANCE OF HOUSEHOLD running cost. A cabin was installed on a domestic
REFRIGERATOR BY RECOVERING HEAT FROM THE refrigerator with condenser coils of refrigerator serving as
CONDENSER” heating coils inside the cabin. Known quantity of water was
heated by the condenser coils (due to convection currents)
Refrigerator has become an essential commodity thereby increasing the overall COP of the refrigerator.
rather than luxury item. The heat absorbed in refrigerated Besides, the refrigerator may be used as conventional
space and the Compressor work added to refrigerant is too refrigerator by keeping the cabin door open in case of
rejected to ambient through a condenser. Our aim is to absence of heat sink.
recover waste heat from condenser unit of a household
refrigerator to improve the performance of the system. The CONCLUSION
heat recovery from the household refrigerator is by thermo
siphon. From the experimentation it was found that after The paper undertook a review based study into
recovering heat from the condenser of the conventional coefficient of performance enhancement of a domestic air
refrigerator its performance get improved than conventional cooled refrigerator by recovering heat from condenser in
refrigerator. The maximum temperature achieved in water terms of its background, originality, current status, and
tank with 100 litre of water is 45ºC at the full load researches. This all work has great significant for
condition. If the water tank contains 50 litres water then it developing new technologies relates to heat recovery from a
gets heated to 45 ºC in just 5 to 6 hrs. After that domestic refrigerator, in order to get cooling at low energy
performance of the system gets decreased. So it needs cost, no harmful effect to environment and also having low
regular use of that hot water. initial cost. So more attention is required in this area and lot
of work has to be done.
G] N. B. CHAUDHARI, P. N. CHAUDHARI, presented a
paper on “HEAT RECOVERY SYSTEM FROM THE REFERENCES
CONDENSER OF A REFRIGERATOR – AN
1] Mohd Faizanraja Qasimraja Sheikh, Prof. P. P. Manwatkar,
EXPERIMENTAL ANALYSIS” “MULTIPURPOSE REFRIGERATION SYSTEM”
The Experimental apparatus of heat recovery 2] S. C. Walawade, B.R. Barve, P. R. Kulkarni, “DESIGN AND
system from the condenser of a refrigerator was designed, DEVELOPMENT OF WASTE HEAT RECOVERY SYSTEM FOR
developed and constructed at cosmic refrigeration, Pune to DOMESTIC REFRIGERATOR”, IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE) ISSN: 2278-1684, PP: 28-32
estimate the waste heat recovery from the condenser of a www.iosrjournals.org
refrigerator. In this article, we will presents an experimental
setup that will help undergraduate mechanical engineering 3] Eng. Naser R. M. Al-Ajmi, “COEFFICIENT OF PERFORMANCE
students in understanding the basic heat transfer processes ENHANCEMENT OF REFRIGERATION CYCLES” ISSN : 2248-9622,
by utilizing real life applications such as using waste heat Vol. 5, Issue 3, ( Part -3) March 2015, pp.117-125. FROM THE
CONDENSER”, International Journal of Research in Advent Technology,
from a condenser of a refrigerator to heat water for Vol.2, No.5, May 2014 E-ISSN: 2321-9637.
residential and commercial use. Heat recovery from
condenser of a refrigerator by thermo-siphon system is 4] G .G. Momin, S. R. Deshmukh, M. T. Deshmukh, P. T. Chavan, P. P.
attractive because it eliminates the need of a circulating Choudhari, “COP ENHANCEMENT OF DOMESTIC REFRIGERATOR
BY RECOVERING HEAT.
pump.
5] P. Santosh Kumar, P. Sitarama Raju, S. Suresh Kumar, P. V. V.
H] TANMAY PATIL, NITESH MEDHANE, YOGESH Satyanarayana, T. Arjun, G. S. D. K. Sravani “REFRIGERANT
MAHAPURE, KALPESH NAGMOTI, PROF. ANIL RECOVERY UNIT”, (IJITR) International Journal Of Innovative
DUBE, presented a paper on “A REVIEW ON Technology And Research Volume No.3, Issue No.2, February – March
2015, 1979 – 1992.
RECOVERING WASTE HEAT FROM CONDENSER OF
DOMESTIC REFRIGERATOR” 6] Y. A. Patil1, H. M. Dange, “IMPROVING THE PERFORMANCE OF
HOUSEHOLD REFRIGERATOR BY RECOVERING HEAT FROM
To review the energy savings associated with THE CONDENSER”, International Journal of Science and Research
improved utilization of waste heat from a domestic (IJSR), India Online ISSN: 2319-7064.
refrigerator. Domestic refrigerators may be operating 7] N. B. Chaudhari, P. N. Chaudhar, “ HEAT RECOVERY SYSTEM
continuously to maintain proper food storage condition. The FROM THE CONDENSER OF A REFRIGERATOR – AN
continuous operation of this equipment accounts more EXPERIMENTAL ANALYSIS”, ISSN (Print): 2319-3182, Volume -4,
electrical energy consumption. So it is that a significant and Issu-2, 2015.
concrete effort should be made for conserving energy
8] Tanmay Patil, Nitesh Medhane, Yogesh Mahapure, Kalpesh Nagmoti,
through waste heat recovery. A significant amount of waste Prof. Anil Dube, “A REVIEW ON RECOVERING WASTE HEAT FROM
heat is rejected by the condensers of refrigerator. So an CONDENSER OF DOMESTIC REFRIGERATOR”, International Journal
attempt has been made to utilize waste heat from the of scientific research and management (IJSRM) ||\
Volume||3||Issue||3||Pages||2409-2414||2015||
condenser of a refrigerator. Practical uses of waste heat from
the domestic refrigerators are typically to space heating and Website: www.ijsrm.in ISSN (e): 2321-341
Design and Fabrication of Dual Purpose
Refrigeration System
Ratnapal Sahare1, Deepak Bhure2,
Students, Tulsiramji Gaikwad- Students, Tulsiramji Gaikwad- Mr.Vishwjeet Ambade 4
Patil College of Engineering, Patil College of Engineering, Assistant Professor,Tulsiramji
Buttibori Buttibori Gaikwad- Patil College of
Nagpur,441108(MS)India Nagpur,441108(MS)India Engineering, Buttibori
Vinit Nibrad3, Nagpur,441108(MS)India
Students, Tulsiramji Gaikwad- (Email: [email protected])
Patil College of Engineering,
Buttibori
Nagpur,441108(MS)India
ABSTRACT it does not require any kind of additional power supply for its
working operation. As the energy saving plays vital role in
In general, vapour compression cycle; the condenser development, the model has lot of importance from that
is used only for condensation process & heat it expelled out to particular point of view. The developed system will perform
atmosphere, which is generally lost in atmosphere. This heat operation without disturbing original refrigerator working.
loss can be utilized for heating purpose by designing a
condenser. The Multipurpose refrigeration system is making Keywords: Vapour Compression System, Waste Heat,
use of both temperature below the atmosphere and above the Condenser.
atmosphere is to be achieved in freezer section and the
temperature above the atmosphere is maintained in hot INTRODUCTION
section. The temperature will below the atmosphere can be
used as a food preservative. A refrigerator is a common household appliance
that consists of a thermally Insulated compartment and
The hot section uses the temperature above
atmospheric to preserve food article at this temperature is which when works, transfer heat from the inside of the
almost constant and well above atmospheric. It keeps compartment to its external environment. Generally it works
temperature of food article high and constant. For example the on the vapour compression cycle that uses a circulating
milk when kept at continuous high temperature prevents the liquid refrigerant which absorbs heat from the space to be
bacteria formation. Thus preventive its spoilage this section cooled and subsequently rejects that heat elsewhere. All
can also be used to heat various other food article. The heat such systems have four components: - a compressor, a
used in the hot section is completely based on the heat condenser, evaporator and expansion valve.
withdrawn from chilling and cold section. The optimum
number of turns can be used to heat the hot section Circulating refrigerant enters the
compartment are used. So that working will not affect the compressor in the thermodynamic state known as a
working of compressor or whole refrigeration system.
saturated vapour and is compressed to a higher pressure,
The project describes the development of resulting in a higher temperature. The hot, compressed
“Dual Purpose Refrigeration System”. Normal refrigerator vapour is then in the thermodynamic state as a known
works on vapor compression cycle, extract the heat from superheated vapour and it is at a temperature and pressure at
substance to be cooled in evaporator and liberate that heat to which it can be Condensed with typically available cooling
the atmosphere through the water or cooling air. That hot vapour is routed through a
condenser where it is cooled and condensed into liquid by
flowing through a coil or tubes with cool water or cool air
flowing across the coil or tubes. This is where the
circulating refrigerant rejects heat from the system and the
device called as condenser. The refrigerator exerts a lot of heat rejected heat is carried away by the air. The condensed
through condenser which is totally wastage of heat. For liquid refrigerant, in the thermodynamic state known as a
recovery of that waste heat, design and fabricate a refrigerator saturated liquid, is next routed through an expansion valve
which will utilizes that waste heat and maintain the things hot where it undergoes an abrupt reduction in pressure. That
for a long time. The main important thing in the model is that pressure reduction results in the adiabatic
flash evaporation of a part of the liquid refrigerant. The
auto-refrigeration effect of the adiabatic flash evaporation
lower the temperature of the liquid and vapour refrigerant
mixture to where it is colder than the temperature of the
enclosed space to be refrigerated. The cold mixture is then
routed through the coil or tubes in the evaporator. A fan
circulates the warm air in the enclosed space across the coil
or tubes carrying the cold refrigerant liquid and vapour
mixture. That warm air evaporates the liquid part of the cold
refrigerant mixture. At the same time, the circulating air is
cooled and thus lowers the temperature of the enclosed
space to the desired temperature. The evaporator is where
the circulating refrigerant absorbs and removes heat which
is subsequently rejected in the condenser and transferred
elsewhere by the water or air used in the condenser. To Fig. Design Of Dual Purpose Refrigeration System
complete the refrigeration cycle, the refrigerant vapour from
the evaporator is again a saturation vapour and is routed In the re-design of condenser, the condenser is cut
back into the compressor. And cycle is continued. into two partitions with the ratio of 2:3 in which 40% length
of condenser tube is used for cooling purpose. While
In the project, the condenser tube is cut in two remaining 60% length is used for heating purpose. For
sections: one is for cooling purpose while other is for heating purpose the 60% of copper coil is wound around the
heating purpose. The waste heat from the compressor is periphery of heating chamber. The copper tube is selected in
delivered to the hot box and the hot temperature is such a way that its diameter is more than the diameter of
maintained inside the heating chamber. The hot box is made condenser coil used for cooling purpose. The reason behind
up of steel box on which copper tubes are wound. Glass selecting bigger diameter of copper coil in heating chamber
wool is used as insulation for this hot box so that the than that of condenser coil, as that the high pressure & high
temperature inside the hot box is more than that of ambient temperature vapour refrigerant should flow slowly through
temperature. the copper tube. So that we will get more heating effect due
to more contact in the heating chamber.
Glass wool is used as insulation for the hot box so
that the temperature inside the hot box will be more than
that of ambient temperature. Hydrocarbon R-134a is used as
a refrigerant in place of R-12 which causes depletion of
ozone layer. It is expected to improve the coefficient of
performance of this system so that it will add the value to
the project.
WORKING PRINCIPLE
The compressed vapour comes out from the

compressor at high temperature & high pressure into the
copper tube, which is wound around the heating chamber.
The heated vapour refrigerant flow through the copper tube.
The heat from the vapour is transferred to the copper tube &
hence to the heating chamber which will maintain the hot
Fig. Vapour Compression Refrigeration System
temperature of heating chamber to preserve the food.
DESIGN AND FABRICATION
TESTING AND READINGS
A] Before arrangement of heating chamber = 321 k
T2 = heat sink Cop =___264.2___

= -8.8 + 273 321.7-264.2
= 264.2 k Cop = 4.594
T1 = heat source
= 48.7+273 B] After arrangement of heating chamber
T2 = heat sink
= -6.4 + 273 Cop = ___266.6 __
= 266.6 k 323.1-266.6
T1 = heat source
= 50.1+273 Cop = 4.718
= 323.1 k
RESULTS REFRIGERATOR CONDENSER USING WATER HEATER AND HOT

1) It does not require any kind of additional power supply BOX”, Volume: 2, Issue: 6, 50-55 June 2015 www.allsubjectjournal.com e-
ISSN: 2349-4182 p-ISSN: 2349-5979 Impact Factor: 3.762
for working operation of heat chamber.
2) It performs operation without disturbing original 4] Eng. Naser R. M. Al-Ajmi, “COEFFICIENT OF PERFORMANCE
refrigerator working. ENHANCEMENT OF REFRIGERATION CYCLES” ISSN : 2248-9622,
3) It utilizes the waste heat from condenser. Vol. 5, Issue 3, ( Part -3) March 2015, pp.117-125.
4) It can be used for cooling as well as heating purpose. 5] G .G. Momin, S. R. Deshmukh, M. T. Deshmukh, P. T. Chavan, P. P.
5) Its C.O.P. is more than normal refrigerator. Choudhari, “COP ENHANCEMENT OF DOMESTIC REFRIGERATOR
FURTHER SUGGESTED WORK BY RECOVERING HEAT FROM THE CONDENSER”, International
Journal of Research in Advent Technology, Vol.2, No.5, May 2014 E-
ISSN: 2321-9637
1) Refrigerator with hot box and water heater tank.
6] P. Santosh Kumar, P. Sitarama Raju, S. Suresh Kumar, P. V. V.
2) C.O.P. enhancement of refrigeration cycle by using
Satyanarayana, T. Arjun, G. S. D. K. Sravani “REFRIGERANT
multistage compressor. RECOVERY UNIT”, (IJITR) International Journal Of Innovative
Technology And Research Volume No.3, Issue No.2, February – March
2015, 1979 – 1992.
REFERENCES
1] Mohd Faizanraja Qasimraja Sheikh, Prof. P.P. Manwatkar 7] R. Sam Sukumar, Dr. A. Gopichand, U. Janardhana, V. Satish Kumar, B.
“MULTIPURPOSE REFRIGERATION SYSTEM”. Veera Chanti, “DESIGN AND FABRICATION OF WATER
REFRIGERATION SYSTEM BY CREATING VACUUM”, International
2] S. C. Walawade, B.R. Barve, P. R. Kulkarni, “DESIGN AND Journal Of Innovative Research In Science, Engineering And Technology,
DEVELOPMENT OF WASTE HEAT RECOVERY SYSTEM FOR Vol. 4, Issue 4, April 2015.
DOMESTIC REFRIGERATOR”, IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE) ISSN: 2278-1684, PP: 28-32 8] Patil Y.A., Dange H.M., “IMPROVING THE PERFORMANCE OF
www.iosrjournals.org HOUSEHOLD REFRIGERATOR BY RECOVERING HEAT FROM
THE CONDENSER”, International Journal Of Science And Research
(IJSR), India Online ISSN: 2319-7064 Volume 2 Issue 6 (2013
3] Raut Digambar M, Narwade Kiran H, Karale Vidhur S, Pardeshi
Kiranshing V, Kabudke P.D. , “HEAT UTILIZATION FROM
Determination of Optimum Tilt Angle of Solar
Collectors for Solar Cities in Maharashtra, India
A.B.Lanjewar1, N.S.Wakchaure1, S.S.Joshi2
Research Scholar, Department of Research Scholar, Department of Assistant Professor, Department
Mechanical Engineering, Mechanical Engineering, of Mechanical Engineering,
RCOEM, Nagpur, India RCOEM, Nagpur, India RCOEM, Nagpur, India
P.R.Tete1,
1. Research Scholar, Department 2.
of Mechanical Engineering,
RCOEM, Nagpur, India
Abstract—To cope with the increasing electricity demand of properly. Hence it is one of the most promising
the country, ‘Development of Solar Cities’ programme is unconventional energy sources. It is environmentally clean
designed by the government of India. This programme aims at source of energy and hence no potential damage to
reduction in projected demand of conventional energy through environment.
enhancing supply from renewable energy sources like solar
The solar energy utilization includes thermal and
energy. It is proposed to enhance the installation of the solar
collectors in the selected ‘Solar Cities’ in the country. It is well photovoltaic conversion. The varieties of thermal applications
known that, the efficiency of the solar collector will increase are water or air heating, drying, cooking and power
when it is always facing the sun. To eliminate the expenses generation. In photovoltaic, solar energy can be used to
towards sun tracking systems, it is always desirable to install the convert into electrical energy through photovoltaic effect.
collectors at an optimum tilt angle. The optimal tilt angle is the To cope with the increasing electricity demand of the
angle where the solar radiation will arrive perpendicularly upon country, „Development of Solar Cities‟ programme is
the surface such that the annual insolation would be maximized designed by the Government of India. This programme aims at
for the solar collector. This angle is determined considering reduction in projected demand of conventional energy through
several factors like location, application, energy demand pattern,
enhancing supply from renewable energy sources like solar
etc. In the current work, a mathematical model is used to
determine the optimum tilt angle of the solar collectors for the six energy. It is proposed to enhance the installation of the solar
Solar Cities of Maharashtra state. In addition, month wise and collectors in the selected „Solar Cities‟ in the country.
season wise optimum tilt angles are also computed for specific The amount of solar energy received by earth varies
applications in different seasons. The calculations and the inversely with the square of the distance between sun and the
computed angles are reported in this paper. earth. As sun- earth distance is not constant because earth
keeps revolving around the sun as well as on its own axis, the
Keywords—Optimum tilt angles, Solar Cities in Maharashtra amount of radiation received by the earth also varies
I. INTRODUCTION throughout day and year. The variation is not much and
accounts for only 5.9% [1]. So in order to collect the
The energy requirement in the world is increasing, maximum solar radiation, it is important to determine the
particularly since the last few centuries. The main driver for correct orientation and slope of the solar collectors. Solar
further increase in the energy demand is techno-economic tracking is one of the systems being used to maximize the
growth of the developing countries. The main sources of amount of solar radiation falling on solar collectors. But
energy which fulfill the energy demand are generally fossil tracking system is expensive and not easily applicable. To
fuels. But the fossil fuel based energy sources are exhaustible improve solar collector performance, optimum tilt angle is one
and also causes an environmental pollution. Therefore there is of the alternatives, if solar tracking is not appropriate.
a need for alternative energy sources which can provide Optimum tilt angle is the angle at which maximum solar
energy in a sustainable manner and pollution free. One of the radiation intercepted by the collector. There is reduction of an
options is to make more regular use of renewable sources of incident radiation by around 5% if tilt angle of solar collector
energy derived from the sun. Solar energy is abundant and is varied by 150 from the optimum tilt angle [2]. So, to receive
inexhaustible. The power from the sun intercepted by the earth the maximum solar radiation on collector, optimum tilt is
is approximately 1.8 x 1011 MW, which is many thousands of necessary. In northern hemisphere, collector orientation is
times greater than present consumption rate on the earth which south facing (γ = 00). In summer months, optimum tilt is less
could meet all the energy requirement of the world, if utilized (usually latitude – 150) and in winter months, it is greater
(usually latitude + 150) [3]. But annually, optimum tilt is given S is the monthly average of the sunshine hours per day at a
by β = 0.9Φ [4]. For Indian cities, in practice the collector location in hours.
plate is usually oriented south facing and at a fixed tilt to Garg and Garg[8] proposed the equation for predicting
receive maximum solar radiation. daily diffused radiation (Hd) for the locations in India.
Hd S
Hg
= 0.8677 − 0.7365 Smax
(9)
II. SOLAR RADIATION TERMINOLOGY
Now, monthly average daily beam radiation (Hb) for the
A. Extra-terrestrial Radiation locations is given by,
Extra-terrestrial radiation is the radiation just outside the Hb = Hg –Hd (10)
earth surface (Isc). Its value is taken as 1367 W/m2 [5]. Extra- For radiation flux to be maximum, optimum tilt angle of
terrestrial flux varies throughout the year due to changes in sun the collector is given by [9],
and earth distance and it is given by, βopt = tan−1 [{ i=12 i=12
i=1 Hbi tan Φ − δi }/{ i=1 Hbi}](11)
360 n
Isc’ = Isc 1 + 0.0333cos (1) D. Total Radiation on a Tilted Surface
365
Liu and Jordan [10] have proposed the relation for total
Where n is the day of the year.
radiation falling on a tilted surface (Ht) which is given by an
B. Declination Angle (δ) equation as
The angle made by lines joining center of earth to the Ht Hd Hd
= 1− Rb + Rd + Rr (12)
center of sun with its projection on equatorial plane of the Hg Hg Hg
earth is called as declination angle (δ). It varies between - For south facing surface (γ = 00),
23.450 to +23.450 due to inclination of the earth‟s polar axis
and its revolution around the sun. The declination angle is ω ′ sin δ sin Φ−β +cos δ sin ω ′ cos ⁡(Φ−β)
Rb= (13)
determined as ω sin δ sin Φ+cos δ sin ω cos Φ
360 1+cos β
δ = 23.45sin 365 (284 + n) (2) Rd = (14)
2
ρ(1−cos β )
Monthly average extra-terrestrial solar radiation (Ho)on Rr = (15)
2
the horizontal surface is given by [6] Where, ω‟ and ω are the sunrise or sunset hour angle for
24 360n
Ho = Isc 1 + 0.0333cos ωsinΦsinδ + cosΦcosδsinω tilted surface and horizontal surface respectively. ρ is the
π 365
ground reflectivity.
(3)
III. METHODOLOGY
Where, ω is sunshine hour angle and is given by,
ω = cos−1 (−tanΦtanδ)(4) Using equations 1 to 15, the maximum solar radiation
incident on collector and optimum tilt angle are calculated for
C. Global, Beam and Diffused Radiation different solar cities in Maharashtra, India. With the help of
The solar radiation which directly reaches at the earth MS-Excel, graphs were plotted between various entities. The
surface without change of direction is called as beam or direct data of latitude, longitude and elevation above mean sea level
radiation. The radiation received at the earth surface from all for solar cities in Maharashtra is tabulated in table 1.
parts of the sky‟s hemisphere called as diffused radiation.
Global radiation is the sum of beam and diffused radiation. TABLE 1. LATITUDE, LONGITUDE AND ELEVATION OF SOLAR CITIES
Gopinathan[7] have been suggested a correlation to Latitude Longitude Elevation

Solar Cities
(in degrees) (in degrees) (in meters)
determine the monthly average daily global radiation on a Nagpur 21.14 79.08 310
horizontal surface (Hg) at a location which is given by, Thane 19.22 72.98 11
Hg S
Kalyan-Dombivli 19.24 73.13 10
Ho
= a+b Smax
(5) Aurangabad 19.88 75.34 595
Nanded 19.14 77.32 356
The constants a, b are related to three parameters i.e. Shirdi 19.77 74.48 516
latitude of the location, elevation and sunshine hours as
follows.
a = −0.309 + 0.539cosΦ − 0.0693EL + 0.290
S
(6)
IV. RESULTS AND DISCUSSION
Smax
The monthly average daily extra-terrestrial, beam, global
S
b = 1.527 − 1.027cosΦ + 0.0926EL − 0.359 Smax
(7) radiations are calculated using equations (1) to (10). It is found
that the radiation decreases in the month of July to August i.e.
Where, EL is the elevation of the given location above in rainy season due to scattering radiations.The variation of
mean sea level in kilometer. extra-terrestrial, beam and global radiation on horizontalsurface
Smax is the monthly average of the maximum possible sun
hours per day at a location i.e. day length in hours.
2
Smax = 15 ω(8)
for Nagpur is shown in Fig. 1.
Fig. 1. Monthly average daily extra-terrestrial (Ho), beam (Hb) and global
radiation (Hg) on horizontal surface Fig. 2. Variation of monthly, seasonal and annual optimum tilt angles for
Nagpur
The angle of the collector at which maximum solar
radiation intercepted is calculated using equation (11), which is For implementation of seasonal optimum tilt angle, the
optimum tilt angle of the collector. The tilt angle is varied from collector tilt has to be changed four times in a year. The annual
0 to 900 for twelve months of the year with variation of solar optimum tilt angle is fixed value for any solar collector
radiation.Also, the average optimum tilt angles are calculated throughout the year. The value of total solar radiation with
for four seasons of the year. Annual optimum tilt angle is different collector tilt angle is calculated for Nagpur which is
calculated by averaging the monthly optimum tilt angles over given in Table 3.
the year.The monthly, seasonal average and annual optimum
TABLE 3. MONTHLY AVERAGE DAILY GLOBAL SOLAR RADIATION FOR
tilt angles for six solar cities in Maharashtra are given in Table 2
VARIOUS COLLECTOR TILT ANGLES FOR NAGPUR (IN KWH/M -DAY)
2.
Ht Ht
Hg (β=0) Ht (β=βopt)
TABLE 2. MONTHLY, SEASONAL AND ANNUAL OPTIMUM TILT ANGLES (IN Month (Seasonal βopt) (Annual βopt)
DEGREES) FOR SIX SOLAR CITIES IN MAHARASHTRA
Jan 5.093 7.769 7.771 6.771
Feb 6.321 8.057 7.733 7.650
City Mar 7.291 7.957 7.955 7.940
Kalyan- Aurang
Nagpur Thane Nanded Shirdi Apr 6.955 6.965 6.749 6.802
Dombivli abad
Month May 5.301 5.301 5.301 4.770
Jan 42.0 40.1 40.1 40.8 40.0 40.7 June 3.938 3.938 3.938 3.409
Feb 34.1 32.2 32.2 32.8 32.1 32.7 July 4.127 4.127 4.127 3.635
Aug 5.800 5.752 5.532 5.475
Mar 23.5 21.6 21.6 22.3 21.5 22.2
Sept 7.179 7.500 7.500 7.493
Apr 11.7 9.8 9.8 10.4 9.7 10.3 Oct 7.070 8.513 8.192 8.269
May 0.0 0.0 0.0 0.0 0.0 0.0 Nov 5.860 8.503 8.558 7.601
Dec 4.942 7.998 7.922 6.758
June 0.0 0.0 0.0 0.0 0.0 0.0
July 0.0 0.0 0.0 0.0 0.0 0.0
Aug 7.7 5.8 5.8 6.4 5.7 6.3 The value of Table 3 is graphically shown in Fig. 3 for easy
Sept 19.0 17.0 17.1 17.7 17.0 17.6 interpretation on variation in values of solar radiation.
Oct 30.8 28.8 28.9 29.5 28.8 29.4
Nov 40.1 38.2 38.2 38.8 38.8 38.7
Dec 44.2 42.9 42.3 42.9 42.2 42.8
Winter 42.1 40.2 40.2 40.8 40.1 40.7
Spring 23.1 21.2 21.2 21.8 21.1 21.7
Summer 0.0 0.0 0.0 0.0 0.0 0.0
Autumn 19.1 17.2 17.2 17.9 17.1 17.8
Annual 21.1 19.2 19.2 19.9 19.1 19.8
The variation of optimum collector tilt angle for monthly,

seasonally and annually basis for Nagpur city is shown
graphically in Fig. 2.
Fig. 3. Monthly average daily global solar radiation on various collector tilt
angles for Nagpur
Similarly, the values of monthly average daily global solar V. CONCLUSION
radiation with various collector tilt angles for other solar cities In the current work, a mathematical model is used to
have been calculated. determine the optimum tilt angle of the solar collectors for the
six different locations. The annual average insolation for the
TABLE 4. ANNUAL AVERAGE SOLAR RADIATION (IN KWH/M2-DAY) FOR
VARIOUS COLLECTOR TILT ANGLES FOR SOLAR CITIES IN MAHARASHTRA
optimum tilt is also reported. In addition, month wise and
season wise optimum tilt angles are also computed for specific
Hg for Ht for Ht for applications in different seasons. In this analysis it is observed
Ht for
horizontal seasonal annual
surface,
monthly
optimum optimum
that the significant gain in the annual average solar radiation
City optimum tilt can be obtained by placing the collector at optimum tilt
(β=0) tilt tilt
Nagpur 5.822 6.866 6.773 6.381
angles.The reported values are useful for the purpose of
installations of different solar utilities for year round or for
Thane 5.847 6.778 6.688 6.304 seasonal applications at the locations considered in this
Kalyan- analysis.
5.847 6.778 6.688 6.304
Dombivli
REFERENCES
Aurangabad 5.934 6.918 6.825 6.430 [1] J.K., “Solar Energy :Principles of thermal collection and storage”,
McGraw Hill Education (India) Pvt. Ltd., New Delhi, 3 rd ed.
Nanded 5.918 6.858 6.764 6.375
[2] Froelich C. and Brusa R.W., “Solar radiation and its variation in time”,
Shirdi 5.923 6.899 6.805 6.414 Solar Physics, Vol. 74, pp. 209, 1981.
[3] Klein S.A., “Calculation of monthly average insolation on tilted
The annual average solar radiation that falls on a meter surfaces”, Solar Energy, Vol. 19, pp. 325, 1977.
square area of solar collector for different collector tilt angles [4] Gopinathan K. K., “A general formula for computing the coefficients of
for six solar cities is given in Table 4. The maximum solar the correlation connecting global solar radiation to sunshine duration”,
radiations can be received by monthly adjustment of the Solar Energy, Vol. 41, pp. 499, 1988.Solanki C.S., Solar Photovoltaics:
Fundamentals, Technologies and Applications, PHI Learning Private
collector tilt angle and the minimum is for horizontal surface.
Limited, Delhi, 2013.
For Nagpur city, the annual average solar radiation fall on a
[5] Yohannes Berhane Gebremedhen, “Determination of Optimum Fixed
horizontal surface is measured to be 5.822 kWh/m2-day. The and Adjustable Tilt Angles for Solar Collectors by Using Typical
annual average solar radiation is found to be 6.866 kWh/m2- Meteorological Year data for Turkey”, IJRER, Vol. 4, pp-924-928,
day for collector at monthly optimum tilt, 6.773 kWh/m2-day 2014.
for seasonal optimum tilt and 6.381 kWh/m2-day for annual [6] M.Jamil ahmad and G.N.Tiwari, “Optimization of Tilt angle for solar
optimum tilt which is same as collector tilt equal to latitude. collector to receive maximum Radiation”, The Open Renewable Energy
Journal, Vol. 2, pp-19-24, 2009.
It can be seen from Table 4, for Nagpur city, 9.6% increase [7] Sukhatme S.P., Nayak
in annual average solar radiation can be obtained by placing the [8] Garg H. P. and Garg S. N., “Correlation of monthly-average daily
collector at a tilt angle equal to the latitude when compared it global, diffuse and beam radiation with bright sunshine hours”, Energy
Conversion and Management, Vol. 25, pp. 409, 1985.
with the collector placed horizontally. Further 6.1% more
[9] Kern J. and Harris J., “On the optimum tilt of a solar collector”, Solar
radiation can be received by seasonally adjusting the tilt angle Energy, Vol. 17, pp. 97, 1975.
of the collector. 1.4% more radiation can be collected by
[10] Liu B.Y.H. and Jordan R. C., “Daily insolation on surfaces tilted
implementing monthly tilt angle. Similar results have been towards the equator”, ASHRAE Transactions , Vol. 67, pp.526, 1961.
obtained for other solar cities in Maharashtra.
DESIGN AND DEVELOPMENT OF HYBRID
MOPED USING ELCTRICAL AND PETROL
OPERATING ARRANGEMEN
Piyush A.Dalke Prof.AbhijeetA.Raut

Mechanical Engineering Department Mechanical Engineering Department
G.H.Raisoni College of Engineering, Nagpur G.H.Raisoni College of Engineering Nagpur
other hand, electric motors are efficient in converting the

ABSTRACT stored energy in driving a vehicle, and electric drive
vehicles do not consume power while coasting. Some of the
Rapid depletion of fossil fuels has forced the necessity energy loss in braking is captured and reused by
of an alternate energy vehicle. Electric vehicles serve as regenerative braking. With the help of regenerative braking
promising technology for the future world transportation one fifth of the energy loss can be regenerated. Typically,
arena Due to minor drawbacks the electric vehicles cannot petrol engines effectively use only 15% of its fuel content to
match up with the fossil fuel powered vehicle which made the
move the vehicle. Whereas an electric drive vehicle has an
invention of hybrid technology. Concentrated efforts are
mainly towards implementing a concept called as hybrid on-board efficiency of about 80%. But due to reasons such
system by which one system will be charged while the other as cost, inability to reach higher speeds electric drive
system provides propulsive power to the vehicle. When the s vehicles failed to capture markets. Contrary to this petrol
runs on the electric motor it is almost nonpolluting. vehicle can cover longer distances with higher speed but it
cannot cover shorter distance with slow speed (say in
This project is deal with the development of the as the traffic) in an efficient way. Two-wheeled vehicles,
only petrol vehicle or electrical vehicle is not as sufficient as especially motorcycles and scooters contribute to a major
hybrid vehicle. This hybrid technology can compensated the part of air pollution, especially in the Asia region.
disadvantages of both type of vehicle. There is various type of
base on the type of charging as it becomes plug-in type or
Thus a hybrid approach, which is to utilize an
other. internal combustion engine (ICE) and a battery, is more
feasible as a much higher range could be achieved compare
to pure electric scooters. The only trade-off is that emissions
I. INTRODUCTION are not reduced to zero. Thus two-wheeled hybrid research
Hybrid electric moped (HEM) have a great is as equally as important
potential in lowering emissions and reducing fuel demand as
the ever growing problems of air pollution and global II. CONCEPT OF HYBRID VEHICLE
warming reached its critical stage. Although various
researches are carried out to reduce emissions and fuel
dependencies for four-wheeled vehicles, not much research
is focused on two wheeled vehicles for example,
motorcycles in Jakarta, Indonesia contributed to more than
20% in both PM10 and CO and 40% of HC emissions
during 1998. Whereas in Hanoi, Vietnam, motorcycles Fig No. 1 Basic Concept diagram
contributes to about 54% of CO,HC and Pb and 43% of dust It is basically a two-way source one of which is
Finally, in Taiwan where emissions reports indicate that rechargeable energy storage system. As shown in diagram
38% of CO, 3% of NOx, 64% of NMHC and 30% of PM that the wheels are get power by the two sources P1 and P2
were emitted from motorcycles and scooters alone. this are the two way sources.
Internal combustion engines are relatively less Hybrid vehicle is an automobile which combine
efficient in converting the on-board fuel energy to more than one method of Propulsion system. It cans
propulsion as most of the energy is wasted as heat. On the anything from petrol with combine’s more than one method
of propulsion system. It can be anything from petrol with a Advantages:
hydraulic motor, diesel with electric or even solar power. In
fact, we already see around us so many hybrid cars and Higher efficiency and reliability Lower acoustic
motorcycles running on CNG with petrol with electric noise Smaller and lighter Greater dynamic response Better
motor, petrol with a hydraulic motor diesel with electric or speed versus torque characteristics Higher speed range
even solar power, In fact, we already see around us so many
hybrid cars and motorcycles with LPG. They are nothing Longer life Motor fundamental concepts:
but form of a parallel Hybrid system. Hybrid technology is
nothing but the solution to the problem of pollution by fuel 1. General principle:
and limited availability of the storage. In future we have to
Motors convert electrical energy into mechanical
think out any alternative source so why not from now?
energy using electromagnetic principles. The energy
That’s why we are dealing with this concept.
conversion method is fundamentally the same in all electric
motors.
TYPES OF HYBEID VEHICLE
Hybrid vehicle is mainly classified in two main 2. Magnetic Force:
types on the basis of power supplied to the vehicle. The
types are as below, Magnetic poles generate invisible lines of magnetic
 Parallel hybrid vehicle force flowing from the North Pole to the South Pole as
 Plug-in hybrid vehicle shown in Figure. When magnetic poles of opposite polarity
A. Parallel hybrid vehicle face each other, they generate an attractive force, while like
In parallel hybrid vehicle, the internal combustion poles generate a repulsive force.
engine and the electric motor are connected to mechanical
transmission and can transmit power simultaneously to
drive the vehicle. The commercialized parallel hybrid
vehicles use a single small electric motor and a small battery
pack. Parallel hybrid vehicles are capable of regenerative
braking and the internal combustion engine present in it is
capable of supplemental charging of the battery.
B. Plug-in hybrid vehicle
A Plug-in hybrid electric vehicle(PHEV), also Fig No.2 Unlike-pole attraction & like-pole repulsion
called as Plug-in hybrid, is a hybrid electric vehicle with 3. Construction of BLDC motor:
rechargeable batteries that can be restored to full charge just
by connecting to an external power source. A Plug-in hybrid I) Stator: There are three classifications of the
electric vehicle shares the characteristics of both BLDC motor: single-phase, two-phase and three-phase, the
conventional hybrid electric vehicle having an electric stator for each type has the same number of windings. The
motor and an internal combustion Engine and of an all- single-phase and three-phase motors are the most widely
electric vehicle, having a plug to connect to an electric grid. used. Figure shows the simplified cross section of a single-
phase and a three-phase BLDC motor. The rotor has
III. CONSTRUCTION DETAIL: permanent magnets to form 2 magnetic pole pairs, and
While converting the ordinary moped into hybrid surrounds the stator, which has the windings.
moped. We required following components.
 Electric motor preferably (Hub motor).
 Batteries (Dry lead acid battery).
Moped (Kinetic kine).
This is main component of the . On the basis of
availability and low cost We select this component. The
various detail of the following component is as below
Electric motor:
The BLDC motor is widely used in applications
including appliances, automotive, aerospace, consumer,
medical, automated industrial equipment and Fig no. 3 (a) & (b) Construction diagram
instrumentation.
The BLDC motor is electrically commutated by There are two types of stator windings: trapezoidal
power switches instead of brushes. Compared with a and sinusoidal, which refers to the shape of the back
brushed DC motor or an induction motor, the BLDC motor electromotive force (BEMF) signal. The shape of the BEMF
has many is determined by different coil interconnections and the
distance of the air gap. In addition to the BEMF, the phase
current also follows a trapezoidal and sinusoidal shape. A
sinusoidal motor produces smoother electromagnetic
torquethan a trapezoidal motor, though at a higher cost due The controller connects the power source to the
to their use of extra copper windings. A BLDC motor uses a motor. It controls speed, direction of rotation, and optimizes
simplified structure with trapezoidal stator windings. energy conversion. While batteries produce constant
voltages which decrease as theyare used up, some
II) Rotor: controllers require a DC to- DC converter to step down this
changeable voltage to the motors expected constant
A rotor consists of a shaft and a hub with operating voltage, but other controllers incorporate a DC-to-
permanent magnets arranged to form between two to eight DC converter and can accept a varying voltage. Converter
pole pairs that alternate between north and south poles. efficiencies are typically greater than 90% [4]. The voltage
There are multiple magnet materials, such as ferrous control is achieved by “chopping” the source current - the
mixtures and rare-earth alloys. Ferrite magnets are voltage is switched on and off, with the ratio of on to off
traditional and relatively inexpensive, though rare-earth determining the average voltage. Chopping is performed by
alloy magnets are becoming increasingly popular because of power electronic circuitry such as diodes and thrusters and
their high magnetic density. The higher density helps to silicon control rectifiers (SCR). Controllers also effect
shrink rotors while maintaining high relative torque when regenerative braking, by which the motor is acted as a
compared to similar ferrite magnets. generator to recharge the batteries.
IV. Working of motor: The controller which we used has following
specification.
Motor operation is based on the attraction or
repulsion between magnetic poles. Using the three-phase
motor shown in Figure, the process starts when current V. BATTERIES:
flows through one of the three stator windings and generates
A lead-acid storage battery is an electrochemical
a magnetic pole that attracts the closest permanent magnet
device that produces voltage and delivers electrical current.
of the opposite pole. The rotor will move if the current shifts
The battery is the primary “source” of electrical energy used
to an adjacent winding. Sequentially charging each winding
in vehicles today. It’s important to remember that a battery
will cause the rotor to follow in a rotating field. The torque
does not store electricity is produced. Basically, two
in this example depends on the current amplitude and the
different types of lead in acid mixture react to produce an
number of turns on the stator windings, the strength and the
electrical pressure called voltage. This electrochemical
size of the permanent magnets, the air gap between the rotor
reaction changes chemical energy to electrical energy and is
and the windings, and the length of the rotating arm.
the basis for all automotive batteries.
ADVANTAGES OF BLDC MOTOR OVER OTHER
The purpose of the battery:
MOTOR:
The battery supplies electricity to the BLDC motor
• Higher efficiency (75% vs. 40% of an AC motor) while the engine is off. That is our second alternative of
moped operation. The motor run the shaft of the rim through
• Less heat generated the coupling. the battery can use to run the other accessories
of the moped.
• Higher reliability (no brushes to wear out)
• Safer to operate in a dangerous environment (no brush The other battery in arrangement is to use in self-
dust generated as is found with brushed motors). staring of the moped.
Table No. 1 VI. TYPES OF BATTERIES:
 Primary cell
 Secondary cell
 Wet charge
 Dry charge
Primary cell:
Fig. 4: controller for BLDC hub motor This type of Batteries are such as flashlight battery
once used, throw it away because the chemical reaction
totally destroys one of the metals after a period of time,
primary cells cannot be recharge. Small batteries such as
flashlight and ratio batteries are primary cells.
Secondary cell: creates and releases electricity as needed by the electrical
system or devices. Since the battery losses its chemical
The metal plates and acid mixture change as the energy in this process, the battery must be recharged by the
battery supplies voltage. As the battery drains the metal alternator. By reversing electrical current flow through the
plates become similar and the acid strength weakens. This battery the chemical process is reversed, thus charging the
process is called discharging .by applying current to the battery. The cycle of discharging and charging is repeated
battery in the reverse direction.the battery materials can be continuously and is called “battery”.
restored, thus recharging the battery. This process is called
charging. Automotive lead-acid batteries are secondary cells BATTERY CELL ELEMENT:
and can be recharged.
The key to the battery operation is the cell element. Positive
Wet charged: plates and negative plates are each connected together by
The lead –acid battery is filled with electrolyte and separate plate straps. These groups of positive and negative
charged when it is built. During storage, a slow chemical plates are then placed alternately, separated by micro-porous
reaction will cause self-discharge. periodic charging is separators. Assembled together, the plates and separators
required. Most batteries sold today are wet charged. form a battery cell element. Grouping the plates in this way
serves to enlarge the surface area between the active
Dry charged: materials and the electrolyte, thus allowing a greater amount
The battery is built, charged washed and dried, of electricity to be supplied. In other words, the battery
sealed, and shipped without electrolyte. It can be stored for capacity is increased because of the increase in the surface
up to 18 months. When put into use, electrolyte and area. More plate surface area means the battery can deliver
charging are required Batteries of this type have a long shelf more current.
life. Motorcycle batteries are typically dry charged batteries
PLATES:
VII. BATTERY CONSTRUCTION:

Battery plates are constructed of a lead alloy
An automobile battery contains a diluted sulfuric
containing a percentage of either antimony or calcium. The
acid electrolyte and positive and negative electrodes in the
plates are designed as thin flat grid, grids crossing at right
form of several plates. Since the plates are made of lead or
angles {shown below} or grids crossing diagonally at
lead-derived materials, this type of battery is often called a
different angles which reduce internal resistance. The grid
lead acid battery. A battery is separated into several cells
provides the necessary framework for active materials to be
(usually six in the case of automobile batteries), and in each
pasted on the plate, making either a positive or negative
cell there are several battery elements, all bathed in the
plate. The active material on a charge positive plate is a
electrolyte solution.
reddish brown Lead Di Oxide [Pbo2] while the active
material on a charge negative plate is a grayish spongy lead.
Fig No.5: Basic Construction

Fig no 6:Battery Case
VIII. CELL OPERATION:
The battery case holds the electrolyte and the
individual battery cell elements. It is divided into six
Two dissimilar metals placed in an acid bath compartment or cells. The plates are raised up off the
produce electrical potential across the poles. The cell bottom of the case with ribs to prevent them from shorting
produces voltage by a chemical reaction between the plates out if any of the active materials (lead, etc) should happen to
and the electrolyte. The positive plate is made of reddish- fall from the plates. The case is made of polypropylene,
brown material such as Lead Dioxide (PBO2). While the hard rubber, and plastic base materials. some battery
negative plate is made of grayish material called Sponge manufactures use translucent plastic cases which allow
Lead (PB) the acid bath is a mixture of sulfuric acid and the checking electrolyte level without removing vent caps.
water cell electrolyte. Together a cell element is formed. These cases often have “upper” and “lower” electrolyte
CYCLING: level markers on the outside of the case.
The battery stores electricity in form of chemical VENT CAPS:

energy. Through a chemical reaction process the battery
Vent caps cover the holes that are used for adding batteries.
electrolyte. They are also designed to separate the sulfuric
acid mist and the hydrogen gas that forms when the battery 5. More plate surface and closer plate spacing
charges. The caps are designed to the sulfuric acid mist to provides a compact case size.
condense and drop back into the battery and allow hydrogen
gas to escape through the vent holes to the atmosphere. Vent X. FULL SPCIFICATION OF KINE:
caps can cover each individual cell as shown below.
1. ENGINE, POWER AND TORQUE
Table 2
VARIABLS VALUE
Displacement 71.55cc
Maximum
IX. SEVERAL BATTERY MATERIAL AND power 4.2Bhp
THEIR ADVANTAGES:
Several variations of the lead-acid battery are used Maximum
today. Variation to the battery plate material and electrolyte Torque 5.7Nm
solution provides different battery characteristics.
Construction is basically the same; however, the materials
Engine 2 Stroke Single
used are slightly different.
Displacement cylinder
1. Lead Antimony:(Most commonly used) Is
commonly used in conventional lead acid battery which Cooling Air cooling
uses lead antimony cell plates
TRMISSION
ADVANTAGES Table 3
1. Longer service life than Calcium batteries. PART TYPE

2. Easier to recharge when completely discharged. Gearbox Automatic
3. Lower cost.
2. Lead Calcium(AC Delco maintenance free batteries). Is a

maintenance free lead acid battery which uses lead calcium 3. BRKAES
cell plates. Table 4
ADVANTAGES TYPE SIZE

1. Larger electrolyte reserve area above the plates.
2. Higher Cold Cranking Amp ratings Front Brake Drum 110 mm

3. Little or No maintenance
Rear Brake Drum 110 mm
4. Recombination (Gel Cell)
Is a completely sealed lead acid battery which uses 4. DIMENSION ,WEIGHT, CAPACITY
an electrolyte that in a gel (solid) rather than a liquid.
Table 5
ADVANTAGES
PART SIZE
1. No liquid electrolyte to spill or leak.
Overall Length 1740 mm
2. Can be Deep Cycled several time without damage.
Overall Weight 640 mm
3. Totally corrosion and maintenance free.
4. Three to four times longer battery life than regular Overall Height 1076 mm
Wheel Base 1235 mm D = 2d = 2 x 14 mm
= 28mm,30mm
Kerb /wet But Actual outer diameter of hub
Weight 86 kg D = 122mm
So for given data our design is safe.
Fuel Tank (b) Hub is hollow shaft for that shear stress
π 𝐷 4 −𝑑 4
Capacity 4 liters T= x τs x [ ]
16 𝐷
π 28 4 −14 4
Front Tyre 3.00×10 inches 10 x 10 = x τs x [
3
]
16 28
τs =2.47 N/mm 2
Rear Tyre 3.00×10 inches For actual diameter of engine shaft

d = 14 mm
Head Light 12v 25w/25w Outer diameter of hub
d = 122 mm
This data is available from the manual of this Ts= 0.23 N/mm2
product.
XI. DESIGN CRITERIA: Form above given data design is safe.
Some part is necessary to design, on the basis of (c)Desing For Flange
the data available from the manual of the moped and Thickness of Flange = 0.5d
standard data book the value are taken and their Tf= 0.5 x 14 = 7mm
3.14 ×𝐷
corresponding value is calculated. T= 𝜏𝑐 × 𝑡𝑓
2
Following part which are necessary to design. 3.14 ×28
10x103 = 𝜏𝑐 × 7
2
(1) Design Procedure for shaft 𝜏𝑐 = 1.16 𝑁/𝑚𝑚2
Given Data
Torque on the Driving Shaft (c) Design for Bolt
=10N-m =10x103 N-mm Given Data
Total Load acting on the shaft 𝜏𝑏 = 20 𝑁/𝑚𝑚2
= 300 kg x 9.81 No. Of bolts n=4
=2943 N d1=Normal diameter of bolt .
Total Length of driving shaft D1 = Pitch circle diameter
= 0.125m = 125 mm D1= 3d= 3 x 14 = 42 mm
For stress
π 𝐷1
Design Procedure for Flange T= 4 x 𝑑2 1 x τbx n x [ 2 ]
: ˑ d = 10.66 mm π
10x103=4 x 𝑑2 1 x 20x 4 x [ 2 ]
42
Method (II)
For Simply Supported Beam 𝑑1 =2.75mm
=WL/4= 2943 x 0.125/4 Outer Diameter of Flange
M=91.96 N-mm
M=91. 96N.m = 91.96 x103 N-mm D2 = 4d = 4 X 14 = 56mm
M=𝜋/32 × 6b × d3
91.96 × 10 3/32 =3.14 x42 x d3 ‫ ·׃‬Thickness of the Protective Circumferential Flange
d = 28.14 mm tp = 0.25 d
Coupling = 0.25 X 14 = 3.5mm = 5 mm

As our bolt actual diameter is 8 mm so our design is safe.
Given Data =
N = 5000 rpm motor (3) (1) Design Specification of Coupling
T = 10 N-m d =Diameter of Shaft = 14mm
Actual Diameter of Engine shaft, D= outside Diameter of flange = 44mm
d = 14mm (given) Thickness of flange = 4 mm
(a) P = 2 x N x T / 60 N-m Allowable shear stress for shaft
P = 5.235 KW =18.58 N/mm2
T = π/16 x s xτs x d3
10 x 103 = π /16 (1) Design specification for Bearing
π
x= τs x 143 Bearing No. 202
16
τs=18.56 N/mm2
Outer diameter of Hub Bore = 15mm
Outer Diameter = 35mm = 53.33 N/mm2
Width = 11mm Consideration (II)

Bearing 203
Bore = 17mm
Outer Diameter = 40mm
Width = 12 mm
(4) Design Procedure for C- Clamp
Bending moment at X-X due to the load P

M= P X e
= 2943 X 77.5
M = 228.08 X 103 N-mm

XII. CAD MODEL:
1) Motor:
Cross Section at X – X
A=bxt
2) Bearing:
40 x 5 = 200mm2
Consideration (I) =
‫ · ׃‬Direct tensile stress at x-x 3) Clamp:
𝑃 2943
𝜎0 = = 4) Rim:
𝐴 200
5) Rim disc:
𝜎0 = 14.71 N/mm2
Behind moment at X-X due to the load P

Coupling:
M=PXe
I) Main Coupling
= 2943 X 17.5
II) Large Coupling:
M = 51502.5 N-mm
Section Modulus
𝑡 ×𝑏 2 5 ×40 2
Z= = Assembly: Explode View
6 6
Z= 1333.33mm3
Behind stress at X-X
σb= M = 51502.5
Z 1333.33
σb = 38.62 N/mm2
Maximum tensile stress
XIII. ADVANTAGE’S:
= σ0 + σb  The range of an Electric bike increased.
 The city traffic air and noise pollution is decreased to a
= 14.17 + 38.62 greater extent.
 One third of energy is captured by regenerative braking, but the initial cost we need to be work on.
which would otherwise go waste. REFERENCES:
 Decreased the dependency of fossil fuels. [1] A. Raskin, S. Shah, The emerge of hybrid electric vehicles, Alliance-
Bernstein, 2006.
[2] M. Anderman., The challenge to fulfil electrical power requirements
XIV. DISADVANTAGE’S: ofadvanced vehicles, Journal of Power Sources, 127(2004).
 The initial cost of the vehicle is marginally increased, [3] P. Denholm, W. Short, An Evaluation of Utility System Impacts and
compared to the conventionally available. Benefits of Optimally Dispatched Plug-In Hybrid Electric Vehicles,
 The disposal of battery is to be properly handed to avoid Technical Report, October 2006.
[4] S. Logghe, B. Van Herbruggen, B. Van Zeebroeck, Emissions of road
pollution. traffic in Belgium, Transport & Mobility Leuven, January 2006.
[5] Clement K., Van Reusel K., Driesen J., The consumption of electrical
energy of plug-in hybrid electric vehicles in Belgium, EET-European Ele-
Drive Transportation conference, Brussels, Belgium, 30th May - 2nd June,
2007.
[6] Commission Energy 2030, Belgium’s energy challenges towards 2030,
preliminary report, November 2006.
[7] Clement K., Haesen E., Driesen J. The impact of uncontrolled and
controlled charging of plug-in hybrid electric vehicles on the distribution
grid, EET-2008 3rd European Ele-Drive Transportation Conference,
Geneva, Switzerland, March 11-13, 2008.
Fig no. 8: [8] Kersting W., Distribution System Modeling and Analysis, Boca Raton,
Actual design and development of hybrid moped. 2002.
[9] Haesen E., Driesen J., Belmans R. Robust planning methodology for
XV. CONCLUSION: integration of stochastic generators in distribution grids, IET Journal on
Finally, we conclude that canreduce consumption Renewable Power Generation, vol.1, no.1, March, 2007.
of the fuel to the great extent. There is always an alternative [10] J. Linderoth, A. Shapiro and S. Wright, The em-pirical behavior of
source of fuel to the vehicle as hybrid technology is the sampling methods for stochastic programming, Annals of Operations
Research, Vol. 142, No. 1,
most promising technology. Typically, petrol engines
effectively use only 15% of its fuel content to move the
vehicle. Whereas an electric drive vehicle has an on-board
efficiency of about 80%. But electrical vehicle cannot reach
to the high speed as petrol engine that’s why the hybrid
technology is use.
This can efficiently work with the hub motor. And
it supplies the power by the battery (lead acid battery). the
disadvantages of the both electric moped and the petrol
moped are compensated by the hybrid technology. and one
whole automobile industry catch this concept soon.
XVI. RESULT:
The following are the result which are obtain from
during operation of the vehicle.Charging Time of the battery
– 6 hr. Max speed of the moped -40km/hr.
XVII. FUTURE SCOPE:

This modeled has a parallel hybrid structure. The
main propulsion units consist of a two stroke internal
combustion engine and a hub motor attached to the Rear
wheel of the moped. The methodology used to optimize the
energy and fuel consumption of the hybrid electric scooter
is the multi-mode approach.
The hybrid vehicles have a wide scope in the
upcoming future. The main reasons of it are-
 Regenerative braking actually makes city driving more
economical than on the highway.Fuel efficiency is greatly
increased (twice).
 Emissions are greatly decreased.
 Dependency on fossils fuels can be decreased.
 Hybrids can be run on alternative fuels as well.
 Battery can be charge by the solar energy.
This is the main area where we need to be focused
in future. All the above option will increase its efficiency.
POWERGENERATION FROM
BIOMASS BRIQUETTES
Prasanna Gaikwad Aditya Nakat Vansh Devhare Jayesh Nandankar
Department of Mechanical Department of Mechanical Department of Mechanical Department of Mechanical
Engineering, Engineering, Engineering, Engineering,
Tulsiramji Gaikwad-Patil Tulsiramji Gaikwad-Patil Tulsiramji Gaikwad-Patil Tulsiramji Gaikwad-Patil
College of Engineering College of Engineering and College of Engineering and College of Engineering and
and Technology, Technology, Technology, Technology, Nagpur, India
Nagpur, India Nagpur, India Nagpur, India [email protected]
[email protected] [email protected] [email protected] Mobile No:8605820090
Mobile No: 8408808218 Mobile No:9860931511 Mobile No:8007224378
ABSTRACT:
Today the energy is vital part of our life. Demand of energy is
everywhere Energy is the key factor in economic development of Fuel C% H% S% N% O ASH GCV HH
any country. The demand of energy increases rapidly in all name % % in V
sectors like domestic use, infrastructure, agriculture, automobile,
power etc. That’s why there is a huge requirement to find
Kcal in
alternative green energy sources to the coal, charcoal, oil, petrol MJ/
diesel and fossil fuels to prevent the environment from toxic gases Kg
and harmful pollution. Also Deforestation is the global problem Coconut 40. 2.4 0.0 0.8 56. 2.3 4524 11.0
and thus from the old days Biomass is use as a source of energy in shells 23 8 1 8 39 7
India and it shows great potential. Biomassbriquettes are a Coffee 53 5.3 0.0 1.0 39. 10 4045 20.7
renewable source of energy and avoid adding fossils carbon to the husk 1 5 78
atmosphere. Therefore this substitute energy medium is given
national priority as appears to be the only permanent solution
Bagasse 45. 4.9 0.0 0.8 48. 3 4380 16.4
into restriction of the national laws and avoid pollutions. 21 3 1 8 96 6
‘Biomass Briquetting’ is the process of physical transformation of Cotton 38 3.4 0.0 1.7 56. 5 4252 11.3
loose raw bio waste material like rice husks, saw dust briquette, stalks 4 2 5 77 2
ground nut shells, bark woods etc into high density fuel Saw dust 46. 4.6 0.0 0.7 48. 5 3898 16.4
briquettes through a compacting process. The resultant form 12 31 24 0 524 2
change increases the calorific value (combustion efficiency) of the
Groundn 55. 4.1 0.0 3.5 36. 5 4524 20.2
product as compared to lose material. As it increases the density
of the product. ut shells 41 47 1 0 929 5
Rice 64. 3.7 0.0 2.1 29. 20 3200 23.4
KEYWORDS: Ingredients, Manufacturing, Types, Techniques, husk 5 82 1 6 5
Case study. Table No.1 Ingredient of Biomass Briquettes
INTRODUCTION The measured percentage H, N and S contents are

generally much lower to that of hydrocarbon fuels and
BIOMASS BRIQUETTE INGREDIENTS oxygencontent is high to that of hydrocarbon. The total nitrogen
The carbon and oxygen content is important in varies in the range 0.88-3.50 (wt %) and the total sulfurrange
biomass energy analysis. As the high Oxygen content tends to 0.0106-0.1090 (wt %). Both nitrogen and sulfur content are not
lower the calorific value while high carbon content tends to important in biomass combustion. They tend
form high-grade biomass fuel. The calorific value is one of the to increase the release of toxic gases that are either irritants
most important characteristics which is the amount of energy (NOx, SO2, aldehydes and acrolein) or asphyxiants(HCN)
per kg it gives off when burnt. Thus it be used to calculate the which may cause adverse effect to living organisms
competitiveness of a processed fuel in a given market situation
also the ease of handling, burning characteristics are also the MANUFACTURING PROCESS
factors to be consider while selecting the raw material.
The table no.1 depicts some important characteristics of Biomass briquetting project is simply a process of
mostly used biomass briquettes. densification of agro waste and forestry waste into biomass
briquettes also called as white coal. All materials containing The Production of Biomass Briquettes is as shown in fig no.1
lignite and cellulose are suitable for densification. Successful
test have been carried out with variety of materials from saw
dust, sander dust, etc. The bio residues can be briquetted
individually or in combination depending on their availability
and blending properties. Main concept of this process is to
produce the material as a white-coal, which is made from the
wastages. We cannot destroy the wastage totally. But we can
use it with the help of briquetting plant and produce the
briquettes, which ultimately produce the energy. The use of
these cheap fertilizers gives low yield as compared to the
modern fertilizer. The briquette made from press mud after
drying and briquetting have calorific value 4000 Kcal. /Kg
Approximately. It can be illustrate step by step.
Sorting/sieving: All unwanted materials or largebiomass

waste are removed to ensure that all thefeedstock is of the
required size. For example, the rawsawdust you collect could
contain unwanted larger piecesof wood. These can be sieved
out with a wire mesh.
Shred biomass materials into small pieces: Thebiomass Fig. No.1 Biomass Briquette Production
materials are chopped into small pieces so asto enhance their
workability and compactness. Theprocess is dependent on the
type of biomass feedstock.
For example, coffee husks and saw dust would notrequire

shredding but materials such as groundnutwaste, bagasse,
wheat straws, barley and maize strawsand cobs would need to
be chopped into small sizes. Inthe case of carbonized biomass,
the materials wouldneed to be grounded into small pieces after
they havebeen carbonized.
Mixing: This process is done in situations where youwant to

use a range of different feedstock to optimize the burning
characteristics of the final fuel. For example,biomass materials
with high ash content could be mixed with biomass material of Fig No.2 Flow Diagram of Briquette Production Process
low ashcontent. Biomass with low energy content such
aspapers can be appropriately mixed with those of highenergy Screw Press and Piston Press Technologies:
content. This helps to attain the right quality(long burning
period, non-smoking and odor free) thatwill make briquettes High compaction technology or binder less technology
competitive in the market. consists of the piston press and the screw press. Most of the
units currently installed in India are the reciprocating type
Binder: In addition to biomass mixing, an appropriatebinder is where the biomass is pressed in a die by a reciprocating ram at
added and mixed with the biomass thoroughly. a very high pressure. In a screw extruder press, the biomass is
extruded continuously by a screw through a heated taper die.
This enhances the compactness of the biomassmaterials and In a piston press the wear of the contact parts e.g., the ram and
prevents them from falling apart. An example of such binders die is less compared to the wear of the screw and die in a
includes starch or clay rich inbiomass. screw extruder press. The power consumption in the former is
less than that of the latter. But in terms of briquette quality and
Adding water: Water is usually added to thefeedstock to production procedure screw press is definitely superior to the
make them loose and easy to work on.Some biomass materials piston press technology. The central hole incorporated into the
require to be soaked in waterfor a number of days to ensure briquettes produced by a screw extruder helps to achieve
that they are soft enoughto work on. uniform and efficient combustion and, also, these briquettes
can be carbonized. The following table shows a comparison
between Piston press and Screw Extruder.
Compaction & Drying: Finally the feedstock is readyfor
Parameters Piston press Screw Extruder
compaction, either by machine or by hand. Thebriquettes will
need to be left to dry for up to a week.
Optimum moisture 10-15 % 8-9%
content
Wear of contact Low in case of High in case of

parts ram and die screw
Output from the In strokes continuous

machine
Power consumption 1-1.2 gm/cm2 60kw/h ton
Density of briquettes high 1-1.4 gm/cm2

Fig no.2 Types of Biomass Briquettes
Maintainance Not so good low Following Industries Can Make Maximum Use Of
Briquettes:
Combustion Not possible Very good
performance of  Ceramic and Refractory Industry
briquettes  Solvent Extraction Plant
 Chemical Units
Carbonization of Not suitable Makes good  Dyeing Plants
charcoal charcoal charcoal  Milk Plants
 Food Processing Industries
Suitability in non suitable  Vegetable Plants
gasifiers  Spinning Mill
 Lamination Industries
Homoginiety of homogeneous homogeneous
briquettes  Leather Industries
 Brick Making Units
 Other Industries having Thermal Applications
 Gasifires system in Thermal
Table No.2 Comparison between Piston Press and Screw  Textile Units
Extruder.
ADVANTAGES OF USING BRIQUETTES:
TYPES OF BRIQUETTES
 Briquettes can replace conventional fuels like
Briquettes are generally made up from Agriculture and forest Diesel, Kerosene, Furnace oil, Lignite, Coal
waste and used in various Industries. Biomass Briquettes, ,Firewood.
Recycle Briquettes, White coal Briquettes, Saw dust  Environmentally, the use of biomass briquettes
Briquettes, etcIn the below diagram some important and produces much fewer greenhouse gases,
regularly used Briquettes are mentioned. specifically, 13.8% to 41.7% CO2and NOX.
There was also a reduction from 11.1% to 38.5%
in SO.
 Briquettes production is much easier at anywhere
thus it does not requirement of transportation.
 Briquettes give much higher boiler efficiency
because of low moisture and higher density.
 It having higher calorific value, biomass
briquettes on average saved 30–40% of boiler
fuel cost.
 It is cheaper than coal and There is no sulfur in
briquettes, thus does not pollutes the
environment.
ADVANTAGES OF SETTING UP PLANT PROJECT through the boiler, heat from the flue gases is recovered in the
economizer. Since there is no sulphur in the fuel, heat can be
There is no fly ash when burning briquettes. extracted at a much higher extent from hot flue gases. In this
project, two dust settling chambers are provided for burnt
 Briquettes have consistent quality BRIQUETTES, gases treatment:
have high burning efficiency, and are ideally sized for
complete combustion.  One at the exit of the furnace.
 The other, at the economizer
 Compared to fire wood or loose biomass, briquettes
give much higher boiler efficiency because of low This is where dust particles from the flue gases get settled and
moisture and higher density. are removed. GHG Emissions from the boiler after the retrofit
are better than that with RFO firing and also well within
 Briquettes, are easy to store, pack and hygienic to prevailing norms. The technology is safe and environmentally
handle. sustainable. The ash generated during the project activity
because of briquette firing, is collected & drenched with water.
 High sulfur content of oil and coal, when burnt, Wetted ash is then carried away with the help of trolleys &
pollutes the environment. used for land filling in the plant itself.
 Combustion is more uniform compared to coal and In the absence of the project activity, one of the existing RFO
boiler response to changes in steam requirement is fired boiler would have been used for steam generation. In this
faster due to higher quantity of volatile matter in project activity, 8 TPH water tube boiler is retrofitted to
briquettes. facilitate briquette firing and is used for steam generation.
Steam production of briquette-fired boiler is 3.81 TPH.
DISADVANTAGES OF USING BRIQUETTES:
Through this conversion, the boiler efficiency goes down from
 Specific heat at constant volume of briquettes is 79.73% to 75.31% and increases electricity consumption by
comparatively very small with coal. 1.12 KWh/MT of steam generated.
 ATF of biomass briquettes is also very very
small as compared coal. RESULT ANALYSIS
 It results in deaerating.
Switching from RFO to Briquette offers various advantages
CASE STUDY:The Industry had two RFO fired with respect to emissions, safety, and leakage of fuel during
boilers: one of 10 TPH (smoke tube boiler) and transportation and storage, which are as follows:
another of 8 TPH (water tube boiler). RFO is
atomized with air in the RFO burner and fired, which 1. GHG(Green House Gases) emissions are reduced from
produces hot flue gases that pass into the boiler tubes 7,856 to 1,298 tonnes of CO2 equivalent per year. Thus the
to generate steam. Water tube boiler, which otherwise project has the capacity to reduce GHG emissions by 6558
kept as standby is retrofitted to facilitate briquette tonnes of CO2 equivalent per year. In addition to this, SOX&
firing.In future, it is also envisaged that the steam NOX emissions are also reduced significantly. Thus the
generation might be shifted to the existing smoke briquette fuel is environment friendly.
tube boiler, which will be retrofitted to facilitate the
briquette firing. However in that case, total steam 2. During transportation of RFO, losses due to evaporation of
generation from the boiler will be the same as that of fuel are more. Chances of leakage during transportation are
the briquette fired water tube boiler. Change in the also there. In case of Briquette, such losses are not there. Thus
briquette consumption & efficiency of the boiler will the transportation losses are minimized.
be get accounted in the monitoring table.
3. During storage of RFO, if the fuel leaks then there is a
Details of Retrofit Technology: chance of fire hazard. During handling ofBriquette such
situation does not arise. Thus the handling of briquette as fuel
In the project activity, water tube boiler has been retrofitted is also comparatively safe.
with external furnace to facilitate briquette firing. The
technology involves a Retro-fitting operation(RFO) where a
burner and a RFO firing system are removed and replaced by a
hot duct, a biomass based fired furnace, and an induced
draught system. A well insulated extended furnace is
constructed near the boiler to facilitate manual briquette firing.
Briquettes burn over the grate and the hot flue gas resulting at
a temperature of 1300-1400ºC is supplied to the shell side of
the boiler through a connecting duct of 6m long. Here the
water is passed through the tubes of the boiler. After going
 Yugo Isobe, Kimiko Yamada, Qingyue Wang, Kazuhiko
Sakamoto, Iwao Uchiyama, TsuguoMizoguchi and Yanrong Zhou.
"Measurement of Indoor Sulfur Dioxide Emission from Coal–
Biomass Briquettes." springerlink.com. Web. 30 November 2010.
Fig. No.3 Arrangement of the Retrofit External Furnace
CONCLUSION:
Biomass briquette is the best alternative for the coal and

charcoal. Biomass briquettes it gives two advantages first is it
reuses the agriculture waste which is abundant in agriculture
fields and another one that it is environment friendly. Also it is
used in lot of Industries. In case Study we seen that if we use
the retrofitting of Briquette to the RFO Boiler it produce
tremendous change in GHG, CO2, SOX&NOX emissions per
year. Therefore in India, the Indian Renewable Energy
Development Agency (IREDA) promoting the utilization of
Biomass Briquettes.
REFRENCES:
 Clean development mechanism project design document form .

Version 03 - in effect as of: 22 December 2006
 Ghosh, K.P (2002),Converting Biomass. The Statesman March 5th
2002.
http://search.proquest.com/docview/284145740?accountid=38885
retrieved on 29.09.11
 Grover P. D. & Mishra S. K (1996), “Biomass briquetting:
Technology and Practices”, Food and Agriculture Organization of
the United Nations Bangkok, April 1996, Field Document No.4
 "Biomass Briquetting: Technology and Practices - Introduction."
Centre for Ecological Sciences INDIAN INSTITUTE OF
SCIENCE BANGALORE. Web. 04 Dec. 2010.
 PRABIR, B. and BUTLER, J. and LEON, M., "Biomass co-firing
options on the emission reduction and electricity generation costs
in coal-fired power plants", Renewable Energy, 36 (2011).
 "Biomass Briquettes for Green Electricity Production."
Bionomicfuel.com. 4 May 2009. Web. 30 Nov. 2010. .
 Mani, Sokhansanj, and L.G. Tabil. "Evaluation of compaction
equations applied to four biomass species." University of
Saskatchewan College of Engineering. Web. 30 Nov. 2010.
 Ramesh Man Singh. "History of Bio-Briquetting." brgcnn.net.
2008. Web. 30 November 2010.
 "Biomass Briquette." Www.gcmachines.com. Web. 30 Nov. 2010.
DEVELOPMENT AND FABRICATION OF
MULTI-NOZZLE PESTICIDES SPRAYING
PUMP
Mr.Akshay Shende1 Mr.NitinGokhe, Mr.AvinashRamteke
U.G. Student, T.G.P.C.E.T. U.G. Student, T.G.P.C.E.T. U.G. Student, T.G.P.C.E.T.
Nagpur, India Nagpur, India Nagpur, India
Prof.HarshwardhanMahawadiw
ar
Faculty, T.G.P.C.E.T. Nagpur,
India
ABSTRACT
India is a land of agriculture which comprises of small, 19.8 percentage, for medium farmers 14 percentage and for
marginal, medium and rich farmers. Small scale farmers are large farmers 4.5 percentage in year 1960-61.Table 1 clearly
very interested in manually lever operated knapsack sprayer explain that the maximum percentage of farm distribution
because of its versatility, cost and design. But this sprayer has belonged to small and marginal category..
certain limitations like it cannot maintain required pressure; it
In India about 73% of population is directly or
lead to problem of back pain. However this equipment can also
lead to misapplication of chemicals and ineffective control of indirectly depends upon the farming. Hence it is said that
target pest which leads to z cause environmental pollution and India is an agricultural based country. But till now our
imbalance in natural echo system. This paper suggests a model farmers are doing farming in same traditional ways. They
of manually operated multi nozzle pesticides sprayer pump are doing seed sowing, fertilizers and pesticides spraying,
which will perform spraying at maximum rate in minimum cultivating by conventional methods. There is need of
time. Constant flow valves can be applied at nozzle to have development in this sector and most commonly on fertilizers
uniform nozzle pressure. pesticides spraying technique, because it requires more
efforts and time to spray by traditional way.
Key words: Mechanization, spraying time, pesticides sprayer
and organic fertilizer
Most of Asian nations are at developing stage and they are
facing the problem of high population and as compared to
that agricultural productivity is much lower as compared to
INTRODUCTION developed nations. India is one of the nations who is facing
the same problem. This is caused due to low level farms,
Agriculture plays a vital role in Indian economy. insufficient power availability to farms and poor level of
Around 65% of population in the state is depending on farm mechanization.
agriculture. Although its contribution to GDP is now around In order to meet the requirement of food of
one sixth, it provides 56% of Indian work force [10]. Table growing population and rapid industrialization, there is a
1 shows that share of marginal and small farmer is around need of the modernization of agriculture sector. On many
81% and land operated is 44 % in 1960-61. As far as Indian farms production suffers because, delay in sowing, improper
scenario is concerned, more than 75 percent farmers are distribution suffer because delay in sowing, improper
belonging to small and marginal land carrying and cotton is distribution of pesticides and fertilizers, harvesting.
alone which provide about 80 % employment to Indian Mechanization solves all the problems which are
workforce. So any improvement in the productivity related responsible for low production. It conserves the input and
task help to increase Indian farmer’s status and economy. precision in work and get better and equal distribution. It
The current backpack sprayer has lot of limitation and it reduces quantity needed for better response, prevent the
required more energy to operate. The percentage distribution losses and wastage of input applied. It get high productivity
of farm holding land for marginal farmers is 39.1 so that cost of production will reduced.
percentage, for small farmers 22.6 percentage, for small and To reach the requirement of production Agriculture
marginal farmers 61.7 percentage, for semi-medium farmers implement and machinery program of the government take
steps to increase availability of implement, pumps, tractors, Special emphasis was laid on the later as more than65
power tillers, harvester and other power operated machines.
LITERATUREREVIEWS
A. Spraying Methods: liquid chemical carrier, such as fertilizer) and chemical into
One of the more common forms of pesticides droplets, which can be large rain type drops or tiny almost
application, especially in conventional agriculture is the use invisible particles. The size of droplets can be altered
of mechanical sprayers. Hydraulic sprayers consists of a through the use of different nozzle sizes, or by altering the
tank, a pump,lance(for single nozzle) or boom and a nozzle pressure under which it is forced. Large droplets have
(or multiple nozzles).sprayers convert a pesticides advantage of being less susceptible to spray drift, but
formulation, often containing a mixture of water( or another require more water per unit of land covered.
Large size droplets are advantages in being less drift while
1) Backpack (Knapsack) Sprayer: spraying but there is wastage of pesticides in this method.
the main principle use in spraying with knapsack type of The smaller size droplet is more evenly sprayed. The main
sprayer is pressure difference created by hand operated demerit of back pack sprayer is that the labour has to carry
lever. It has usually single nozzle through which liquid nearly 5 gallon capacity on his back which cause severe
pesticides is forced to come out of the nozzle in fine droplet back pain and cause fatigue to labour.
form. Some sprayers can generate pressure of 7kg/ cm2. 2) Hydraulic Sprayer:
Capacity are usually less than 20 liter or less. Most of the world’s pesticides are mixed with water and
The main components of hydraulic sprayer are tank, pump, sprayed through hydraulic nozzle: of one short of another.
lance, boon and a nozzle. Sprayers convert the pesticides There are enormous variation in the scale, the way pumping
into small droplets which can vary according to pressure & is achieved and the configuration of atomizer, this >100
size of perforation of the nozzle. year old technology is still considered the method of choice
by farmers and other spray operators.
3) Large –Scale Tractor Mounted & Self Propelled

Equipment Or Lite-Trac:
In this the motorized technique of spraying the pesticides in Sr. no. Types of Area for Time
which “lite-tractor” is used. The lite- trac name comes from sprayer which required
“lite tractor” due to patented chassis design, facilitating the spraying
naturally leaving machines manufactured by company to is used
have a light footprint for minimal soil compression. Lite- 1 Bullock Larger Less time and
Trac is currently the European largest manufacturer of four driven area effort
wheeled.spraying tractor for crops. The stainless steel can
accommodate around 8000 liters of pesticides for spraying
so no need of frequent refilling. But main drawback is its 2 Hand Smaller Larger time
high cost which small or medium scale farmer in India can’t driven area and effort
bear. So we have designed a less expensive device for
spraying of both organic pesticides and fertilizer for small
scale farmers.
Table1: Existing high features of sprayer
DESIGN REQUIREMET
B. Providing Alternative to Small Farmers:
A. Shortcoming in Existing Sprayer Pumps: the backpack(Knap-sack) sprayer for spraying pesticides by
The normally used spraying pump by farmers in India the farmer cost around Rs. 2000-4500 and for rich farmers
(small, marginal or medium) is the back pack sprayer. The there are lite-Trac available ch are beneficial for larger land
main limitation of using it is that of its small capacity and a but it cost more which the small farmers can’t bear.
carrying it on back cause back pain and continuous lever
So, we have proposed an organic fertilizer cum pesticides
movement for pressure generation can cause muscular sprayer device for convenience of the farmer. Which can be
disorder. Developing adequate pressure is a laborious and hand driven or bullock driven. The cost may be around Rs.
tedious and time consuming process. It takes longer time to 25000/- but it would be one time investment for the farmers
spray the entire land due to frequent refilling it because it for higher productivity of crops.
has small capacity of 10-15 liter tank
Sr. Name of Distance Height of 3) The c.f. valves can also be applied which help in reducing
no. crop between( crop(mm) the change of pressure fluctuation and c.f. Valves helps to
mm) maintain pressure.
1 cotton 600-900 600-1500 4) Proper adjustment facility in the model with respect to
2 groundnut 400-500 400-450 crop helps to avoid excessive use of pesticides which result
3 Pigeon pea 400-500 250-300 into less pollution.
4 Sugarcane 400-500 1600- 5) Imported hollow cone nozzles should be used in the field
2100 for better performance.
6) Muscular problems are removed and there is no need to
working of this manually operated organic fertilizers cum operate the lever.
pesticides sprayer is based on the principles of motion of 7) This alone pump can used for multiple crops
trolley which transmit its rotary motion from slider crank
mechanism arrangement and reciprocating piston into the REFERENCES
cylinder for pumping the pesticides. When the operator
pushes the trolley forward, the wheel rotates in counter [1] Application technology: Problems and opportunities with Knapsack
sprayer, Including the cf valves or Constant Flow Valves.-David McAuliffe
clockwise direction hence slider move in counter clockwise and Vanessa P. Gray
which is attached to crank shaft. This motion is transfer [2] Journal of arboriculture weed control in landscape plantings1 by J.F.
through slider crank to disc, it rotates in counter clockwise Ahrens April 1981 vol. 7, no. 4.
direction. Its motion rotates the disk on which there is a [3]I.Daut, N.Gomesh, M.Irwanto, Y.M. Irwan, “Energy Saving Suction
Hood” World Academy of Science, Engineeering and Technology 6 jan
linkpresentwhich move reciprocating motion.the piston or 2012, Pages 612-616.
plunger also move in reciprocating motion, hence spray the [4] BhubaneswariParida, S. Iniyan, rankoGoic, “A review of solar
pesticides through the nozzle. photovoltaic technlogies” Renewable and Sustainable Energy Reviews,
Volume 15, Issue 3, April 2011, Pages 1625-1636.
CONCLUSION [5]Maharashtra progressive Agriculture –A new Horizon- confederation
of Indian Industry.
1)The suggested model has removed the problem of back [6]Modification of a knapsack for more efficient use j. Founk.
[7]Eco-friendly Mechanically operated multipurpose spray pump,by-
pain, since there is no need to carry the tank (pesticides prof.SwapnilKolhe of NileshGajbhiye
tank) on the back.
2) as suggested model has more number of nozzles which
will cover maximum area of spraying in minimum time & at
maximum rate.
DEVELOPMENT AND FABRICATION OF
MULTI-NOZZLE PESTICIDES SPRAYING
PUMP
Mr. Ajay Rathod Mr.Arun Chavan prof. Harshwardhan
U.G. Student, Department U.G. Student, Department of Mahawadiwar
4
ofMechanical engineering Mechanical engineering Assistant professor,
4
T.G.P.C.E.T. Nagpur, India T.G.P.C.E.T. Nagpur, India Department of Mechanical
engineering T.G.P.C.E.T
Mr.Dhiraj Bramhane ,Nagpur, India
U.G. Student, 4Department of
Mechanical engineering
T.G.P.C.E.T. , Nagpur, India
ABSTRACT the reason in less yield of crops in improper seed bed,

preparation and late sowing, harvesting and threshing.
As the world’s population increases and the diets of Mechanization will improve the circumstance through
the developing world continue to improve, demand for meat definiteness in metering ensuring more appropriate
and crops means food production could need to increase by up
distribution lessening quantity needed for better prevention
to 70% by 2050. Fertilizers will undoubtedly play a major role
in this production uplift. The mechanization process may of wastage of fertilizer and pesticides.Mechanization helps
helpful in yields of crop, small scale farmers are aiming for less in giving higher productivity through less effort. Most
investment in form of backpack type sprayer’s but it may farmer are acapital thus, there is an apportunity to suggest
causes mainly back pain and muscular disorder so to avoid all on inexpensive mechanical sprayer for organic pesticides
these demerit we have propose sprayer of fertilizer and which can be easily mobile and carry large capacity tank so
pesticides which can simply be pulled by hand. This paper no need of frequent refilling the traditional backpack.
suggest a model of manually operated multi-nozzle pesticide
sprayer. This will perform spraying at maximum rate in LITERATUREREVIEW
minimum time and optimum utilization of organic pesticides
and evenly distributing it. In another tank there is of organic A. Spraying Methods:
fertilizer and two knob arrangement for flow of liquid fertilizer
which flows with gravity force, constant flow, valve can be One of the more common forms of pesticides application,
provided at nozzle to have control the flow of fertilizer.
especially in conventional agriculture is the use of
Keywords: Mechanization, spraying time, pesticides sprayer mechanical sprayers. Hydraulic sprayers consists of a tank, a
and organic fertilizer pump,lance(for single nozzle) or boom and a nozzle (or
multiple nozzles).sprayers convert a pesticides formulation,
INTRODUCTION often containing a mixture of water( or another liquid
chemical carrier, such as fertilizer) and chemical into
India is agricultural country, most of people in India are droplets, which can be large rain type drops or tiny almost
farmer and they lives in villages, so we have made suitable invisible particles. The size of droplets can be altered
pump for the farmer. Because they have used harmful and through the use of different nozzle sizes, or by altering the
expensive fertilizer and pesticides, there is need for pressure under which it is forced. Large droplets have
improvement in farming procedure and used of cheep and advantage of being less susceptible to spray drift, but
beneficial equipment for effective spraying and weeding for require more water per unit of land covered.
increase in productivity. Insects are largely responsible for
crop destruction and for curing we use chemical fertilizer 1. Hand driven sprayer:
and pesticides which causes adverse effect on our health.
Insecticides preparation is used to kill insects otherwise we Hand driven pumps consist of a flexible diaphragm made of
can control their reproduction. These are sprayed on the synthetic rubber connected to the pump handle by a
crops by devices known as sprayer. For small farmer one of crankshaft mechanism, a rigid diaphragm chamber and
either flat or ball-type inlet and outlet valves. The outlet
valve is connected to a pressure chamber, which in many
hand driven pump sprayers has a variable pressure setting
Sr. Name of Distance Height of
valve. These pumps typically operate between pressures of 1
no. crop between( crop(mm)
and 3 bar (15-44 psi) and it is suitable for
mm)
herbicideapplication where large droplets are required to
minimize spray-drift.
1 cotton 600-900 600-1500
2) Hydraulic Sprayer:
Most of the world’s pesticides are mixed with water and 2 groundnut 400-500 400-450
sprayed through hydraulic nozzle: of one short of another.
There are enormous variation in the scale, the way pumping
is achieved and the configuration of atomizer, this >100 3 Pigeon pea 400-500 250-300
year old technology is still considered the method of choice
by farmers and other spray operator.
4 Sugarcane 400-500 1600-2100
3. Fuel Operated Sprayer:
The power sprayer consists of an integrated or external Sr. no. Types of Area for Time
spray tank; a high pressure piston pump usually powered by sprayer which required
a petrol engine a pressure regulating valve and a hose of up spraying
to 50 m of length. Spray tanks are too big to be carried as a is used
knapsack. The power sprayer is produced in a number of
versions. Most simple and common is an Engine driven
pump mounted on a frame. 1 Bullock Larger Less time
driven area and effort
DESIGN REQUIREMET
A. Shortcoming in Existing Sprayer Pumps: 2 Hand Smaller Larger time

driven area
The normally used spraying pump by farmers in India and effort
(small, marginal or medium) is the back pack sprayer. The
main limitation of using it is that of its small capacity and
carrying it on back cause back pain and continuous lever
movement for pressure generation can cause muscular Table1: Existing spraying methods
disorder. Developing adequate pressure is a laborious and
tedious and time consuming process. It takes longer time to Table2: distance between and height of crops
spray the entire land due to frequent refilling it because it
has small capacity of 10-15 liter tank. WORKING
B. Providing Alternative to Small Farmers: The working of this manually operated organic fertilizers
cum pesticides sprayer is based on the principles of motion
the backpack(Knap-sack) sprayer for spraying pesticides by of trolley which transmit its rotary motion from slider crank
the farmer cost around Rs. 2000-4500 and for rich farmers mechanism arrangement and reciprocating piston into the
there are lite-Trac available ch are beneficial for larger land cylinder for pumping the pesticides. When the operator
a but it cost more which the small farmers can’t bear. So, we pushes the trolley forward, the wheel rotates in counter
have proposed an organic fertilizer cum pesticides sprayer clockwise direction hence slider move in counter clockwise
device for the convenience of the farmer. Which can be which is attached to crank shaft. This motion is transfer
hand driven or bullock driven. The cost may be around Rs. through slider crank to disc, it rotates in counter clockwise
25000/- but it would be one time investment for the farmers direction. Its motion rotates the disk on which there is a
for higher productivity of crops. linkpresentwhich move reciprocating motion.the piston or
plunger also move in reciprocating motion, hence spray the
pesticides through the nozzle
CONCLUSION
1)The suggested model has removed the problem of back

pain, since there is no need to carry the tank (pesticides
tank) on the back.
2) as suggested model has more number of nozzles which
will cover maximum area of spraying in minimum time & at
maximum rate.
3) The c.f. valves can also be applied which help in reducing

the change of pressure fluctuation and c.f. Valves helps to
maintain pressure.
4) Proper adjustment facility in the model with respect to

crop helps to avoid excessive use of pesticides which result
into less pollution.
5) Imported hollow cone nozzles should be used in the field

for better performance.
6) Muscular problems are removed and there is no need to

operate the lever.
7) This alone pump can used for multiple crops
REFERENCES
[1] Application technology: Problems and opportunities with Knapsack
sprayer, Including the cf valves or Constant Flow Valves.-David McAuliffe
and Vanessa P. Gray
[2] Journal of arboriculture weed control in landscape plantings1 by J.F.

Ahrens April 1981 vol. 7, no. 4.
[3]I.Daut, N.Gomesh, M.Irwanto, Y.M. Irwan, “Energy Saving Suction

Hood” World Academy of Science, Engineeering and Technology 6 jan
2012, Pages 612-616.
[4] BhubaneswariParida, S. Iniyan, rankoGoic, “A review of solar

photovoltaic technlogies” Renewable and Sustainable Energy Reviews,
Volume 15, Issue 3, April 2011, Pages 1625-1636.
[5]Maharashtra progressive Agriculture –A new Horizon- confederation

of Indian Industry.
[6]Modification of a knapsack for more efficient use j. Founk.
[7]Eco-friendly Mechanically operated multipurpose spray pump,by-

prof.SwapnilKolhe,prof.NileshGajbhiye
Digital Human Modeling an Aid For Ergonomic
Evaluation
Mrs.Anjali Kadam Dr.G.K.Awari
Asst.Professor,Mechanical Engineering Principal,
Priyadarshini J.L.College of Engineering, Tulsiramji Gaikwad-Patil College of Engg & Tech.,
Nagpur,India [email protected] Nagpur,India
Abstract— over the last few years there has been a massive capabilities and limitations [2]. Traditional ergonomic
development and use of information technology. These evaluation methods for studying human performance and
technologies are probably the only answer to success in a highly productivity, involves physical mock ups and trial with real
globalized and turbulent market environment. The development human beings are found to be time consuming and quite
of computer and communication technology enables that the expensive. As computer technology has become advanced and
methods of engineering work can be changed from scratch. This affordable, spreading its tentacles in each and every scientific
trend in digitalization has an effect on ergonomics. Digital discipline(s), ergonomics proved to be no exception [3].
Human Modeling is the state of the art technology for virtual
ergonomic evaluation of products and workstations. Ergonomic
evaluations using Digital Mock-up and Digital Human Models
which are computer generated two dimensional or three
II. IMPORTANCE OF DHM
dimensional structure of a human representing the complex
physical and cognitive aspects of human beings are economical in
A. Ergonomics and musculoskeletal disorders (MSDs)
the long run when compared with traditional ergonomic Ergonomics is the science of fitting jobs to people. The
evaluation process in a typical product or process development discipline encompasses a body of knowledge about physical
sequences Traditional ergonomic evaluation methods for
studying human performance and productivity, involves physical
abilities and limitations as well as other human characteristics
mock ups and trial with real human beings are found to be time that are relevant to job design. Essentially ergonomics is the
consuming and quite expensive. This paper reviews the literature relationship between the worker and the job and focuses on
of Digital Human Modeling and provides overview of up-to-date the design of work areas to enhance job performance.
research in virtual ergonomics evaluation technology through Ergonomics can help prevent injuries and limit secondary
DHM. An Attempt has also been made to highlight future injuries as well as accommodate individuals with various
research direction in many areas disabilities; including those with musculoskeletal disorders
(MSDs).Disorders Musculoskeletal of the system that is
Keywords—digital human modelingt; ergonomic caused precipitated or aggravated by repeated exertions or
evaluation;simulation
movements of the body. MSDs are caused from wear and tear
on tendons, muscles, and sensitive nerve tissue caused by
I. Introduction continuous use or pressure over an extended period of time
[4]. Through ergonomic assessment and related interventions
Ergonomics is according to IEA (International Ergonomics not only the WMSDs risk factors will be explored but also
Association,2000) defined as a scientific discipline concerned some practical ways for the prevention of awkward postures
with the understanding of interactions among human and other are introduced. According to WHO (1985), there are some
elements of a system, and the profession that applies theory,
factors that create or aggravate work-related disorders, such as
principles, data and methods to design in order to optimize
human well-being and overall system performance[1]. work demands, social and cultural factors, work place
Ergonomics promotes a holistic approach in which characteristics, and environmental factors. In this respect, as
considerations of physical, cognitive, social, organizational, ergonomics covers all of the mentioned farms, it has an
environmental and other relevant factors are taken into important role in occupational health [5].
account. Physical ergonomics is concerned with human B. Digital human modeling
anatomical, anthropometric, physiological and biomechanical
characteristics as they relate to physical activity. Applying a The development of computer and communication
scientific, evidence-based approach to ergonomics process is technology enables that the methods of engineering work can
important with the goal to identify ergonomic risk factors, be changed from scratch. This trend in digitalization has an
quantify then, and then make measurable improvements to the effect on ergonomics [6]. As computer technology has become
workplace, ensuring that jobs and tasks are within workers’ advanced and affordable, spreading its tentacles in each and
every scientific discipline(s), ergonomics proved to be no Quantitative evaluation tools
exception. In today’s scenario, Digital Human Modeling Metabolic Energy characterizes the requirements of tasks in
(DHM) is fast becoming an integral part of Computer Aided Expenditure (MEE) terms of metabolic energy expenditure.
Ergonomics (CAE). It is the state of the art technology for assesses tasks that require carrying, lifting,
Manual Handling lowering, pushing or pulling in relation to the
virtual ergonomic evaluation of products and workstations. Limits (MHL) percentage of working population able to
Simulations/ergonomic evaluations using Digital Mock-up and execute the tasks.
Digital Human Models (computer generated two dimensional determines whether, after each task, there is
or three dimensional structure of a human representing the Fatigue Analysis an adequate recovery time able to avoid
complex physical and cognitive aspects of human beings) are (FA) excessive physical fatigue for the worker.
economical in the long run when compared with traditional
Ovako Working
ergonomic evaluation process in a typical product/process estimates the possible discomfort related to
development sequences. Repeated trials which were otherwise Posture Analysis
the posture taken by the worker.
not easily possible in traditional ergonomic investigations are (OWAS)
predicts the maximum acceptable force that a
now achievable due to virtual simulations using DHMs [7]. Force Solver (FS) human could exert under the prescribed
DHM can be used advantageously to a great extent in conditions.
developing countries for variety of applications and its diverse
scope of application is yet to be explored to its full potential
Fig. 1. Quantitative evaluation tools
Further it is deemed important to highlight that traditional
ergonomic evaluation techniques based on trial and error  Semi-quantitative tools
method using physical mock-ups and real human, has proved Semi-quantitative tools are used to visualize or analyze the
to be time consuming, costly and mostly overlook manikin’s interaction with the environment. Examples of such
anthropometric and biomechanical aspects involved in tools are Eye View (EV), View Cones (VC), Reach Zones
performing tasks [8]. Virtual evaluations of a CAD product (RZ), Collision Detection (CD), and Foot Prints (FP).
with digital manikins have the potential to overcome known  Tools for discomfort, anthropometry, human
drawbacks of traditional ergonomic evaluation methods [9]. Anthropometry, human performance, and cognition are used
As a technology, digital human modeling (DHM) which has
for many applications, such as to support vehicle interior
always been at the forefront of ergonomic research is being
design or to create manikins with specific anthropometric
propelled at an unprecedented tempo in the digital age by the
measurements [11].
advancement of computer technology. DHM is a means to
create, manipulate, and control human representations and
human–machine system scenes on computers for interactive III. APPLICATION OF DHM
ergonomics and design problem solving. Throughout the globe, diverse industrial sectors are
harnessing benefits of DHM applications. Some of them
C. Digital human modeling:evaluation tools include automobile, aviation and aerospace, defense research,
Digital Evaluation tools could be divided in three groups: healthcare, general industrial applications, clothing and textile,
 Quantitative evaluation tools service and animation, agricultural division, product design
 and applications of DHM technology in reference to various
  Semi-quantitative tools industrial sectors and also manufacturing shop-floor [3]. In
 Tools for discomfort, anthropometry, human India, available literatures indicate that DHMS are being used
Anthropometry, human performance, and cognition in diverse application fields by Indian engineers, designers and
Quantitative tools are used to evaluate working postures and people from other professions.
physical workloads, considering specific risk factors related to
a single posture/movement or to a complete task [10].  Automobile Sector
DHM has ability to improve efficiency and ergonomics of
TABLE I. assembly operations using participatory ergonomic approach.
It is capable to optimize comfort, reach, fit, and vision for
Quantitative evaluation tools user/occupant [12] and thus improve vehicle design in
Lower Back determines the forces acting on the low back accordance with sound ergonomic principles [13]. DHM is
Analysis (LBA) by evaluating postures and load conditions.
estimates the percentage of the working
helpful in achieving quicker and cost effective design process
Static Strength as this software can be used in design, modification,
population able to perform (in terms of
Prediction (SSP) visualization, analysis of workplace layouts/product
muscular static strength) a task.
calculates a recommended weight limit and a interactions in automobile industry and has potential to be
lifting index for a given manual used in operator training [14]. Mueller and Maier[15] stated
NIOSH
lifting/lowering action or an overall index in that user centered vehicle layout can be generated
the case of multiple tasks. systematically from ergonomic point of view using DHMs
quantifies the time required to perform a task giving due consideration to trunk loading and unloading
Predetermined Time
Standards (PTS)
by dividing it into a set of elementary movements.
movements.
identifies the manual tasks, mainly of
handling of low loads at high frequency,  Aviation and Aerospace Technology
Rapid Upper Limb which expose workers to increased risk of “Open Skies” policy of various Governments across world has
Assessment RULA) upper limb disorders, taking into account led to the foray of many companies in this sector resulting
posture, muscular strain, weight, duration and
frequency of the tasks increased air travel. DHM is now playing a significant role in
this sector to improve passenger amenities and will be sought in computer-aided design of human- machine systems for
after by aeronautic industries. These software are being used simulating man-machine interactions in virtual environment as
in assessing comfort of airplane passenger seats from user’s real-world conditions. Application of DHM is becoming
perspective [16]. Manikins can be accurately positioned for increasingly popular today among designers and manufactures
accommodation related investigations in cockpit design [17]. as it increases productivity, reduces design time-frame and
Fighter aircraft pilots are required to make split second decreases associated costs. Core functionality of DHM
decisions in real battlefield situations based on visual inputs software is realistic display of anthropometric data and
from cockpit displays/instrumentation. Presence of displays in efficient analysis of ergonomic questions concerning sight,
blind spot regions can prove to be fatal. DHM can be maximum force, reach ability and comfort. Designers can
productively used to perform vision analysis for pilots in a jet subsequently utilize a human model in the creation,
aircraft as shown in a case study [18]. modification, presentation and analysis to ensure enough
clearance and space to human for their ease and comfortable
 Defense Research movement within workplace [26].
Differently built human models representing diverse
anthropometry of army personnel are used to evaluate their
workstations easily [19]. Manikins can be accurately positioned IV. DISCUSSION aND conclusion
for accommodation related investigations in cockpit design [16].
Fighter aircraft pilots are required to make split second decisions DHM software are now successfully being used in
in real battlefield situations based on visual inputs from cockpit various sectors including military research .automobile sector,
displays/instrumentation. Presence of displays in blind spot aerospace and aviation technology ,industrial applications ,
health care and occupational safety , service industry etc.
regions can prove to be fatal. DHM can be productively used to
DHM tools provide complete digital humans to explore
perform vision analysis for pilots in a jet aircraft as shown in a infinite number of ergonomic scenarios including human size
case study [18]. scaling, evaluation of posture, motion, reach, and vision
within a computer-rendered environment. It is expected that
 Healthcare Industry present review on DHM an aid for ergonomic evaluation
Simulation using DHM with respect to ladder climbing would deliver a concrete knowledge. Adoption of DHM looks
scenario for an under-knee amputee was performed with an very promising in near future.
aim to design comfortable limb prosthesis for complex
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[19]
A
Review on Study of Saw Gin Stand for Improving
the Ginning Process
Nikhil H. Patil Sharad S. Chaudhari
Department of Mechanical Engineering Department of Mechanical Engineering
YeshwantraoChavan College of YeshwantraoChavan College of
Egineering Nagpur, MH, India Engineering Nagpur, MH, India
Abstract: Ginning is the first effective process of separating the Cottonseed are sold to dairies for feed, to oil mills for
seeds from cotton.Harvested cotton is taken to ginning mills where production of many valuable products, or saved for planting
it is separated from seeds. Cotton fiber quality is mainly dependent next year‟s crop. The fibers are the more valuable product,
on ginning processes. In India, roller and saw ginning technologies however, and the design and operation of cotton gins are
are used.Nowadays it is necessary to improve these technologies for oriented toward fiber production. In essence, the modern
increasing the outturn and to preserve the quality of fiber as cotton cotton gin enhances the value of the cotton by separating the
sector in India is progressing with high speed .In India
fibers from the seed and by removing objectionable non-fiber
matter, while preserving as nearly as possible the inherent
comparatively very less research has been done in saw ginning. qualities of the fiber.
This review paper includes the present scenario of ginning
technologies used in India. This article focuses more light on the The earliest gin was probably invented in the days when price
saw gin stand component and parameter study which should be of animal skin in market became so great that it was necessary
considered during investigation process. . This article suggests the to look for a cheaper substitute for clothes. The „charkha‟ is
new possible developments in saw gin stand used in India. an early gin. It consists of two plain rollers mounted on a
frame & revolved in contact.
Keywords– Cotton; Ginning; Ginning technologies; saw gin stand.
In northern and central region of India the saw gin which Eli
1. Introduction Whitney invented in 1794 is still used to gin cotton. This
cotton gin is a perfect machine invented by the inventor. Very
Ginning is the first mechanical process involved in the cotton little evolution has been done to change its three essential
processing. Ginning mill separates cotton fiber from seeds and elements, the saws, ribs and brush. There is no any machine
dust particles. The primary function of the ginning mill is to invented till today which can excel saw gin in capacity. It was
separate fiber from seed. The main application of ginned found that fibers of cotton were injured by saw action then the
cotton is for spinning operations. The ginned cotton is also McCarthy roller gin was introduced.
called as lint and the lint is converted to yarn. As fibers are
2 Present Scenario:
attached to seed, the harvested cotton can be referred to as
seed cotton. Ginning process mainly removes seeds along 2.1 Ginning technologies
with cleaning of fiber.
In olden days, the charkha was used for cotton ginning
According to Roy V. Baker,(ARS-USDA Lubbock Texas), process. Then it was upgraded to single crank charkha
“The principal function of a cotton gin is to convert the consisted of one serrated steel roller and one wooden roller
farmers‟ harvested seed cotton into salable commodities, i.e., along with crank and flywheel. With the development of roller
fiber and seed. Thus, ginning is the bridge between cotton and saw gin, history of cotton ginning changed completely.
production and cotton textile manufacturing. To satisfactorily Basically there are two methods employed for cotton ginning
convert today‟s mechanically harvested cotton into salable process. In first the fibers are held firmly by external
commodities, gins have to dry and clean the seed cotton, mechanism and simultaneously seed itself is being hit to
separate the fibers from the seed, further clean the fibers and separate fibers from seed. In second fibers are pulled from
place the fibers into an acceptable package for commerce.
seed which is held firmly. First principle is used in roller gin 2.3 Saw ginning
while latter one is used in saw gin.
Saw gin belongs to second generation tool invented by Eli
Whitney in 1794 in USA. It consists of series of circular saws
305 to 407 mm in diameter. All saws which are mounted on an
axle are made to revolve at high speed to tear lint from seed
cotton. The saw projects slightly between the bars referred as
ribs. These ribs are spaced such that they prevents the seeds
from going forward. These ribs are also called as ginning ribs.
Thus fibers are separated from seeds at high speed. The seed
cotton is fed continuously into hopper. The seedsfall through a
grid onto seed conveyor. The lint is whipped off the teeth of
sawa by an air blast or rotating high speed brushes.
Fig 1: Ginning Technologies

2.2 Roller ginning
In this the roller are provided which carry the seed cotton to a
stationary knife and rotary or reciprocating knife. In this
process cotton fibers are separated from seeds by adhering to
roller surface. This surface (leather or any suitable material)
holds the cotton fiber on surface and carries it between
stationary knife and roller so that fibers are partially gripped
between them. Fibers are separated by stretching action as
oscillating or rotary knife beats the seeds. This process is Fig. 3: Saw gin[1]
repeated and fibers are separated from seed due to push-pull-
hit action. This process is gentle and produces less short fiber The Saw Ginning Technology is normally used for short and
content, fewer neps. Less qualified and experienced workers medium staple cotton i.e. up to 28 mm and the plant designs
can work on roller gin. Maintenance of roller gin is easy but developed so far in the world is keeping in view the machine
sometimes more costly (roller replacement). Quality of lint picked cotton with higher trash contents and most of the
and seeds produced is better than the saw ginning. cleaning equipments and feeders to the gins have been
designed to handle high trash cotton however the fibre
parameters get deteriorated in terms of neps, length and
spinability parameters more particularly when any long or
extra longfibre is ginned on Saw Gin.
3 Saw gin stand
The gin stand consists of a set of saws rotating between

ginning ribs. The saw teeth pass between the ribs at ginning
point. Here the leading edge of the teeth is approximately
parallel to rib to pull the fibers from seed rather than cutting
them. In traditional gin stand, there is a huller front from
where cotton enters the stand. The rotating saws grasp the
cotton and draw it through a widely spaced set of ribs known
Fig. 2 : Roller gin[1]
as “huller ribs”. This causes hulls and sticks to fall out of the
machine. The locks of cotton are drawn into the bottom of roll new varieties. These smaller cottonseeds are looked upon as a
box through the huller ribs. challenge for ginners. These smaller seeds affect the quality of
lint produced. The quality parameters of lint produced
deteriorates due to entry of seeds along with cotton. So, it is
important factor in preserving quality of lint. Also its
alignment with saws is a measure aspect. The alignment
should be such that it should not touch the saw which may
lead to damage of either. Ginning rib also plays important in
seed discharge.
Fig 4: Gin stand of saw ginning machine without huller

front[2]
In newer gin stand, there is no provision of huller front. The

seed cotton drop directly into the roll box. Because of this Fig 5: Ginning ribs
elimination of huller front, stand capacity increases but the
final stage of seed cotton cleaning is eliminated. The actual 4.2 Gin saws
separation of seed and cotton takes place in roll box. After
separation seeds fall along the ginning rib onto the seed The gin saws are steel discs rotating on axle to tear lint from
conveyor under the stand. Rotating brush or an air blast is seed cotton. These saws have number of teeth which directly
provided to remove lint from rotating saws. It is then affect the ginning and quality of lint produced. Saws are
conveyed to next machine for further processing. rotating with high speed. Numbers of teeth on saw, diameter
of saw, saw tooth design are important parameters in
4 Saw gin stand- components and their parameter study performance gin stand.
Gin stand is the heart of ginning process where actual

separation of lint and seed takes place. The performance of
ginning machine mainly depends on the gin stand
performance. Three essential elements of gin stand are
ginning ribs, saws and brush. These components are mainly
responsible for ginning process. The combination and setting
of ginning ribs and saws affect the quality of lint and
discharge of seeds.
4.1 Ginning ribs
Ginning ribs are important. The crucial aspect is its alignment

in the machine. They should be fitted in level with a space of
2 mm between each other as it avoids cut seed coming in lint. Fig 6: Gin saw
The major concern for ginners at the present is the gradual
progression of smaller cottonseeds through the introduction of 4.3 Frictional forces in roll box
The roll box of the gin stand is subjected to friction as a result mm. This reduction in diameter reduces the ginning capacity
of force applied to the stainless steel casing by the seed of the gin stand.
cotton. Friction is an important aspect of the workings of the 4.6 Rib spacing
seed roll and the ginning process. As the mass of seed cotton It is the important parameter as far as the quality of lint
increases within the roll box, the density increases. With the produced at gin stand is concerned. Rib spacing is that portion
increase in density comes an increase in forces that are in which saws are to be placed. It is also responsible for the
applied to the surfaces within the roll box. These surfaces progression of smaller cottonseed along the lint. This
include the roll box stainless steel skin, the ribs, the seed parameter is having special importance since it directly
fingers and the saw blades. influence the quality of lint produced. Rib spacing should be
4.4 Saw teeth density maintained so that there will not be any entrance of the seeds
along with lint considering saws also.
The saws ranged in teeth quantity from 264 up to 600 teeth.
The saw teeth density usually changes with respect to
The spacing between ribs at ginning point is maintained
diameter. The saws used in existing machine have 352 teeth.
around 2.5 to 4mm. For portion above the ginning point,
The performance with this number seems to be good. The
spacing is 2.5 to 4.5 mm and for portion below ginning point,
increasing number of teeth adversely affects the ginning rate.
3 to 6 mm.
In study it is realized that if the teeth density increased to
increase ginning rate, most of the teeth operates without
4.7 Saw spacing
performing ginning action. Consequently, the ginning rate
The wider saw spacing produced greater fiber length and less
reduces. It also plays important role in keeping maximum
neps. The amount of lint produced per unit time decreased
length of cotton. With maximum teeth density, the length of
with the higher saw spacing. However, the wider saw
lint produced is less.
spacing‟s were ginning at a higher rate (per saw) than that of
the close saw spacing. A 30 per cent increase in the amount of
4.5 Saw diameter
saws on the gin stand for the same area increased ginning rate
Saw teeth are subjected to continuous wear and become worn as a
by only 7 per cent. The effect decreased the ginning rate by 17
result of the interaction of the saw teeth with the lint and other
per cent per saw blade.
matter. The gin saws are steel discs approx. 0.037 inches thick.
Generally the standard diameter of the saw is 12” or 16” and
5 Related works
running speed from 650 to 700 revolution / min. An ideal saw
Various researchers had done research work in the machinery
should have straight edges for leading and with slightly curved
required for the cotton ginning. In ginning of cotton,
“modified roach back” or trailing edge. The saw must be sharp
important aspect is the quality of lint produced. Another
and the teeth undamaged. The pitch and the shape of the saw
important aspect is capacity of gin stand as far as mass
teeth are also important in maintaining capacity and cotton
production of cotton is concerned. Researchers had
quality. To ensure good ginning the teeth must pass through the
concentrated on improving the quality of lint.
ribs at the proper angle. Saws should be replaced once they
reduced in diameter by more than approximately 1.6 G. Holt [3] conducted the study on design of experiments
optimization study on the powered roll gin stand and
presented results of an optimization study concentrating three cotton loss, and fiber quality preservation. The results
main components of the power roll gin stand that is paddle indicated that as open space between grid bars increased,
roll, seed finger roll, and gin saw.The results were based on foreign matter removal and seed cotton loss increased.
lint samples taken after the gin stand (before lint cleaning) and S. Azizov [9] carried out analysis of the strength of the saws
after one stage of lint cleaning, seed samples, and to the dynamic and static loads and found that saw wear-out
performance data. occurs due to the bending of the shaft under dynamic loads
E. Koc [4] conducted theoretical study to investigate the and also observed that the high density of raw cotton leads
performance of a saw-gin ginning machine with special higher damage to fibers during ginning.
reference to separator units. A theoretical model of separator Hughes [10] developed a simple plastic guide that was
unit was developed by introducing the non-dimensional attached to the gin ribs, yet wider than the gin ribs and
parameters defining the mechanical operating conditions and resultantly, much closer to the saw surface than a gin rib. The
also designed the procedure to estimate cotton flow rate and guide restricts the gin saw gap from increasing as a result of
cotton loss. Flow rate estimation results were obtained. seeds flexing the saw blade to an extent that seed was able to
N. Soomro [5] examined that rough ginning is often caused by pass through the gap between the saw blade and the rib.
dense seed rolls, also found that dense seed rolls come from
feeding cotton to the gins beyond the capacity which occur 6 Objectives of study
damage to cotton at gins has incorrectly been credited to the The study of gin stand of 161 saw gin is required to achieve
speed of the gin saws, rather than to the rate of feeding. following objectives
AzizovShuhratMamatovich [6] carried out mathematical • To improve overall performance of 161 saw gin
simulation of brush drums in a dual saw cylinder chamber gin stand.
for the purpose of increasing the quantity of captured cotton
• To improve the quality of lint produced.
fiber from saw. An analysis of the efficiency of the ginning of
cotton fibers with two saw cylinders carried out and it was • To analyze all working parts.
found that, in comparison to a one-cylinder machine, the 2
cylinder approach can help to preserve the natural • To make necessary modifications in existing
characteristics of cotton fiber and seeds.This technology machine.
allowed economizing electricity and decreasing damage to

• To increase the capacity of gin stand.
fiber and also increased the productivity of the machine.
W. Stanley Anthony [7] reviewed and compiled most of the • To achieve better seed discharge from gin stand.
significant developments and research conducted on saw gin
7 Possible modifications to gin stand
stands for cotton gins since about 1958. Also described the
design and operation of various types and models of saw gin As far as performance of gin stand is concerned, saws and
stands, and had given an appraisal of gin stand designs and ginning ribs are two significant parts. These two parts
settings that may be most useful at current cotton gins. contributes more to the gin stand performance. Saws separate
M. Pelletier [8] conducted research work to evaluate the the seed from cotton and ginning ribs prevent the entry of
influence of grid bar cross sectional geometry on extractor seeds along with lint produced.
performance with regard to foreign matter removal, seed
To achieve the objectives of increasing the capacity of gin used in India. The saw gin stand component and their
stand and improving quality of lint, the major factors to be parameter study for investigation process has been done
changed or to be modified are saws and ginning ribs. which suggests the possible modifications in gin stand for its
Saw blades plays very important role in increasing capacity of overall performance improvement.
gin stand. If number of saw blades is increased, the capacity of References
the gin stand can be improved. But increasing the amount of [1] Cotton Ginning Technologies – Selection Criteria for Optimum
blades for same area reduces the ginning rate per saw blade. So, it Results
(A Paper Presented by Mr. M. K. Sharma – President, Bajaj Steel
is required to find the optimum amount of saw blades so that the
Industries Ltd., Nagpur India At, “The First International
ginning rate can be increased and ginning rate per saw blade Conference on Science, Industry and Trade of Cotton” Held, on
October 2-4, 2012 at Gorgan, Iran)
should not be reduced by significant amount. So it is the area
[2] Introduction to cotton gin by W.D. Mayfield, National
where it is possible to make modifications. program leader cotton mechanism and ginning USDA
Ginning rib is very important and plays crucial role in [3] G. Holt, „Design Of Experiments Optimization Study On The
Powered Roll Gin Stand: Part I‟, American Society of Agricultural
preserving quality of lint in gin stand as prevents seed entry and Biological Engineers ISSN 0001−2351, Vol. 50(3) :pp. 765−772
through ribs. After the separation of seed and lint, seeds fall [4] E. Koc, „Theoretical Investigation of Separator Units In Saw-Gin
along the ginning rib. So it also plays a very important role in Machines‟, Fibres & Textiles in Eastern Europe Vol. 13, No. 3
[5] N. Soomro, „Submissions of Saw Gin Speed on the Quality of
seed discharge. The seeds should not be accumulated on Cotton‟, Sindh Univ. Res. Jour. (Sci. Ser.) Vol.47 (1): pp. 25-28
ginning rib. The ginning ribs with existing machine have the [6] A. Shuhrat, „The Mathematical Simulation of Brush Drums in a
profile which is more elevated below the ginning point. Dual Saw Cylinder Chamber Gin for the Purpose of Increasing the
Quantity of Captured Cotton Fiber from Saw‟, World Journal of
Because of this profile the possibility of wad formation is Mechanics, 2013, vol 3, pp. 58-61
more on the ginning ribs. This affects the performance of the [7]Mangialardi, GJ & Anthony, „Cotton saw gin developments‟, The
National Cotton Ginners Association
machine along with quality of lint.
[8] M. Pelletier, „Influence of Grid Bar Shape on Field Cleaner
So it can be possible to modify the profile of the ginning ribs Performance‟, The Journal of Cotton Science 15: pp. 144-153
to achieve better seed discharge and avoid progression of [9] S. Azizov, „Analysis of the strength of the saws to the dynamic
rd
and static loads‟, 3 International Conference & Exhibition On
small cottonseeds. So, it is another area where modifications Material Science And Engineering 2005
are possible. [10] Hughes, „Ginning Rib modifications to reduce seedcoat
8 Conclusion fragments‟, American Society of Agricultural Engineers, vol. 18 (1)
pp. 13-16.
This paper focuses more light on the ginning technologies
Comparative Evaluation of Hex Socket Used In
Torque Wrench by Using Finite Element
Analysis Approach
Vinay L. Jiwtode Rahul K. Bhoyar Sandeep M. Pimpalgaokar
#
Assistant Professor, Department of Assistant Professor, Department of Assistant Professor, Department of
Mechanical Engineering, Mechanical Engineering, Mechanical Engineering,
PriyadarshiniBhagwati College of PriyadarshiniBhagwati College of PriyadarshiniBhagwati College of
Engineering, Nagpur, Maharashtra, Engineering, Nagpur, Maharashtra, Engineering, Nagpur, Maharashtra,
india. india. india.
[email protected]
Abstract: used for transmitting high torque provided by the torque

wrench to the fastener for tightening or loosening of the
A torque wrench is used in bolting application for tightening or connections. Hex socket rotated in a strokes provided by the
loosening of connections in automobile industries, petrochemical hydraulic torque wrench. In one stroke of hydraulic cylinder
industries, refineries and small scale industries. Hex socket is 0 0
interchangeable component of wrench which connects the drive shaft
impact socket rotated by 36 causes fastener to rotate by 36 .
of torque wrench to the bolts to be tight or loose. In Present work Impact sockets are interchangeable tools that can allow a
finite element analysis approach is used to modify existing hex single wrench, impact driver or breaker bar to work with a
socket of torque wrench. Fatigue failure of the hex socket finite large number of fastener sizes.
element model was predicted after the torque was imposed on it. The
finite element analysis of existing hex socket of torque wrench
revealed the stresses distribution on hex socket. So, an effort is made
to modify the design of existing hex socket along with change of
material so that advantage of minimizing failure rate and safe stress
can be obtained.
Keywords: Fatigue failure, finite element analysis, hex socket.

Fastener
1. Introduction:
Hex socket
Hex socket is a tool designed to exert a torque on a fastener to
achieve proper tightening or loosening of a connection. A
torque wrenches are applied to the nut or Allen bolt either torque
directly or in conjunction with an impact socket. Torque
wrenches apply control amount of torque to a properly
wrench
lubricated fastener through hex socket. The purpose of hex
sockets is to withstand the force applied by impact tools, Fig 1. Torque wrench setup.
which cause the standard sockets to failure. The hex socket
have female square groove at one end. The drive shaft of 2. Investigation on Existing Hex Socket:
torque wrench connected to the female square groove of
impact socket by pins andring arrangement to secure with the The hex socket under consideration is hot rolled square
drive. The impact socket having hex bit structure at other end section of low carbon steel of cross section 23x35.9mm &
is casted to the main cylindrical body. A hex bit of socket is length 100mm, machined at both ends for fitment of hubs and
bit. The elemental analysis of materials is done on
spectrometer and as per the component wt % found; steel The fracture surface of the failed hex socket exhibits stress
belongs to SAE9840 standard of steel, as shown in Table 1, concentration regions as shown in fig3, where crack initiation
having typical microstructure as shown in fig 2 with around starts, progressive flat fatigue fracture regions, and the final
25% of pearlite (black) & 75% of ferrite matrix (white). fracture region produced by overload as shown in fig 3.
The fracture appeared to be typical of unidirectional bending
Table. No. 1 Chemical composition of the failed hex fatigue under conditions of a low stress with a high stress
socket and SAE 9840 concentration. From the above observations, it is clear that
fatigue cracks have initiated at stress concentration points
Element Failed hex socket SAE 9840 leading to fracturing of the axle shaft. When the local stress
C% 0.392 0.38-0.43 exceeds the material yield strength, it is possible to form a
fatigue crack. Since the resistance of steel to fatigue initiation
Si% 0.290 0.2-0.32 in proportional to its yield strength, the low properties of the
[2][7].
Mn% 0.690 0.7-0.9 steel in this case left it open to fatigue initiation The area
of final fracture due to overload is large, approximately 40%
Ni% 1.207 0.85-1.15 of total area, indicating that the material is also not adequate
for the applied stresses.
Cr% 0.856 0.7-0.9
Mo% 0.224 0.2-0.3
S% 0.018 0.04 MAX
P% 0.019 0.04 MAX
Fig 3 Failure of Hex socket at the hex bit
2.1 Building Finite Element Model of Existing Hex socket:
For the FE Analysis, it is necessary to create a solid model of

hex socket and also to create a FE model. In the present work,
static analysis has been carried out for the hex socket
considering sudden load effects. As shown in figure 4, PRO-E
is used for modeling the Hex socket. The model has a solid
hex socket of square cross sectional area of 23mmX35.9mm,
machined at both ends with length 100 mm. using the
technical specification of impact socket the FE analysis has
Fig 2. Typical microstructure of low carbon steel (SAE9840) been carried out in ANSYS 12.0. A higher order 3-D, 10-node
element having three degree of freedom at each node,
Visual examination of the failure hex socket revealed that the translations in the nodal x, y and z directions SOLID187 were
fracture had been initiated close to the hex bit, at the bit from used. In this analysis, the moment of 4500 Nm is applied at
where the corners starts for fitting of hub. This fracture the end of impact socket and remote displacement is given in
location is to be expected because fatigue failures start at the y-direction. The boundary condition and FE results in Ansys
most vulnerable point in a dynamically stressed area for moment and remote displacement at static and dynamic are
particularly where there is a stress raiser, as in our case sharp as below.
corners to facilitate proper sitting of bearing locking ring as Mesh model:
shown in fig 3. The highest stress concentration and high Number of nodes- 22312
residual stress would be anticipated to occur in this region. Number of element-12853
Type of element-Tetrahedral (SOLID187)
Behavior of element-DOF-3
2.2 Finite Element Analysis and Results:
Structural analysis revealed that the failed impact socket

material is SAE 9840 alloy steel. Stress analysis performed by
Ansys 12.0 software show that maximum stresses generated at
corner of male hex of impact socket. This indicates that wear
failure initiate at that area. The component to be preventing
wear failure, maximum shear stresses should be less than
allowable stress of material. In this case it is greater than the
allowable shear stress of material. For static loading maximum
shear stress 659.43 MPa is develop which exceeding the
allowable stress of 552.5 MPa. Equivalent (von-mises) stress
is 1142.8 MPa which is also exceeding the allowable
Fig. 4 Mesh model of impact socket and fastener assembly.
equivalent (von-mises) stress of 1105 MPa. This results in
shear failure of impact socket. The failure of the impact socket
is taking place at the corner of male hex.
3. Modifications Suggested In Existing Hex socket:
From the investigation of material & FE analysis it is seen that

tensile stress concentrated regions are at transition area of hex
bit in hub mountings due to sharp corner at the start of torque
to facilitate proper tightening causing slippage of joint due to
clearance results into stress concentration area.Modification of
Fig. 5 Shear stress distribution in assembly. existing hex socket is done aiming to avoid this stress
concentration region which is possible ifexisting rear axle is
manufactured with casting process with close tolerances and
subsequently finished by machining operations atboth ends for
fitment of hub, as it is done in this work. The design
flexibility offered by the casting process farexceeds that of
any other process used for the production of engineering
components. This flexibility enables thedesign engineer to
match the design of the component to its function. Metal can
be placed where it is required tooptimize the load carrying
capacity of the part. Changes in cross-section can be
streamlined to reduce stress concentrations.
Fig. 6 Shear stress distribution in impact socket 3.1 Selection of Material:
EN 31 contains nodular graphite (black) in a matrix of ferrite

(white) with small amounts of pearlite(black). The ferritic
structure gives excellent machinability with good surface
finishes along with optimal impact strengths, fatigue
properties. Ferritic/Pearlitic matrix obtained as cast. Having
good machinability, excellent surface finish and very good
strength. They present ultimate tensile strength and yield
strength which is close to SAE 9840 steel grades. This grade
is good for applications such as machine components that
suffer impact and are crack-resistance. Table 2 showing the
typical chemical composition of class EN31.
Table No. 2chemical composition of EN31

Fig. 7 Equivalent Von- Mises stress distribution on
impact socket Element EN 31
C% 0.9-1.20
Si% 0.1-0.35
Mn% 0.3-0.75
Ni% 0.85-1.15
Cr% 0.1-1.6
Mo% 0.2-0.3
S% 0.04 MAX
P% 0.04 MAX
Fig 8 Equivalent stress in EN31
5. Comparative Evaluation:
Any comparison of material/process combinations must be
4. Finite Element Analysis of Modified Hex socket:
justified with the results of the materials & process under
EN31 material is used for the redesign purpose. The material consideration. Table 4 shows the comparison of result with
properties have been collected. The different materials of hex both the cases.
socket have been selected and calculate the value of maximum
shear stress and equivalent stress. Analysis of different Table No 4: Comparative Evaluation.
materials has done with the help of ANSYS 12.0. EN31 is a
high carbon Alloy steel which achieves a high degree of Stresses SAE 9840 EN 31
hardness with compressive strength and abrasion resistance.
The mechanical properties of material are as fallow: Maximum shear stress (MPa) 526.25 452.64
Allowable maximum shear stress
Table No. 3 Mechanical properties of EN31 592.5 450
(MPa)
Properties Value Unit Equivalent stress (MPa) 911.75 784.04
Ultimate tensile strength 750 MPa
Ultimate yield strength 900 MPa Allowable equivalent stress (MPa) 1185 900
Poisson’s ration 0.28 -
Young’s modulus 215 GPa From table 4, it has been found that, maximum stress present
3
Density 7810 kg/m in existing hex socket is 526.25Mpa which is more than
Hardness 63 HRC thetensile yield strength of material. Whereas maximum stress
present in modified hex socket is452.64 which is much
lessthan the tensile yield strength of its material. We therefore
conclude that the torque wrench having modified hex socket
will defiantly work satisfactorily under this stress level
without fatigue initiation.
Conclusion:
This study was conducted on a existing Hex socketused in
torque wrench. Spectrum analysis revealed that the failed hex
socket material is SAE 9840 steel. Fractographic features
indicated that fatigue was the main cause of failure of the hex
socket. It was observed that the fatigue cracks originated from
transition areas due to sharp corners. Modified hex socket
produced with casting process with the use of EN31
material.This ultimately solves the problem of initiation of
Fig 7 Maximum shear stress in EN31 fatigue cracks in this area.An application including both
redesigning of the hex socket transition area and change of
material i.e. suitable for casting of hex socket which may be a
good alternative to enhance the fatigue life and can satisfy Greensboro, NC, USA.
minimum design criteria. 5. M.E. Stevenson, J.L. McDougall, K.G. Clin, “Metallurgical
Failure Analysis of Titanium Wing Attachment Bolts”, Practical Failure
Analysis, Volume 3(4), ASM International, August 2003.
References: 6. Kenneth R. Milligan, Terry Taylor ,Wane Snyder,
“Reinforced Impact socket”, US Patent 7,841,261 B2, OH (Us),2010.
1. I. Lopatukhin and A. Ber, “Accuracy and Strength of a Joint Loaded 7. Rolf Gunter Rosenhan, “Screwdriver, Screwdriver bit or the like”,
by Suddenly Applied Torque”, The International Journal of advance manufacturing Us Patent 5,953,969, Germany, 1999.
technology, 13, pp 692-695, 1997.
2. James J. Scutti, Massachusetts Materials Research, Inc.; 8. Bill Thomas Brazil, “Non-marring Tool”, US Patent 2005/0022631
A1, Pennington, NJ(Us), 2005.
William J. McBrine, ALTRAN Corporation, “Introduction to Failure
Analysis and Prevention”, ASM International. 9. M. Zamanzadeh, E. Larkin and D. Gibbon, “A Re-Examination
3. Herng-Shuoh Jang, Sheng-Leh Liang, So-Ter Chen, of Failure Analysis and Root Cause Determination”, Gibbon Matco
Associates, Pittsburgh, Pennsylvania, December 2004.
“Development of Screwdriver Bit Steel with High Hardness and Torque
Value”, China Steel Technical Report, No. 22, pp 1-6, 2009 10. “Chemical Composition of Structural Steels”, Design of Steel
4. Jonquil R. Flowers B.S., Matthew B. McCullough, Structures MIT Department of Civil and Environmental Engineering Spring
“Comparison of StressDistribution Patterns Within Trigonal, Semester, 1999.
Quadradle, And Hexagonal Screw Drive Designs of An Acl Interference 11. Avner Sidney H., Introduction to Physical metallurgy, New York, Tata
Screw Using Finite Element Analysis”, North Carolina A&T State University, McGraw-Hill, 1997.
DESIGN, ANALYSIS AND OPTIMIZATION OF
AUTOMOBILE TRAILER USING FEA
Salman Khan
Third Sem, M.Tech./M.E (CAD/CAM)
Abstract
The portable toilets are mounted on the trailer, this trailer is
manufactured by a company (ExcellFibrotech, MIDC Nagpur).
Many of new product designs are based on existing products and
years of experience. Therefore, the trailer is assumed to have
unexplored areas of potential improvements. Today the trailer is
a mainly welded design, which is both expensive and
unsatisfactory from a maintainability viewpoint. Welding is not
only expensive but introduces heat to the steel alloy, and thereby
changes the material properties, and also requires a high degree
of manual labor. A truck chassis has a more standardized
manufacturing method and application of some of the
manufacturing techniques from it to the trailer could perhaps
make the production of it more efficient. The current trailer have
robust designs, and there have been no actual calculations or
investigation to find out what dimensions are needed to
withstand the forces applied to a trailer during use. Instead, the
design is based on experience of what works, and what does not.
A more thorough investigation of the design parameters can
create better understanding of which parts of the trailer that are
most exposed to high stresses, and which parts that can have
reduced dimensions. II. LITERATURE REVIEW
Keywords:trailer, truck chassis. L.A.W. Horn, HAN University of Applied Sciences[1] During
the previous HVTT conference in Melbourne, results have
I. INTRODUCTION been presented of a project FORWARD, including eleven
different trailer manufacturers, involving testing and modeling
Portable toilets, are simple portable enclosures containing a activities to establish a practical basis for realistic fatigue
chemical toilet (a toilet bowl filled with disinfectant instead of assessment as a step towards an improved light-weight trailer
water) which are typically used as a temporary toilet for design. The present paper describes the next step as part of the
construction sites or large gatherings because of their follow-up project LIFE (Lifetime Fatigue Enhancement),
durability and convenience. Most portable toilets have black starting with the model-based assessment of a realistic loading
open-front U-shaped toilet seats with a cover. They are often history for a semi-trailer. Representative loading conditions in
constructed out of lightweight molded plastic.
this history, being derived from three weeks of field testing,
Mounted on purpose built trailers, these standard toilets are then used in Finite Element analyses to estimate fatigue
provide a convenient and cost effective option to satisfy all life at a critical high loaded welded connection in the
requirements. The trailer gives the added benefit and cost aluminum trailer chassis. Results are discussed with respect to
saving choice of being able to pick up the unit yourself, plus the order of different loading cycles (Palmgren-Miner
you can maneuver between locations at your own number, based on fatigue tests), 3D loading at the weld, the
convenience. varying weld quality, and the impact of bonded connections in
the trailer. These „lessons learned‟ are interpreted, to result in
The efforts required where car is moving are comparatively improved general guidelines in light-weight.
less with stationary car. The working strength of the tie rod is
that of the product of the allowable working stress and the AslıSoytürk, HüseyinYıldırım, VolkanAkıncı[2]Semi–trailers
minimum cross-sectional area. are manufactured in long body design and aimed for heavy
load transportations. As so, torsion stiffness in these vehicles The portable toilets are mounted on the trailer, this trailer is
is the key element in a design which provides light chassis manufactured by a company (ExcellFibrotech, MIDC
weight, while obtaining high performance, high load carrying Nagpur). Many of new product designs are based on existing
capacity, driving securely and stable road holding. In this products and years of experience. Therefore, the trailer is
study, torsional stiffness of semitrailer chassis was analyzed assumed to have unexplored areas of potential improvements.
by finite element method, fundamental static rules, also
IV. PROBLEM FORMULATION
experimental datas were used for calculations and all results
were compared with respect to each other. Fundamental static The portable toilets are mounted on the trailer; this trailer is
calculations for torsional stiffness were performed per manufactured by a company (ExcellFibrotech, MIDC
guidelines of rigid body mechanics and vehicle dynamics Nagpur). Many of new product designs are based on existing
having some assumptions. In the finite element method, the products and years of experience. Therefore, the trailer is
semi-trailer chassis was modelled in CATIA software and assumed to have unexplored areas of potential improvements.
stiffness was calculated in mesh form in ANSYS Workbench Today the trailer is a mainly welded design, which is both
14.5. In experimental studies, chassis frames‟ torsional expensive and unsatisfactory from a maintainability
stiffness test method was used. Torsional stiffness was viewpoint. Welding is not only expensive but introduces heat
calculated by obtaining applied force, strain and torsion angle. to the steel alloy, and thereby changes the material properties,
These results show that both methods are convenient and and also requires a high degree of manual labor. A truck
confident in calculations of torsion stiffness and can be used chassis has a more standardized manufacturing method and
in designs for succeeding light and robust trailer chassis goal. application of some of the manufacturing techniques from it to
the trailer could perhaps make the production of it more
Mr. Venukumar R Bankapur1, Prof. Sanjeev. A. Janawade[3]
efficient. The current trailer have robust designs, and there
Tractor trailers are agricultural products transporting vehicle,
have been no actual calculations or investigation to find out
this vehicle used to transport agricultural products from one
what dimensions are needed to withstand the forces applied to
place to other place. Therefore, it is essential to do static
a trailer during use. Instead, the design is based on experience
fatigue analysis of trailer chassis. Based on analysis the life
of what works, and what does not. A more thorough
estimation of trailer chassis can be done. In this project work,
investigation of the design parameters can create better
the trailer chassis model has been designed using 3D
understanding of which parts of the trailer that are most
modeling software CATIA. The designed 3D model is
exposed to high stresses, and which parts that can have
imported into FEA software Ansys. On imported 3D model
reduced dimensions.
the pre-processed, postprocessed and solving are performed in
FEA software Ansys Meshing model with different element V. CONCLUSIONS
size are performed in pre-processing on imported 3D model,
in next stage, the boundary condition on meshed model are The current trailer has robust designs, and there have been no
applied. In last stage, solving for different loading with varied actual calculations or investigation to find out what
element size is performed. For 3 different fatigue theories, dimensions are needed to withstand the forces applied to a
those three different fatigue theories are Goodman, Gerber trailer during use. Instead, the design is based on experience
and Soderberg, the analysis results are obtained for 3 different of what works, and what does not. A more thorough
load scenarios with varied element size. 3 different loads are investigation of the design parameters can create better
consider in this project are, 6Tonne, 12 Tonne and 18 Tonne. understanding of which parts of the trailer that are most
Analysis results have demonstrated that the chassis has 106 exposed to high stresses, and which parts that can have
cycles of life time for 12 Tonne of loading without fatigue reduced dimensions.
failure. It is observed that there is a fatigue failure for 18 REFERENCES
Tonne loading. The convergence method is used to verify the
[1] L.A.W. Horn, HAN University of Applied Sciences, “Semitrailer chassis
accuracy of analysis results for element size: 15 mm, 10mm design against fatigue on the basis of field test data” Heavy Vehicle
and 5 mm. The summary of this project work is analysis Transport Technology symposium, Stockholm (2012).
results are approximate to convergence method and the
[2] AslıSoytürk, HüseyinYıldırım, VolkanAkıncı, “Methods to Determine
chassis has lifetime of 106 cycles for 12 Tonne load without Torsional Stiffness in a Semi-Trailer Chassis Frame”
fatigue failure.
[3] Mr. Venukumar R Bankapur1, Prof. Sanjeev. A. Janawade, “Fatigue
Analysis of Tractor Trailer Chassis”e-ISSN: 2395 -0056 ,Volume: 02 Issue:
03 , June-2015
DESIGNING AND DEVELOPMENT OF DIE WITH
LEAN MANUFACTURING
Aswad A SagdeoStudent, Dept. of Mechanical Prof V.P. Kshrisagar, Professor,
Engineering, Wainganga College of Dept. of Mechanical Engineering, Wainganga College
Engineering & Management, Nagpur of Engineering & Management, Nagpur
Abstract:This paper gives the general introduction to the organisation’s continuous improvement.In the computer-
arrangement, design and some basic concept of designing the aidedmanufacturing(CAM), Pro-Manufacturingfrom Pro-
die. CAD plays an important role in this type of die design. Eparametricsoftware wasused to develop
Some losses due to design parameters are also discussed. To theMachiningprogram.
meet the requirements of low cost, good performance and
manufacturing feasibility. This paper will provide a design {Reference from Defining Lean Production: Some conceptual
overview of the die designing, main characteristics, key and practical issues By: JosteinPettersen}
subsystems and control strategies.This gives better
understanding about working principle of lean manufacturing 1.2 Literature Review
to avoid the un-necessary operation and  minimise the waste The concept of LM was pioneered by a Japanese automotive
materials. Effect of design consideration can be further studied company, Toyota, during 1950’s which was famously known as
during its application in various conditions. In the CAD model Toyota Production System (TPS). The primary goal of TPS were
actual designhas also been explained. The design approach is to reduce the cost and to improve productivity by eliminating
wastes or non-value added activities. During 1980’s there was an
in the way of improving the efficiency of manufacturing
intense interest on LM implementation among the western
efficiency. Lastly there is the solution given to the analysed
manufacturers because of growing Japanese imports. It became a
error. Advantages, disadvantages and various practical serious concern to the western producers. After the oil crises in
applications are also discussed. the early of 1990’s, in a published book named
Whereas,Operations strategy is the total pattern of decisions
which shape the long-term capabilities of any type operation and
1. Introduction their contribution to overall strategy, Slack and Lewis (2002).
Firms and companies which focus is on the production of goods
1.1 Background use to refer their operations as Manufacturing. Thus,
Manufacturing Strategy (MS) comprises a series of decisions
This paper also examines the drivers and barriers that influence concerning process and infrastructure investments of a
the implementation of lean manufacturing.The findings show production firm, i.e. what the manufacturing has and what it
that most of the respondent firms are classified as in-transition does. { Reference from Lean in Product Developmentby Marc
towards lean manufacturing practice.Service organisations are Lind}
It aims to provide the necessary support to develop strategic
now pursuing lean thinking and actively deploying lean
competences, which will enable the company to develop a
principles.Onepartis usingclipfunction andanotherpartis using sustainable competitive advantage in its markets. Competitive
tick function. In thecomputer-aideddesign(CAD), two advantages that might be considered as qualifiers(Q), those that
plasticpartsweredrawnin 3dimension(3D) viewbyusingPro- get and keep the company in the marketplace, or as order
Engineer(Pro-E) parametricsoftware. These firms believe that winners(OW), those that let the company win orders in the
the factors that drive the implementation of lean manufacturing marketplace, Hill (2000).
are the desire to focus on customers and to achieve the
thermoplasticorbychemicalreactionforthermosetting.
Injection Moulding Machine DIE CAVITY
1.3 Materialsof DIE LEAN WASTES
Sr.no. Raw material Drying temp. Time Different kinds of wastes in a process are categorized in
0
1 PE, PP 80 c 2 hr following categories.
0
2 PS 82 c 2 hr
0
3 Acrylic ABS,AS 82 c 2 hr 1. Overproduction
0
4 Cellulose series 71 c 3 hr 2. Waiting
0
5 Poly carbonate 120 c 3 hr 3. Unnecessary Transport
0
6 Hylon 82 c 2.5 hr 4. Over processing.
0
7 PVC 71 c 1.6 hr 5. Excess Inventory
6. Unnecessary Motion
1.4 Components of Injection mould Die 7. Defects
8. Unused Employee Creativity
 Cavity  {from Seven wastes elimination by lean manufacturing case
 Cavity back-up plate study “gaza strip manufacturing firms’’ By: Khalil A. El-
 Core Namrouty, Mohammed S. AbuShaaban.}
 Core back-up plate
 Stripper plate
 Ejector plate Lean Thinking
 Ejector pins Five step approach:
 Bottom plate
• Find a change agent.
• Find a sensei (to get the knowledge.)
• Seize or create the crisis.
• Map your value streams.
• Get started on creating better value streams.
But…how do lean leaders lead this process?
5. Result
This study analyzed the existing state of manufacturing and
DIE CORE
testing the medical devices in batches. An implementation plan
2. Design optimisation
was developed to implement lean manufacturing principles to
Nowadays,the technology ofthe tool anddiefabrication support one-piece flow. The plan was implemented and the
in plasticinjection is oneofthe world'sfastest growing
results of the implementation resulted in improved productivity
industries. Plasticis nowusedin
and resulted in a reduction in work-in-process.
almosteveryapplication,ranging from householdarticles
to space travel, from transportation to 6. Conclusion
packing,frommedicineto toys, from bridgebuildingto Manufacturers are under intense, remorseless pressure to find a
sports. Generally,injectionmouldingis aprocessthat
new ways to production cost, elimination of waste, enhance
forms the plasticinto adesiredshapebymeltingthe plastic
material landforcing the plastic high quality of product, increase the productivity, and better
materialunderpressureinto the mouldcavity. Theshape customer satisfaction through the implementation of
ofthePlasticthatis desiredis achievedbycoolingin
lean traditional manufacturing practices are indicated study. I also at the outset thank and express our profound
gratitude to ourguides for their inspiring assistance,
inadequate representation in lean Manufacturing. This project
encouragement and useful guidance.
manufacturing implementation in manufacturing We are also indebted to all the teaching Staff of the department
of mechanical engineering for their cooperation and
industries. Hence, appropriate lean education, training, and
suggestions, which is the spirit behind this report.
research setup in association with manufacturing industries Thanks to all our seniors who gave me the information
and basic important knowledge about the topic.
are to stimulate the lean awareness and technologic in all type
Our best regards go to all my colleagues for their pleasant
of manufacturing industries. This helps to industries and cooperation last but not the least, we wish to express our
sincere thanks to all our friends for their goodwill and
researchers create awareness about Lean Manufacturing opt
constructive ideas. .
suitable lean practices for implementation, continuous in 9. References
the competitive environment of current scenarios. There is our  1.Seven wastes elimination targeted by lean manufacturing case
final product is decided according to which we have calculated study “gaza strip manufacturing firms’’
only overall cost which will be up to 32000-35000 rupees. By: Khalil A. El-Namrouty, Mohammed S. AbuShaaban.
 2.Defining Lean Production: Some conceptual and practical
6.1 Design in 3D issues
By: JosteinPettersen
 3.DesignandSimulationofPlasticInjectionMouldingProcess
By:
Wong,C.T.,ShamsuddinSulaiman,NapsiahIsmail&AM.S.Hamoud
a
 4.Fundamentals of Lean By: Professor Deborah Nightingale
 5.Lean in Product Developmentby Marc Lind
 6.Lean Management and the Role of Lean LeadershipBy: James
Conceptual Die Model in CRE-O P. Womack,John Shook
 7.A Survey on Lean Manufacturing
7.Future work / scope
Implementation in Malaysian Automotive
This is a general decision methodology, which can be adapted Industry By: NoraniNordin, Baba MdDeros and
and enriched with the information of a firm, and according to DzuraidahAbdWahab
its specific needs. Also, as new alternatives and techniques  8.Lean: Concepts and Realities By: Andrew Aitken, COO,
come out, they can also be considered in this framework. There Lanner Group.
are some alternatives that can be adapted to combine  9.The principles of the lean business systemBy: Peter hines

differentproduction processes, e.g. using a focused facility it is 10.Implementin Lean Manufacturing Principles in a
possible to have separate production processes for different Manufacturing Environment By: Rodney S. Rogstad
products. But it wasn’t found any framework including  11.Manufacturing Strategy Linkedto Product Life CycleBy: Edna
Ferro García Luna
different alternatives, or any proposal for deciding which one  12.Reverse Engineering: Why and How to Reverse Engineer
to use. As the existing theories and proposals do not seem to be Software
enough, it was necessary to propose a solution for the problem By: René R. Klosch
of deciding a manufacturing strategy for products with
different life cycles. A solution for this decision problem was
already proposed and explained in the present paper. Now the
question would be to apply the proposed methodology in real
cases, in several companies, and evaluate the results.
8. Acknowledgement
First of all we thank the almighty for providing us with the
strength and courage to do the research study.
We avail this opportunity to express my sincere gratitude
towardsour guide Prof.V.P.Kshirsagar of mechanical
engineering department, for permitting me to do the research
DESIGN , ANALYSIS AND RAPID
MANUFACTURING OF TURBINE BLADE
Suhas V. Kale Prof. S.G.Ghugal Prof A.B.Ganorkar
Department of Mechanical Engineering Department of Mechanical Engineering Department of Mechanical Engineering
P.B.C.E Nagpur. P.B.C.E Nagpur. P.B.C.E Nagpur
1.1 INTRODUCTION 1.2 COMPUTER AIDED DESIGN

Gas turbine blades are as complex industrial parts due CAD has, in recent years, become an important and
to their material, narrow dimensional tolerances and widely used technology. CAD systems have the potential to
complicate freeform surfaces. In gas turbines, compressor improve design quality, cut design costs, and shorten the
and turbine blades play vital roles and one or aeries of development time of new products .Companies have
blades transfer energy through dynamical function. The invested large amounts in the systems and are becoming
function of any industrial turbine directly relates to angular very dependent on CAD technology for the development of
movement changes of fluid while passing through a row of new products yet the effective application of CAD
blades. As the surface of blades is comprised from freeform technology has proven to be a difficult task in many
surfaces, they accounted as complex industrial parts. At companies. Many managers feel that CAD systems have not
present, there are used processes such as forging, investment delivered the benefits expected of them. The results of years
casting, machining and single crystal growth for of CAD research show mixed and inconclusive results, Even
manufacturing of the blades but any of these methods are when CAD technology is applied in ways that produce
time consuming and expensive especially in Research and ostensible gains, these gains may not translate into overall
Development, optimization and prototyping steps and have improvements in product development effectiveness. The
some limitations. Specially, in the phase of Research and mixed results, reported by both researcher and practitioners,
Development while turbine blades with complex internal can be attributed to widely varying perceptions of the
cooling channels are considered, even CNC machines technology and its capabilities. These perceptions affect
having 4 or 5 simultaneous axis have such complications. how CAD technology is applied, and will thus affect the
Hence manufacturing these parts required another benefits received from the technology.
approaches like rapid prototyping technologies [3]
A gas turbine is a rotating engine that extracts energy
from a flow of combustion gases that result from the
ignition of compressed air and a fuel either a gas or liquid,
most commonly natural gas as shown in fig 1 . It has an
upstream compressor module coupled to a downstream
turbine module, and a combustion chambers module with
igniters in between. Energy is added to the gas stream in the
combustor, where air is mixed with fuel and ignited
Combustion increases the temperature, velocity, and volume
of the gas flow. This is directed through a nozzle over the 1.2.1 CAD MODEL
turbine’s blades, spinning the turbine and powering the
PART MODELLING:
compressor Energy is extracted in the form of shaft power,
compressed air, and thrust, in any combination. The pro-e modeling was carried out using the 2 D
drawing provided by C.P.R.I, Nagpur. The various
options used for modeling are discussed in brief as below:
 Starting Out in Part Mode--Describes how to start
creating a part with Pro/ENGINEER.
 Sketcher--Describes how to create sketches in a
stand-alone Sketcher mode.




 Datum’s--Describes how to create datum features: parameters. Result in this method decreases time and cost
for production of sample parts with best quality, rapid and
datum planes, datum points, datum curves, datum
low cost [3, 4]. While 20 or 50 casting parts are required,
axes, coordinates features, graphs, evaluate RP method isn’t economic, especially if it is required
features. surface roughness. For simple and small part, using of the
multiple cavity die is economical. This die can save 50% in
 Sketching on a Model--Describes how to create 3- production cost due to the reduction of production cycle
time and elimination of connection runner to model. It is
D sections in the process of feature creation.
also reduce probable failure of small part and brittle material
 Feature Creation Basics--Describes how to create due to the reduction of displacement. The machining of
extruded and revolved protrusions. cavity can’t sure all models are the same, but the entire
models are the same by using RT [5]. Furthermore, RT is
 Sweeps, Blends, and Advanced Features-- allowing casting foundry to apply contraction parameter in
 production .
Describes how to create sweeps, blends,
and advanced features. Construction 1.4 OPERATIONAL DESCRIPTION
The existing commercial RP processes use a layered
Features--Describes how to create construction fabrication method to create the physical prototype from a
of features such as holes, slots, and cuts. 3D CAD model. The CAD model to be prototyped is first
converted into a standard format known as STL file format.
Rounds--Describes how to add rounds to part In this format the surface of the CAD model is
approximated by triangular faces[7]. The STL file consists
geometry. of a list of the vertices of each of these triangles and a unit
normal to each triangle indicating which side of the triangle
 Tweak Features--Describes how to create tweak is solid The rapid prototyping device reads the STL file
features, such as draft, local push, and section and decomposes the 3D part into a series of 2D
dome. cross sections or slices[7]. The machine then
constructs the physical prototype by sequentially
1.3 RAPID PROTOTYPING
creating each cross sectional layer and bonding
each layer to the previous layer. Once all the
Today, the competition of the industries in the overall layers are created and registered, a solid object is
the world are provided to fabricate a new product with high
quality, low cost and low lead time of marketing, thereby, obtained. The accuracy of the object formed
using of CAD/CAM systems, rapid prototyping and rapid depends on the slice thickness and material
tooling are not avoidable. At the present time, in most large dependent factors such as shrinkage, war page etc
industries such as automotive, aerospace, house equipments
and medical facilities, rapid tooling is used. When solid 1.4.1 Making SLA Model
modeling system was introduced in 1970, many researchers
try to make physical model directly from geometric model Among RP methods, SLA has better feature definition
data without using traditional tooling. From 1970 to 1980, and can create better surface roughness [7]. Turbine blade
companies had some achievement in manufacturing parts model is made by SLA method by the following procedure;
layer by layer by photopolymer material. In 1986, 3D 1. Convert CAD model in the STL format and send to
System company was introduce SLA rapid prototyping 3DLightyear software.
method and first rapid prototype machine was manufactured
. In rapid prototyping against traditional machining method, 2. Positioning workpiece on the SLA5000 platform
work piece is produce with additive method and layer by 3. Positioning support
layer, result in this method is faster than from the
subtraction of the material. This method hasn’t the 4. Slicing workpiece and support by thickness 0.15mm
restriction of machining method and complex feature can 5. Preparing SLA5000: content define recoat in any
produce with high accuracy and high quality . Rapid tooling slice and Z-wait
is extension of rapid prototyping, in reality it is the
development of CAD/CAM and rapid prototype 6. Making workpiece
technologies. It uses from rapid prototype technology
7. Remove SLA model from machine chamber and
directly or indirectly and reduce the product cycle time. remove support
Using of RP&RT allow the casting foundry to produce work
piece without using tooling in low volume production. That The maximum error of SLA model is about 0.017 mm [3]
helps to approve design, process condition and runner these deviation is measured by a CMM supplied PC-
DMIS software to find the accuracy of SLA model.
1.4.3 Example: Prototype Wind
Turbine Blade
A prototype wind generator turbine blade, based on a
NASA design referred to as the LS( 1)-417MOD, has been
produced using SM2. First, a computer solid model was
generated using a series of spline points to describe the foil
cross-section geometry at specific points along its
Gambar 1. Part Files are Converted to STL Files longitudinal axis Using these spline points and commercial
solid modeling software, a surface model and subsequent
1.4.2 Prototype Or solid model were generated. Next, the model file was
Production Parts exported as an STL file and the airfoil was sliced into 1"
thick layers, to match the foam thickness. Each layer's slice
While many commercial rapid prototyping machines geometry was ported to Shape Maker II and the layer
have made significant improvements with their fabrication geometry was cut from a sheet of extruded polystyrene
techniques during the past five years, it is not yet possible to foam. Finally, a thin coat of adhesive was applied to each
go directly from the CAD model to the final production layer, and the layers were manually registered and bonded
part as is done with Computer Numerical Control together The gross dimensions for this turbine blade design
machining However, new alternative modeling materials are are 46" x 7" cross-section and 7' long Fabrication time,
currently being tested by all commercially available rapid excluding CAD modeling was approximately 11 hours. The
prototyping machines. Many of these new materials have accuracy for this first attempt at fabricating the airfoil is in
already demonstrated they are acceptable for producing 3- D the range of 0.1-0.6% of cross-section dimensions.
objects with limited function Current limitations result from Translating these values into useable dimensions, all
size, surface finish, and tolerances RP is expanding its dimensions were within 0.135" of the desired value. The z-
usefulness from prototyping parts into the manufacture of axis accuracy is estimated to be 1% of the overall length or
actual production parts An electronics manufacturer uses approximately 0.7".
Stereo lithography to fabricate final-use carrier components
for use in manufacturing integrated circuits In another 1.4.4 Abbreviations and
example, replacement of a cam follower was accomplished Acronyms
overnight using Stereo lithography and high strength
photopolymer. Normally this cam follower would take two Computer Numerical Control (CNC) ,
to three weeks for delivery Likewise, 3-D printing, using a Computer-Aided Design (CAD) , Rapid Prototype
colloidal silica binder and alumina-silica ceramic powder (RP) , Rapid Prototype Manufacturing (RPM) ,
has been used to fabricate ceramic cores for lost wax casting Stereo lithography (SLA) , 3 Dimensional (3D) , 2
models . Adding to that, Fused Deposition Modeling has
been used to produce wax patterns to fabricate moulds for Dimensional (2D) , Reverse Engineering (RE) ,
investment casting . Coordinate Measuring Machine - CMM
1.5 CONCLUSION
We came to the conclusion after the above discussion
that the rapid Prototyping is one of the best methods to
manufacture turbine blades within the given tolerance level
Some important advantages achieved by using rapid
prototyping as follows
1. Reduction in cost and time while for this blade
observe in comparison with traditional method we save 50%
in time and 60% in cost
2. Develop machining technology in short time:
because for production of any blade, it required some test
cut in order to solve machining problems
REFERENCES
[1] S.Ramamurthy and S.Thennavarajan “Cost Effective
Method for Manufacturing Micro Gas Turbine Components
Gambar 2. Machine Control Flow Chart ” Total Engineering, Analysis and Manufacturing
Technologies 22nd – 24th September 2008 .
[2] David Robertson and Thomas J. Allen “CAD System Utilizing a Combination of Rapid Prototyping Technology
Use and Engineering Performance ” IEEE Transactions on and Conventional Investment Casting”
Engineering Management , Vol 40 No 3.
[7] Charles L. Thomas, Thomas M. Gaffney, Srinivas Kaza,
[3] D. Safaeian, M. Vaezi “Investment Casting of Gas Cheol H. Lee “Rapid Prototyping of Large Scale Aerospace
Turbine Blade by Used of Rapid Technologies ” Australian Structures”
Journal of Basic and Applied Sciences , 3(3): 2979-2988,
[8] G Madhavulu , SVN Ani1 Sundar , Basheer Ahmed
2009
“CAD/CAM Solutions for efficient Machining of Turbo
[4] Lal Gopal Das and Naresh Chandra Murmu “A Unified Machinery Components by Sturz Milling Method ”
Methodology for Micro Gas Turbine ” The 11th Asian
[9] Jürgen M. Anders and Jörg Haarmeyer BMW Rolls-
International Conference on Fluid Machinery November 21-
Royce GmbH, Dahlewitz, Germany “A Parametric Blade
23, 2011, IIT Madras, Chennai, India
Design System (Part I + II) ”
[5] B.A. Weeden, A.P. Sanders, D.L. LaSalle, G.P. Trottier
“Alternative Methods for Custom Implant Production
The Perception and Methodology of Lean
Manufacturing
Sumit yadav Sumit Roy Sumit Yadav
Depament of Mechanical Department of Mechanical Department of Mechanical
Engineering, Tulsiramji Gaikwad- Engineering, Tulsiramji Gaikwad- Engineering, Tulsiramji Gaikwad-
Patil College of Engineering and Patil College of Engineering and Patil College of Engineering and
Technology, Mohgaon, Nagpur Technology, Mohgaon, Nagpur Technology, Mohgaon, Nagpur
Abstract— In the present global and competitive play in new product development and the improvement of
environment all organizations needs to perform existing products and the improvement of existing products,
efficiently with higher productivity. For performing including idea creation, design for manufacture, assembly
efficiently with higher productivity there are so many and test, rapid prototyping, product portfolio management,
tools and techniques. Lean is one of them it means using market and competitor analysis, risk management, sales
only what is necessary lean manufacturing techniques forecasting, setting key performance indicators and value
aim to significantly identify waste and eliminate it from analysis to reduce the cost of existing products.
the manufacturing processes. Purpose of this paper is to
present Lean Manufacturing elements, benefits, Lean Manufacturing in India:
implementation strategy and obstacles in
implementation for small scale manufacturing units and India is emerging as a new manufacturing destination and
industry. many industries are seeking ways to excel their
manufacturing capabilities by elimination of wasteful
INTRODUCTION: activities from their systems. Lean is one of the approach the
Indian industries are looking to become more competitive in
Lean is defined as a strategy for achieving significant local as well as global market. Yadav indicated in their
continuous improvement in performance thought the study a keen interest on the part of Indian manufacturing
elimination of all wastes of resources and time in the total companies to adopt or learn new approaches and techniques
business process.. It evolved from Toyota after world war in order to improve their performance; but it was only the
2nd as a business strategy due to the limited resources beginning of a long journey for them. In recent study,
available in Japan, in contrast to the vast resources available Panizzolo et al. (2012) investigated the adoption of lean
to manufactures in the US. Its principles apply to nearly all production in India. The Indian Automotive sector has the
business operations, from administration and product design very high level of lean implementation followed by
to hardware productions. Lean manufacturing is about Mechanical / Engineering sector. Other sectors are seen on
eliminating waste and non value added tasks. Examples of medium to low level.
waste in manufacturing include overproduction, over
processing, waiting, unnecessary part movement, excess Industry sector in India Level of diffusion
Automotive Very high
inventory and defects, as applied to hardware production Machine tool Medium to low
lean manufacturing focuses on eliminating all sources of Electronics/ IT /engineering High
waste by applying the following strategies FMCG Medium to low
Process industries Medium to low
1. One piece workflow Aerospace Medium to low
Decision-making (MCDM) for lean assessment to assess
2. Take time lean performance holistically. The literature pointed toward
popularity of lean in India; but when it comes to success, its
3. Pull system only start of journey. Other than automobile and electronics
industry, others are having medium to low diffusion of lean
Lean identifies the bottlenecks in design and development in India.
processes that add unnecessary delays and cost. It can help
create a more efficient system that reduces time to market
without compromising on quality. Lean has a key role to
2. Principles and Practices of LeanManufacturing standard set of skills.
It is a common sense Sharing a common
of what the ideal goal
Lean production is a multi-dimensional approach that system would be,
encompasses a wide variety of managementPractices, and that shared goal
including just-in-time, quality systems, Work teams, cellular 9. Pursuit for motivation to make
manufacturing, supplier Management, etc. in an integrated perfection / improvements
striving for ideal goal beyond what would be
system (Shah et al., 2003).Yadav et al. (2010) identified ten necessary to meet the
fundamental Lean principles (Table 1) on the basis of current
exhaustive Literature review and authors’ industrial Needs of their
experience, Which further used for investigation of lean customers.
10. Cultivating It shows the faith of knowledge sharing
Implementation. organizational organization that the practices
Lean manufacturing What it means? Enablers knowledge skills and
Principles Knowledge generated
will pay off later.
Standardized work Standard work
procedure to do procedures,Design
routine and repetitive blue
1.Standardization tasks to improve prints MUDA, MURI, AND MURA
efficiency and quality
Flow of work to the Kanban system, JIT Muda, Muri, and Mura (1988) are Japanese words that were
right machine or
person in the rightform regularly used by Toyota through their development of
at the right time at the Lean. Muda means waste, Muri means overburden, and
2. Simple and specified lowest cost with the Mura means unevenness. Variation in the order arrival rate
Pathways highest and deviation in the capacity is unevenness (Mura).
Quality possible which
reduces production Capacity is straight connected with overburden. Mura and
lead time. Muri lead to Muda‖. According to Ohno Muda is categorized
Through continuous Scientific methods of into seven wastes Figure: Wastes are
effort of managers and problem
supervisors solving
3. Teaching and Acting as enablers or
Seven Wastes:
learning mentor in solving  Overproduction/early production—producing what the
problems.  customer does not want.
An atmosphere of Consistency,  Waiting—idle time when no value is being added to the
trust, respect and consensus
common purpose in and communication  product or service.
which work is  Transportation—unnecessary moving or handling, delays in
4. Socialization performed to improve
efficiency and
 moving material.
Productivity.
 Inventory—unnecessary stored materials, WIP, finished
Experimentation by Kaizen, TQM, Six  products.
the people at every Sigma,  Motion—movement of equipment, inventory, or people that
5. Continuous level toward JIT etc.
Improvement Improving their own  adds no value.
work systems.  Over processing—unnecessary processing and procedures
that add no value.
 Defects—producing defective products.
Supplier-customer Long term
relationship specifies cooperative
the form and Quantity relationship
of the goods and
services to be
provided, the way
6.Supplier-customer Requests are made by
Relationship each customer, and the
expected time In
which the request will
be met.
Coordination through go-see, involvement
7. Coordination rich communication is of
through required to suppliers early during
rich communication Develop the idea into PD
an innovation.
Every company Job rotation policy
depends on highly Fig. 7 Wastes
skilled engineers,
8. Functional expertise designers, and
and stability technicians to bring a
BENEFITS RESULTING FROM LEAN
product to the market; MANUFACTURING:
It is about developing
Lean manufacturing has a group of benefits for the growth course correction in strategy while implementing lean
of organization. The establishment of lean manufacturing throughout the organization. Some of the steps are as
will provide the following benefits for a particular follows:
organization
 Senior Management Involvement-For any major change,
1. Waste reduction by 75%-80% support and commitment from top management is vital. It is
very much possible that problems will arise when lean
2. Production cost reduction by 30%-40% implementation will progress and these issues must be
understood and solved by top management without effecting
3. Manufacturing cycle time reduction by 60%-70%
lean implementation process.
4. Labour reduction by 55%-65% 
 Initiate with smaller projects - Initial project must be small
5. Inventory reduction by 40% so that more resources are utilized and more chances are for
better results with lesser risk moreover people working on
6. Capacity increase by 40%-50% project and around will learn while doing project. The
results will motivate other to follow the same and people
7. Production of better quality will start having faith in lean techniques. So
recommendation is to start with smaller project at tool level.
Barriers to implement lean: 
 Start with limited execution – Lean implementation should
Barriers to Small Medium Large sized Sourc
Implement Organizatio sized Organizatio es be within limited area during start so that it can be
Lean ns Organizatio ns monitored, corrected and directed for further
ns implementation starting lean all-around the organization will
reduce control and mentoring of people involved in lean
Cost of the √ √ (1)
investment
implementation. Once movement is gained it should be
Insufficient √ √ (1) spread in other areas.
internal funding
Insufficient √ √ √ (1)  Employ a professional –Services of a professional mentor
supervisory
skills to
should be taken at least at the start. During conversion of a
implement lean conventional organization to a lean organization lots ofIssue
Insufficient √ √ √ (1), (2) will arise and should be handled professionally they can be
management taken care with the use of expert.
time 
Employee √ √ √ (1),
attitudes/resista (2), Obstacles in Lean Manufacturing implementation:
nce to change (3) 
Insufficient √ (1)  Lack of management support: the reason can be pressure
external
funding
from customer side; competitor is following lean practices
Insufficient √ √ √ (1) or others. In this case management just starts and does not
senior propel further this results only superficial lean and neither
management lean is implemented nor does it get benefit.
skills to

implement lean
Insufficient √ √ √ (1)  Lack of training: Another reason is lack of clear
workforce skills understanding about lean throughout the organization. The
to implement organization where knowledge of lean lacks it cannot be
lean implemented.
Cultural issues √ √ (1),
(4), 
(5)  Communication – Lack of communication is one of the
Insufficient √ √ (1), prime obstacles in lean manufacturing implementation.
understanding (6)

of the potential
benefits  Resistance to Change – Resistance to change is very
common phenomena as it increases fear of failure, initial
cost so many of routine liking people doesn’t want to change
 Lean Manufacturing Implementation strategies: Lean and hence it stops the progress of lean implementation.
manufacturing is a philosophy which cannot be 
implemented instantly so it requires tolerantly developing 
understanding within the organization about lean, starting  No direct financial advantage – Lean does not produces any
with smaller projects of lean at tool level, taking guidelines direct financial benefits but it helps in identification and
of an expert, making and following the strategy with due elimination of waste hence reduction of cost. Lean does not
have any financial measure in terms of input and output so 7. Hines, P., Holwe, M. and Rich, N. (2004), Learning to evolve: A
sometimes lean idea is superseded by other organizational review of contemporary lean thinking, International Journal of
Operations & Production Management, Vol. 24, No. 10, pp. 994-
priorities. 1011.
8. Lewis, M. A. (2000), Lean production and sustainable competitive
Past failures – In case of poor launching of Lean is itself big advantage, International Journal of Operations & Production
obstacle. Lack of implementation strategy may lead to lack Management, Vol. 20 No. 8, pp. 959-978.
9. Meier, H. S. and Forrester, P. L. (2002), A model for evaluating the
of faith in whole philosophy. degree of leanness of manufacturing firms, Integrated Manufacturing
Systems, 13, 2, pp. 104-109.
CONCLUSION: 10. Melton, T. (2005), THE BENEFITS OF LEAN MANUFACTURING
What Lean Thinking has to Offer the Process Industries, Chemical
This paper presents the review of lean thinking and its Engineering Research and Design, 83(A6), pp. 662–673.
11. Panizzolo, R., Garengo, P., Sharma, M. K. and Gore, A. (2012), Lean
concept through definitions from literature. The main focus manufacturing in developing countries: evidence from Indian SMEs,
of lean manufacturing is to eliminate waste, doing things Production
better in half of the resources as mass production requires, 12. Planning & Control, Vol. 23, No. 10-11, pp. 769– 788.
providing higher quality with lesser cost. More and more 13. Papadopoulos, T. C.and Ozbayrak, and M. (2005), Leanness:
experiences from the journey to date, Journal of Manufacturing
facets of lean manufacturing will come forth as researchers Technology Management, Vol. 16 No. 7, pp. 784-807.
are keenly bringing through continual research. The good 14. Piercy, N. and Rich, N. (2009), Lean transformation in the pure
understanding of lean principles and practices is required for service environment: the case of the call service centre, International
successful implementation of lean as lean practices without Journal of Operations & Production Management, Vol. 29, No. 1, pp.
54-75.
knowing lean principles can give short term success but may 15. Shah, R. and Ward, P. T. (2003), Lean manufacturing: context,
fail as long term strategy. The paper tried to present best practice bundles, and performance, Journal of Operations
way for lean implementation available in literature along Management, 21, pp. 129–149.
with discussion that lean is applied successfully in different 16. Shah, R. and Ward, P. T. (2007), Defining and developing measures
of lean production, Journal of Operations Management, 25, pp. 785-
sectors than automobile sector such as service sector, 805.
discrete manufacturing, etc. The recent literature shows that 17. Shah, R., Chandrasekaran, A. and Linderman, K. (2008), In pursuit of
the trend in lean manufacturing for research now is focused implementation patterns: the context of Lean and Six Sigma,
on lean assessment. Leanness attracts focus to answer International Journal of Production Research, Vol. 46, No. 23, pp.
6679- 6699.
specific questions of managers responsible for lean 18. Singh, B., Garg, S. K. and Sharma, S. K. (2010), Development of
implementation to assess the lean implementation level and index for measuring leanness: study of an Indian auto component
to justify spending over lean implementation. In this paper, industry, Measuring Business Excellence, Vol. 14, No. 2, pp. 46-53.
presents the review of barriers of lean implementation from 19. Sullivan, W. G., McDonald, T. N. and Van Aken, E. M. (2002),
Equipment replacement decisions and lean manufacturing, Robotics
literature review. Understanding the barriers is important for and Computer Integrated Manufacturing, Vol. 18, pp. 255-265.
managers to avoid failures and to sustain lean leap. The
future research may be to identify such barriers through
extensive literature review and interviews of working
professionals as very little work happened on this subject.
The way forward for research in this area may be multiple
criteria. The paper contributes by identifying enablers &
barriers in implementing the lean principles and practices,
methodologies used in leanness measurement of an
organization in the Indian manufacturing industry.
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1. Abdulmalek, F. A. and Fajgopal, J. (2007), Analyzing the benefits of lean
manufacturing and value stream mapping via simulation: A process sector
case study, Int. J. Production Economics, Vol. 107, pp. 223-236.
2. Bhasin, S. (2012), Performance of Lean in large organisations, Journal of
Manufacturing Systems, Vol. 31, 349-357.
3. Doolen, T. L. and Hacker, M. E. (2005), A Review of Lean Assessment in
Organizations: An Exploratory Study of Lean Practices by Electronics
Manufacturers, Journal of Manufacturing Systems, 24, 1, pp. 55-67.
4. Gurumurthy, A. and Kodali, R. (2009), Application of benchmarking for
assessing the lean manufacturing implementation, Benchmarking: An
International Journal, Vol. 16, No. 2, pp. 274-308.
5. Hallgren, M. and Olhager, J. (2009), Lean and agile manufacturing:
external and internal drivers and performance outcomes, International
Journal of Operations & Production Management, Vol. 29 No. 10, pp. 976-
999.
6. Herron, C. and Christian, H. (2008), The transfer of selected lean
manufacturing techniques from Japanese automotive manufacturing into
general manufacturing (UK) through change agents, Robotics and
Computer-Integrated Manufacturing, 24, pp. 524-531.
MIST BASED HVAC PERFORMANCE
OPTIMISATION OF AIR CONDITIONER
Rahul Singh Anoop Chauhan Aditya Dhawale AkshayBalkhande
MechEngg, MechEngg, MechEngg, MechEngg,
TGPCET, Nagpur TGPCET, Nagpur TGPCET, Nagpur TGPCET, Nagpur
[email protected] [email protected] [email protected] [email protected]
ABSTRACT: dissolved solids which will form scaling on the tubings thus
compromise on the heat transfer was upfront accommodated by
Air conditioning units are used for small and medium scale coating the tube by Teflon coating. The length of the condenser
residential buildings. With the ever increasing energy cost the tubes will be increased to compensate the reduction in heat
operations of the Air conditioners are further escalating the transfer.
allocated budgets. Our project aims at establishing easy,
practical and cost effective way to achieve the performance A mist box arrangement has been provided to the condenser. The
optimization without compromising the output (comfort levels). mist box includes fine orifice through which a spray of water will
The project will investigate and identify various possible and be discharged on the condenser coils. This arrangement has been
effective methods to improve thermal performance of existing installed at the inlet of the condenser circulation fan. Due to this
AC systems without retrofitting the cost centric components evaporation of water takes place and it results in the cooling of
(compressor, condenser, evaporator). the incoming ambient air.
Our project concentrates at optimization of the vapor based Due to continuous evaporation of water a residual of calcium
compression cycle. The energy efficiency can be achieved by carbonate remain on the tubings which results in scale
1 23 formation. This can be eliminated by coating a Teflon PTFE of
below measures ,
0.4mil (1mil= 0.01 inch). This will greatly increase the
a. Reducing compressor work/ power utilization performance of air conditioner and will increase the life of
b. Increasing cooling effect condenser.
c. Increasing temperature difference between condenser
and ambient air Keywords
(since Q α ∆T )
d. By using a material having high thermal conductivity Water mist, air cooled condenser, air conditioner, Thermal
(QαK) performance.
Considering the least amount of retrofitting is incurred for step INTRODUCTION:

a,b,c the project concentrates to achieve reduction in the
condenser pressure. Thus basic theme for achieving the energy Refrigeration system is used to provide cooling by the use of
efficiency is reduction of the condenser pressure. The reduction mainly four components Compressor, Condenser, expansion
in the condenser pressure is proposed by increasing the rate of
device and evaporator. These four components are operated
heat transfer; by increasing temperature difference between the
condenser tubing and surrounding. By spraying water around with a refrigerant which works as heat carrier in this system. It
4 5 extracts the heat from evaporator in the form of latent heat and
condenser theoretically air (at DBT ) can be cooled upto WBT .
Practically we have planned to undertake experimentations on rejects that heat to atmosphere through the condenser.
the proposed experimental setup. Before undertaking Therefore heat rejection capacity depends on difference
experimentation the Assessment Team knows that water contains between refrigerant temperature at condenser and atmospheric
temperature. Quantity of heat rejection also affects the
1 quantity of heat absorption through evaporator. It is clear that
HEAT AND MASS TRANSFER by R. K. RAJPUT more heat rejection will result more heat absorption.
2
ENGINEERING THERMODYNAMICS by P. K. NAG 6
3 Atmospheric temperature varies according to Environmental
BEE Book 03
4
THERMAL ENGINEERING by R. K. RAJPUT
5 6
Dry bulb temperature VCR is a closed loop system, the amount of heat extracted
6
Wet bulb temperature from the system will be equal to the amount of heat gainedto
condition i.e. during the summer atmospheric temperature condenser fans. These coolers are installed in front of air-
becomes higher which decreases the temperature difference cooled condensers to precool outdoor air before entering the
between refrigerant and atmosphere, results less heat rejection condensers. With the direct evaporative cooler, compressor
which decreases the overall performance of refrigeration power dropped following the decrease in the condensing
system. temperature in most operating conditions, while the pressure
drop across the cooler caused additional condenser fan power.
LITERATURE SURVEY: The overall saving of chiller power varied from 1.4 to 14.4%
Hassan et al. studied an innovative condenser for residential
Condenser Misting System is a cost-effective, sensible refrigerator. To allow for evaporative cooling, sheets of cloth
solution to capacity and energy usage issues that occur during were wrapped around condenser to suck the water from a
upper ambient temperatures. By injecting atomized water in water basin by capillary effect.
the inlet air of condenser the temperature is reduced and the
condenser is able to reject significantly more heat. This The experimental results showed that the dry bulb temperature
reduces the head pressure and compression ratio, so electrical of entering condenser air with water mist pre-cooling could
demand (kW) and usage (kWh) are reduced and cooling drop by up to 9.40 C from the ambient air temperature. COP
capacity is increased. Furthermore, these benefits are realized 7
could be improved by up to 8.6% his study showed that the
exactly when the load on the system created by high ambient water mist system coupled to air-cooled chillers is an energy
temperatures exceeds the system’s cooling capability i.e. the efficient and environment friendly technique. Kopko et al.
higher the ambient temperature, the better the performance of investigated evaporative cooling and conventional cooling for
the Condenser misting system. a split heat pump system. The evaporative condenser was
retrofitted onto an existing split heat pump system. For the
The Condenser Misting System is a simple, elegant, purpose of this test heat pump only operated in cooling mode.
measurable solution. With no moving parts to malfunction, it Two separate sections maintained indoor & outdoor conditions
is safe, dependable, and requires little maintenance. for the respective units.
Furthermore, the cost of the Condenser Misting System is
quickly recovered through reduced demand charges, energy In the evaporative condenser, as the disks rotate, their wetted
usage, water and sewerage usage. surfaces pull a film of water out of the bath into the air stream.
The passing air evaporates some of the water film, cooling the
Eghtedari H. et al. investigated about the Application of water that remains on the disks. This cooled water is returned
evaporative cooled air condenser instead of air cooled to the bath as the disks rotates, cooling the bath and thus the
condenser to solve the problem of maintaining higher COP in condenser tubes. The final results showed improved steady
hot weather conditions. He built an evaporative cooler and state performance; a higher capacity of COP by 11.1 to 21.6%.
coupled it to the existing air-cooled condenser of a split air R. Boukhanouf et al presented a computer model and
conditioner in order to measure its effect on the cycle experimental results of a sub-wet bulb temperature
performance. . Experimental results showed that application evaporative cooling system for space cooling in buildings in
of evaporative cooled air condenser has significant effect on hot and dry climates. The cooler uses porous ceramic
the performance improvement of the cycle and the rate of materials as the wet media for water evaporation.
improvement increases as ambient air temperature increases.
HajidavallooEbrahim investigated incorporation of The porous ceramic panels were placed between the dry and
evaporative cooling in the condenser of window-air- wet air ducts to form small and narrow ducts with air flowing
conditioner. An air conditioner was used to test the innovation at low velocity. The dry channel side of the porous ceramic
by putting two cooling pads in both sides of the air panel is sealed with a thin non-permeable membrane while the
conditioner and injecting water on them in order to cool down wet channel side allows water to sip through its micro-pores
the air before passing it over the condenser. onto its surface forming a thin water film. This allows direct
contact with the airflow and hence causing water evaporation.
The experimental results show that thermodynamic The air streams in the dry and wet channel flow in counter
characteristics of new system are considerably improved. The flow arrangement and the supply air exchanges sensible heat
power consumption decreased by about 16% and the with the water in the porous ceramic panels that in turn are
coefficient of performance increased by about 55%.Chan et al. cooled through water evaporation on the wet channel side.
described how direct evaporative coolers can be used to This results in a drop in temperature of the air in the dry
improve the energy efficiency of air-cooled chillers in various channel without changing its moisture content while the air in
operating conditions and with different strategies for staging the wet channel is rejected at saturation state. Under selected
the refrigerant. So the refrigerant will dissipate heat through 7

= 1−2 =
the condenser. −
1 ℎ
o
test conditions of air flow dry bulb temperature of up to 45 C condenser. A detailed model is developed and numerical
and relative humidity of up to 50%, it was found that the simulations are carried out using finite difference techniques.
supply air could be cooled to below the wet bulb temperature The simulations are performed for a single unfinned tube of
with a maximum cooling capacity of 280 W/m2 of the wet the condenser with the air flowing across the tube. Water is
ceramic surface area. It was also shown that the overall wet sprayed on top of the tube in the form of fine sprays and the
bulb effectiveness is greater than unity. This performance flow rate is set to achieve film thicknesses of 0.075, 0.1, and
would make the system a potential alternative to conventional 0.15 mm, respectively. The tube wall temperature is assumed
mechanical air conditioning systems in hot and dry regions. constant due to the fact that for most of the tube length,
K.A. Jahangeer et al. [8] concentrated on lowering of the condensation of the refrigerant occurs at the saturation
condensing temperature will help to reduce compressor temperature of the refrigerant. Wall to air overall heat transfer
pressure lift, thereby reducing the power required by the coefficient value as high as 2000 W/m2 K was observed with
compressor. This paper reports a numerical investigation of the incorporation of the evaporative cooling.
the heat transfer characteristics of an evaporative-cooled
Fig P-H Diagram Of The Conventional And Mist based Air Conditioning System
Many studies report that reduced compressor discharge supply water will consists of condensate of air conditioner &
pressures and the corresponding reduction of compression make up water.
ratios in a refrigeration cycle are advantageous when it comes
to HVAC energy saving and increasing its service time. There The supply water contains sediments & suspended solid
are, however, some solutions to significantly particles which deposits as a hard layer on the condenser tubes
lower compressor discharge pressures whilst preventing so compensation is made on the heat transfer rate for the
the flash vapour occurrence. For example, pre-cooling the protection of condenser tubes which involves a coating of
ambient air before it reaches the air-cooled condenser of the Teflon FEP on the condenser tubes. This eliminates the risk of
vapour compression cooling systems can reduce the hard deposited scaling layer over condenser.
condensing temperatures to drop the condensing pressure.
Yu and Chen investigated how the coefficient of This arrangement facilitates the efficient utilization of energy
performance (COP) of air-cooled chillers can be improved by reducing compressor work and increasing heat transfer rate.
by using mist pre-cooling. They estimated around 18%
decrease in the annual electricity usage could be achieved
with mist pre-cooling of air entering the air-cooled condenser CALCULATION:
of chiller, used to serve a hotel in a sub-tropical climate. The
8 Based on the modifications of our project, we have stated the
application of LPA to air cooled air conditioning systems can effect on heat transfer rate theoretically. The following are the
assist in achieving a considerable reduction in compressor calculation which shows the percentage increase in the length
discharge pressure. LPA can be realized with a hermetically- of copper tubes.
sealed, magnetically-driven liquid refrigerant
pump installed in the liquid line between the condenser For Bare Copper tube:
and expansion valve. The LPA pump increases the
pressure of the liquid refrigerant before it enters the expansion = 1 { 1 + 1 ln 2
+ 1 }
valve. This method allows the condensing temperature to
fluctuate with ambient temperature changes, and hence, 2
ℎ
1 1
ℎ
reducing the condensing pressure and lowering overall energy For coated Copper Tube with Teflon:
consumption.
1 1 1 1 1
= { + ln 2
+ ln( 3
)+ }
METHODOLOGY:
ℎ ℎ
2 1 1 2 2
The Paper “MIST BASED HVAC PERFORMANCE Where:

OPTIMISATION OF AIR CONDITIONING” relates to
highly efficient air conditioning units; and more specifically, K1 = 375 W/mK
to a method of improving the efficiency of the air cooling
function in air conditioners by dispersing a Water or vapour K2 = 0.25 W/mK
mist onto the condensers of air cooling units effectively and 0 2 -3
efficiency thereby reducing the use of power by the condenser ha= 10 w/m r1 = 6.15*10 m
and reducing the time the condenser must run. -3
r2 = 6.35*10 m
The proposed setup applies Water or mist to a condenser by -3
utilizing a mist dispersal system for dispersing Water or r3 = 6.39*10 m
vapour mists over a condenser unit. As described herein,
dispersing Water or vapor mist onto the condenser of an air
cooling unit, improves the efficiency of the air cooling 1 [ 1 −3
= + 1 ln 6.35 ∗ 10
function in air conditioners. The setup provides a novel
project and method for increasing the efficiency of the air 1
2 ∗ 1 10 ∗ 6.15 ∗ 10−3 375 6.15 ∗ 10−3
conditioner. 1
+ ]
The heat transfer through the condenser can be increased by 10 ∗ 6.35 ∗ 10−3
spraying a fine mist of water on the condenser. This can be = 5.0942

done with the help of a fine orifice nozzle attached to a supply
1
pipe of water. The condenser will be surrounded by a cage of 1 1 1 6.35 ∗ 10−3

= { + ln
piping arrangement to which orifice will be connected. The 2
2 ∗ 1 10 ∗ 6.15 ∗ 10−3 375 6.15 ∗ 10−3
1 6.39 ∗ 10−3 1
8
LPA – Liquid Pressure Amplification Pump + ln(
−3
)+
−3
}
. 25 6.35 ∗ 10 10 ∗ 6.39 ∗ 10
2 = 5.0825
% of Increase Q = 1− 2
1
CONCLUSION: Q = 5.0825 −5.0942 5.0942

Q = 2.2967*10−3
= 0.2296%
The dependency of air cooled condensers on the ambient air REFERENCES:

temperature prevents it from giving a constant performance.
Here the water cooled condensers prove beneficial as their 1. Yu, F.W, Chan, K.T. 2005. Energy signatures for
performance is independent of the atmospheric temperature. A assessing the energy performance of chillers Energy
golden mean has to be achieved. There are lot of and Buildings. Vol. 37, pp 739-746.
investigations carried out on the performance improvement of 2. Wen-jei yang and D. W. Clark Spray Cooling of Air
air cooled condensers using evaporative cooling. The cooled compact heat exchanger.
evaporative cooling is generally achieved by evaporating 3. A text book of Refrigeration and air conditioning by
some portion of water which will cool the remaining water. R.S Khurmi and J.K Gupta, Edition 2006, Page 43
The evaporating cooling may be direct or indirect. Depending 4. Engineering Thermodynamics, Fourth Edition by
upon the atmospheric conditions and system parameters either P.K Nag, Page 583
may be more effective. From the papers reviewed here it can 5. Air conditioning and refrigeration by Rex Miller and
be concluded that the performance of air cooled condensers Mark R. Miller, Page 56
can be improved up to some extent. Many different methods 6. Refrigeration and air conditioning by G.F Hundy,
like using cooling media, water mist spraying etc. can be Page 16
used.There is scope for exploring different cooling media’s. 7. Engineering Thermodynamics, Fourth Edition by
Many other different innovative methods for evaporative P.K Nag, Page 583
cooling can still be developed. 8. A text book of Refrigeration and air conditioning by
R.S Khurmi and J.K Gupta, Edition 2006, Page 44
Based on the research, we have reached to a conclusion that
by using a mist box arrangement, we can improve the
performance
IMPORTANCE OF RENEWABLE ENERGY IN
AGRICULTURE
Shubham Thakre Shrikant Kothari Mr.Vishwjeet.V.Ambade
Tulsiramji Gaikwad- Patil College Tulsiramji Gaikwad- Patil College Assistant Professor,Tulsiramji
of Engineering, Buttibori of Engineering, Buttibori Gaikwad- Patil College of
Nagpur,441108(MS)India Nagpur,441108(MS)India Engineering, Buttibori
,Shubham Sarde Nitin Mirge Nagpur,441108(MS)India
Tulsiramji Gaikwad- Patil College Tulsiramji Gaikwad- Patil College
of Engineering, Buttibori of Engineering, Buttibori
Nagpur,441108(MS)India Nagpur,441108(MS)India,
Abstract- is available from different sources as human, animal, sun, wind,

biomass, coal, fertilizer, seed, agro-chemicals, petroleum products,
Energy is one of the major parameters for establishing growth electricity etc. Energy sources that release availableenergy directly to
and progress of the country, rather the standard of living the system are classified as direct energy sources. Renewable energy
depends directly upon the per capita energy consumption. Most and farming are a winning combination. Wind, solar, and biomass
of energy on the earth is received from the sun. Solar energy energy can be harvested forever, providing farmers with a long-term
creates circulation of wind and ocean water, causes water source of income. This paper is an overview of renewable energy
evaporation and consequent precipitation. Plants use solar uses for farmers and ranchers on how they can help make renewable
energy for photosynthesis and store carbohydrates, protein, fats, a growing source of energy and rural income in India.
oils, alcohols, cellulose and lignin.. In agricultural systems, energy
Keywords: Photosynthesis, Yard, Manure, Agrochemicals distribution systems. The power from the sun intercepted by
ll
the earth is approximately 1.8 x l0 MW. This makes it one of
I. INTRODUCTION the most promising unconventional energy sources. Solar
energy is available in abundance in most part of our country
Use of renewable energy in farming systems can mean several throughout the year. In India,' the annual average daily solar
different things. For example, fossil fuels such as oil are non- radiation received over the whole of the country is around
renewable, so finding alternative ways of fertilizing the land 2
1800 J/cm /day. Drying of various agricultural produce in
and controlling pests that do not depend on chemicals, will
open sunlight is an age-old practice. Development of various
normally involve the use of renewable resources. Such solar devices for thermal applications such as water heating
methods reduce farmers‟ vulnerability to the rising price of and space heating, drying, cooking and power generation
oil. Renewable energy also includes generation of power to do began during the most centuries.
a number of farm tasks: pumping water for irrigation, for
livestock or for domestic use; lighting farm buildings;
powering processing operations and others. These forms of
renewable energy include solar energy, wind and water
power, oil from plants, wood from sustainable sources, other
forms of biomass (plant material), and biogas (gas produced
from fermentation of manure and crop residues).
II. SOLAR ENERGY
Widespread use of solar energy for domestic, agricultural and

agro-industrial activities has been practiced almost since the
development of civilization. Increasing threat of acute
shortage of the commercial sources of energy coupled with Fig.1Solar PV panels providing green energy for agricultural
serious environmental pollution problems has accelerated growth
interest in the scientific exploitation of renewable sources of
energy. Energy available from the sun is inexhaustible and 2.1. Solar cookers
environment friendly.
Two different types of solar cookers i.e. indirect and direct
Therefore, the solar energy technologies are likely to play an focusing type have been developed in the country. The
important role in the near future through a variety ofthermal indirect type solar cookers consisting of an insulated box with
applications and decentralized power generation and transparent window through which sunlight enters into the box
have been satisfactorily developed and commercially
exploited for domestic cooking. Such solar cookers are being
marketed on commercial scale in most of the states through
State Energy Development Corporations or other nodal
agencies of the Ministry of Non-conventional Energy Sources
(MNES), Government of India.
2.2. Solar dryers
Open sun drying of various agricultural produce is the most

common application of solar energy. With the objective of
increasing the drying rate and improving quality of the
produce, natural convection and forced convection type solar .
dryers have been developed for various commodities. The Fig3. Solar Water Heating system
movement of air in the forced convection solar dryer is
through a power blower whereas in natural convection solar 2.4. Solar photovoltaic systems
dryer air moves through the produce due to natural thermal
gradient. In solar photovoltaic (SPV) technology the solar radiation
falling on a device called solar cells and is converted directly
into electricity without any environmental pollution. Spy
pumping systems are ideal for lifting water for drinking and
irrigation without harming the environment. These pumps can
be installed in boreholes, tanks, cisterns or rivers. DC surface
pumps are designed for high flow rates at low heads. DC
floating pumps are suitable for wide range of flow and head
situations.
III. HOW WIND ENERGY CAN HELP FARMERS
Farmers and ranchers are in a unique position to benefit from

the growth in the wind industry. To tap this market, farmers
Fig.2 Rice grains dried using solar Dryer can lease land to wind developers, use the wind to generate
power for their farms, or become wind power producers
2.3. Solar water heater themselves. Farmers and ranchers can generate their own
power from the wind .Small wind generators, ranging from
Water heating is one of the most common applications of 400 watts to 40 kilowatts or more, can meet the needs of an
solar energy for domestic and industrial applications. Similar entire farm or can be targeted to specific applications. In
to solar dryers, water heating systems are also available in Texas and the West, for example, many ranchers use wind
natural convection and forced convection designs. Natural generators to pump water for cattle. Electric wind generators
convection water heating system is known as thermo syphon are much more efficient and reliable than the old water-
water heating system.It consists of a flat plate solar collector, pumping fan-bladed windmills. They may also be cheaper
insulated water storage tank and necessary insulated pipe than extending power lines and are more convenient and
fittings. cheaper than diesel generators.
"Net metering" enables farmers to get the most out of their

wind turbines. When a turbine produces more power than the
farm needs at that moment, the extra power flows back into
the electricity system for others to use, turning the electric
meter backwards. When the turbine produces less than the
farm is using, the meter spins forward, as it normally does.
At the end of the month or year, the farmer pays for the net
consumption or the electric company pays for the net
production. Net metering rules and laws are in place in most
states.
Water is a resource that may create tensions among countries
down and upstream. Irrigated agriculture is driving much of
the competition since it accounts for 70-90% of water use in
many of these regions. Water used for agriculture comes from
natural or other alternative sources.
Natural sources include rainwater and surface water (lakes and

rivers). These resources must be used in a sustainable way.
Rain water resources rely on the atmospheric conditions of the

Fig.4Wind farms as a source of energy for the farmers area. Surface water is a limited resource and normally requires
the construction of dams and reservoirs with a significant
environmental impact. Alternative sources of irrigation water
are the reuse of municipal wastewater and drainage water.
IV. EFFECTIVE UTILISATION OF HYDRO ENERGY
ON AGRICULTURE However the use of recycled water for irrigation may have
some adverse impacts on the public health and the
Hydroelectric power comes from the natural flow of water. environment. This will depend on the recycled water
The energy is produced by the fall of water turning the blades application, soil characteristics, climate conditions and
of a turbine. The turbine is connected to a generator that agronomic practices.
converts the energy into electricity. The amount of electricity
a system can produce depends on the quantity of water Therefore it is important that all these factors are taken into
passing through a turbine (the volume of water flow) and the account in the management of recycled water.
height from which the water „falls‟ (head). The greater the
flow and the head, the more electricity produced. Water reuse for irrigation is a normal practice worldwide. In
Europe, for example there is a large project in Clermont-
3
Hydropower is a clean, domestic, and renewable source of Ferrand, France since 1997 where more than 10.000m /day of
energy. It provides inexpensive electricity and produces no tertiary treated urban wastewater are reused for irrigation of
pollution. Unlike fossil fuels, hydropower does not destroy 700Ha of maize. In Italy more than 4000 Ha of various crops
water during the production of electricity. Hydropower is the are irrigated with recycled water. Spain also counts with
only renewable source of energy that can replace fossil fuels‟ several similar projects. The water quality used for irrigation
electricity production while satisfying growing energy needs. is essential for the yield and quantity of crops, maintenance of
soil productivity, and protection of the environment. For
Hydroelectric systems vary in size and application. Micro- example, the physical and mechanical properties of the soil,
hydroelectric plants are the smallest types of hydroelectric ex. soil structure (stability of aggregates) and permeability are
systems. They can generate between 1 kW and 1 MW of very sensitive to the type of exchangeable ions present in
power and are ideal for powering smaller services such as irrigation.
processing machines, small farms, and communities. Large
hydroelectric systems can produce large amounts of
electricity. These systems can be used to power large
communities and cities.
4.1. Water use for irrigation
Agriculture is by far the largest water use at global level.

Irrigation of agricultural lands accounted for 70% of the water
used worldwide. In several developing countries, irrigation
represents up to 95% of all water uses, and plays a major role
in food production and food security. Fig.5Hydroenergy (water from dams)is used for
irrigation purpose.
Future agricultural development strategies of most of these
countries depend on the possibility to maintain, improve and V. ROLE OF BIOMASS
expand irrigated agriculture.On the other hand, the increasing
pressure on water resources by agriculture faces competition Authorities‟ studies reveal that that the forest cover of country
from other water use sectors and represents a threat to the is depleting every year at a rate more than 1.5 million
environment. hectares. The situation is particular grave in rural areas. This
rate of deforestation is alarming. Much of the wood felled is VI. CONCLUSION
used as fuel for cooking. Charring and briquetting
technologies reduce various problems associated with the The only realistic solution to the problem go non-renewable is
management and utilization of biomass in domestic and to find sources of renewable energy to replace today‟s
industrial sectors. Briquetting of some of the crop residues has dwindling supplies of affordable and usable fossil energy.
becomes cost competitive and the briquettes being used as Solar energy is the only source of truly renewable energy –
replacement of firewood in many regions of the country. renewable at least for the next few billion years. Windmills,
falling water, solar collectors, and photovoltaic cells are all
sources of renewable solar energy. The most common solar
energy collectors are green plants. After all, plants were the
original collectors of today‟s fossil energy. So, it‟s only
logical to look to agriculture as a renewable source of
alternative energy for the future. However, we need to be
realistic about the extent to which energy from agriculture can
replace our current use of fossil energy. While the energy
experts may not agree on specific quantities or percentages,
the overall limits on energy from agriculture are fairly basic
and straightforward.
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[1] Patrick Murphy, Plan C: Community Survival Strategies for Peak Oil and
Climate Change (Gabriola Island, BC: New Society Publishers, 2008).
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account for increased energy use from earlier estimate published in David and
Marcia Pimentel, Food, Energy, and Society (Niwot, CO: University Press of
Colorado), 1996.
[3] David and Marcia Pimentel, Food, Energy, and Society (Niwot, CO:
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[4] Energy estimates in this paragraph also from Pimentel, Food, Energy, and
Society.
[5] Susan S. Lang, Cornell University News Service, “Cornell ecologist's

study finds that producing ethanol and biodiesel from corn and other crops is
Domestic biogas plants instal1ed in our country use cattle not worth the energy,”
dung mixed with an equal quantity of water to maintain 8-9%
total solids concentration (TSC) in the influent sl7urry. The [7] Dave McShaffrey, “Environmental Biology- Ecosystems,” Department of
Biology and Environmental Science, Marietta College
effluent discharged from the plants is, in general, col1ected http://www.marietta.edu/~biol/102/ecosystem.html.
into the slurry pits or spread on to the ground for drying
before transportation to fields for use as organic manure. [8] Aldo Leopold, A Sand County Almanac, “The Land Ethic” (1949, New
York: Ballantine Books, 1966), 252.
[9] David and Marcia Pimentel, Food, Energy, and Society.
[10] Helen York, “From the Farm to Your Table,” World Ark, Heifer
International, May/June 2008: 28-31.
[11] Congress of the United States, Congressional Budget Office. “The

Economic Effects of Recent Increases in Energy Prices.” Available [Online]
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Staecker, E. Ma, L. Brueckner, L. Trovato, C. Chow, U. Govindarajulu, and
S. Boerke. “Renewable Energy: Economic Issues.” BioScience, 44(8), 1994.
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B. Horan, G. Keppy, A. Rider, D. Villwock, S. Wyant, and E. Shea. “25 by 25 accessed April, 2008.
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“DESIGN AND FABRICATION OF REVERSE
GEAR MECHANISM IN HANDICAPPED PERSON
VEHICLE-
AN OVERVIEW”
A.S Puttewar Latikesh Khedkar
Assistant Professor, Department of Mechanical
Engineering, Dr. Babasaheb Ambedkar College of Undergraduate Students, Department of Mechanical
Engineering and Research,Wanadongri, NAGPUR – Engineering, Dr. Babasaheb Ambedkar College of
441110, Engineering and Research,Wanadongri, NAGPUR –
441110
Krishna Yadav
Ashwin Gajbhiye
Undergraduate Students, Department of Mechanical
441110 Engineering and Research,Wanadongri, NAGPUR –
441110
Ketan Warjurkar
Bhimrao Devtale
Undergraduate Students, Department of Mechanical
441110 Engineering and Research,Wanadongri, NAGPUR –
441110
ABSTRACT I. INTRODUCTION
Mobility of physically disabled persons is a concerning Nowadays, the intensity of traffic on Indian roads is increasing
social issue nowadays.In case of the handicapped people, at high pace.As in this date there are many options for
who drive two wheelers with extra support wheels face transportation available for physically challenged persons like,
much problem to take the vehicle out of the parking by Motorized wheel chair, Hand powered tri-cycle, Scooters..etc.
pushing the vehicle with legs. In order to take the vehicle The problem associated with motorized wheel chair is that it
out of the parking, they need to seek others help or they way too costly and is not suitable for commuting. Hand
should push it out of the parking. As a help to them this powered tri-cycle requires heavy human effort. So, disable
research paper aims at designing and fabrication a reverse people, now days prefer two wheelers as better mode of
gear mechanism, which will be fitting to the vehicle with transportation.Since it is comfortable and cost efficient.The
little modifications of the existing mechanism. major problem associated with the two wheelers that are
available in India is that they don‟t have provision for
Keywords: Mobility, Handicapped person, reverse reversing the scooter which is very much necessary for a
gear mechanism. disable person. In order to overcome this drawback, we‟ve
designed and fabricated a vehicle with reverse mode.
II. LITERATURE REVIEW V.DESIGN CALCULATION
G.Satish Kumar, et al. [1] This research paper gives
the detail about designed a gear box which will be fit to the Design of gear box:
rear side of vehicle without altering the existing gear
box.Vinod K. Banthia, et. al [2] This research work deals with Concept:
feasible design solution in form of a user friendly three
wheeler vehicle, which allows physically challenged people to The engine drives provides the power to the gear box and the
commute on their own and perform their activities without gear gives out the power to the rear wheel in two direction
anyone‟s assistance, has been proposed.Sandesh G.Ughade, et .when output in clockwise direction the vehicle move forward
al. [3] This paper gives the details about the solar power and when the output is in counter clockwise direction vehicle
tricycle project and includes the methods and considerations moves backward. Thus reversing of the vehicle can be
regarding the proper working of the tricycle.Ajit A. Mohekar, achieved.
et al. [4] This paper discusses an attempt to design and
fabricate a retrofitted tricycle for disabled people. This The following calculations are to be performing for the
tricycle is specifically designed to suit wheelchair designing and fabrication of the reverse gear mechanism.
occupants.Arpit Mehra, et al. [5] In this paper, an attractive
(1) Design of gear box.
modern electric car also called Electro Handy has been
designed for handicapped people. Electro Handy is a powerful  Input Gear.
car for disabled people powered by rechargeable battery.  Intermediate Gear.
 Output Gear.
After going through the exhaustive literature survey, we   Gear ratio calculation.
very well understood that it is very difficult for handicapped (2) Design of Shaft.
person to drive the vehicle on the road due to heavy intensity  Input Shaft.
and as well as for parking and un parking vehicle.  Intermediate Shaft.
 Output Shaft.
III. METHODOLOGY
The following methodology is adopted for the designing and (3)Design and selection of bearing.
fabrication of the reverse gear mechanism:
 Design Calculations. (4)Design of frame.
 Identification of components.
 Fabrication and assembly of mechanism. (5)Selection of Suspension system.
 Inspection and Testing. VI. IDENTIFICATION OF COMPONENTS
 Result and Conclusion.
 Moped vehicle.
IV. PROPOSED SKETCH  Two wheels with tyre.
 Axel shaft.
 Suspension system.
 Gear box of autorikshaw‟s.
 Frame.
 Hand lever for shifting gear.
Vehicle
Gearbox Conceptual Sketch
[3]Sandesh G.Ughade, „„Literature Review on Solar Powered Tricycle for
Handicapped Person”, International Journal for Innovative Research in
Science & Technology, Volume 1, Issue 10, March 2015.
[4]AjitA.Mohekar, „„DesignOfAn Innovative Retrofitted Tricycle For A
Disabled Person”ISSSN, Volume No 4, Issue 07, July 2015.
[5]Arpit Mehra, Arindam Ghosal, „„A 3- Wheels Electric Car For Physically
Disabled People”, International Journal Of Innovative Technology And
Exploring Engineering, ISSN: 2278-3075, Volume-3, Issue-11, April 2014.
[6] V.Subrahmanyam, „„Fabrication of Tri-wheeled Electric Vehicle to Aid
Disabled”, International Journal of Technology Enhancements and merging
Engineering Research, Volume 3, Issue 04, ISSN 2347-4289,feb 2012.
[7] R.S.Khurmi, Gupta - “Design of Machine Elements”, 14TH
revisededition, 2013.
Tyre Axle shafts
Gearbox
Suspension system Frame
VII.CONCLUSION
Thus, by adopting the methodology as discussed above the

design and fabrication of vehicle will be carried out. The
designed vehicle will prove to be of great importance for the
handicapped persons and aid them in driving on the heavy
traffic intensity roads. Also it will provide a lot of comfort and
safety while driving. So, implementing our project will
surelyprovide mobility to all disabled people without any help
from others.
VIII. REFERENCES
[1]G.Satish Kumar, “Development and Implementation of Reverse Drive

Mechanism in Bikes”, International Journal of scientific research, To
fabricate the designed gear mechanism,volume3,Issue 11,ISSN No-2277-
8179,nov 2014.
[2]Vinod K. Banthia, “Design of Three Wheeler Vehicles for Physically
Challenged People”, SAS Tech Journal, Volume 12, Issue 1, April 2013.
INTRODUCTION TO HYBRID VEHICLE
SACHIN KHOBRAGADE MOHANKHANGAR AKSHAY DHANORKAR
ABSTRACT extended range and avoid frequent refueling that

A'gasoline-electric hybrid car' or 'hybrid electric vehicle' is consumers expect from a conventional vehicle, with a
a vehicle which runs on batteries as well as on the internal significant portion of the energy and environmental
combustion engine which drive a generator cum motor to benefits of an electric vehicle. The practical benefits of
provide the electricity and also the vehicle. It has great
HEVs include improved fuel economy and lower
advantages over the previously used gasoline engine that
drives the vehicle from gasoline only. It is also a major emissions of the full host of criteria pollutants, as well as
source of air pollution. The objective is to design and CO2, compared to conventional vehicles.
fabricate a hybrid electric vehicle powered by battery and Modern HEVs make use of efficient technologies
gasoline both. The combination of power makes the vehicle such as regenerative braking, which converts the kinetic
simple in nature and efficient. It provides its owner with energy of vehicle into electric energy to charge the
advantages in fuel economy. battery, rather than wasting it as heat energy by
conventional braking system. Some type of HEVs use
Hybrid electric vehicles combine an electric motor, their internal combustion engine to generate electricity by
battery and power system with an internal combustion
rotating an electrical generator to generate the electricity
engine to achieve better fuel economy and reduce the
pollution emissions. In HEV, the battery alone provides and recharge the batteries or to directly power the electric
power for low-speed driving conditions where internal motors. Many HEVs reduce idle emissions by shutting
combustion engines are less efficient. In long highways, or down the IC engine at idle and restarting when it needed
hill climbing the electric motor provides additional power to this is known as a start-stop system. A HEV produces less
assist the engine. Thus a smaller, more efficient engine can emissions from its IC engine as compare to the normal
be used. Besides it also utilizes the concept of regenerative gasoline car, therefore in HEV the engine is
braking for optimized utilization of energy. Energy comparatively smaller in size as normal gasoline car.
dissipated during braking in HEV is used to charge the
battery. Thus the vehicle is best suited for growing urban
CONSTRUCTION
areas with high traffic.
Hybrid electric vehicle consist of an electric
KEYWORD
Regenerative braking system, plug in hybrid, series and storage device such as battery and ultra-capacitor. They
parallel hybrids, Supervisory Control, Four wheel drive also combines the energy storage source with a
mechanical device are internal combustion engine, fuel
INTRODUCTION cell. This combination reduces both fuel consumption and
Ferdinand Porsche in 1901 developed the tailpipe emission.
Lohner-Porsche Mixed Hybrid, the first gasoline electric
hybrid automobile in the world. The hybrid-electric
vehicle did not become widely available until the release
of the Toyota Prius in Japan in 1997, followed by the
Honda Insight in 1999 While initially perceived as
unnecessary due to the low cost of gasoline, worldwide
increase in the price of petroleum caused many
automakers to release hybrids in the late 2000s; they are
now perceiving it as a core segment of the automotive
market of the future.A hybrid electric vehicle is a
combination of gasoline or diesel vehicle and electric .
vehicle which combine’s a conventional internal
combustion engine with an electric motor to obtain the Figure 1; show the construction of hybrid vehicle
maximum fuel efficiency. This combination offers the with regenerative braking system
The hybrid vehicle serves several advantages advanced technologies to reduce emissions and increase
over pure electric vehicle because hybrid vehicle engine efficiency. Receives its energy from the fuel tank where
shares the workload with electric motor. And also it allow the gasoline is stored.
to construct the engine smaller in size and reduces the
weight and give good fuel economy. Also hybrid electric
vehicle engine can be optimized to operate within the
specific speed range characterized by better fuel economy GENERATOR
and reduces emission. This eliminate the poor fuel
economy. The generator is similar to an electric motor, but
it acts only to produce electrical power for the battery.
One of the most important advantages of hybrid
vehicle is regenerative braking system. In which POWER SPLIT DEVICE
powertrain converts stored energy into vehicle motion
The power-split-device resides between the two
moreover, it convers vehicle motion back into stored
motors and together with the two motors creates a type of
energy through the use of regenerative braking.
continuously variable transmission.
Regenerative braking system provide vast benefits and
estimated 60% of the total energy consumption in urban ELECTRIC MOTOR
driving is spent for overcoming the effect of inertia.
Means half of energy may be recovered in hybrid electric The electric motor on a hybrid car acts as a
vehicle. motor as well as a generator. For example, when needed,
it takes energy from the batteries to accelerate the car. But
The hybrid vehicle contain the following main acting as a generator, it slows the car down and returns
parts that is energy to the batteries.
1) Battery WORKING
2) Internal combustion engine
3) Generator The hybrid electric vehicle work and constructed
4) Power split device in two way are,
5) Electric motor
1) Series hybrid vehicle
2) Parallel hybrid vehicle
SERIES HYBRID VEHICLE
Figure 2; show the parts of hybrid electric vehicle
BATTERY
The batteries in a hybrid car are the energy Figure 3(A) schematic of a series hybrid propulsion
storage device for the electric motor. Unlike the gasoline system
in the fuel tank, which can only power the gasoline
engine, the electric motor on a hybrid car can put energy In a series hybrid the IC engine runs an electric
into the batteries as well as draw energy from them. generator which produces electricity to charge batteries.
The batteries drive the electric motor to run the vehicle –
INTERNAL COMBUSTION ENGINE (ICE) the arrangement is similar in principle to well-known
diesel-electric locomotives. Since the engine does not
The hybrid car has an ICE, also known as a
`see’ the wheel, it can be made torun at an optimized
gasoline engine, much like the ones found on most cars.
operating condition (best in terms of fuel efficiency and
However, the engine on a hybrid is smaller and uses
emissions). The DC motor driving the wheel can take care
of all vehicle speed changes. It is also possible to charge energy in a high voltage battery. This process known as
the batteries by connecting to external grid power, and regenerative braking. The electric motor can the used this
depending on the storage capability of the batteries the stored energy when driving or acceleration.
vehicle can run in a purely electric mode for certain
distances with the IC engine started only when the Regenerative braking make it possible to
batteries are almost discharged. increase the range of electric vehicle and reduces the fuel
consumption and carbon footprint of hybrid vehicle.
PARALLEL HYBRID VEHICLE
When braking in the hybrid vehicle the electric
In a parallel hybrid, the power can flow in motor switches to generator mode. The wheel transfer
parallel to the wheels from either the batteries or the IC kinetic energy via the drivetrain to the generator. The
engine. An electronic controller can sense the load and generator turns in a similar way to a bicycle light
speed of the wheel/vehicle and using built-in algorithms, generator transfer part of kinetic energy into electrical
the power can be made to flow either from the batteries or energy which is then stored in a high voltage battery at the
the IC engine or from both. In most urban driving same time generator resistance produces from the
(especially in crowded and narrow streets in less electricity created slow the vehicle. When more braking
developed countries), the peak speed or power is rarely torque is required then additional braking is provided by
required. In such situations, the parallel hybrid can be frictional brakes.
configured in a way such that most of the time, the
vehicle runs on batteries resulting in low emissions and In many situation the generator braking power is
high fuel efficiency. sufficient to slow the vehicle as desired by the driver as a
result the friction brakes is used less often for example in
instances of very rapid deceleration at very low speed and
stationary regenerative braking contributes toward
increasing the range of electric vehicle it help to save fuel
in hybrid vehicle and to reduced emission of CO2 and
pollutants particularly in urban traffics situation involving
frequent braking and acceleration using the generator for
braking also reduces brakes wear and the buildup of
brakes dust.
Regenerative braking system control the

interaction between frictional brakes and the generator to
generate efficient energy. Recuperation they also ensure
that deceleration behavior and pedal feel are identical to
Figure 3(B) schematic of a parallel hybrid propulsion conventional braking system.
system
The generator braking potential is dependent on
Only when required, power can be added to the the engine driving speed. At low engine speed maximum
wheels from the IC engine. In this framework, the IC braking torque is available. At high or very low speed,
engine, the batteries and generator, and the electric motor sufficient braking torque cannot be provided meaning the
individually need not be designed to meet peak friction brakes must be activated. Generator brakes torque
requirements. This makes a parallel hybrid configuration is proportional to the generator output and is also
potentially cheaper. There is the added complication of influenced by the battery level of charge. Brake torque
designing power trains where power can be added and use from the generator is only available when the high voltage
of an electronic controller. The basic parallel hybrid battery is not fully charge.
architecture of figure is often implemented in several
ways. Figure shows four ways a parallel hybrid Brakes torque is distributed between the
propulsion system can be implemented. frictional brakes and generator taking safety comfort and
efficient criteria into consideration. If the vehicle becomes
REGENERATIVE BRAKING SYSTEM unstable. It is usually deceleration safely via the friction
brake as wheel specific invention of the antilock braking
When braking in a conventional system or electronic stability program.
vehicle, the friction brakes converts much of the kinetic
energy into heat that is emitted unused into the CONCLUSION
environment. Hybrid vehicle with regenerative braking
system are different in that they recover some kinetic HEV is a vehicle that uses two sources of
energy by the electric motor and stored it as an electric power- gasoline and battery. For low power
application battery drive is used whereas for high
power application where power requirement is very India, Division of Instrumentation & Control Engg.,
NetajiSubhas Institute of Technology, Dwarka New Delhi,
high gasoline engine is used. Gasoline drive is most India
efficient at high speed drive. Thus HEV’s both mode Journal of Power Electronics, Vol. 11, No. 4, July 2011,
of operation occurs at their maximum efficiency. But pp.393-400
in gasoline engine low speed operation is not 3) AshitavaGhosal, V. Prasad Atluri Indian Institute of
efficient. Its high speed mode is only efficient. Science GM Global Research and Development Bangalore,
India Warren, USA, 13th World Congress in Mechanism
Therefore, it gives twice the mileage given by a and Machine Science, Guanajuato, México, 19-25 June,
normal vehicle. As this hybrid vehicle emits 50% 2011,pp 1-8
less emission than normal vehicle it plays an 4) S. C. Saha, A. Goswami and Md. Ehsan Department of
important role for reducingpollution to certain extent Mechanical Engineering, Bangladesh University of
Engineering and Technology, Dhaka, Bangladesh,
without compromising with efficiency. Thus it is Proceedings of the International Conference on Mechanical
most efficient in urban areas mainly in high traffic Engineering 2011 (ICME2011-RT-032) 18-20 December
where gasoline engines are least efficient as the 2011, Dhaka, Bangladesh,pp-01-06
energy from gasoline is being wasted away and 5) Mariam Khan and Narayan C. KarDepartment of
Electrical & Computer Engineering, University of
creates pollution. WindsorWindsor, ON N9B 3P4, Canada World Electric
Vehicle Journal Vol. 3-ISSN No. 2032-6653-2009
REFERENCE Avere,pp-1-12
6) Robert Bosch GmbH, Regenerative braking system and
1) Cristian Musardo, Giorgio Rizzoni, Yann Guezennec, control
and Benedetto Staccia Research Department at Renault, 7) Salvador Acha, Student Member, IEEE, Tim C. Green,
France; 2Center for Automotive Research; 3Professor of Senior Member, IEEE, and Nilay Shah Ph.D. in Chemical
Mechanical Engineering, Ohio State University, OH, USA; Engineering from Imperial College London, London, U.K.
4McKinsey &Co European journal of control(2005),pp,509- in 1992.
524
2) Anil Kumar Yadav, Prerna Gaur, Shyama Kant Jha, J.
R. P. Gupta, and A. P. Mittal Dept. of Electronics and
Instrumentation Engg., Meerut Institute of Eng. &
Technology Meerut, Uttar Pradesh,
FINITE ELEMENT ANALYSIS OF
RECIPROCATING SCREW FOR MINIMIZING
THE WEAR OF SCREW IN INJECTION
MOULDING MACHINE
Anil H. Ingle Krunali R. Charpe
Associate Prof & Head, Asst. Professor
Department of Mechanical Engineering, Department of Mechanical Engineering,
SRPCE, Nagpur, India. SRPCE, Nagpur, India.
Email:[email protected] Email:[email protected]
+91 9923279424 +91 9503404491
Abstract requiresthe use of raw plastic material, and a mould. The

Injection moulding machine is used in the industries barrel contains the mechanism for heating and injecting the
for manufacturing or fabrication of the plastic parts. The material into the mould. The reciprocating screw advance
screw issubjected to different temperature zones. It is the most the material forwarded by either a hydraulic or electric
critical components of the injection moulding machine. The
motor. During this process material is melted by heat and
raw granules of plastic is melted in the injection moulding
machine and injected into the mould .The material is feed into pressure. The material enters the grooves of the screw. The
the hopper in the granules form. The barrel contains screw completes the shot volume and retunes to reverse
reciprocating screw for infusing the material into the mould position. Due to the effect of high melting temperature and
and material is additionally liquefied into the barrel. The issue pressure of mold material the problem is occurred in the
happen in the screw of machine which is wearing of screw reciprocating screw. To make repair of threads on the lathe
because of influence of mould temperature and utilizing 30% machine industries are having this temporary solution. This
glass field material i. e. Nylon, low thickness polypropylene, reduces weight and strength of screw resulting misalignment
polystyrene ,PVC etc. The industries are having temporary in assembly. The screw is the crucial part of the screw. The
solutions but it is not so effective in improving life of the screw,
material for the screw is Latrobe LSS 01 Tool steel (ASTM
because the stresses will be more in machined screw on lathe
machine as compared to normal screw. Hence, the modeling 01) OHNS, and other alternate materials areAISI Type 06
and analysis technique is used to solve the problem.This Tool Steel , HSS 142 Tool steel.
project deals with, the solution of problem occurred for
reciprocating screw of Injection molding machine. It identifies
andsolves the problem by using the modeling and analysis
techniques. The problem occurred in the reciprocating screw
of machine which is wearing of threads due to effect of
temperature of mold materials (flow materials).
Keywords— reciprocating screw, Barrel, and mould, wear,
Plastic Injection moldingmachine.Pro-E 5.0 and Ansys R15
INTRODUCTION
Injection moulding is the most commonly used

manufacturing process for the fabrication of plastic parts. A
wide variety of products are manufactured using injection
moulding machine, such as plastics housings, consumer Fig 1.Injection molding machine arrangement
electronics , medical devices including valves and syringes
which vary greatly in their size, complexity and application. Description of machine
The plastic is melted in the injection moulding machine and
then injected into the mould, where it cools and solidifies a) Injection system
into the final part. The injection moulding process
This system transports the plastic. The injection system are a)
To model all the components using modeling
having hopper, barrel, reciprocating screw and injection software Pro-E 5.0
nozzle assembly. It progress through melting compressing, b) To assemble all the components in the software.
degassing, injection, feeding and packing stages. c) Analysis of screw using ANSYS software.
d) To identify the wearing of threads and to provide
b) The hopper the possible Solutions.
Problem Statement
In the form of small pellets the thermoplastic material is The problem identified in the operation condition
supplied to molders. The hopper hold the pellets. The barrel of injection moulding machine of reciprocating screw is the
and screw assembly pellets are gravity –fed from hopper wear of screw takes place after 3 to 4 months due to the use
through the hopper throat. of glass filled material (i.e., nylon66, low density
polyethylene, PVC, polystyrene) in plastic injection
c) The barrel moulding machine. The cost of the reciprocating screw is
about 4 to 5 laces.
The reciprocating plastering screws are supported by barrel
in the injection moulding machine. The electric heater bands
are used for the heating purpose.
d) The rotating screw

Wearing of
For compress, melt, and convey the material the rotating
screw is used. There are three zones in rotating screw threads
(illustrated below):
Fig 3:Wearing of threads of reciprocating screw
 the feeding zone
 Materials AndMethods
 the metering zone
 This are describes the details of injection molding
 the compressing (or transition) zone process, design of reciprocating screw with different two
material is used with having their properties they are LSS 01
e) The nozzle Tool steel (ASTM 01) OHNS (existing material of screw).
Then change or replace the material of the screw by using
It is forms seal between barrel and the mold because the this two new materials AISI Type 06 Tool ,HSS 142 Tool
nozzle is connects the barrel to spur bushing of the mold. Steel and compare the results of this two material with the
The temperature of the nozzle should be set to the material's existing material of the screw. We used the different mold
melt temperature or just below it, depending on the materials such as nylon 66,(LDP), polypropylene in this two
recommendation of the material supplier. new material of the screw and analyze the results compare
their results with existing one and find out which material is
better for the replacement of the screw material. Various
mold materials can be used in this process like linear low
density polyethylene, Nylon, polystyrene, PVC etc.
Input Parameters For Finite Element Analysis Of Screw

Using ANSYS R15
 Materials for Reciprocating Screw (Physical

Properties)
Fig 2. Reciprocating screw arrangement
Objective Latrobe HSS 142

Materials LSS 01 Tool Tool
The problem occurred in the reciprocating screw of steel steel
injection moulding machine was wearing of threads. The
objective of project is to find out the causes of wearing and
Young's
provide the solution. The industries are having temporary 200Gpa 215Gpa
modules(PA)
solution to make repair of threads on the lathe machine
industries are having this temporary solution. This reduces
Poisons ratio 0.3 0.3
weight and strength of screw resulting misalignment in
assembly. The objectives involved are:- Density (kg/m³) 7800 7850
-6 -6 conditions of torque 4942.6 N-mm applied at one end and
Thermal Expansion 12 x 10 10 x 10
remote displacement are provide to the assembly. And stress
-6 -6 results is obtained.
Yield Tensile 350 x 10 350 x 10
strength(PA)
-6 -6
Ultimate Tensile 630 x 10 585 x 10
Strength(PA)
Specific heat J/g-K 0.434 0.4
Thermal
conductivity W/m- 60.5 42.7
K
Modeling of Reciprocation Screw Using Pro-E Wildfire

5.0
Click on new part file
a. Give name as screw.prt

b. Click on the features tool bar. Revolving the
sketch by using revolve feature. Torsional analysis using different materials
c. Select the sketcher plane, make the sketch and
Boundary condition is loading condition to the
select the centerline (vertical axis) about which
assembly. Supplied a torque of 4942.6 N-mm at one end of
we revolve the sketch.
reciprocating screw. And reciprocating screw transmits this
d. Spin the model to see it in the 3-D view.
torque at another end of the screw. The maximum stress is
e. Activate helical sweep from insert menu.
shown in the below figure.
f. Select plane to draw profile.
g. Use attribute tool box for right hand square
threads.
h. Draw the screw cross sectional tool.
i. Geometry is created.
Fig Nomenclature of screw
Fig:- LSS 01 Tool steel (ASTM 01) OHNS (existing

material of screw) - Boundary condition Torsion Analysis
Fig Screw Tip
Finite Element Analysis of reciprocating screw
As mesh model of assembly is prepared for which

tetrahedron element is used with fine meshing and boundary
Here, main material of screw is used i.e. .LSS 01
Tool Steel (ASTM01) OHNS where various different
temperatures are applied in different zones. Further, using
different mold materials such as (LDP), total heat flux,
directional heat flux and is analyzed.
Fig: - HSS 142 Tool steel (material) Boundary condition

Torsion Analysis
Analysis of Existing Reciprocating Screw
Analysis of existing reciprocating screw is done by

using software ANSYS R15 by providing properties of
reciprocating screw material and CATIA model. Then it is
feed into the ANSYS R15 and static and thermal analysis
has been done. We have madeanalysis by using properties
of three different materials. First of all we have made
analysis by using material Latrobe LSS 01 Tool steel
(ASTM 01), it could not avoid that much failure of
reciprocating screw.
Here, main material of screw is used i.eLSS 01 Tool Steel

(ASTM01) OHNS where various different temperatures are
applied in different zones. Further, using different mold
materials such as nylon 66, total heat flux, directional heat
flux and maximum temperature is analyzed.
Thermal Analysis
Analysis results for material LSS 01 Tool steel

(ASTM01)
Temperature for mould materials applied at various zones Fig :- Boundary condition Thermal Analysis of screw
of screw using mould material (low density polyethylene)
Analysis results for material HSS 142 Tool Steel
Here, main material of screw is used i.e. HSS 142

Tool Steel where various different temperatures are applied
in different zones. Further, using different mold materials
such as nylon 66, total heat flux, directional heat flux and is
analyzed.
Temperature for mold materials applied at various zones

of screw
Fig LSS 01 Tool steel (ASTM 01) OHNS (screw

material) - Boundary condition Thermal Analysis (Nylon
66 mold material)
Fig:-Boundary condition Thermal Analysis of screw
using mould material(Nylon 66)
Results Using Screw MaterialHSS 142 Tool steel
Here, main material of screw is used i.e. HSS 142
Tool Steel where various different temperatures are applied
in different zones. Further, using different mold materials
such as LDP, total heat flux, directional heat flux and is
analyzed.
Torsional analysis:-
Conclusion
This is presents reciprocating screw of material Latrobe LSS

01 Tool steel (ASTM 01) OHNS of injection molding
machine thermal and torsional analysis performed on screw
using ANSYS R15 software analysis applying torque at the
end on motor side and keeping whole surface of screw as
fixed support side and different temperatures are applied at
the various zones of the screw and having different mold
Fig: Boundary condition Thermal Analysis of screw using material ,it is found that reciprocating screw has more
mold material (LDP) chances of failure. In the same way For reciprocating screw
of material HSS 142 Tool steel of injection molding
Results Using Screw Material And Mould Material machine Steady state Thermal analysis & torsional analysis
performed on screw using ANSYS R15 software analysis
Thermal analysis applying torque at the end on motor side and keeping whole
surface of screw as fixed support side, The HSS 142 Tool
Results Using Screw Material Latrobe LSS 01 Tool Steel steel material is better than the existing material of the
(ASTM 01) OHNS screw. The thermal heat flux is minimum 349 W/mm2 and
the directional heat flux is 203 W/mm2. Hence, the HSS
142Toolis better material for minimizing the wear of screw 2 A simulation test for wear in injection moulding machines S.J. Bull
a, Qiusha Zhou, University of Newcastle, Chongqing.
and increase the life of screw.
3 Self-optimizing MPC of melt temperature in injection moulding -R.
FUTURESCOPE Dubay. The University of New Brunswick.
a) For analyzing load condition, analysis results of 4 Ke Yao , FurongGao , Frank Allgower .Barrel temperature control
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b) New fabrication Methodology workout for fabrication of 5 Vikas.R.Rajoria, Prof.P.K.Jadhao, ―Finite Element Analysis
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LEAN MANUFACTURING: ELEMENTS AND
ITS BENEFITS FOR MANUFACTURING
INDUSTRY
GauravPuri LankeshJadhav MilindPalandurkar
Department of Mechanical Engineering, Department of Mechanical Engineering, Department of Mechanical Engineering,
TulsiramjiGaikwad-Patil College of TulsiramjiGaikwad-Patil College of TulsiramjiGaikwad-Patil College of
Engineering and Technology, Mohgaon, Engineering and Technology, Mohgaon, Engineering and Technology, Mohgaon,
Nagpur Nagpur Nagpur
Abstract Lean identifies the bottlenecks in design and

In today’s competitive environment organizations development processes that add unnecessary delays and
needs to leverage the strength it has and must work cost. It can help create a more efficient system that
to improve upon its weakness. Lean manufacturing reduces time to market without compromising on
has been recognized as a key to improve aspect quality.
competitiveness for manufacturing organizations
throughout the world. Lean manufacturing offers a Lean has a key role to play in new product development
basket full of tools and techniques which can help in and the improvement of existing products and the
waste identification, reduction or elimination, to improvement of existing products, including idea
enables manufacture of product with superior creation, design for manufacture, assembly and test,
quality, lower cost and on time with lesser efforts. rapid prototyping, product portfolio management,
Considering its potential of improving operational market and competitor analysis, risk management, sales
performance lean manufacturing is gaining forecasting, setting key performance indicators and
popularity among manufacturing industries. value analysis to reduce the cost of existing products.
Purpose of this paper is to present Lean
Manufacturing elements, benefits, implementation Lean manufacturing is “A systematic approach for
strategy and obstacles in implementation for identifying and eliminating waste through continuous
manufacturing industry. improvement by flowing the product at the pull of
customer in pursuit of perfection”.
Keywords:-Productivity, lean, waste, quality, Various techniques such as Six Sigma,5S, Total
technique. Quality Management (TQM), Theory of
constraints(TOC), Total Productive Maintenance
I. INTRODUCTION:(TPM), Business Process Management (BPM),
Visual Management, etc. supports the lean
Lean is defined as a strategy for achieving significant transformation in order to remove waste, variability
continuous improvement in performance through the and overburden and deliver improvements in specific
elimination of all wastes of resources and time in the areas. Every tool has its own way of eliminating
total business process. Its principles apply to nearly all waste; SMED reduces waiting and overproduction by
business operations, from administration and product creating shorter machine setup times. Value Stream
design to hardware productions. Lean manufacturing is Mapping draws the actual product flow through the
about eliminating waste and non-value added tasks. manufacturing resources and can uncover important
Examples of waste in manufacturing include areas for improvement.
overproduction, over processing, waiting,Unnecessary
part movement, excess inventory and defects, as applied
to hardware production lean manufacturing focuses on II. Literature review:
eliminating all sources of waste by applying the
following strategies. The works on the lean manufacturing are abundant; those
1. One piece workflow that concern lean manufacturing in India are rather limited.
2. Take time Approaches towards lean manufacturing practice have been
3. Pull system identified by various researchers. A case was described
where lean principles were adapted for the process sector
for application at a large integrated steel mill. Value There is a one methodology of lean implementation
Stream Mapping was the main tool used to identify the according to lean principles.
opportunities for various lean techniques. They also
described a simulation model that was developed to The first principle is to specify value from the point of view
contrast the “before” and “after” scenarios in detail and in of the customer‖ Manufacturers will give to their customers
order to illustrate potential benefits such as reduction in what is suitable for them, or imagine as cheap for the
production lead time and work in process inventory. The customers. It is imperative to know who the customer is: the
lean practices was divided into six areas which are process final customer, next process, next company along the supply
and equipment; manufacturing, planning and control, chain, or the customer„s customer.
human resources, product design, supplier relationships
and customer relationships. This study confirms that many The second principle is the Value Stream. This refers to the
firms seem to have difficulty in adopting lean tools that series of processes from raw resources to the final client, or
concern with external relationships with suppliers and from the invention to its market open. The value stream
customers even for high performance firms. Empirical should permit for unobstructed material, information, and
results from this study also prove that lean tools in internal people flow; the material flow focuses on the flow of
areas are adopted most widely in the firms, where the materials from raw to ending product, the information flow
operation and management methods are more direct. Lean focuses on the communication flow of customer necessities
manufacturing was defined as an integrated system and orders within a supply chain, and people flow focuses
composed of highly inter-related elements and a wide on how people are able to move within and around the
variety of management practices, including Just-in-Time processes.
(JIT), quality systems, work teams, cellular manufacturing.
The success of Lean Manufacturing implementation The third principle is Flow. Batch and queue processes
depends on four critical factors: leadership and should be avoid or continuously compact so that there is a
management; finance; skills and expertise; and supportive smooth and quick flow of information, products, and
organizational culture of the organization. Some services. Flow requires much preparation activity. But the
researchers also suggested that applying the full set of lean most important thing is vision‖. According to Trent when
principles and tools also contribute to the successful Lean looking through the point of view of an entire supply chain,
Manufacturing transformation. it makes sense for activities to be organized in a way that
allows for uninterrupted flow of work at the rate of demand
Table 1: Traditional manufacturing v/s lean pull from the customer. Disruptions to the supply chain flow
manufacturing. affect the supply chain throughput, capacity, and cycle time
and it ultimately adds little value that the customers
appreciate‖.
The fourth principle is Pull. Pull means short-term reply to

the customer„s rate of demand, and not over produce.
The fifth principle is Perfection. Having worked one after
the other through the previous four principles, a company
would now be able to see that perfection within the company
processes is now possible. This not only means a
imperfection free company but also means delivering
exactly what the customer desires, exactly when, at a light
price and with smallest amount waste.
1. Specify
5. PERFECTION 2. Value
4. PULL 3. CREATE
III. Principles and Practices of
LeanManufacturing
IV. Type of Waste Definition
4. POKA YOKE: It is a Japanese technique which means
mistake proofing. Innovation is the key for POKA YOKE.
5. KAIZEN: Kaizen means small continuous improvements.

It is a Japanese philosophy.
KAIZEN helps to decrease the risk in process
improvement, which is involved in the lean
implementation. It is basically dependent on PDCA cycle
which is also called Deming cycle.
Fig. 7 Wastes PLAN

A. Waiting:-Time spent waiting for items required
to complete a task (i.e. information, material,
supplies, instruction etc.) ACT DO
B. Unnecessary Motion: - Any motion that does
not add value to a product or service
C. Over processing: - Effort and time spent on
processing material which doesn‟t add value
D. Excess Inventory: - Material that is waiting for CHECK
processing or not required per customer demand
E. Unnecessary Handling: - Unnecessary
transportation of material by conveyor, forklift,
or foot travel 6. 5S’s: “A place for everything and everything in its
F. Overproduction: - Producing more products place” is the slogan that is usually followed when 5 S is
than the ultimate customer requires applied. Following five elements are fundamental to 5S.
G. Rework or Defects: - Time spent on reworking or
repairing defective products (1) SERI: Sorting and disposing of unwanted item
V. Lean Manufacturing Tools and (2) SEITION: Organizing

Techniques:-
(3) SEISO: Cleaning
Lean manufacturing is based on the continuous
identification & removal of all kinds of wastes which are (4) SEIKETSU: Standardizing
explained above. All the tools for LM aim at identifying
different kinds of waste and their sources and then devise (5) SHITSUKE: Discipline
methodology to remove these from the system continuously.
For highlighting the root causes of the problem and method
to remove these, the following tools and techniques are VI. CHALLENGES IN LEAN
used. IMPLEMENTATION
1.Total Quality Management (TQM): It is a philosophy
which is totally based on the customer‟s approach. It means The challenges face in the procedure of implementing
“SATISFYING CUSTOMER FIRST TIME EVERY and maintain lean is a boring job as the concept relate to
TIME”. time, cost, awareness, and participation, the concepts that
jointly support the new revise for growth in an firm. The
2.7-Quality Control (QC):The seven QC tools are used in
any industry to solve the problems. The seven QC tools are following important factor of resistance to change in
manufacturing sectors is
divided into four stages as given in fig below.
i) Identify the Problem Fear to change the bequest system with the new
winning trend and methodologies
ii) Development of planning Not utilize the opportunity and return of the new
policy
iii) Formulation of action plans Market damage will lead to force the change, which
will be in a non-standard format.
iv) Continuous small improvements VII. Benefits of Lean Manufacturing:-
3. Just In Time (JIT):JIT concepts are based on pull demand

model. Everything is done when they are actually needed.
1. Reduced cost: By implementation of Lean 1. Lack of management support: the reason can
Manufacturing organizations can achieve reduced be pressure from customer side; competitor is
cycle times, increased labour productivity and following lean practices or others. In this case
elimination of bottlenecks and reduced machine management just starts and does not propel further this
downtime can be achieved, and companies can results only superficial lean and neither lean is
generally significantly increased output with implemented nor does it get benefit.
reduced cost from their existing facilities. 2. Lack of training: Another reason is lack of
2. Reduced lead time: With the effect of reduced cycle clear understanding about lean throughout the
time and work in progress inventory lead time to organization. The organization where knowledge of
manufacture and deliver the product is drastically lean lacks it cannot be implemented.
reduces. 3. Communication – Lack of communication is
3. Waste reduction: Waste identification and reduction one of the prime obstacles in lean manufacturing
is one of the main functions of Lean Manufacturing implementation.
implementation plan. All the form of waste i.e. 4. Resistance to Change – Resistance to change is
overproduction, defect, transportation, work in very common phenomena as it increases fear of
progress inventory, over processing, waiting and failure, initial cost so many of routine liking people
motion are reduced with Lean manufacturing doesn‟t want to change and hence it stops the progress
implementation. of lean implementation.
4. Improved productivity - Improve labour 5. No direct financial advantage – Lean does not
productivity, both by reducing the idle time of produces any direct financial benefits but it helps in
workers and ensuring that when workers are identification and elimination of waste hence reduction
working, they are using their effort as productively of cost. Lean does not have any financial measure in
as possible (including not doing unnecessary tasks terms of input and output so sometimes lean idea is
or unnecessary motions). superseded by other organizational priorities.
5. Reduced work in progress (WIP) Inventory - 6. Past failures – In case of poor launching of
Minimize inventory levels at all stages of Lean is itself big obstacle. Lack of implementation
production, particularly works-in-progress between strategy may lead to lack of faith in whole philosophy.
production stages. Lower inventories also mean
lower working capital requirements. IX. Conclusion:
6. Lower Cycle Times - Reduce manufacturing lead
times and production cycle times by reducing This paper presents the review of lean thinking and
waiting times between processing stages, as well as its concept through definitions from literature. The main
process preparation times and product/model focus of lean manufacturing is to eliminate waste, doing
conversion times. things better in half of the resources as mass production
7. Improved Flexibility - Have the ability to produce requires, providing higher quality with lesser cost. More
a more flexible range of products with minimum and more facets of lean manufacturing will come forth
changeover costs and changeover time. as researchers are keenly bringing through continual
8. Multi skill worker – Involvement of worker in research. The good understanding of lean principles and
various Lean tools i.e. quality circles, kaizen circle, practices is required for successful implementation of
layout improvement; value stream mapping, set up lean as lean practices without knowing lean principles
time reduction etc. creates better understanding of can give short term success but may fail as long term
processes, machines, material flow among the team strategy.
and improves core competencies of worker.
9. Better Utilization of equipment and space - Use Lack of Planning, Lack of top management
equipment and manufacturing space more commitment, Lack of Methodology, Unwillingness to
efficiently by eliminating bottlenecks and learn and see and Human Aspects are the main barriers
maximizing the rate of production though existing or problems which can be faced while implementing
equipment, while minimizing machine downtime the Lean Manufacturing. These have already been
discussed in the previous section. This paper shows
10. Reduced Defects - Reduce defects and unnecessary that one the major difficulties companies encounter in
physical wastage, including excess use of raw attempting to apply lean is not knowledge of particular
material inputs, preventable defects, costs tools and techniques, perhaps lack of comprehensive
associated with reprocessing defective items, and and suitable lean knowledge related to probable
unnecessary product characteristics which are not problems within the companies by the managers,
required by customers. direction, gap and a lack of recognition of lean culture
in whole of the organization and planning cause the
VIII. Obstacles in Lean Manufacturing fails within the implementations. Additionally, some
implementation: managers try to enhance the implementation by some
The following may be some obstacles in Lean of the lean tools and mostly try to only implement the
manufacturing implementation: "continuous improvement" and explicitly forget
another basic lean principle, "respect for people". The 6) Herron, C. and Christian, H. (2008), The transfer of selected lean
manufacturing techniques from Japanese automotive manufacturing
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during a short time, and they should prepare the and Computer-Integrated Manufacturing, 24, pp. 524-531.
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sectors than automobile sector such as service sector, Production Management, Vol. 20 No. 8, pp. 959-978.
discrete manufacturing, etc. The recent literature shows 9) Meier, H. S. and Forrester, P. L. (2002), A model for evaluating
the degree of leanness of manufacturing firms, Integrated
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662–673.
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In this paper, presents the review of barriers of lean Lean manufacturing in developing countries: evidence from Indian
implementation from literature review. Understanding SMEs, Production
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12) Papadopoulos, T. C.andOzbayrak, and M. (2005), Leanness:
and to sustain lean leap. The future research may be to experiences from the journey to date, Journal of Manufacturing
identify such barriers through extensive literature Technology Management, Vol. 16 No. 7, pp. 784-807.
review and interviews of working professionals as very 13) Piercy, N. and Rich, N. (2009), Lean transformation in the pure
little work happened on this subject. The way forward service environment: the case of the call service centre, International
Journal of Operations & Production Management, Vol. 29, No. 1, pp.
for research in this area may be multiple criteria. The 54-75.
paper contributes by identifying enablers & barriers in 14) Shah, R. and Ward, P. T. (2003), Lean manufacturing: context,
implementing the lean principles and practices, practice bundles, and performance, Journal of Operations
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organization in the Indian manufacturing industry. measures of lean production, Journal of Operations Management, 25,
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pursuit of implementation patterns: the context of Lean and Six
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of lean manufacturing and value stream mapping via simulation: A pp. 6679- 6699.
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DESIGN AND ANALYSIS OF DISC BRAKE
Prof.S.V.Borkar Mr.KunalI Mahajan Mr.Sanket V Bure Mr.PrashantN Khadatkar
PriyadarshiniBhagwati College Priyadarshini Institute Of PriyadarshiniBhagwati College PriyadarshiniBhagwati College
Of Engineering Nagpur Engineering And Technology Of Engineering Nagpur Of Engineering Nagpur
Nagpur
ABSTRACT brakeSystem. Long repetitive braking, such as one

Each single system has been studied and developed inorder to whichOccurs during a mountain descent, will result in aBrake
meet safety requirement. Instead of having air bag, fluid temperature rise and may cause brakeFluid vaporization.
goodsuspension systems, good handling and safe cornering, there This may be a concern particularlyfor passenger cars equipped
isone most critical system in the vehicle which is brake
with aluminum calipersand with a limited airflow to the wheel
systems.Without brake system in the vehicle will put a passenger
inunsafe position. Therefore, it is must for all vehicles to brake Systems.
haveproper brake system. In this paper carbon ceramic matrix A schematic diagram is shown in the fig
disc Fig1DiskBrake.
Brake material use for calculating normal force, shear force
andpiston force. And also calculating the brake distance of
discbrake. The standard disc brake two wheelers model using
inAnsys and done the Thermal analysis and Modal analysis
alsocalculate the deflection and Heat flux, Temperature of disc
brakemodel. This is important to understand action force and
frictionforce on the disc brake new material, how disc brake
works moreefficiently, which can help to reduce the accident that
mayhappen in each day.
KEYWORDS— Disc Brake, Thermal Analysis, Modal
Analysis,Heat flux
I. INTRODUCTION
The disc brake is used to stop or slow down the
vehicleeffectively. The brake disc or rotor is usually made of
cast iron, but may insome cases be made of composites such
as reinforced carbon-Carbon or ceramic matrix composites.
This is connected to theWheel and/or the axle. To stop the
wheel, friction material inthe form of brake pads, mounted on
a device called a brakeCaliper, is forced mechanically,
hydraulically, pneumaticallyor electromagnetically against 1 CALLIPER
both sides of the disc. FrictionCauses the disc and attached
wheel to slow or stop. A brake disk rotor forms pan of a Foundation of any disc brake is the caliper body: the U-shaped
foundation brake and rotates with the wheel hub assembly. casting thatwraps around the rotor (like a hydraulic C-clamp) is
The mainFunction of a foundation brake is to generate usually made of NodularCast iron but some are aluminum for
aRetarding torque by converting mechanical energy lighter weight. Single piston calipers are usually one piece, and
toThermal energy by virtue of the frictional work donein multi pistoncalipers that have pistons on both sides of the rotor
relative sliding at the rotor-pad interface. Disc-style brakes are madein two pieces that are bolted together with high strength
development and use began in Englandin the 1890s. The first bridgebolts. Most calipers have an inspection hole in the bridge
caliper-type automobile disc brake waspatented by Frederick where the padthickness can be quickly checked.
William Lanchester in his Birmingham,UK factory in 1902
and used successfully on Lanchestercars. Recently,Disk 1.1 Fixed Caliper: Body usually manufactured in two halves;
brakes have been widely used in light vehicles.Long repetitive has two, three or fourpistonsGets its name from the fact that it
braking leads toTemperature rise of various brake components is rigidly mounted to theknuckle; no part of the caliper body
of theVehicle that reduces the performance of the moves when the brakesare applied.
3Piston:Brake caliper pistons form the interface between the
1.2 Floating / Sliding Calipers: Not rigidly mounted, are free hydraulicsystem and the mechanical action of the disc brake
to move within a limited range on ananchor that is solidly by moving
mounted to the vehicle Outward in the bore converting pressure to mechanical force
Anchor may be cast into the knuckle or it can be a separate Pushing the pads against the rotor to stop the vehicle.
piecethat bolts onWhen floating / sliding disc brakes are They must be:
applied the caliper piston moves out ofits bore and forces the  strong
inner pad against the rotor while the pressure on theclosed end  durable
of the bore moves the caliper body in the opposite
  resist corrosion
directionforcing the outer pad against the rotor at the same  maintain size & shape under extremes of temperature
time.  and pressure
 light as possible to reduce unsprung weight
 Prevent or slow the transfer of heat to the brake fluid.


3.1 Aluminum pistons: These are very light weight with
some disadvantages:
• Expands much faster than cast iron when heated; requires
Fairly large clearance in the bore and can lead to leaks (also
Shrinks much faster in cold) and other problems.
• Although anodized, more susceptible to corrosion and
scuffing
• Excellent conductor of heat and poor at keeping heat away
From brake fluid.
3.2 Steel pistons: very strong and maintain size and shape
over a
Wide range of temperature and pressure
Fig 2 floatingcalliper body • Chrome plated to resist corrosion
• Relatively heavy and conduct more heat than desirable in
Hotter running brake systems
4 DiscBrakes Seal
Calipers require seals to prevent fluid from escaping through
the clearance
Between the piston and its bore.Early disc brake designs
sometimes experienced unacceptable piston“knockback”. This
knockback causes inconsistent and excessive pedal travel
at brake apply. Can be quite a surprise. Most seals are lathe-
cut “O” rings with a square cross section thatfit into a groove
machined into the caliper body bore.
The piston slides through the inside of the seal; outside
diameter
of the piston provides one sealing surface and the seal groove Is
2Bleed Screw:Bleeder screws are located at the highest point the other sealing surface. This is usually a compression fit.
of the bores
When the caliper is installed on the vehicle (don‟t forget the 5 BrakePads:Contact the rotor to create the friction that
Caster angle).Bleed screw always on top where the air will be converts kinetic
and try to energy into heat when stopping the vehicle
Think about the technicians who will be working on your Two pads are used in a disc brake: one on each side of the
design in this rotor
Regard and with other features incorporated. Designed and manufactured in all sorts of various shapes
and Sizes usually to fit the package space available while
Fig 3 Bleed Screw Maximizing lining area and volume for optimum lining life
All have a metal backing plate (usually steel) to which lining We know that tangential braking force acting at the point
is of contact of the brake, and
Molded or riveted Work done = FT. x ..................(Equation
A) Where FT = FTRI + FTRO
6 DiskRotor X = Distance travelled (in meter) by the
Rotors are the largest and heaviest parts of the disc brake vehicle before it come to rest.
Assembly.They provide friction surfaces for the linings to rub We know kinetic energy of the vehicle.
against and Kinetic energy = (mv2) / 2 ................(Equation
Together these parts create the “friction couple” that converts B) Where m = Mass of vehicle
Kinetic energy into heat and stops the vehicle. v = Velocity of vehicle
They absorb and dissipate most of the heat generated in In order to bring the vehicle to rest, the work done against
braking. friction must be equal to kinetic energy of the vehicle.
Made of cast iron because of its relative: low cost, good wear Therefore equating (Equation A) and (Equation B)
andfriction properties and ease of machining FT. x = (mv2) / 2
Assumption v = 100 kg/h = 27.77 m/s
II. DISK BRAKE CALUCALTION M = 132 kg. (Dry weight of
Vehicle)
Disc Brake Standard So we get x = (mv2) / 2 FT
Rotor disc dimension = 240 mm. (240×10-3 x = (132×27.772) / (2×1000)
m) Rotor disc material = Carbon Ceramic m. x = 50.89 m
Matrix Pad brake area = 2000 mm2 (2000×10- Heat Generated (Q) = M .Cр. ΔT J/S
6 m) Pad brake material = Asbestos Flux (q) = Q/A W/m²
Coefficient of friction (Wet) = 0.07-0.13 Thermal Gradient (K) = q / k K / m
Coefficient of friction (Dry) = 0.3-0.5 Carbon Ceramic Matrix –
Maximum temperature = 350 ºC Heat generated Q= m*cp*ΔT
Maximum pressure = 1MPa (106 Pa) Mass of disc = 0.5 kg
Specific Heat Capacity = 800 J/kg 0 c
3.1 Tangential force between pad and rotor (Inner face) Time taken Stopping the Vehicle = 5sec
FTRI = μ1.FRI Developed Temperature difference = 15 0 c
Where, FTRI = Normal force between pad brakeAnd Rotor Q = 0.5 * 800 * 15= 6000 J
(Inner) Area of Disc = Π * ( R2 – r2 ) = Π * (0.120 2 – 0.055 2 )
μ1 = Coefficient of friction = 0.5 = 0.03573 m 2
FRI = P max / 2 × A pad brake area Heat Flux = Heat Generated /Second /area = 6000 /5 /
So, FTRI = μ1.FRI 0.0357 = 33.585 kw/m 2
FTRI = (0.5)(0.5)(1×106 N/m2) (2000×106 Thermal Gradient = Heat Flux / Thermal Conductivity
m2) FTRI = 500 N. = 33.582*10 3 / 40
Tangential force between pad and rotor (outer face) , FTRO. = 839.63 k/m
In this FTRO equal FTRI because same normal force and
same material
3.2 Brake Torque (TB) –

With the assumption of equal coefficients of friction and
Normal forces FR on the inner and outer faces:
TB = FT.R
Where TB = Brake torque
μ = Coefficient of friction
FT = Total normal forces on disc
brake, = FTRI + FTRO
FT = 1000 N.
R = Radius of rotor disc.
So, TB = (1000) (120×10-3)
TB = 120 N.m
3.3 Brake Distance (x) –

Fig 4 How Disk Brake Works
III. PROBLEMS IN DISK BRAKE possibleOutcomes: thermal shock that generates
surfaceCracks; and/or large amounts of plastic deformation
Braking performance of a vehicle can be In the brake rotor. In the absence of thermal shock,
significantlyaffectedby the temperature rise in the brake arelativelysmall number of high braking cycles arefoundto
Components. High temperature during braking mayCause generate macroscopic cracks runningthroughthe rotor
brake fade, premature wear, brake fluid Vaporization, bearing thickness and along the radius of
failure, thermal cracks, andthermallyexcited vibration. The disk brake. Heat generation due to friction in theSliding
Therefore, it is importanttopredict the temperature rise of a contact of two bodies influences friction andWear
given brakeSystem and assess its thermal performance in characteristics of brake systems
theearlydesign stage. Recently, brake fluid
vaporizationhasbeen suspected as a possible cause of IV. ACKNOWLEDGMENT
someCollisions and a proper inspection procedure has The authors are thankful to all friends and Professors
beenrecommended. Disk brakes are exposed to large thermal tohelpthis paper and would like to thank the
stresses anonymousReviewers for their comments which were very
During routine braking and extraordinary thermalStresses helpful inImproving the quality and presentation of this paper.
during hard braking. High decelerationsTypical of passenger
vehicles are known to generateHigh temperatures in a fraction
of a second. TheseLarge temperature excursions have two
[3]chogducho and sooickahn, “thermo-elastic analysis for chattering
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Distribution analysis of aluminum composite and cast iron brake [4] gurumurthynathi, k. Gowtham and satishreddy, “coupled
Drum using ansys”, „international journal of emerging trends in Structual / thermal analysis of disc brake”, ijret 2012, vol.1,
Engineering and development‟, 2012, vol. 3, issn 2249-6149, pp Pp.539-553.
281-292. [5] v. M. Thilak , r. Krishnaradeepan&r.palani ,“transient thermal
[2]ameershaik and lakshmisrinivas,“structural and thermal analysis And structural analysis of the rotor disc of disc brake”, international
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2012 , vol. I, issn 2249-8974, pp 39-43
BAMBOO: AN ECOFRIENDLY MATERIAL
FOR SUSTAINABLE DEVELOPMENT
SHUBHANGI GONDANE Dr.P. N. BELKHODE MANISHA JOSHI
Tulsiramji Gaikwad-Patil College of Lakshminarayan Institute of Priyadarshini College
Engg.& Tech.Nagpur Technology,Nagpur of Engineering,Nagpur
Abstract: moving development efforts (Brian Kermath, 2007).

Widely used in Asian, Pacific Islander and Central and Southern Sustainable development refers to the equity, in particular
American cultures, bamboo is a sustainable and sturdy building concerning the todays's and future generations as defined by
material.. Bamboo is a naturally occurring composite material Brundtland Commission (WCED, 1987).This true for the
which grows abundantly in most of the part of the world. It is
treated as a composite material because it has cellulose fibers
resources as well as for any business. If we consider the
imbedded in a lignin matrix. Using bamboo rather than metal also sustainability of wood resource around the globe,
holds several advantages for producers — and for the environment. availability of industrial wood from natural forests has been
As a cheap and fast-grown resource, with superior physical and on decline for many years. This has raised a growing
mechanical properties, bamboo offers great potential as an concern to save forests. Consequently the wood based
alternative to wood. Using bamboo rather than metal also holds industry as well as the opportunities in this area have also
several advantages for producers — and for the environment. affected to a large extent. Wood is largely being replaced by
Bamboo based industry has vast potential for generating income plastics, wherever possible. However the environmental
and employment, especially in the rural areas. The paper brings out hazards of the plastics always keep a hanging sword. On the
the taxonomy, chemical composition, physical and mechanical
properties of bamboo with a focus on sustainable development.
other hand the strength properties of the plastics can never
be compared with the industrial wood. Even the timbers
Keywords: Sustainable Development, bamboo, mechanical available from fast growing plantation species generally
properties have lower strength properties, dimensional stability and
service life. Bamboo is renewable, abundantly available,
Introduction low cost and environment friendly (Azmy H.J. Mohamed et
Unlike wood, bamboo (a member of the grass family) al., 2007) wood resource that creates an eye of hope for the
regenerates very quickly. It is, in-fact, one of the fastest struggling wood based industry with its excellent strength
growing plants in the world, with the fastest growth rate (A.C. Sekhar et al, 1962; Limaye, V.D., 1952). It has
reaching 100cm in a 24-hr period (Farrelly, David (1984). tremendous economic potential with its significant
The Book of Bamboo. Sierra Club Books.). Sustainable applications and innovative products. Since the bamboo is
development (Carlos J. Castro, 2004) is widely widely available across the different parts of India, it offers
acknowledged as a key concept for humanities future. great opportunities to the micro, small and medium scale
Sustainability calls for balancing short term business enterprises (Markus Will, 2008). Since the bamboo resource
interest and long term development of both the society and is widely available across the rural domains and industrial
company itself. It involves the simultaneous pursuit of effort requires a lot of labour, bamboo has a great potential
economic, social and environmental objectives (Markus to offer job opportunity and income source to the rural
will, 2005). After more than 200 years of industrialization in masses. This can ultimately lead to the sustainable
the Western world and more than 50 years of 'development' development of rural folks (V. Sorna Gowri, 2003;
in the Third World, the benefits delivered by the grand
design of progress and modernity are, at best, ambiguous. Suresh Moktan, 2007) and hence contributing significantly
Despite phenomenal advances in science, technology, to the economy.
medicine and agricultural production, the promise that
'development' would eradicate world poverty remains Mechanical and Physio-chemical Properties of Bamboos
unfulfilled in several parts of the globe, especially in the
Third World (Subhabrata Bobby Banerjee, 2003). Even the Bamboo offers a vast variety of commercial and domestic
biggest economies shiver with small up and down in the products due to its excellent mechanical, physical and
industry. Reason behind this ambiguity is that the chemical properties (Li Xiaobo, 2004). Bamboo is a natural
sustainability aspect is not being addressed properly in fast lingo-cellulosic composite in which cellulose fibers are
embedded in the lignin and hemi cellulose matrix. Bamboo found that the fiber distribution has the highest
contains 44.5% cellulose, .5% lignin, 32% soluble matter, concentration in the outer layer of bamboo. The moisture
0.3% nitrogen and 2% ash. Average length is 2 mm and content of three year old bamboo in the green condition
average diameter is between 10-20m (Adamson, W.C, decreased from the bottom to the top portion. Specific
1978). The geometry of bamboo's longitudinal profile has gravity and bending properties of bamboo vary with age ,
macroscopically functionally graded structure, which can height location as well as horizontal layer. They all increase
withstand extreme wind loads. Fiber distribution is from one year old to five year old culms. The outer layer
transverse cross-section at any particular height of bamboo, had significantly higher specific gravity and bending
is dense in outer periphery and sparse in inner periphery. properties than the inner layer. The top portion had a
Bamboos mainly consist of the roots, culm and leaves. The consistently higher specific gravity than the bottom portion.
culms are the most useful part in a bamboo. They are hollow The outer layer had a more decisive role in supporting
and vary in sizes, diameters, colors and textures. The culm bamboo than the inner layer. Bending strength had a strong
consists of the strands of cellulose fibers and the lignin positive correlation with specific gravity. In order to
matrix. Spaces between adjacent strands of fibers are filled industrially use bamboo strips efficiently, it is advisable to
with lignin, a type of resin. The number of fibrous strands retain outer surface material to produce high strength
increases toward the outer surface of the culm. Cellulose bamboo composites. Compression properties parallel to the
fiber is stronger than the lignin matrix. Also the cross- longitudinal direction were significantly higher than
sectional area of the culm changes from location to location. perpendicular to the longitudinal direction. The variability
Hence, the cellulose strand distribution would be different at of compression perpendicular to the longitudinal direction
different sections plant species. Bamboo has different was significantly higher than parallel to the longitudinal
mechanical properties in the three dimensions: axial, radial direction. Bamboo grows in different climates from plane to
and tangential. However, bamboo is a biological material high mountain side. The mechanical and physico-chemical
and it is subjected to great variability and complexity due to properties of the bamboo as well as bamboo composites are
various conditions such as years of growth, soil and also influenced by the climatic and ecological factors,
environmental conditions and the location of bamboo culm cultivation techniques and harvesting details. Thus the
within the bamboo. Hence, it is observed that the origin of the bamboo must be considered, whenever finding
mechanical properties of bamboos vary enormously (A. K. specific applications.
Ray et al., 2005). Bamboos are available in the form of
different species and the mechanical and physio-chemical Bamboo Products
properties vary from one species to other species.
Bamboos is most suitable for structural products due to its
Throughout the world there are about 500 different species good mechanical and physical properties. Bamboo
of bamboo. Mechanical and chemical properties are not composites (Seema Jain et al., 1992) are normally used for
fixed for all the species. It depends on type of species, structural products rather than the raw bamboos. This is
length (from top to bottom), horizontal layer (from inner because of possible variability of properties along the
side to outer periphery), age of the tree (in years). N. K Naik longitudinal and radial directions as well as physical
(2005) characterized seven species of bamboos: Bambusa dimensions of the products required. For load carrying
Balcooa, Bambusa Bambos, Bambusa Nutans, Bambusa structural composite products, mechanical properties such as
Tulda, Dendrocalamus Giganteus, Dendrocalamus Strictus, tensile strength, compressive strength, shear strength,
and Melocanna Bambusoides. He found great variation in flexural strength and bending elasticity modulus are
mechanical properties for these seven species. Aging of a important. For flooring tiles and veneers, through-the-
bamboo culm affects physical, chemical, and mechanical thickness compressive strength, hardness, abrasion
properties. The physical and mechanical properties of resistance and slip resistance are important. For structural
bamboo vary with the age of the bamboo and the height of assemblies, nail withdrawal strength is important.
the culm (Chauhan, 2000) bamboo. The increase in weight Applications of bamboo products have been increasing. The
is cumulative and directly related with age. Strength main application areas are: flooring, veneer, handicrafts,
properties are reported to decrease in older culms (Zhou, decorative boards, sports equipment and other building
1981). Limaye (1948,1952) found that older culms of materials. Bamboo is used as raw material for pulp, paper
Dendrocalamus strictus became 40-50 percent stronger and and panel board industries. They are also common in many
stiffer than young ones. Sekhar et al. (1962) found highest traditional applications such as: for fencing, water pipes,
values in 3-4 year old culms of Bambusa nutans. fishing rods, umbrella handles, musical instruments and
decorative handicrafts. The applications of bamboo, which
Except one year old bamboo, alcohol-toluene and hot water can really push the small and medium scale enterprises, are
extractive contents increased from the bottom to the top discussed in the following section.
portion. Alcohol-toluene extractive content showed a
continuous increase from one year old to five year old Bamboo Based Panels
bamboo. Hot water extractives showed an increase from one
year old to three year old bamboo and then decreased from Bamboo based panels are products made from raw bamboo
three year old to five year old bamboo. Li Xiaobo (2004) through a series of mechanical and chemical procedures,
such as spraying glue, laying up, and hot pressing. The Bamboo fiber based fabrics are naturally anti-microbial and
bamboo-based panels have advantages of large size, high requires no harmful chemicals. Bamboo textiles contain an
strength, stabilization in shape and size, and its parallel and agent, called 'bamboo kunh', this agent prevents bacteria
perpendicular strength and property that can be adjusted from cultivating. Bamboo clothing not only feels cooler in
according to different demands (Zhang et al, 1995). Bamboo the summer but it is significantly warmer in the winter.
based panels are relatively ideal engineering materials. At Bamboo fabrics make a lighter garment that is more
present, the main sorts of bamboo based panels which can comfortable.
be developed in the construction field are: Mat Plybamboo,
Curtain Plybamboo, Laminated Bamboo of Strips, Bamboo Food
Plybamboo, Bamboo Particleboard, Bamboo Composite
Board. At present, bamboo based panels have been widely Bamboo finds a new fashion in food with wonderful recipes
used to the manufacture the bottom boards of vehicles, of Bamboo shoots. These bamboo shoots are young, new
moulding boards of construction, scaffoldings, and has canes that are harvested for food before they are two weeks
partly taken the place of wood, steel, plastic etc as raw old or one-foot tall. Bamboo shoots are crisp and tender.
materials of furniture and decorating materials. Bamboo- Bamboo shoots are low in fat and calories. The shoots are a
based composite may also be the suitable alternative as the good source of fiber. Fiber helps keep cholesterol levels in
materials of prefabrication in terms of the various check and plays a role in preventing colon cancer. Bamboo
advantages they contain. However, the application of shoots are also a good source of potassium. It helps to
bamboo based panels for this utilization is still very limited. maintain normal blood pressure and a steady heart beat.
Development of panel products based on bamboo strip are When it comes to phytochemicals, natural substances found
gaining importance as these panel products reassemble in plants, bamboo shoots hold promise. They contain
wood when used in a particular fashion as in parallel lignans and phenolic acids. Lignans, a component of fiber,
laminates. These laminates will have superior physical exhibit a number of important properties that are undergoing
mechanical properties and are suitable for structural and research. Lignans appear to have anticancer, antibacterial,
specialized application. More over requirement of resin antifungal and antiviral activity. Phenolic acids have mild
adhesives is expected to be lower compared to bamboo mat anti-inflammatory properties and are potent antioxidants.
based composites and therefore making the products cost Antioxidants help prevent cancer and the blood vessel injury
effective which are considered to be ideal for alternates to that can start atherosclerosis. About 200 species of bamboo
wood and plywood for several end use applications. can provide edible and palatable bamboo shoots, including:
Bamboo laminates could replace timber in many monopodial bamboos: Acidosasa edulis, Chimonobambusa
applications such as doors and windows, frames, partitions, quadrangularis, Phyllostachys heterocycla var. pubescens, P.
furniture, flooring and some structural applications. IPIRTI praecox, P. dulcis, P. iridescens, P. makinoi, P. nuda, P.
has already developed a technology for bamboo laminates prominens, P. sulphurea cv. viridis, P. vivax, Pleioblastus
that is ready for commercialization.' amarus and Qiongzhuea tumidinoda; and 2. sympodial
bamboos: Bambusa rigida, B. pervariabilis, Dendrocalamus
Paper, Textiles and Board latiflorus, D. asper, D. brandisii, D. hamiltonii,
Dendrocalamopsis oldhami, D .beecheyana, D. beecheyana
Bamboo fibers are relatively long (1.5-3.2 mm) and thus var. pubescens, D. stenoaurita, D. variostriata and
ideal for paper production (El Bassam, 1998). In India, 2.2 Schizostachyum funghomii. Fresh bamboo shoots are
million tonnes of bamboo per year are processed into pulp, delicious and healthy, with a high fibre content. Bamboo
making up about two-thirds of total pulp production vegetables can be found in Chinese grocery stores and
(Adamson et al., 1978; IFAR/INBAR, 1991). At least eight restaurants worldwide. After cooking the shoots are still
North American suppliers are importing and marketing crisp, because cooking does not destroy their texture.
tongue-and-groove flooring made from laminated bamboo, Cooked bamboo shoots can be stored in containers and
which is said to be as hard, durable and dimensionally stable shipped worldwide. bamboo shoots of a number of species
as oak or other hardwood flooring (e.g. Plyboo America are a well-known feature of Chinese and other Asian
Inc., Kirkville, NY). Bamboo culms are sliced into strips, cuisine, generally imported into the USA in canned form
which are boiled to remove starch, dried, and laminated into (one estimate suggests 30,000 t/year in the early 1990s).
solid boards using urea-formaldehyde adhesives. The boards Exports from Taiwan are worth $50 million annually, and
may be treated with preservatives such as boric acid, before those from Thailand $30 million, with much of this going to
or after laminating, or both, and a darker amber color may meet Japanese demand (Scurlock et al., 2000).
be produced by pressure-steaming the bamboo to carbonize
it. Although the adhesive tends to emit formaldehyde for a Combustion and other Bio-energy Applications
long time after production, the amount of ureaformaldehyde
resin in a laminated product is much less than in a panel Molini and Irizarry (1983) proposed the use of bamboo as a
board product (Environmental Building News, 1999). fuel for power generation in Puerto Rico in preference to
Bamboo textiles are much softer than the softest cotton, sugar cane, since its lower moisture content at harvest
bamboo fabrics have a natural sheen to the surface and they obviates the need for drying, but they provide few data in
really do feel similar to silk textiles or cashmere fabrics. support of their case. Limited experience has been gained
using de-lignified bamboo pulp as a substrate for ethanolic The opportunity is particular of concern to bamboo as the
fermentation (Ram and Seenayya, 1991). Early work on wastage of bamboo industry can be efficiently utilized. The
preparing a diesel-like fuel from bamboo culms (Piatti, process of conversion of bamboo into mat boards, laminated
1947) is cited by Tewari (1992); the process appears to have boards, flooring tiles etc. generates a lot of waste material in
been the pyrolysis of "black liquor" from bamboo pulping, dust & chip forms. Also about 30% of the culm length (top
but does not seem to have progressed beyond the laboratory portion for reduced diameter & wall thickness and bottom
scale (Piatti, 1947). The review by Scurlock et al. (2000) part for semi-rigid construction with too many knots) cannot
evaluates bamboo as a potential bio energy feedstock, and be converted into the aforesaid products. These bamboo
tackles some of the myths and facts surrounding it--its wastes are thus best converted into activated carbon for a
"prodigious" productivity, its "disastrous" flowering, its high value-addition. With a view to exploring the potential
multiple uses, etc. of bamboo based activated carbon on a commercial scale,
the National Mission on Bamboo Applications
Bamboo Charcoal and Activated Carbon (www.tifac.org.in) prepared a complete 'business
Bamboo charcoal is traditionally used as a substitute for opportunity' report altogether with the techno-economic
wood charcoal or mineral coal. Bamboo charcoal is a good evaluation, assessment of market demand and necessary
air purifier as it has the property of absorbing odor, moisture investment for entrepreneurial actions. The report provides a
and harmful gases. It is also a good water purifier as it filters road map for a viable project for producing activated carbon
and absorbs pollutants, chlorine, pesticides and poisonous on a commercial scale. The Mission supports such projects
materials. It has an extremely porous structure and is a in partnership with the industries.
better and eco-friendly option to wood charcoal. The
domestic applications include charcoal pillows, mattresses Bamboo Housing
and to preserve freshness in refrigerators, deodorizer in The bamboo species are widespread through the tropical,
moist places. This charcoal has a number of potential subtropical and temperate climates around the globe. The
applications in the agriculture activities, such as to change fibers of bamboo poles posses' high strength both in tension
the soil structure, eliminate negative effects of pesticides on and compression. Its compressive strength is roughly twice
plants, increase soil temperature and amount of water the compressive strength of concrete and bamboo has
content. The industrial applications are health-care, gas roughly the same tensile strength to weight ratio as steel has.
masks, absorbing radioactive xenon and krypton, safe The hollow cross section and solid diaphragms at regular
disposal of water and waste gases. The calorific value of intervals contribute to the strength of the bamboo pole. It is
bamboo charcoal is almost half that of oil of the same a renewable plant with a very short rotation period. Bamboo
weight. Activated bamboo charcoal can be used for cleaning grows to its full size for about a year. Another two or three
the environment, absorbing excess moisture and producing years are required for the plant to gain its high strength.
medicines. China is a leader in its production. At present, Bamboo production doesn't involve much energy
Japan, the Republic of Korea and Taiwan Province of China consumption and therefore adoption of bamboo housing
are the main consumers, but its importation is rapidly helps to preserve the environment. There are three main
expanding in Europe and North America. Production of types of bamboo housing: (i) traditional houses, which use
bamboo charcoal does not require a very high level of bamboo culms as a primary building material; (ii) traditional
infrastructural and machinery investment. Thus, the bahareque bamboo houses, in which a bamboo frame is
opportunity is open to micro, small as well as medium plastered with cement or clay; and (iii) modern
enterprises. Not only the export has a lot of scope, but the prefabricated houses made of bamboo laminated boards,
local marketplace also has a plenty of consumers for this veneers and panels. Experts estimate that over one billion
product. people live in traditional bamboo houses. These buildings
are usually cheaper than wooden houses, light, strong and
Similar to the Bamboo Charcoal, Activated Carbon (S. earthquake resistant, unlike brick or cement constructions.
Bakshi et al., 2003) throws other vistas of opportunities. It is New types of prefabricated houses made of engineered
a black solid substance resembling granular or powdered bamboo have certain advantages. They can be packed flat
charcoal. It is extremely porous with a large surface area, and transported long distances at a reasonable cost. They are
and typically produced from organic precursors such as better designed and environmentally friendly. Bamboo
bamboo, coconut shells, palm-kernel shells, wood chips, housing is being successful used around the globe and even
sawdust, corncob and seeds. The raw material is first heated in India, this is very popular in the north eastern states
in an inert environment to obtain the carbonaceous material, (Ramachandra Laha, 2000). Bamboo is being widely used in
which is activated further to derive a highly porous final these states for the supporting posts, flooring, frames,
product. Activated carbon has several important uses partitions, ceilings, walls, thatching, doors, windows and
including solution purification, removal of tastes and odours tying.
from domestic and industrial water supplies, vegetable and
animal fats and oils, alcoholic beverages, chemicals and Bamboo Flooring
pharmaceuticals and in the waste water treatment. It also Bamboo flooring is a quality product that can be used
finds use in purification of gases, liquid phase recovery, widely and has a large, global consumer market. It has
separation processes and as catalyst and catalyst supports. certain advantages over wooden floors due to its
smoothness, brightness, stability, high resistance, insulation envisaged laying down a foundation of a modern bamboo
qualities and flexibility. Bamboo flooring has a soft natural economy with input from science and technology, people's
luster and maintains the natural gloss and elegance of participation, industrial application and strong linkage with
bamboo fibre. This flooring is attractive to the demanding market capable of meeting global competition. In addition to
markets in Europe, Japan and North America. The estimated the paper pulp industries, the potential of bamboo on other
annual production of bamboo flooring in China was 17.5 large-scale industries like bamboo shoot processing, bamboo
million m2 in 2004. Exports account for some 65 percent of based boards, flooring boards, furniture, new uses in building
total production (Customs General Administration of China, and road construction, etc. was also emphasized. Following the
2004). Planning Commission's effort on bamboo sector development,
the Minister of Science and Technology on Technology Day,
Bamboo weaving products and crafts 2002 established a National Mission on Bamboo Application
(NMBA) under Technology, Information, Forecasting and
Bamboo crafts and woven mats are traditional products in Assessment Council (TIFAC), Department of Science and
China, India, Malaysia, the Philippines and Thailand. The Technology to focus on the commercialisation of value added
technique has been known for several thousand years. These applications in the bamboo sector. Different State Governments
diverse products have become an indispensable part of daily have also taken initiative to develop bamboo sector on a
life, literature and art. There are nearly 20 categories of commercial basis.
woven bamboo products in Asia, including fruit baskets,
trays, bottles, jars, boxes, cases, bowls, fans, screens, Bamboo is a versatile and useful group of plants, capable of
curtains, cushions, lampshades and lanterns. providing ecological, economic and livelihood security to
people. As per estimates, 8.96 million ha forest area of the
Bamboo Furniture country contains bamboo amounting to 12.8 percent of the
forest cover. India has the largest bamboo forests in the
Traditional bamboo furniture uses natural round or split world. Two-third of the growing stock of the bamboo in
bamboo. A new type of 'pack-flat,' 'knockdown' furniture India is available in the North-Eastern States. India ranks
uses glue-laminated bamboo panels. Unlike the traditional second in the world in bamboo diversity with 136 species,
design, this furniture may be shipped in compact flat packs, while China with 300 species is leading in genetic diversity
to be assembled on the spot. The new design overcomes of bamboo. Out of this, 58 species belonging to 10 genera
many of the problems of traditional bamboo furniture, such are found in the North-Eastern region. In Asia, Bamboo is
as high labour and transportation costs, low productivity, known as the poor man's timber/poor man's gold/green gold
instability, varying quality and susceptibility to insects and because growing, harvesting and processing are essential
fungi. At the same time, it retains the distinct physical, subsistence activities. It is mainly used for domestic
mechanical, chemical, environmental and aesthetic features consumption as a raw material for useful utensil and farm
of bamboo. The bamboo furniture offers excellent durability tools, as a building material for shelter, fences, bridges and
and light weight characteristics at a much cheaper price. It is even water pipes. There has been a growing awareness in
becoming popular, even in hotels and resorts. A number of recent years about the importance of bamboo being an
micro and small scale industries are producing bamboo important means of economic growth and of improving the
furniture in the north-east India and this is being supplied in socio-economic conditions of the rural poor. Bamboo as an
the different parts of India. Export of laminated bamboo industrial material can substitute wood and that too at low
furniture is growing rapidly. However, trade statistics cost. Bamboo has been traditionally harvested from forest
currently do not capture the value, owing to the absence of a lands in India and the homesteads which may have a few
special code for bamboo furniture. It is usually classified as clumps of one of the many species of bamboo for household
wooden furniture. use but very little intervention in terms of purposive
planting has been done in the past. The demand for bamboo
Government of India Initiatives has increased, in recent years, within the country and abroad
as a raw material for furniture making, as panel boards
In India, recently a re-discovery of the potential of bamboo
substituting wood, as agricultural implements,
for developing it as one of the sunrise industries resulted in
house/construction related uses and as a vegetable. China's
launching of an integrated bamboo development programme
focused intervention to harness bamboo's potential has led
by the Prime Minister on 05 June 1999 with a view to focus
to increase in its productivity by more than 10 times since
on the development of bamboo sector. Subsequently, the
1970 when it was 2-3 tonnes/ha/annum and today China's
Planning Commission, Government of India prepared an
total export value of bamboo products is more than $ 550
Action Plan to give maximum emphasis for promotion and
million per annum. With a view to harness the potential of
development of bamboo during the Tenth Plan. The Action
bamboo crop in the country through a multi-disciplinary
Plan proposed creation of 8.6 million jobs in the bamboo
approach, the Planning Commission brought out a report
based development programmes to enable 5.01 million
titled "National Mission on Bamboo Technology and Trade
families to escape poverty on a sustainable basis,
Development" (NMBTTD) in 2001-02. The report clearly
upgradation of skills of crafts person, food and nutritional
brings out the country's future potential in bamboo for the
security through consumption of bamboo shoots, etc. for
next two decades.
livelihood and nutritional security. The Action Plan also
Conclusion management of the bamboo resource and its contribution to
environmental conservation in Malaysia, Management of
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2697
Production of Enriched Compost from Water hyacinth
(Eichorina crassipes)
Mrs Arti Mathur, Sanjeev K Mathur Dr A.B.Singh Dr A subbarao

Phd Scholar Phd Scholar Principal Scientist Ex Director
Barkatullah University Bhopal S.A.T.I. Polytechnic College Indian Institute of Soil Science Indian Institute of Soil Science
Vidisha Nabi bag Bairasia Road Bhopal Nabi bag Bairasia Road Bhopal
development and consequently promoting higher yield

Abstract - Water hyacinth, an aquatic weed is known for and higher quality of crops.
causing a series of problems for aquatic life. It also has a few (www.agritech.tnau.ac.in/org_farm/orgfarm_compos
advantages to its recognition. If targeted properly, it can act ting.html).
as an extremely important alternative for meeting some of
the most urgent needs of agriculture community. This study
proposes and signifies that water hyacinth has remarkable
Composting process refers to the conversion of green
nutritive properties that can be used for the production of waste into organic fertilizer with compost as an end
nutrient enriched compost which not only result in healthy product. Composting is the biological decomposition and
aquatic system but also add as a advantages on agriculture stabilization of organic substance under condition that
lands. The proximate analysis of different types of water allows development of the thermophilic temperature as a
hyacinth composts is observed. The results shown that result of biologically produced heat, with a final product
various compost formed by using different amendments, an sufficiently stable for storage and application to land
indicator for enriched water hyacinth composts. without any adverse environmental effect (Haug, 1980).
Composting is a biooxidative process in which the
Key words – water hyacinth, compost, amendments.
microorganism transform the more easily biodegradable
Introduction - Water hyacinth is one of the most organic matter into carbon dioxide, water, vapours, and
productive plants on earth and considered as one of the other minerals (mineralisation process) or, with time, into
world’s worst invasive aquatic plants (Gopal, 1984; more stable organic matter (humiliation process) called
Malik, 2006). Water hyacinth is one of the worst weed in humic substances which are physically very similar to
the world aquatic or terrestrial environment (Holm et al., those present in soil. Composting is not a new idea. In the
1977). Compost is defined as the product resulting from natural world, composting is what happens as leaves pile
the controlled biological decomposition of organic up on the forest floor and begin to decay. Eventually,
materials. Compost can be derived from a number of feed nutrients from the rotting leaves are reclaimed by living
stocks including yard trimmings, bio solids (sewage roots. This completes nature’s recycling process. As
sludge), wood by-products, animal manures, crop defined by Diaz et al. (1993).
residues, biodegradable packing, and food scraps. Mature The project will be beneficial for those cities where the
compost has little resemblance in physical form to the problems of aquatic weeds are much that can be over
original biodegradable from which it is made. Compost is come through removal of such weeds. Composting (S
valued for its organic matter content, and it typically used Ajay et al. 2011) as an alternative treatment has the
as a soil amendment to enhance the chemical, physical advantage of producing a product that is easy to work into
and biological properties of soil. Compost is typically not the soil compared with dried water hyacinth, because of
a fertilizer, although when used at normal rates it can the decomposed structure.
reduce the amount of required fertilizer. Compost can Much work has been carried out in different parts of
increase the water holding capacity of sandy textured the world to develop environmentally sound and
soils, and can improve structure and water movement appropriate methods for the management and control of
through heavier textured soils that are high in silt and clay water hyacinth. It recapitulated that the only means of
content. utilization of water hyacinth which has proved
Compost has been considered as a valuable soil economically viable across the world (Gajalakshmi et al
amendment for centuries. Most people are aware that 2001). In this background authors studied the utilization
using composts is an effective way to increase healthy of water hyacinth as substituting bean straw with water
plant production. It helps save money, reduces the use of hyacinth as animal feed (Tag El-Din et al 1992) feed for
chemical fertilizers, and conserves natural resources. solid-phase fermentation raw material for making pulp,
Compost provides a stable organic matter that improves paper and paper board and the vermicomposting of water
the physical, chemical, and biological properties of soils, hyacinth (Gupta et al 2007) However, a novel technology
thereby enhancing soil quality and crop production. When with ecological sound and economically viable is urgently
correctly applied, compost has the beneficial effects on required to solve the problem of aquatic weed disposal
soil properties, thus creating suitable conditions for root and management. So this has been decided to prepare
water hyacinth compost by using different amendment. In
Bhopal there are many numbers of pond and small
lakes,river like Kaliasot. All are suffered by aquatic  The bottom of the pit filled with compost about
weeds like water hyacinth. Every year cities expenses big 1 inch thick containing about 10 kgs of farm
amount of money and use of machinery to remove water yard manure.
hyacinth from these ponds and lakes. There is no use of  The second layer above the manure compost’s
this removed weed, so this was the great ideacomes in layer was of chopped fresh water hyacinth which
mind that this can be utilized in best way by converting it was about 5 inch thick containing about 15.7 kgs
into water hyacinth composting. of water hyacinth.
Hopefully this compost could be solving problems and  The third layer above second layer was of fresh
utilized in our agriculture based country significantly. cow dung which was about 2 inch thick
With an aim to solve the problems associated with water containing approx 13.33 kgs of cow dung.
hyacinth the project has been proposed to prepare  The fourth layer above the cow dung layer was
compost by using water hyacinth to improve nutritional of chopped fresh water hyacinth (~15.7 kgs) of 5
contents by incorporation of different amendments. inch thickness.
 The fifth layer above fourth layer was of fresh
Materials and methods - This experiment was cow dung (~13.33 kgs) of 2 inch thickness.
conducted at the form of Indian Institute of Soil Science  The sixth layer above the fifth layer was of
Bhopal (geographical location 230 18” N latitude, 770 chopped fresh water hyacinth (~15.7 kgs) of 5
24” E longitude, altitude 485 m amsl). Water hyacinth as inch thickness.
a source of waste material collected from Kaliasot river
 The seventh layer above sixth layer was of fresh
passing by Danish Kunj Bhopal.and Cow dung as a raw
cow dung (~13.33 kgs) of 2 inch thick Each pit
material collected from Lamba Kheda village near IISS remained empty by about 8 inch for turning and
Bhopal. Rock phosphate, lime, urea, microbial enriched
watering operation.
compound and epigeic earth warm are the amendments
arranged from Soil Biology Division ICAR, IISS Bhopal.
Water hyacinth was chopped manually at IISS Bhopal
The details of experiment set up are given below:
a. Experimental setup: There were seven pits for

composting, dimension of each compost pits
were length 6 to 7 feet. Width 3 feet and depth
2.5 feet. Fresh water hyacinth was chopped in
small pieces and filled in each of those pits along
with cow dung in the ratio of 2:1 as shown in fig
1
Fig 2: A&B. Filling of pits for composting, C. Pits were

covered to facilitate composting, D. Turning for aeration
In each pit, different materials were used for composting

fresh water hyacinth with cow dung. It was observed that
after 21 days material in each pit was partially
decomposed, and then in each pit various treatments were
imposed as mentioned in table 1.0 Earthworms and
microbial culture were inoculated after 32 days.
Following treatments were applied in each of those
prepared pits:
Table 1: Composition of different materials used for

composting from water hyacinth
S.No. Material Quantity Material
in Kg
%
1 Water hyacinth + Cow 77+40 15.7+13
dung .3
2 Rock phosphate 2.925 2.5
3 Lime 2.34 2
4 Urea 0.06 0.5
5 Gypsum 11.7 10
6 Earth warm 2 -
Fig. 1: Order of different layers of materials
7 Microbial culture 0.0585 -
constituted for carrying out composting in pit
As per the shown table above mentioned materials were
applied in each pit.
Prepration of microbial culture and their sub cultures of
fungai (A. awamori, A hetromorphous and R. pusillus)
were prepared by using potato dextrose agar media.
Seven types of composts were developed by

incorporating the materials in varied ratio as.
Different formulations of composts

T1 (control) = Water hyacinth + cow dung
T2 (Phospho Compost) = T1 + Rock Phophate
T3 (Phospho Compost with lime) = T2 + Lime
T4 (Phosphor Nitro Compost) = T3 + Urea
T5 (Phospho Sulpho Nitro Compost) = T2 + Gypsom +
Urea
T6 (Vermi Compost) = T1 + Epigeic earth warm
T7 (Microbial Enriched Compost) = T1 + Microbial
Culture
Fig.3a: Matured composts (Control,
b. Analytical Techniques: Different parameters
were analyzed for the characterization of both
substrates (water hyacinth and cow dung) and
products (water hyacinth compost) by dry ashing
and wet oxidation method (Issac and Johson,
1975). Total Nitrogen (N) in substrates and
composts were determined by (Kjeldahl, 1883),
A suitable sample is digested with a strong acid
so that it releases nitrogen which can be
determined by a suitable titration
technique. Substrates and composts samples for
N determination were digested in sulphuric acid
at a temperature between 360°C and 410°C.
Total phosphorus (P) in substrates and composts
(Jackson, 1967).Total Potassium (K) in
substrates and composts (Jackson, 1967), the
most common method for K determination is
through flame photometer. The substrates and
composts sample for K estimation can be Phosphocompost, Phospho compost with lime)
digested in di-acid or in tri-acid. In addition
digest obtained from dry ash is also taken for K
determination.
Fig.3b: Matured composts (Phospho Nitro compost,
Phospho Sulpho Nitro compost, Vermi Compost, Microbial
Result and Discussion - Composting of water hyacinth
enriched compost)
biomass was completed in 7 – 8 weeks. The mature
composts were black in colour, granular and fibrous with Initial studies performed with S1 and S2 showed
pleasant earthy smell compared with control mixture significant higher levels of nitrogen and Potassium in S1
which was light brown in colour, coarse in appearance in comparison to S2.
with a foul smell. The appearance of black colour is
indicative of its maturity. Pandharipande et al. Table 2: Analysis of N, P, K parameters of water
(2004)reported that the mature compost must be dark hyacinth and cow dung
brown or black granular spongy in feel and smell
normally shown in figure 3(a) and 3(b). S. Water Cow dung
Parameter
No. Hyacinth (S1) (S2)
Water hyacinth and cow dung constituted the main
ingredients in this study for the preparation of composts. 1 TN (%) 2.06 1.08
Varied compositions of chemicals, earthworms and
microbes have important role in the decomposition of
substrates. The macronutrients substrates and composts 2 TP2O5 (%) 0.48 0.41
(T1, T2, T3, T4, T5, T6 and T7) were determined.
3 TK (%) 1.85 0.41
Table 3: Analysis of N, P, K parameters of Water hyacinth composts
Parameters Phospho
Phospho Phospho Microbial
Phospho Sulpho Vermi
S. Control compost Nitro enriched
compost Nitro Compost
No. (Lime) compost compost
compost
T1 T2 T3 T4 T5 T6 T7
1 TN (%) 1.14 1.2 1.27 1.32 1.16 1.16 1.23
2 TP (%) 0.56 0.86 0.87 0.88 0.89 0.59 0.58
3 TK (%) 1.02 1.03 1.03 1.036 1.04 1.03 1.03
Table 3: provides the data on analysis of water hyacinth compost made with incorporation of different organic, mineral
and microbial cultures. The general properties of composts and the nutrient compositions of composts varied depending
on the amendments applied to the organic manure. With the addition of P through rock phosphate the phosphorous
concentration increased in the compost.The N contents and K contents have also exceeded 1.00%.
According to above mentioned table 2 and 3 there are various comparisons between different contents of parameters of
substrates and prepared composts
content of treated composts was in the range of 1.16 to

1.23 g kg-1 after composting. Plaza et al. (2007) have
reported that the nitrogen content of vermicomposts
increase due to mineralization of C-rich materials and,
nitrogen retention by compost which otherwise may be
lost as ammonia at higher pH values. The difference in
TN content of composts was different from each other.
Fig.4: Physio-chemical parameters of water hyacinth and

cow dung.
Total N: Total N content of compost depends on the
initial N content present in the feed material and the
degree of decomposition (Crawford, 1983). Presence of N
rich weeds having lesser toxicity proved to be favourable
for microbial mineralization of raw material. Decrease in Fig. 5: Graphical comparison of Total Nitrogen content in
pH, mineralization of proteinous organic material and different studies
conversion of ammonium nitrogen into nitrate may be
responsible for addition of N in compost (Yadav and Total Phosphorous: Phosphorous is also an essential
Garg, 2011). Total nitrogen (TN) content in the prepared element for plant growth which also increased on
composts was approximately equal to initial substrate composting. This may be due to transformation of
(S2). The initial TN content of the substrates was 2.06 unavailable forms of phosphorus to easily available forms
and 1.08 g kg-1 for S1 and S2, respectively. Whereas, TN by microbial enzymes like alkaline and acid phosphatases
etc. On composting, phosphorous content were enhanced
in all composts. Maximal increase was found in compost
(T5) approx 58.90% followed by T4 (57.1%) and T3 TK (%)
(55.4%) composts. Acid phosphatases and alkaline
phosphatases may be responsible for this transformation 1.04
1.036
(Ghosh et al., 1999). 1.04 1.03 1.03 1.03 1.03
1.02
TK (%)
TP (%) 1.02
1 0.86 0.87 0.88 0.89

1
0.56 0.59 0.58
TP (%)
0.5
TK (%)
0 Water hyacinth composts
Fig.7: Graphical comparison of total potassium content in

TP (%) different studies
Conclusion - This study signifies that water hyacinth has
remarkable nutritive properties that can be used for the
production of nutrient enriched compost which not only
result in healthy aquatic system but also add as an
advantage on agricultural lands as soil amendments.
Water hyacinth composts The result of the studies have shown that the water
hyacinth composts prepared by combining different
Fig6: Graphical comparison of total phosphorous amendments such as rock phosphate, lime, urea, gypsum
content in different studies microbial cultures and earthworm inoculation and
prepared different composts.. These are control, phospho
After vermicomposting phosphorus content was compost, phospho compost with lime, phospho nitro
highest in T4 and T5, and minimum in T1, CD + WH compost, phospho sulpho nitro compost, vermicompost
mixture Le Bayon and Binet (2006) have reported that and microbial enriched compost. Among composts, the
some amount of phosphorus is converted to more highest percentage of N was evaluated in phospho nitro
available forms partly by earthworm gut enzymes, i.e., compost and in phospho compost . The highest
acid phosphatases and alkaline phosphatases. Actions of percentage of P and K were also recorded in phospho
phosphorus-solubilizing microorganisms present in sulpho nitro compost ( P 0.89and K 1.04) and the lowest
earthworm’s casts may also be responsible for the release percentage of P and K in control compost (P 0.56 and K
of phosphorus in vermicomposting (Prakash and 1.02).
Karmegam, 2010).
Ackowledgment : It is a great pleasure to express my
Total Potassium: The potassium (K) content was greater sincere thanks to my research guide The Director, of
in all the composts than initial waste (S2) (Table3). The prestigious research Institute, ICAR, Indian Institute Of
increase in potassium content was 1–2% in the composts Soil Science (IISS), Bhopal Dr. A Subba Roa, Principal
as compared with K content in control. The differences in Scientist Dr.A.B.Singh and Dr.M.C.Manna Soil biology
the results can be attributed to the differences in the Division of IISS and also thankful to Department of Soil
chemical nature of the initial raw materials. Suthar (2008) Chemistry and Environmental chemistry ,technical officer
has reported 104 - 160% increase in potassium content V.B. Paul and Choudhery sir his valuable guidance,
during vermicomposting. Sangwan et al. (2010) have helpful attitude, valuable scientific discussions during the
also reported an increase in K in vermi composts after course of this work and the freedom to perform
bioconversion of sugar industry waste. experiments in my own way. On a personal level, I
would like to thank for all their direct and indirect
support in times of difficulty.
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RESEARCH ON IN-
VITRO CLONAL MULTIPLICATION PROTOCOL IN VARIOUS CULTIVARS O
F CHLOROPHYTUM.
Aditi Pandey*
*Priyadarshini Institute of Engineering & Technology, Hingna Road, CRPF Gate, Nagpur,
Maharashtra. E-mail- [email protected].
Corrosponding Author: Dr. (Mrs.) Aditi Pandey, Assitt. Prof., Department of Chemistry
Priyadarshini Institute of Engineering & Technology, Mouza Shivangaon, Khasara Number
1/IA, 1909/12C, Hingna Road, Near CRPF Gate, Nagpur, Maharashtra. E-mail-
[email protected].

Abstract:
Chlorophytum commonly known as ‘Safed Musli’ has become an endangered species due t
o its over exploitation, used as tonic and aphrodisiac. Root of the plant contains steroidal sa
ponin as secondary metabolite. It has a worldwide demand in ayurvedic and allopathic syst
ems of medicine to cure general debility, fatigue, weakness and male sterility. Although thi
s species has been brought under commercial cultivation but the systematic research on coll
ection and evaluation of germplasm still in demands.A tissue culture method has been deve
loped for its large scale multiplication and conservation. Micropropagation using stem disc
as explant has been achieved on Murashige and Skoog (MS) medium containing 5.0 mg.L-
1 BAP. Survival rate of these rooted plantlet in soil is about 80 %. A comparative studies h
ave been carried out to compare the protocol in different cultivars of Chlorophytum.
Keywords- Safed Musli, saponin, Micro propagation, Murashige and Skoog medium
Introduction:
‘Safed musli’ is an endangered medicinal plant of Liliaceae family belonging to genus
Chlorophytum. The tuberous roots of the plant are used in ayurvedic tonic and has
aphrodisiac property due to the presence of saponin. Safed musli has wide distribution in
India, mainly in the southern Rajasthan, Western MP and North Gujarat (Borodia
et.al.).More than 175 species of Chlorophytum have been reported in world, about 13
species of genus are found in India out of which roots of species C. borivillianum and C.
tuberosum only are used as safed musli in many ayurvedic preparations. It has a worldwide
demand in ayurvedic and allopathic systems of medicine to cure general debility, fatigue,
weakness and male sterility (Bhagat. et.al). In view of its day-to-day increasing demand not
only by the user of our country but of abroad too, it may be a dollar-earning crop.

Population of the plant is dwindling at an alarming rate. In nature the plant is propagated by
seeds and has become an endangered species due to low seed set, viability and germination,
associated with over exploitation from the wild strands. The planting material/ tubers as
well as seeds have dormancy for a certain period.
Owing to its enormous uses, its worldwide demand is estimated to be 35000 tons annually
as compared to current annual production of 5000 tons. The immediate task is to conserve
and multiply the plant in bulk amount required for its domestication to meet the present
demand. In recent years a large-scale propagation of plant has been developed by use of the
tissue culture technique and the number of plant species being enabled to multiply by this
technique annually. Plant tissue culture has been successfully used to micro-propagate
medicinal plants. Plantlet regeneration has been reported through apical meristem in C.
Comosum. Plantlet regeneration and bulbil formation has been reported through leaf and
stem explant in Curculigo orchiodes (Suri et al.1999).
In the present study, an efficient and rapid In-vitro micro propagation method of Safed
musli (Chlorophytum borivillianum) has been established through optimization of medium
and cytokinin and auxin ratio for shoot proliferation and root formation.
Material & Methods:
Leaf segment, root segment and stem disc of two different collection of Chlorophytum
borivillianum ( Fig-A, Fig.-B) were collected from mature plants as explants from the field
and brought to the laboratory. The source tissues were kept under running tap water (5
mints) and washed with a 5 % laboline detergent for 5-10 mints. Different concentration
and combination of sterilent tried for the surface sterilization of explants. After washing
with detergent surface sterilization was done with 1 % bleaching powder solution with

0.1% amplicillin for 20 mints. After removing few scales and waste part, explants were
washed three times with sterile water. After washing explants immersed in 0.2% mercuric
chloride solution with few drops of tween 20 for 15 min. in laminar flow. Last treatment
given by 70% ethanol for 60 seconds. Explants were inoculated after washing with sterile
water and drying with sterile blotting paper.
The materials were cut into appropriate sizes (leaf- 1cm., root segment 1 cm, stem disc)
and cultured on MS medium (Murashige and Skoog, 1962). The medium was used at
different strengths. The medium was supplemented with 3 % sucrose and gelled with 0.8%
agar. Basal medium was supplemented with different concentration of growth regulators
(2,4-D, Kin, 2iP,NAA,BAP) either alone or in combination for shoot initiation as well as
shoot multiplication. The pH of the medium was adjusted to 5.8 before autoclaving at a
pressure of 15 lbs for 15 mints. The cultures were incubated at 25 +- 20C with 16/18 hours
photoperiod under white fluorescent tubes. Experiments were set up in a completely
randomized design. Minimum 6 explants were used for each treatment and all treatments
were repeated twice. Data were presented in mean number of shoot. Plantlets were
transferred to small pots containing soil and sand (1: 1) and subsequently to the field.
Result:
In this experiment most of the explants were contaminated with fungi and thus explants
were sterilized with different concentration and combination of sterilent. Strong treatment
has been given to explants to protect them for contamination. Shoot initiation was observed
only in stem disc explant. No response has been seen in leaf as well as root segment.
Growth regulators NAA, 2,4-D,BAP, 2iP and Kin. either alone or in combination tested in
the present study (Table 1). Callus development has been seen on MS medium enriched

with 2,4-D(1-2.5mgL-1) ( Fig.-C). Cream coloured callus was not found suitable for shoot
initiation as well as multiplication. Good response has been seen by Stem disc (crown) on
the medium containing different concentration of BAP. BAP in higher amount is the best
for shoot initiation in comparison to 2,4-D, Kin, 2iP. MS medium supplemented with 5.0
mgL-1 BAP was best for shoot initiation. Mean number of shoot initiated in MS medium
supplemented with 5.0mgL-1 BAP is 7.8 in sample 1 and 6.6 in sample 2, which is highest
among others (Fig.D, ). More than 80% response has been seen in 5.0 mgL-1 BAP
treatments. These cultured shoots were used for sub culturing. MS medium supplemented
with 5.0 mgL-1 BAP used as a parent media. Different concentration and combination of
growth regulators tried for multiple shoot formation. Auxin and Cytokinin ratio has given
average response of 75% with 6-8 mean numbers of shoots. When sub culturing has been
done on to the medium of same composition (5.0 mgL-1 BAP) resulted in an increase in
size and extra ordinary response has been seen. 100% response with more than 15 mean
number of shoots in sample 1 and 17 in sample 2 generated from the MS medium
supplemented with 5.0 mgL-1 BAP (Fig.-E). 75 % response reported when BAP
concentration increased after 5.0 mgL-1 BAP. (Table 2).
Healthy roots were found when shoots transferred to half strength MS medium
supplemented with 500mgL-1 charcoal (Fig.-F.1,2). Plantlets developed through tissue
culture were successfully transferred in soil and sand (1: 1) with high rate of survivability
(80%) (Fig.-G).
Tissue culture has been used to accelerate plantation development, to shorten breeding
cycle and to rapid multiplication. The best use of micro propagation technique is to

overcome dormancy problem. The plantlets obtained by this technique are expected to be
pathogen free.
Discussion:
Due to large scale and indiscriminate collection of the wild material and insufficient
attempts either to allow its replenishment or its cultivation Chlorophytum is rapidly
disappearing from nature Growth regulators NAA, 2,4-D, BAP, 2iP and KIN either alone
or in combination tested in the present study. Response has been recorded by Stem disc
(crown) on the medium containing different concentrations of BAP. BAP in higher amount
was found best for shoot initiation in comparison to 2,4-D, KIN, 2iP. MS medium
supplemented with 5.0 mgL-1 BAP was best for shoot initiation. Mean number of shoot
initiated in MS medium supplemented with 5.0 mgL-1 BAP is 7.8 in sample1 and 6.6 in
sample 2. More than 80% response has been found in 5.0 mgL-1 BAP treatments. These
cultured shoots were used for sub culturing. MS medium supplemented with 5.0mgL-1 BAP
used as a parent media. Different concentrations and combinations of growth regulators
tried for multiple shoot formation. Average response of 75% with 6-8 mean numbers of
shoots was found in auxin and cytokinin ratio. When sub culturing was done on to the
medium of same composition (5.0mgL-1 BAP) resulted in an increase in size and extra
ordinary response was found. 100% response with more than 15 mean numbers of shoots in
sample 1 and 17 in sample 2 generated from the MS medium supplemented with 5.0 mgL-1
BAP. 75 % response reported when BAP concentration increased more than 5.0 mgL-1
BAP. Healthy roots were found when shoots transferred to half strength MS medium
supplemented with 500 mgL-1 charcoal. Plantlets developed through tissue culture were
successfully transferred in soil and sand (1: 1) with high rate of survivability (80%) Arora

et al., (1999) developed an improved method for large-scale rapid multiplication of C.
borivillianum through somatic embryogenesis. Somatic embryos were obtained on MS
medium containing 2.25 micro molar 2,4-D and 1.5 micro molar kinetin. The technique
developed is highly efficient to get miniature plantlets for field transfer in 2 months,
starting from callus.
Tissue culture has been used to accelerate plantation development, to shorten
breeding cycle and to rapid multiplication. The best use of micro propagation technique is
to overcome dormancy problem. Plant tissue culture has been successfully used to micro-
propagate medicinal plants. Plantlet regeneration has been reported through apical
meristem in C. comosum. Plantlet regeneration and bulbil formation has been reported
through leaf and stem explant in Curculigo orchiodes (Suri et al., 1999).

(Table 1)- Effect of different concentrations and combinations of phytohormones on shoot
initiation Hormone Sample 1 Sample 2
Concentration
(mg/1)
% response Mean no. of % response Mean no. of
Shoots initiated shoots initiated
2,4 D
0.5 25 2.0 25 1
1.0 20 2.0 20 1.5
1.5 50 3.5 50 4
2.0 25 2.0 25 2.5
2.5 25 1.0 25 1
2,4 D + KIN
1.0+1.0 20 1.0 20 1
1.0+1.5 50 2.5 50 1
1.0+2.0 25 2.0 25 2.0
1.0+2.5 40 2.5 40 2.0
2iP
0.5 20 4.0 20 0
1.0 33.3 5.5 33.3 1
1.5 40 2.0 40 0
2.0 40 1.0 40 2
KIN
0.5 25 1.0 25 3
1.0 33.3 2.0 33.3 0
1.5 40 1.0 40 0
2.0 40 2.5 40 0
2.5 50 2.0 50 2.0
NAA+KIN
1.0+1.0 40 1.5 40 1.5
1.0+1.5 20 1.0 20 3.5
1.0+2.0 25 2.0 25 2.5
1.0+2.5 40 2.5 40 2.5
BAP
1.0 50 3.5 66.6 3.0
1.5 50 3.33 50 2.5
2.0 80 2.25 50 3.0
2.5 75 5.0 60 3.33
3.0 83.3 6.6 60 3.66
4.0 80 5.0 75 4.3
5.0 83.3 7.8 83.3 6.6
6.0 75 5.0 75 5.5
8.0 75 4.3 75 3.0
10.0 50 2.5 75 3.33

(Table 2 ) Effect of subculture media on multiple shoot formation.
Hormone Sample 1 Sample 2
Concentration
(mg/1)
Mean no. of % Response Mean no. of % Response
shoots initiated shoots initiated
NAA+BAP
1.0+0.5 6.66 75 6.0 50
1.5+1.0 3.33 75 6.0 33.3
1.0+2.0 4.00 50 3.5 66.6
1.0+2.5 3.33 75 3.5 66.6
NAA+KIN

1.0+0.5 3.5 66.6 3.0 75
1.0+1.0 3.00 75 1.5 50
1.5+1.5 2.33 75 2.0 33.3
1.0+2.0 2.00 75 3.0 50
1.0+2.5 2.00 50 3.0 50
BAP
0.5 6.66 75 2.0 25
1.0 8.00 75 3.5 66.6
1.5 7.5 66 3.0 66.6
2.0 6.00 75 2.0 66.6
2.5 6.0 66 2.5 33.3
3.0 6.5 50 7.0 75
4.0 6.6 75 7.6 75
5.0 14.75 100 17.0 100
6.0 8.6 75 9.0 75
7.0 8.33 75 9.3 75
8.0 9.00 75 6.6 75
10.0 5.00 75 9.3 75
Protocol for Multiplication of Chlorophytum borivillianum.
Explant (Stem disc)
Surface sterilization
Culture initiation (MS medium + 5.0 mg./l. BAP, 7.8 mean no. of shoots)
Shoot Multiplication (MS medium + 5.0 mg./l. BAP, 15 mean no. of shoots)
Rooted plantlets
Field establishment

In-vitro regeneration potential of different Chlorophytum genotypes
To study the in-vitro regeneration potential of different Chlorophytum genotypes, all the
collected genotypes were cultured on the standardized medium. Among the three only two
responded on the same standardized medium (Table 4.16). 50.0-percentage response with
2.55 mean numbers of shoots was recorded for M4 and 60.00 percent response with 3.33
mean numbers of shoots were recorded for M5. Genotype M3 not responded in the
standardized medium (5.0 mg/l BAP). It has been concluded that in-vitro regeneration
technology can be successfully employed for Chlorophytum plantlets, if careful selection of
proper combination and concentrations of phytohormones for explants is made for specific
genotype.

References
Arora, D. K, Suri S. S., Ramawat, K. G. and Meerillon, J. (1999) Factors Affecting Somatic
Embrygenesis in Long Term Callus Culture of Safed musli (Chlorophytum borivillianum):
An Endangered Wonder Herb. A Journal of Experimental Biology. 75-82.
Bordia ,P.C., Joshi A. and Simlot MM. (1995) Safed Moosli. In: Advances in Horticulture
Vol. 11- Medicinal and Aromatic Plants. Eds:Chandha and Rajendra Gupta. Pbl.
Malhotra Publishing House, New Delhi: 429-451.
Bhagat,C. and Jadeja ,G.C. (2003) Variation and correlation in root yield and biochemical
traits of Safed musli. ( Chlorophytum borivillianum). Journal of Medicinal and
Aromatic Plant Sciences 25: 33-36.
Murashige, T. and Skoog, F. (1962) A Revised Medium for Rapid Growth and Bioassays
with Tobacco Tissue Culture. Physiol. Plant 15: 473-497
Suri, S., jain,S., Ramawat, k.G. (1999) Plantlet regeneration and bulbil formation in-vitro
from leaf and stem explants of curculigo orchioides, an endangered medicinal plant.
Scientia horticulturae 79: 127-134.

        
Fig.-B
Fig.-E
Fig.-G


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Sr.

From above literature, review it is indicated that References

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