V.bbachilor of Main Projet
V.bbachilor of Main Projet
V.bbachilor of Main Projet
In order to obtain the appropriate levels of the vibratory plate compactor working vibrations and
to reduce the vibrations at the other subassemblies, a study of the soil stiffness and damping
influence upon the machine natural angular frequencies is required. In this aspect, this paper
studies and includes the variation of the natural angular frequencies of vibratory plate compactor,
upon the soil class [based on granular soil].
1
Vibratory plate compactor 2007
To solve maintenance problem which we see in the purchased compactors
To reduce vibration problems on the engine and other components to increase the life time
1.6. Methodology
Data Source
Data’s are assessed from different books in the library and internet. The data’s of the materials
which we cannot manufacture locally are also gathered from internet, through direct interview
and observations.
Direct observation, Different research works and compactor manufacturing foreign companies
from internet.
Data Analysis
Using vibrating equation of motion we solve the soil response during compaction and the
isolation system.
Using different static and fatigue machine element analysis we use to design machine
parts like pulley, belt, eccentric rotary shaft, plate etc..
2
Vibratory plate compactor 2007
2.1. Introduction
Soil compaction is defined as the method of mechanically increasing the density of soil. In
construction, this is a significant part of the building process. If performed improperly,
settlement of the soil could occur and result in unnecessary maintenance costs or structure
failure. Almost all types of building sites and construction projects utilize mechanical
compaction techniques.
What is soil?
Soil is formed in place or deposited by various forces of nature—such as glaciers, wind, lakes
and rivers—residually or organically.
Soil type
Why compact?
3. Provides stability
Two factors are important in determining the type of force a compaction machine produces:
frequency and amplitude.
3
Vibratory plate compactor 2007
Frequency: is the speed at which an eccentric shaft rotates or the machine jumps. Each
compaction machine is designed to operate at an optimum frequency to supply the maximum
force. Frequency is usually given in terms of vibrations per minute (vpm).
Amplitude (or nominal amplitude) is the maximum movement of a vibrating body from its axis
in one direction. Double amplitude is the maximum distance a vibrating body moves in both
directions from its axis. The apparent amplitude varies for each machine under different job site
conditions. The apparent amplitude increases as the material becomes more dense and
compacted.
Where centrifugal force is measured in KNS, Frequency is measured in VPM and effective
weight is measured in KW.
Compactor Productivity
Effects of soil condition
The type and condition of the soil can affect the compactor’s efficiency. The soil being
compacted must be at or near its optimum moisture. It will be difficult to compact if there is
either too much or too little moisture in the material. If the soil is too dry, the compactor ma y
generate clouds of dust, and if the soil is too moist, the compactor’s base plate may stick to the
material.
Maximum compaction area
To determine the compactor’s productivity, evaluate its maximum forward speed and its
effective plate width the plate width that actually touches the soil. Plate widths generally range
from 10 to 26 inches, and plate lengths from 10 to 30 inches. Narrower plate widths can be
especially useful for curb-and-gutter and utility work.
Maximum lift
Manufacturers report that the maximum lift or layer of soil, that the typical machine can
compact ranges from 8 to 30 inches. The size of the required maximum lift varies depending on
the application. Sidewalks, for example, typically require a 4-6 inch lift, but larger commercial
applications generally require lifts that are at least 1 foot deep.
4
Vibratory plate compactor 2007
Lift height and machine performance
Lift height (depth of the soil layer) is an important factor that affects machine performance and
compaction cost. Vibratory and rammer-type equipment compact soil in the same direction: from
top to bottom and bottom to top. As the machine hits the soil, the impact travels to the hard
surface below and then returns upward. This sets all particles in motion and compaction takes
place.
As the soil becomes compacted, the impact has a shorter distance to travel. More force returns to
the machine, making it lift off the ground higher in its stroke cycle. If the lift is too deep, the
machine will take longer to compact the soil and a layer within the lift will not be compacted.
Soil can also be over-compacted if the compactor makes too many passes (a pass is the machine
going across a lift in one direction). Over-compaction is like constantly hitting concrete with a
sledgehammer. Cracks will eventually appear, reducing density. This is a waste of man-hours
and adds unnecessary wear to the machine.
Compaction specifications
Generally, compaction performance parameters are given on a construction project in one of two
ways:
Equipment types
1. Rammers
Rammers deliver a high impact force (high amplitude) making them an excellent choice for
cohesive and semi-cohesive soils. Frequency range is 500 to 750 blows per minute. Rammers get
compaction force from a small gasoline or diesel engine powering a large piston set with two sets
of springs. The rammer is inclined at a forward angle to allow forward travel as the machine
jumps. Rammers cover three types of compaction: impact, vibration and kneading.
2. Vibratory plates
Vibratory plates are low amplitude and high frequency, designed to compact granular soils and
asphalt. Gasoline or diesel engines drive one or two eccentric weights at a high speed to develop
compaction force. The resulting vibrations cause forward motion. The engine and handle are
vibration-isolated from the vibrating plate. The heavier the plate, the more compaction force it
5
Vibratory plate compactor 2007
generates. Frequency range is usually 2500 vpm to 6000 vpm. Plates used for asphalt have a
water tank and sprinkler system to prevent asphalt from sticking to the bottom of the base plate.
Vibration is the one principal compaction effect.
In addition to some of the standard vibratory plate features, reversible plates have two eccentric
weights that allow smooth transition for forward or reverse travel, plus increased compaction
force as the result of dual weights. Due to their weight and force, reversible plates are ideal for
semi-cohesive soils. A reversible is possibly the best compaction buy dollar for dollar. Unlike
standard plates, the reversible forward travel may be stopped and the machine will maintain its
force for ―spot‖ compaction.
Capable of moving both forward and backward, reversible plate compactors are particularly
useful on jobs with little turnaround room, such as trenches. Since they are bulkier than most
forward- only compactors, reversible can also help operators tackle larger jobs. The critical
difference between a forward only and a reversible compactor is the exciter unit. Most reversible
feature an exciter with counter- rotating eccentric’s two eccentric weights that revolve in
opposite directions. The eccentric weights are positioned to reverse the compactor’s direction
every time the relative position of one eccentric changes 180 degrees relative to the other.
Changing the compactor’s direction does not require stopping the machine or bringing it to a
neutral position. Although some reversible weigh less than 300 pounds, most weigh between 425
and 725 pounds, and some are as heavy as 1,600 pounds. Compactors weighing more than 300
pounds are well suited to compact larger, more cohesive soil particles: These units rely not
only on frequency but also on static weight to compact soil. Thicker maximum lifts are also
possible with these heavy reversible. Reported maximum lifts, for example, can range from 1 4-
4 0 inches. Also, base plate extensions come with many reversible plates compactors to
increase the maximum compaction area. To facilitate handling and increase operator safety,
many manufacturers of reversible suffer remote controlled steering.
Types of compaction
There are four types of compaction effort on soil or asphalt:
Vibration
Impact
Kneading
Pressure
These different types of effort are found in the two principle types of compaction force: static
and vibratory.
6
Vibratory plate compactor 2007
Static force is simply the deadweight of the machine, applying downward force on the
soil surface, compressing the soil particles. The only way to change the effective
compaction force is by adding or subtracting the weight of the machine. Static
compaction is confined to upper soil layers and is limited to any appreciable depth.
Kneading and pressure are two examples of static compaction.
A vibratory plate compactor consists of two key elements: an engine and an exciter unit.
Powered by the engine, the exciter unit determines the compactors:
7
Vibratory plate compactor 2007
Inside the exciter unit an unbalanced (eccentric) weight turns at high speed, generating enough
centrifugal force to vibrate the iron or steel base plate that is bolted to the exciter unit. The
plate’s vibratory action compacts granular soil by reducing the friction between soil particles,
allowing the smaller pieces to settle into the voids between larger particles.
Structure
The upper part is made up of Power source, Handle, Belt Cover, Water Tank for sprinkling and
Guard hook which are fixed by Engine base. The Engine base is fixed on Vibrating Plate by
Shock absorbing Rubber. The lower part is made up of Vibrating plate and Vibrator unit that has
an Eccentric rotary shaft built in. The power source is transmitted from the centrifugal clutch on
engine output shaft to the Eccentric rotary shaft via V-belt.
Power Transfer
Air-cooled Single cylinder Engine is amounted as power source and Centrifugal Clutch is fixed
on engine output shaft. Petrol Engine (2 cycles, 4 cycles) and Diesel Gasoline Engine can be
mounted as option. Centrifugal Clutch engages by running up the engine and engine R.P.M. is
reduced to suitable number for compacting. The rotation of engine is transmitted form V-pulley
integrated with clutch drum to Vibrator pulley through V-belt. Vibrator Pulley rotates Eccentric
rotor shaft that is contained in Vibrator case. The generated vibration created from eccentric
rotor is transmitted to Compacting plate.
8
Vibratory plate compactor 2007
Designed to work in confined areas and close up to columns, wall and kerbs. Trenches,
patchwork on roads, pool surrounds and foundation fills are easily and effectively compacted.
Speed and compaction depth are adjusted through hydraulic control of the eccentric element.
This gives the plate smooth motion and makes it easy to operate.
9
Vibratory plate compactor 2007
Fig 3.3Rammers
10
Vibratory plate compactor 2007
As you see in the above table the first one or design concept 1 is better than the others and it is
selected to be designed.
Advantage of forward vibratory plate compactor over the others
A front mounted exciter is placed at the front of the base plate, and the engine is mounted in the
rear. The amplitude at the front of the base plate is larger than that at the back. The result is faster
forward speed and the ability to compact soil with a certain amount of cohesive material content.
This design also allows for lower overall center of gravity which contributes to the stability of
the machine.
11
Vibratory plate compactor 2007
3.2. Compaction force analysis
To compact a soil or asphalt of the required places we should calculate the force that needs to
compact to the required lift depth. So, to analyze the force needed we must know all the soil
parameters that resist the compaction.
Important parameters having influence on compaction by vibratory plate compactor are given as
below:
Influence of vibration and amplitude on compaction of soil is profound. All soils have their
natural frequency and it is found that the frequency of plate compactor should be between 0.5
and 1.5 times the natural frequency of soil for obtaining best compaction results.
Fig. 3.6 Free body diagram of soil response in the case of compaction
The basic equation used in analyzing the translator vibrating motion of a system with a single
degree of freedom is:
𝑀𝑥 + 𝐶𝑥 + 𝐾𝑥 = 𝐹𝑜𝑠𝑖𝑛𝜔𝑡 , 𝐹𝑜 = 𝑚𝑒 𝑒𝑐 𝜔2
12
Vibratory plate compactor 2007
Where: 𝐹𝑜 = Exciting vertical force.
𝜔 = rotational speed
M = equivalent mass
𝑥 = 𝐴𝑐𝑜𝑠 (𝜔𝑡 − 𝜑)
𝐹𝑜
𝐴=
(( 𝐾 − 𝑀𝜔 2 )2 + 𝐶 2 𝜔 2 )
One of the basic requirements for a dynamic analysis is the selection and analyzing the
appropriate values for M, C and K of the soil.
Frequency
Fig 3.7 amplitudes of different compaction machines
13
Vibratory plate compactor 2007
Assumption:
Known values:
From: TABLE 3.2 Sandy soil, 𝜇 = 0.20 s
𝑘𝑔
Density of gravel soil, 𝜌 = 2000
𝑚3
3
Volume (V) = L*B*y = 0.006𝑚
The equivalent mass of the machine, the mass of the foundation and also in phase mass of soil
which vibrates with the foundation. Unfortunately with the present available knowledge it is not
possible to identify the quantity of in phase soil mass. It is recommended that for a spread
footing, equivalent mass may be taken as the mass of the machine. Let’s assume the mass of the
vibratory plate compactor; M= 100Kg
The spring constant is the most difficult and the most important parameter to be determined to
know the force needed to compact the soil. Its value affects the resonant frequency, amplitude at
resonance as well as operating frequencies (unless operating is well far away from the resonance
condition).
For vertical motion and rectangular footing, spring constant (K) is:
𝐺
𝐾=1 𝛽𝑉
𝐵𝐿 − 𝜇
14
Vibratory plate compactor 2007
Table ―3.2‖ Typical Range of values for Poisson’s Ratio (from winter corn and fang 1975;
Bowles 1968)
G = dynamic shear modulus of soil
𝑬
G= Where E = dynamic elastic modulus of soil.
𝟐 ( 𝟏+ 𝝁 )
Dynamic shear modulus (G) and elastic modulus (E) are determined from field tests, laboratory
tests or estimated based on empirical formulae. Values of dynamic shear modulus in general
depend on many factors like:
(i). Soil type and its grading, structure, initial void ratio, temperature, degree of saturation.
But, these all parameters are very difficult to measure in our campus civil engineering
department lab. As a result, we take a data that is tasted with accurate measurements which
describes the elastic modulus of the soil.
15
Vibratory plate compactor 2007
Table ―3.3‖ Typical values of young’s modulus for granular material (MPa) based on
obrzud&Tuty 21012 compiled from Kezdi 1974 and Pra et al. 1995)
Spring constant ( K ) is
16
Vibratory plate compactor 2007
𝐺
𝐾=1 𝛽𝑉
𝐵𝐿 − 𝜇
𝑬
Now 𝑮= E = dynamic elastic modulus of soil.
𝟐 ( 𝟏+ 𝝁 )
From TABLE 3.3 for Gravels/Sand well-graded and loose (since it is going to compact)
30Mpa
𝑮= = 𝟏𝟐. 𝟓𝐌𝐩𝐚
2 1 + 0.20
12.5𝑀𝑝𝑎
𝐾= × 1.1 × 0.50 × 0.40
1−0.20
rad
ω𝑛 277 .3 second
𝒇𝒏 =𝟐𝛑= 𝐫𝐚𝐝 =44𝑯𝒛 ,where
𝟐𝛑
𝐜𝐲𝐜𝐥𝐞
𝒇𝒏 =natural frequency
Damping, in general consists of two components these are geometric or radiation damping, and
internal damping,. Thus
The geometric damping is due to loss of energy through the propagation of elastic waves away
from the immediate vicinity of the testing. This type of damping does not account for internal
loss of energy due to in-elastic behavior.
0.425 1−𝜇 𝑚
For vertical mode of vibration 𝐷𝑔 = 𝑤𝑒𝑟𝑒 𝐵𝑣 = ( ) 𝜌 𝑅3
𝐵𝑣 4
𝐵𝐿 1
R = (( 𝜋 )2 ) that is B =width of the compacter L = length of the compacter.
17
Vibratory plate compactor 2007
The internal damping, 𝐷𝑖 in soil is due to loss of internal energy within the soil resulting from
hysteric and viscous effects i.e., from in-elastic behavior of soil. For ideally elastic material the
values of internal damping is zero.
The following table summarizes the currently available information relating to internal damping:
Table "3.4", some typical value for the internal damping ratios of soils
0.4 ×0.5 1
R=( )2 = 𝟎. 𝟐𝟓𝟐𝒎
𝜋
1−0.20 0.06𝑚 3
𝐵𝑣 = = 𝟎. 𝟕𝟓
4 0.25𝑚 3
18
Vibratory plate compactor 2007
𝐹𝑜
𝐴=
(( 𝐾 − 𝑀𝜔 2 )2 + 𝐶 2 𝜔 2 )
Then, the centrifugal force that needs to compact the soil with the assumed amplitude is:
= 628.3𝒓𝒂𝒅 𝒔𝒆𝒄
2𝜋𝑁 2𝜋×6000 𝑟𝑝𝑚
𝜔= =
60 60
𝐹𝑜=𝐴 ( 𝐾−𝑀𝜔 2 + 𝐶 2 𝜔 2
𝑭𝟎=𝟐𝟒.𝟗×𝟏𝟎𝟑 𝑵=𝟐𝟓𝑲𝑵
19
Vibratory plate compactor 2007
F 6HP single cylinder 4 stroke air cooled diesel engine for sales170, 178,186,188
Diesel powered vibratory plates offer several advantages over similar gasoline models. One is
diesel, a common fuel on jobsites used to power loaders, trucks, and many types of light
equipment which eliminates the need for multiple fuels. Secondly, maintenance costs are also
lower because diesels have no spark plugs, carburetor, or electrical ignition components to
service. Third, one can expect longer engine life due to the sturdier construction of diesels. A
diesel powered plate has higher initial cost, although its lifetime cost per hour of operation is
lower than that of a gasoline engine.
Although, the plate compactor uses the above selected horsepower we give the machine service
factor to have safe parts in any condition that the compactor faces.
Therefore, we design all the parts of the plate compactor with this design power which remains
on its design analysis.
20
Vibratory plate compactor 2007
The outer surface of pulley is covered with friction material. These shoes which can move radial
in guides are held against the boss on the driving shaft by means of springs.
Material selection
Cast iron has low cost and high thermal conductivity as compared with ductile iron. However,
ductile is better able to withstand shock or impact loading. So to fulfill the considerations we
want we choose the material to be ductile cast iron. So its cover, spider and shoes are ductile cast
iron. Almost all centrifugal clutches use friction lining called ferrodo material.
Known values:
21
Vibratory plate compactor 2007
Assumption
I. TRANSMITTED TORQUE
𝑃×60
𝑇= 2𝜋𝑁
Where:
𝑃𝑐 = 𝑚𝜔2 𝑟
Where,
22
Vibratory plate compactor 2007
𝜔 = Angular running speed, rad/sec
𝑟𝑎𝑑 2
𝑃𝐶 = 𝑚(376.99 ) × 0.085𝑚
𝑠𝑒𝑐
𝑷𝑪 = 12.08m KN
𝑃𝑠 = 𝑚𝜔1 2 𝑟
Since the speed at which the engagement begins to take place is generally taken as 3/4th of the
running speed, therefore the inward force on each shoe exerted by the spring is given by:
3 3
𝑃𝑠 = 𝑚(4 𝜔)2 𝑟 𝑤𝑒𝑟𝑒 𝜔1 = 4 𝜔 The plate compacter starts to work.
2
𝑃 𝑠= 9 𝑚𝜔 𝑟
16
Where,
9
𝑃𝑠 = 𝑚(376.99 𝑟𝑎𝑑 𝑠𝑒𝑐 )2 × 0.085𝑚 = 𝟔. 𝟕𝟗𝟓𝑲𝑵
16
Net outward radial force
9
= 𝑃𝐶 − 𝑃𝑆 𝑃𝐶 − 𝑃𝑆 = 𝑚𝜔2 𝑟 − 16 𝑚𝜔2 𝑟
7 7
PC − PS = mω2 r = m(376.99 rad sec)2 × 0.085 = 𝟓. 𝟐𝟖𝟓𝐦 𝐊
16 16
Frictional force acting on each shoe 𝐹 = 𝜇(𝑃𝐶 − 𝑃𝑆 )
Where,
F = Frictional force, N
23
Vibratory plate compactor 2007
Total Frictional torque transmitted
𝑇 = 𝜇(𝑃𝐶 − 𝑃𝑆 ) Rn
𝑇 = 𝑛𝐹𝑅
Where,
13.263NM = 502.075mNM
m = 0.02641kg
𝐴=𝑙×𝑏
𝐴×𝑝 = 𝑙×𝑏×𝑝
Force with which shoe press against the rim at running speed,
𝑙 × 𝑏 × 𝑝 = 𝑃𝑐 × 𝑃𝑆
b = 0.0157m = 0.016m
24
Vibratory plate compactor 2007
9
𝑷𝑺 = mω2 r
16
9
𝑃𝑆 = × 0.0264𝐾𝑔 × (376.99 𝑟𝑎𝑑 𝑠𝑒𝑐 )2 × 0.085 = 𝟏𝟕𝟗. 𝟗𝟑𝟑𝑵
16
We know that Wahl's stress factor,
4𝐶 − 1 0.615
𝐾= +
4𝐶 − 4 𝐶
Where, C = spring index = D/d,
25
Vibratory plate compactor 2007
4 × 6 − 1 0.615
𝐾= + = 1.2525
4×6−4 6
We also know that maximum shear stress induced in the wire (τ),
8𝐶𝑃𝑠
𝜏=𝐾
𝜋𝑑 2
179.933𝑁 × 6
392 × 106 𝑃𝑎 = 1.2525 ×
𝜋𝑑 2
d = 3.1964mm
8 × 63 × 179.933𝑁 × 𝑛
4.5 × 10−3 𝑚 = 𝑛 = 3.4764 ≈ 𝟒
80 × 109 𝑃𝑎 × 3.251𝑚
26
Vibratory plate compactor 2007
𝑳𝑭 = n × d + n − 1 2
𝐿𝐹 = 4 × 3.251𝑚𝑚 + 4 − 1 4𝑚𝑚 = 25.004𝑚𝑚
And
Pitch of the coil,
We know that pitch of the coil
𝐿𝐹
𝑝𝑖𝑡𝑐 𝑜𝑓 𝑡𝑒 𝑐𝑜𝑖𝑙𝑠 =
𝑛−1
25.004𝑚𝑚
= = 8.35𝑚𝑚
4−1
27
Vibratory plate compactor 2007
Known values
From TABEL 3.6 the belt section ―B‖ due to the recommended power
From TABLE 3.5 the service factor 1.4 - 1.6; let say 1.5
𝑁1 3600 3
𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑑 𝑡𝑒 𝑠𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜 = 𝑉. 𝑅 = = =
𝑁2 6000 5
Selected the pitch diameter of the smaller pulley from TABLE 3.9 the minimum pulley diameter
is given as 137 mm and correction factor for this is 12.5mm
Now
45 × 60
𝐷1 = = 𝟐𝟑𝟖. 𝟖𝒎𝒎 𝒔𝒂𝒚 𝟐𝟒𝟎𝒎𝒎
𝜋 × 3600
28
Vibratory plate compactor 2007
Determine the diameter of the smallest (driven) pulley.
𝐷2 = 𝐷1 1 − 𝑠 𝑉. 𝑅
Let s = 0.02
3
𝐷2 = 238.8 × 0.98 × = 𝟏𝟒𝟏𝒎𝒎
4
Find the belt speed
Now
Find the belt length referring to the neutral axis of belt section
(𝐷1 + 𝐷1 )2
𝐿 = 2𝑐 + 1.57 𝐷1 + 𝐷2 +
4𝐶
L = 1414.2mm
Now from standard the nearest standard belt for B is 1415mm now the exact center distance
should found out by the relation.
𝐶 = 𝑃 𝑃2 + 𝑞
𝐿 𝜋
𝑝= − × 0.24 + 0.141 = 0.20413
4 8
29
Vibratory plate compactor 2007
(𝐷1 + 𝐷2 )2 (0.24 − 0.1411)2
𝑞= = = 𝟎. 𝟎𝟎𝟏𝟐𝟐𝟓
8 8
𝐷2 + 𝐷2
𝑄 = 𝜋 − 2𝑠𝑖𝑛 −
2𝐶
240 − 141
𝑄 = 180𝑂 − 2𝑠𝑖𝑛 − = 165.96𝑜 = 2.896𝑟𝑎𝑑𝑖𝑎𝑛 > 2.1 … … … . . 𝑜𝑘
2 × 405.23
Find the maximum belt tension
𝐹1−𝐹2 𝑉 6.714 ×1000
𝑑𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = = 𝐹1 − 𝐹2 = =148.48N
1000 45 .216
𝐹1 𝜇
Now = 𝑒 𝜇 𝑒𝜃 𝑊𝐻𝐸𝑅𝐸 𝜇𝑒 = 𝛽
𝐹2 𝑠𝑖𝑛 2
𝐹1
= e0.992×2.896 = 14.4𝑓𝑜𝑟𝑒4 𝑡𝑒𝑟𝑒𝑓𝑜𝑟𝑒 F1 = 𝟏𝟒. 𝟒𝟒𝐅𝟐
𝐹2
F1 – F2 = 148.487N
148.487
𝐹2 = = 𝟏𝟏. 𝟎𝟒𝟖𝑵
13.44
𝐹1 = 𝟏𝟓𝟗. 𝟓𝟑𝟓𝟏𝑵
𝐹1
𝑍≥
(𝑓𝑡 − 𝜌𝑣 2 )𝐴𝐶1 𝐶2
1 1
𝑤𝑒𝑟𝑒, 𝑍 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑒𝑙𝑡, & 𝑏𝑒𝑙𝑡 𝑠𝑡𝑟𝑒𝑛𝑔𝑡(𝑓𝑡 ) = 𝑡𝑜 𝑜𝑓 6.5𝑡𝑜10.5 𝑀𝑃𝑎
6 8
𝑓𝑡 = 1.5𝑀𝑃𝑎 = 1.5𝑁/𝑚𝑚2
𝜌𝑣 2 = 2.86𝑁/𝑚𝑚2
30
Vibratory plate compactor 2007
Now from 𝐓𝐀𝐁𝐋𝐄 𝟑. 𝟏𝟎 the area section of B belt 1.4𝑐𝑚2 = 140𝑚𝑚2
Now,
1 4
𝐿𝑑 − 𝐿𝑖𝑛 = 2𝜋 𝑡 − 𝑡0 ∶ 𝑡0 = 𝑡 = 𝜋𝑡
3 3
4 4
𝐿𝑖 = 𝑖𝑛𝑛𝑒𝑟 𝑙𝑒𝑛𝑔𝑡 = 𝐿𝑑 − 𝜋𝑡 = 1415 − 𝜋 ∗ 11 = 𝟏𝟑𝟔𝟖. 𝟗𝟒𝒎𝒎
3 3
Now from table the exact inside length
159.535
𝑍=
(1.5 − 2.86) ∗ 140 ∗ 0.98 ∗ 0.9
Material selection
From 𝐓𝐀𝐁𝐋𝐄 𝟑. 𝟔 :
For ductile cast iron A536-84, Grade 60-40-18
Yielding strength, 𝜍𝑦 = 276 𝑀𝑃𝑎
Ultimate strength, 𝜍𝑢 = 414 𝑀𝑃𝑎
Elastic modulus, E = 152 GPa
𝐾𝑔
Density, 𝜌 = 7428 𝑚 3
31
Vibratory plate compactor 2007
Fig. 3.14 3D view of eccentric rotary shaft with its bearing and pulley
Σ𝐹𝑌 = 0
Σ𝑀𝐴 = 0
32
Vibratory plate compactor 2007
2500𝑁 − 0.085𝑚 − 0.17𝑅𝐵 + 0.2 × 170𝑁𝑚 = 0 , 𝑡𝑒𝑛 𝑅𝐵 = 𝟏𝟐𝟕𝟐𝟎𝑵
𝑅𝐴 = 12450𝑁
Now, by sectioning each stage of force let’s find shear and bending moment diagram to know the
maximum bending moment and where in exists which is useful in designing this shaft .
I. Section AC
33
Vibratory plate compactor 2007
III. Section DB
Σ𝐹𝑌 = 0
𝑉3 = −12550𝑁
Σ𝑀3 = 0
IV. Section BE
Σ𝐹𝑌 = 0
𝑉4 = 170𝑁
34
Vibratory plate compactor 2007
Σ𝑀4 = 0
𝑀4 = 170𝑥 − 37.40
Therefore, from the results above the shear and bending moment diagram of this shaft will be as
shown below:
Figure 3.16 shear and bending moment diagram eccentric rotary shaft
Therefore, as we see from the above diagram the maximum bending moment will be,
𝑀 = 249𝑁𝑚
𝑇𝑒 = 𝑀2 + 𝑇 2
𝑇 = 𝑇1 + 𝑇2 × 𝑅
Where, 𝑇1 = tension in tight side & T2 = tention in the slack sid𝑒 of the belt
Surface Factor 𝑲𝑨
The surface of a rotating-beam specimen is highly polished, with a final polishing in the axial
direction to smooth out any circumferential scratches. The surface modification factor depends
on the quality of the finish of the actual part surface and on the tensile strength of the part
material.
35
Vibratory plate compactor 2007
𝑘𝑎 = 4.51 × 723−0.265 = 0.79
𝑆𝑒 = 𝐾𝑎 𝐾𝑏 𝐾𝑐 𝐾𝑑 𝐾𝑒 𝐾𝑓 𝑆𝑢𝑡 𝑡
𝐾𝑐 𝐾𝑑 𝐾𝑒 𝐾𝑓 = 1
First estimation of the smallest diameter at the shoulder at the point b uses the DE Good man
criteria.
1
1 3
16𝑛 2𝑘𝑓 𝑀𝑎 (3(𝐾𝑓𝑠 𝑇𝑚 )2 )2
𝑑= ×( +
𝜋 𝑆𝑒 𝑆𝑢𝑡
𝑑 = 0.0551665688249𝑚 𝑠𝑒𝑦 𝟓𝟓 𝒎𝒎
The design of rolling element bearing concern only the selection of the most suitable bearing from the
catalogue of a manufacture according to procedure given in the catalogue
Assumption
36
Vibratory plate compactor 2007
The machine is to be used approximately 8 hr. per day
The average service life of 5 years
300 working day per year
Heavy Shock load
Known value
Shaft revolve at 6000 vpm
The shaft diameter is 55 mm
Analysis
𝐹 = 𝑃 × 𝐾𝑎 × 𝐾𝑡
Where
Now it is a usually practice with bearing manufacturing to specify the rated radial bearing load
capacity to the certain speed in rev/min and certain life But the actual or desired radial load F
may be have to be carried for different life and at different speed that given in the catalogue or
table therefore important that when comparing the rated capacity of bearing made by different
manufacture, capacity of bearing made by different manufacture , capacities are reduce to the
same life expectancy.
𝑟 𝑑𝑎𝑦
𝑡𝑒 𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑙𝑖𝑓𝑒 = 8 × 300 × 5𝑦𝑒𝑎𝑟 = 12000𝑟
𝑑𝑎𝑦 𝑦𝑒𝑎𝑟
The catalog life of bearing 𝑟𝑠 = 5000𝑟
37
Vibratory plate compactor 2007
The individual bearing reliabilities, if equal must be
𝐶𝑅 = 𝐾𝑡 × 𝐾𝑠 × 𝐾𝑦 × 𝐾𝑎 = 𝐹 × 𝐾𝑆 × 𝐾𝐿
From source [www.globalspec.com] from SKF single row deep groove ball bearing catalogue
life of bearing is, 𝐿𝐶 = 5000𝑟𝑠
𝐿𝑑 1 1200 1
𝑙𝑖𝑓𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = ( )3 = ( )3 = 2.5
𝐿𝐶 500
𝑛𝑑 = 6000𝑣𝑝𝑚
6000 1
𝐾𝑆 = ( )3 = 1.06
5000
Design radial load
Cylindrical roller bearings are available from several sources [www.globalspec.com] in this
range. A specification is chosen a common supplier of bearings, with the following
specifications
From source [www.globalspec.com] SKF
provide a separating film between rolling and sliding conducting surface and thus prevent
wear
To act as the a coolant to maintain proper bearing temperature
To prevent the bearing from being contaminated by dirt and other contaminants
To prevent corrosion of bearing surface
38
Vibratory plate compactor 2007
A typical D/d ratio for support at a shoulder is D/d = 1.6, thus, D =1.6(55) =88mm Increase to
D= 88 mm. A nominal 88mm in. cold-drawn shaft diameter can be used. Check if estimates were
acceptable.
Check d=55mm
𝑟
Assume fillet radius 𝑑 = 0.1
𝐾𝑎 = 0.79
Size Factor 𝑲𝒃
The size factor has been evaluated using 133 sets of data points.15 the results for bending and
torsion may be expressed as
Known values,
Now, we can easily know the mass of the eccentric rotary shaft from the centrifugal force
formula. To be an eccentric shaft the mass should be in one side. So, we start it from center of
the main shaft and to be easily got its cross sectional area we put the center of the eccentric shaft
circle be at the end point of the normal shaft circle as you see in the figure below.
𝐹𝑜 = 𝒎𝑒𝜔2
2𝜋 ∗ 6000 2
25000𝑁 = 𝒎 × 2 2 + 2 ∗ 10−2 𝑚 × ( )
60
𝒎 = 3.17𝐾𝑔 … … … … … … 𝑎𝑛𝑠
𝑚 3.17𝐾𝑔
𝑉= = = 0.000403𝑚3
𝜌 7860 𝐾𝑔
𝑚3
𝐴𝑒𝑐𝑐 = 𝐴2 − 𝐴1
Σ𝐴𝑌
𝑦=
Σ𝐴
Σ𝐴𝑥
𝑥=
Σ𝐴
40
Vibratory plate compactor 2007
Fig 3.18 Cross sectional view of the eccentric shaft with its eccentric mass and shaft centers
Material selection
41
Vibratory plate compactor 2007
From table
1
𝑤 = 𝑖𝑛 ≈ 12.7𝑚𝑚
2
3
𝑙 = 𝑖𝑛 ≈ 9.5𝑚𝑚
8
Design power =power transmitted * service factor
4476𝑤 × 1.5 = 1614𝑤
= 6.714kw
Transmitted torque
𝑝 × 60 6714 × 60
𝑇= = = 𝟏𝟎. 𝟔𝟗𝑵𝒎
2𝜋𝑛 3 × 3.14 × 6000
From the above figure, the force F at the surface of the shaft is
𝑇 10.67𝑁𝑚
𝐹= = = 𝟒𝟏𝟏. 𝟏𝟗𝟓𝑵
𝑟 0.026𝑚
By the distortion-energy theory, the shear strength is for ductile behavior the preferred criterion
is the distortion-energy theory,
𝛿1 276
𝑠𝑎𝑙𝑙 = = = 𝟔𝟗𝑴𝒑𝒂
𝐹𝑆 4
𝑠𝑠𝑦 𝐹 414.195
= =
𝑛 𝑡𝑙 12.7𝑙
39.8 × 106 414.195
= = 𝟎. 𝟎𝟎𝟑𝟑𝟒𝒎
4 0.0105𝑙
l =0.00334m
42
Vibratory plate compactor 2007
Elastomeric Isolators
―Rubber‖ is a synthetic or natural material whose long-coiled, high molecular weight chains have
been cross bridged by certain chemical ingredients to form a network. It is characterized by the
ability to accept and recover from extreme deformation of 200% or more. The term
―elastomeric‖ includes natural rubber and the many synthetic materials that possess rubber-like
properties.
Elastomers are well adapted for use in shock isolators because of their high energy storage
capacity and because the convenience of molding to any shape makes it possible to attain the
linearity or nonlinearity required for adequate shock isolation.
Flex-Bolt® Sandwich Mounts are designed to protect equipment and machinery against
damaging vibration. This family of mounts has excellent capacity for energy control.
They constructed with high-strength bonds and specially compounded elastomers; these mounts
provide high load-carrying capacity and assure long life.
The simple design and unitized construction provide low-cost mounting systems which are
compact, lightweight, easy to install and maintenance-free. These mounts are available in three
size groups to suit a variety of applications. Small Flex-Bolt Sandwich Mounts are available in
metric and standard (UNC) thssreads.
Typical applications for Flex-Bolt Sandwich Mounts include business machines, motorcycles,
heating, ventilating and air conditioning equipment, light motors, appliances, shipping
containers, feeders, compactors and vibratory rollers.
43
Vibratory plate compactor 2007
The main purpose of these isolators is protecting the supported mass from the vibratory
disturbances of the supporting structure as we see below:
The vibrating or moving structure causes a deflection across the spring which transmits a force to
the supported mass. This causes the mass to move and this motion must be reduced.
Known values:
44
Vibratory plate compactor 2007
Fig. 3.23 Family of transmissibility curves for a single degree of freedom system.
1+𝑟 2 ∗4∗0.052
|0.05 |= = r= 4.582
(1+𝑟 2 )2 +4∗0.052 ∗𝑟 2
Therefore;
𝑓𝑑 83.33𝐻𝑍
𝑓𝑛= = = =18.17𝐻𝑍.
𝑟 4.582
45
Vibratory plate compactor 2007
Properties:
Design Formulas:
Level of isolation = 1 – T then, T = 1 – I = 0.05
Isolator stiffness;
2
𝑤2 𝑚𝑇 523.6 60∗0.05
K= (1+𝑇) = =783.30KN/m = 783,330N/mm
(1+0.05)
Or,
𝑘 783.30𝑁/𝑚𝑚
𝑘𝑖𝑛𝑑𝑖𝑣𝑖𝑑𝑢𝑎𝑙 = = = 195.83𝑁/𝑚𝑚
𝑛 4
Where: m = system mass = operating frequency
Static deflection:
𝑚𝑔 𝑔 9.81
𝛿𝑠 = = (1+T) =(1+0.05) =0.0075mm
𝑘 𝑤 2𝑇 523.62 ∗0.05
From Table “3.15‖ the standard value of the appropriate natural rubber is;
Maximum static load (W) = 60 Kg*9.81 m/ = 588.6 N and
Type 1, J-5425-15,
art dimension (A=79.2mm,B=31.8mm,C=76.2mm,D=31.8mm )
46
Vibratory plate compactor 2007
In the early 1980s, MBW was an active member of the’S light equipment manufacturer bureau
(LEMB) of the contraction industry manufacturers association (CIMA)that produced LEMB
Standard # 1 gives the amplitude formula for vibratory plates and expressed as follows:
768∗𝑐𝑒𝑛𝑡𝑟𝑖𝑓𝑢𝑔𝑎𝑙 𝑓𝑜𝑟𝑐𝑒
Amplitude= 2
𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦
𝜋∗ ∗𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑣𝑖𝑏𝑟𝑎𝑡𝑜𝑟𝑦 𝑚𝑎𝑠𝑠
30
Where centrifugal force is measured in lbs., frequency is measured in VPM and effective weight
(unsprung mass) is measured in lbs.
In machine design, most fasteners are made from steel because of its high strength, high
stiffness, good ductility, and good mach inability and formability. But varying compositions and
conditions of steel are used. The strength of steels used for bolts and screws is used to determine
47
Vibratory plate compactor 2007
its grade, according to one of several standards. Three strength ratings are frequently available:
the familiar tensile strength and yield strength plus the proof strength. The proof strength, similar
to the elastic limit, is defined as the stress at which the bolt or the screw would undergo
permanent deformation. It usually ranges between 0.90 and 0.95 times the yield strength.
I. Design of hexagonal-head bolt for engine mount and eccentric rotary shaft cover housing
with the base
Material selection
Known values
Assumption
25∗10 3 𝑁∗2.5
𝑟2 = = 2.072∗ 10−5 𝑚2
4∗𝜋∗240∗10 6 𝑝𝑎
4∗25∗10 3 N∗2.5
𝑑𝑐 2 =4∗π∗0.8∗240 ∗10 6 =1.036∗ 1𝑂−4 𝑚2
48
Vibratory plate compactor 2007
𝑑𝑐 = 0.01018m≈ 11𝑚𝑚
Known values
Mass of the plate (m) = 30Kg
Length (L) = 500mm
Width (W) = 400mm
The length given by adding the bended plate side which uses for cleaning is self.
(0.5m+0.8m+0.8m = 0.66m)
Area (A) = L*W = 0.66*0.4 = 0.264𝑚2
V 4.011 ∗10 −3 𝑚 3
t= A = =0.015m=15mm
0.264 𝑚 2
During the work there is a vibration load which is compressive and causing crushing stress on
the plate. The greater stress occur on the plate is this compressive stress. So we are going to
compare it with its allowable compressive strength.
49
Vibratory plate compactor 2007
Let’s take the smaller value of the compressive strength,
𝐹 25KN
𝛿𝑐 = 𝐴 =0.4m ∗0.015m = 4.167Mpa
𝑐
It is quite small when we compare with compressive yielding strength. But, the mass is very
important for the compaction of the soil as we said in the compaction force analysis.
Known values
The figure above illustrates a failure by crushing of the bolt or plate. Calculation of this stress,
which is usually called a bearing stress, is complicated by the distribution of the load on the
cylindrical surface of the bolt. The exact values of the forces acting upon the bolt are known, and
it is customary to assume that the components of these forces are uniformly distributed over the
projected contact area of the bolt. This gives for the stress:-
50
Vibratory plate compactor 2007
δ
F= A
Where the projected area for a single bolt is A = td. Here, t is the thickness of the plate and d is
the bolt or bolt diameter.
Analysis
2083.33N∗2
t= = 0.001509m≈2mm
0.01m∗276∗10 6 pa
51
Vibratory plate compactor 2007
Base plate
Shaft housing
52
Vibratory plate compactor 2007
Handle
Belt cover
53
Vibratory plate compactor 2007
Fuel tank
Shaft
54
Vibratory plate compactor 2007
Centrifugal clutch
55
Vibratory plate compactor 2007
3.11. 1 3D Modeling of vibratory plate compacter
56
Vibratory plate compactor 2007
3.12 Designed parameter summery
10 Isolators 4 A=79.2mm,B=
31.8mm,C=76.
2mm,D=31
3.13 Table
57
Vibratory plate compactor 2007
58
Vibratory plate compactor 2007
Warning: these factors are only estimates for use when actual dimensions are not yet determined.
do not use these once actual dimensions are available.
59
Vibratory plate compactor 2007
Bending Torsional Axial
Shoulder fillet- 2.7 2.2 3.0
𝒓
sharp = 𝟎. 𝟎𝟐
𝒅
Shoulder fillet-well 1.7 1.5 1.9
𝒓
rounded 𝒅 = 𝟎. 𝟏
End –mill key seat 2.14 3.0 -
Table 3.13 Damping factors for materials commonly used for isolators
60
Vibratory plate compactor 2007
Properties Natural rubber Neoprene Hi-Damp Barry LT
silicone compound
Adhesion to metal Excellent Excellent Good Very good
Table 3.15 Standard elastomers of-flex-bolt small and medium sandwich mounts
61
Vibratory plate compactor 2007
Metric mechanical property classes for steel bolts, screws and studs
2𝑑 + 6 𝑙 ≤ 125
LT= 2𝑑 + 12 125 < 𝑙 ≤ 200
2𝑑 + 25 𝑙 > 200
Where L is the bolt length. The thread length for structural bolt is slightly shorter than given
above.
62
Vibratory plate compactor 2007
4.1. Conclusion
With an increase of the need of compaction machineries there is a need of joining contract
market with best use of new equipment. Because an area which requires special attention is
compaction. The link between the performance and degree of compaction has been shown the
basic importance for analyzing the proper compactor. The paper has presented an approach for
designing vibratory plate compactor. The basic idea of proposed design is calculating the
compaction force by controlling angular frequency of exciting system depending on the state of
compacted soil. This is achieved by coupling the compactor engine with the eccentric rotary
shaft through V belt by defining amplitude of vibrating system. However, the simplicity of
proposed compactor looks promising for further investigation of supplementary compactors and
vibration related machineries.
63
Vibratory plate compactor 2007
4.2. Recommendation
The design of this vibratory plate compactor has developed for maximum value of 25KN.
It is recommended that compactor values greater than 25KN should be studied, and based
on that, all the parts values can be determined.
Future research should investigate the properties of the different type of soils due to
different soil test equipment’s.
It is recommend that further field tests should be conducted to revalidate the relations
proposed in this study. These tests should include different types of materials with a wide
stiffness module range.
Finally, we acclaim the simple machineries like this vibratory plate compactors should be
manufactured for farther research.
64
Vibratory plate compactor 2007
Reference
[2]. Machine elements in mechanical design, Fourth Edition Robert L. Mott, RE University of
Dayton
[6]. Foundation design manual, for practicing engineering and civil engineering students, fifth
fully edition by NARAYAN V.NAYAK
[7]. Text book of machine design, first multicolor edition by R.S KHURMI and J.K. GUPTA
[9].Mechanical vibration
10 .Machine by Sharma
65