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Vibratory plate compactor 2007

Chapter One: Introduction

1.1. Background Information and Justification


A large amount of compaction processes during construction works is completed by dynamic
compactors. For smaller areas plate vibratory compactors are use in road construction mostly
vibratory rollers are applied. The vibratory plate compactor compacting machines, called also
one way vibrator, are aimed to perform vibratory soil compactions for confined areas and close
up to columns, wall and trenches, patchwork on roads, pool surrounds. This vibratory plate
compactor must be designed to simultaneously accomplish two opposite goals: to generate and
maintain the desired working vibrations of the dynamic plate-compactor, on one hand, and to
isolate the undesired vibrations transmitted to the compacting machine engine and operator hand,
on the other hand. We have designed such vibratory plate compactor, with single stages of
vibration isolation elements (based on rubber dampers).

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].

1.2. Problem statement


Compactor machineries are the valuable equipment’s for the civil engineering works which now
days vastly distributed in Ethiopia. But, these machineries are not manufactured in this country
which reduces a lot of stuffs for the contractors and it gives tremendous profit for the
manufacturers. In addition to the above problem the lack of vibration concept hampers or gets a
difficulty on creating appropriate vibration and isolation of other machineries. Vibratory Plate
compactor is one of the machineries which encountered the above

1.3. Objective of the study

1.3.1 General objective


The main objective of this project is to design vibratory plate compactor to be locally
manufactured.

1.3.2 Specific objectives

This vibratory plate compactor is designed for ensuing different objectives:

To minimize foreign currency to designing and manufacturing

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Vibratory plate compactor 2007
To solve maintenance problem which we see in the purchased compactors

1.4. Significant of the project


Upgrade our vibration concept on practical application to use it for different machineries related
to vibration difficulties

The project provides the way of appropriate technology

This project also introducing easily to manufacture in our country

1.5 Scope of the Project


The scope of this project is:-

To manufacture vibratory plate compactor and its components

To reduce unnecessary maintenance cost

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..

1.7 organization of the study


The thesis is organized by four chapters. The first chapter introduces the back ground
information, statement of the problem, objective and methodology of the study. the second
chapter states an over view of vibratory plate compactor.

In chapter three describes design analysis of the compactor.

The final chapter illustrates the conclusion and recommendation.

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Vibratory plate compactor 2007

Chapter two: Literature Review

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.

Following are important elements in soil compaction:

Soil type

1. Soil moisture content

2 .Compaction efforts required

3 .Generally, soil consists of solid particles, water and air;

Why compact?

There are five principle reasons to compact soil:

1.Increases load-bearing capacity

2. Prevents soil settlement and frost damage

3. Provides stability

4. Reduces water seepage, swelling and contraction

5.Reduce settling of soil

Compaction machine characteristics

Two factors are important in determining the type of force a compaction machine produces:
frequency and amplitude.

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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.

The amplitude formula for vibratory plates is expressed as follows

768 X Centrifugal force


𝐴𝑀𝑃𝐿𝐼𝑇𝑈𝐷𝐸 =
( π x Frequency )2
x Effective vibratory mass
30

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.

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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:

 Method Specification—detailed instructions specify machine type, lift depths, number of


passes, machine speed and moisture content. A ―recipe‖ is given as part of the job specs
to accomplish the compaction needed. This method is outdated, as machine technology
has far outpaced common method specification requirements.

 End-Result Specification—engineers indicate final compaction requirements, thus giving


the contractor much more flexibility in determining the best, most economical method of
meeting the required specs. Fortunately, this is the trend, allowing the contractor to take
advantage of the latest technology available.

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

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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.

3. Reversible vibratory plates

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.

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 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.

 Vibratory force uses a mechanism, usually engine-driven, to create a downward force in


addition to the machine’s static weight. The vibrating mechanism is usually a rotating
eccentric weight or piston/spring combination (in rammers). The compactors deliver a
rapid sequence of blows (impacts) to the surface, thereby affecting the top layers as well
as deeper layers. Vibration moves through the material, setting particles in motion and
moving them closer together for the highest density possible. Based on the materials
being compacted, a certain amount of force must be used to overcome the cohesive
nature of particular particles.

Fig.2.1 Results of poor compaction

2.2 Plate Compactor


Compactor Performance

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:

Centrifugal force, expressed as pounds

Amplitude or the height the machine ―jumps‖ off the ground

Operating frequency, expressed as vibrations per minute

Travel speed, expressed as feet per minute

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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.

Fig 2.2 vibratory plate compactor

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.

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Vibratory plate compactor 2007

Chapter Three: Design Analysis

3.1. Design concept


Compaction is significant part of the building process. It increases load-bearing capacity,
provides stability, reduces water seepage, swelling and contraction and reduces settling of soil.
To design one type of compaction machine we compare the machines with different criteria to
precede with the data’s below.

Compaction is significant part of the building process. It increases load-bearing capacity,


provides stability, reduces water seepage, swelling and contraction and reduces settling of soil.
To design one type of compaction machine we compare the machines with different criteria to
precede with the data’s below.

Design Concept 1. Vibrating Plate Compactor

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.

Fig 3.1 Vibrating Plate Compactor

Design Concept 2. Reversible Plate Compactor

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.

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Vibratory plate compactor 2007

Fig 3.2Reversible Plate Compactor


Design concept 3. Rammers
It provides all the performance and durability that a contractor expects with the added benefit of
a four stroke petrol engine. Tried and tested in the harshest work environments,

These rammers are built to perform.

Fig 3.3Rammers

Design concept 4.Roller (walk behind)


It is fully hydrostatic walk behind duplex roller. Strong and robust design, compact in size.
Combined with the most reliability for the most difficult site condition.

Fig 3.4 Roller


Design concept 5. Roller (ride-on)
The compact ride is designed for pedestrian or bicycle paths, parking lots, driveways, patchwork
and other asphalt application.

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Vibratory plate compactor 2007

Fig 3.5 Roller

Table ―3.1‖ Design concept of compactors

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.

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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:

 Frequency - No. of resolutions per minute


 Amplitude - Vertical displacement of plate
 Dead load - Gross weight of the compactor
 Dynamic force - Force developed during each oscillation
 Area of contact - Contact area of the roller on soil
 Influence of vibration and amplitude on compaction of soil is profound.
 All soils have their natural frequency

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

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Vibratory plate compactor 2007
Where: 𝐹𝑜 = Exciting vertical force.

𝑚𝑒 = counter rotating eccentric mass

e =eccentricity of the unbalanced mass

𝜔 = rotational speed

M = equivalent mass

C = effective damping constant of the soil

K = effective spring constant of the soil

A particular solution of the above equation is of the form.

𝑥 = 𝐴𝑐𝑜𝑠 (𝜔𝑡 − 𝜑)

𝐹𝑜
𝐴=
(( 𝐾 − 𝑀𝜔 2 )2 + 𝐶 2 𝜔 2 )

Where A = amplitude of vibration.


𝐶𝜔
Phase angle between force and displacement 𝜑 = 𝑡𝑎𝑛−1 𝐾−𝑀𝜔 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.

 Vibratory plates Low amplitude & high frequency


 Most forward plate compactor frequency ranges: 2500vpm to 6000vpm
 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.

Frequency
Fig 3.7 amplitudes of different compaction machines

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Vibratory plate compactor 2007

Assumption:

 Length, L = 500mm and width, B = 400mm


 Height y = 30mm
 Eccentric rotary shaft speed, N = 6000rpm
𝑚
 Travel speed (V) = 0.3𝑠𝑒𝑐
 From fig.3.7 for vibratory plate compactor; Amplitude, A = 3mm

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

Equivalent mass (M):

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

Effective spring constant (K):

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

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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.

(ii). Initial static sustained stress level or effective confining pressure.

(iii). Over consolidation ratio.

(iv). Dynamic stress level and number of repetition of dynamic stress.

(v). Shear strain level and

(vi). Time effects etc…

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.

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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)

Coefficient βv for rectangular footing (after Whitman and Richart, 1967)

From this figure 𝛽𝑣 = 1.1

Spring constant ( K ) is

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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)

Dynamic elastic modulus of soil, E = 30Mpa

30Mpa
𝑮= = 𝟏𝟐. 𝟓𝐌𝐩𝐚
2 1 + 0.20
12.5𝑀𝑝𝑎
𝐾= × 1.1 × 0.50 × 0.40
1−0.20

K = 7686483.67 = 7.69 × 𝟏𝟎𝟔 𝑵 𝒎

𝐾 = 𝟕.𝟔𝟗 ×𝟏𝟎𝟔 𝑵 𝒎 𝑟𝑎𝑑


ω𝑛 = = =277.3 , where 𝜔𝑛 =angularfrequency
𝑀 100 𝑘𝑔 𝑠𝑒𝑐𝑜𝑛𝑑

rad
ω𝑛 277 .3 second
𝒇𝒏 =𝟐𝛑= 𝐫𝐚𝐝 =44𝑯𝒛 ,where
𝟐𝛑
𝐜𝐲𝐜𝐥𝐞

𝒇𝒏 =natural frequency

Effective damping (C):

Damping, in general consists of two components these are geometric or radiation damping, and
internal damping,. Thus

D = 𝐷𝑔 + 𝐷𝑖 where D= total damping

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 = 𝑤𝑕𝑒𝑟𝑒 𝐵𝑣 = ( ) 𝜌 𝑅3
𝐵𝑣 4

Where: 𝜇 = Poisson from 𝐓𝐀𝐁𝐋𝐄 𝟑. 𝟐

R = equivalent radius of the footing, for non-circular

𝐵𝐿 1
R = (( 𝜋 )2 ) that is B =width of the compacter L = length of the compacter.

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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

 For Dry and saturated sands and gravels, 𝐷𝑖 = 0.06

Damping ratio will be: 𝐷𝑖 + 𝐷𝑔


0.425 1−𝜇 𝑚
For vertical mode of vibration 𝐷𝑔 = 𝑤𝑕𝑒𝑟𝑒 𝐵𝑣 = ( ) 𝜌 𝑅3
𝐵𝑣 4

0.4 ×0.5 1
R=( )2 = 𝟎. 𝟐𝟓𝟐𝒎
𝜋

1−0.20 0.06𝑚 3
𝐵𝑣 = = 𝟎. 𝟕𝟓
4 0.25𝑚 3

Geometric damping ratio will be:


0.425 0.425
𝐷𝑔 = = = 𝟎. 𝟒𝟗𝟏
𝐵𝑣 0.75

Thus: D = 𝐷𝑔 + 𝐷𝑖 = 0.491 + 0.06 = 𝟎. 𝟓𝟓𝟏

Therefore the effective damping (C) is:

𝐶 = 2𝐷 ̸ 𝐾𝑀 = 2× 0.551 100𝐾𝑔 × 7.69 × 106 𝑁 𝑚 = 3.9739×10-5kg ̸s

As we stated in the above the amplitude of the vibration is

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Vibratory plate compactor 2007
𝐹𝑜
𝐴=
(( 𝐾 − 𝑀𝜔 2 )2 + 𝐶 2 𝜔 2 )

Where A = amplitude of vibration.

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

0.003𝑚 × ( (7.69 × 106 − 100𝐾𝑔 × (628.32 𝑟𝑎𝑑 𝑠𝑒𝑐 )2 )2

+ 3.9739 × 10 −5 𝐾𝑔 × 628.32 𝑟𝑎𝑑 𝑠𝑒𝑐 )2 )


𝑠

𝑭𝟎=𝟐𝟒.𝟗×𝟏𝟎𝟑 𝑵=𝟐𝟓𝑲𝑵

 The centrifugal force needed to compact the soil or asphalt is

𝐅𝐎 = 𝟐𝟒. 𝟗 × 𝟏𝟎𝟑 = 25KN

3.3. Engine selection


Forward vibratory plate compactors are used single cylinder 4-stroke gasoline or diesel engine
since; they need small power as compared with reversible or other compactor types. Therefore

 Engine power = 6HP (4.476KW)


 Rated speed = 3600rpm

Fig 3.8 Diesel Engine

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Vibratory plate compactor 2007
F 6HP single cylinder 4 stroke air cooled diesel engine for sales170, 178,186,188

Why we choose diesel over gasoline?

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.

Analysis of design power for the plate compactor

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.

Design power = rated engine power × 𝑠𝑒𝑟𝑣𝑖𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟(𝐶𝑜 )

Let give 𝐶𝑜 = 1.12 FROM TABLE 3.5

Design power = 4.476 × 1.12 ≈ 5 × 103 = 𝟓𝑲𝑾

Therefore, we design all the parts of the plate compactor with this design power which remains
on its design analysis.

3.4 Design of centrifugal clutch


A clutch is a machine member used to connect the driving shaft to a driven shaft, so that the
driven shaft may be started or stopped at will, without stopping the driving shaft. A clutch
provides an interruptible connection between two shafts. The centrifugal clutch is usually used
into motor pulley. It consists of number of shoe on the inside of a rim of pulley.

Figure 3.9 pulley and centrifugal clutch drum assembly

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.

Fig 3.10 Internal parts of Centrifugal clutch

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.

From: TABLE 3.6


For ductile cast iron A536-84, Grade 60-40-18
Yielding strength,𝜍𝑦 = 276𝑀𝑝𝑎

Ultimate strength,𝜍𝑢 = 4.4𝑀𝑝𝑎


Elastic modulus, E = 152 GPa

For ferrodo lining:


Intensity pressure, p = 0.1MPa

Coefficient of friction,𝜇 = 0.25

Known values:

 Design engine power, P = 5 KW


 Rotational speed, N = 3600 rpm

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Assumption

 Inner diameter of the rim pulley, R = 95 mm


 Clearance between the lining and the drum or cover, C = 0.3 mm
 Distance of center of gravity of the shoe from the center of the spider, r = 85 mm
 Number of shoes, n = 4

I. TRANSMITTED TORQUE
𝑃×60
𝑇= 2𝜋𝑁

Where:

T = Transmitted Torque, N.mm

P = Intensity of Pressure, N/mm²

N = Running speed of Pulley, rpm

𝑃×60 5×10 3 ×60


𝑇= = 𝑇= = 13.265Nm …………………………… Esq.(1)
2𝜋𝑁 2𝜋×3600 𝑟𝑝𝑚

2𝜋𝑁 2𝜋3600 𝑟𝑝𝑚 𝒓𝒂𝒅


𝜔= = = 376.99 𝒔𝒆𝒄
60 60

II. MASS OF SHOE

Fig 3.11 Forces distribution on the shoe

 Centrifugal force acting on each shoe:

𝑃𝑐 = 𝑚𝜔2 𝑟

Where,

Pc =Centrifugal force acting on each shoe, N

m =Mass on each shoe, Kg

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𝜔 = Angular running speed, rad/sec

r = Distance of center of the shoe from the center of the spider, mm

𝑟𝑎𝑑 2
𝑃𝐶 = 𝑚(376.99 ) × 0.085𝑚
𝑠𝑒𝑐

𝑷𝑪 = 12.08m KN

Force exerted on each shoe by the spring is:

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 𝑤𝑕𝑒𝑟𝑒 𝜔1 = 4 𝜔 The plate compacter starts to work.

2
𝑃 𝑠= 9 𝑚𝜔 𝑟
16

Where,

Ps = Force exerted on each shoe by the spring, N

𝜔1 = Angular speed at which the engagement begins to take place, rad/sec.

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

𝜇 =Co-efficient of Friction between shoe and rim

Frictional torque acting on each shoe = F x R 𝑇 = 𝜇(𝑃𝐶 − 𝑃𝑆 ) R

Where, R=Inside radius of pulley

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Total Frictional torque transmitted

𝑇 = 𝜇(𝑃𝐶 − 𝑃𝑆 ) Rn

𝑇 = 𝑛𝐹𝑅

Where,

n = number of shoes 𝑇 = 𝜇(𝑃𝐶 − 𝑃𝑆 ) Rn

𝑇 = 0.25 × 5.285𝑚𝐾𝑁 × 0.085 × 4 = 𝟓𝟎𝟐. 𝟎𝟕𝟓𝒎𝑲𝑵……………………eq (2)

Substituting equation (1) into equation (2)

13.263NM = 502.075mNM

m = 0.02641kg

III. SIZE OF SHOE


1
𝜃 = 𝑜𝑟 𝑙 = 𝜃𝑅 𝑚𝑜𝑠𝑡𝑙𝑦 𝜃 = 600
𝑟

Area contact of shoe,

𝐴=𝑙×𝑏

Force with which the shoe process against the rim,

𝐴×𝑝 = 𝑙×𝑏×𝑝

Where, l = Contact length of shoe, mm


b = Width of shoe, mm
R = Contact radius of shoe, mm

𝜃= Angle subtended by shoe, rad


A = Area of contact of shoe, mm 2

Force with which shoe press against the rim at running speed,

𝑙 × 𝑏 × 𝑝 = 𝑃𝑐 × 𝑃𝑆

0.089𝑚 × 𝑏 × 0.1 × 106 𝑃𝑎 = 5.285 × 1𝑜3 × 0.0246𝐾𝑔𝑁𝑀

b = 0.0157m = 0.016m

IV. DIMENSION OF SPRING

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Fig 3.12 Tension helical spring

 Music wire is used for small springs

Material and properties of the spring


From TABLE 3.7 for Music wire,

 Condition: severe service


 Allowable shear stress (τ) = 392 MPa
 Modulus of Modulus of rigidity (G) = 80 GPa
 Modulus of elasticity (E) = 210 GPa
Assumption: spring index (C) = 6

 Mean diameter of the spring coil,

Force exerted on shoe by spring,

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,

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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

FROME TABLE 3.8


We shall take a standard wire of size SWG 10 having diameter (d) = 3.251 mm and Mean
diameter of the spring is
𝐷 = 𝐶 × 𝑑 = 6 × 3.251𝑚𝑚 = 𝟏𝟗. 𝟓𝟎𝒎𝒎

D = Mean diameter of the spring, and d = Diameter of the spring wire.

 Number of turns of the coil,


From the above mass of the shoe analysis we decide the clearance between the lining and the
cover plate is, = 3 mm. Therefore this clearance will be the deflection of the spring when the
centrifugal force is greater than the spring force. To have a better engagement at the intended
speed and force let’s add a little bit deflection,

𝛿 = 3𝑚𝑚 + 1.5𝑚𝑚 = 4.5𝑚𝑚

Therefore compression of the spring,


8𝐶 3 𝑛𝑃𝑠
𝛿=
𝐺𝑑

8 × 63 × 179.933𝑁 × 𝑛
4.5 × 10−3 𝑚 = 𝑛 = 3.4764 ≈ 𝟒
80 × 109 𝑃𝑎 × 3.251𝑚

Where, n = number of active turn, G = modulus of rigidity


Since this spring needs a loop to connect the shoe and the input shaft, so, for a spring having
loop on both ends, the total number of turns is,
𝑛. = 𝑛 + 1 = 4 + 1 = 5
Free length of the spring,
Taking the least gap between the adjacent coils as 4 mm when the spring is in Free State, the free
length of the tension spring,

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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 𝑡𝑕𝑒 𝑐𝑜𝑖𝑙𝑠 =
𝑛−1

25.004𝑚𝑚
= = 8.35𝑚𝑚
4−1

3.5 Design of power transmission

3.5.1 Design of V- Belt and V-grooved pulley


V belt or O-ring drive belt systems are used in a wide variety of applications such as vibration
dampening in precision mechanisms and reduction of distortion the equipment. V belt are made
in trapezoidal section they are made of cotton fabric cords and rubber and vulcanized in molds of
any desire cross section.
V belt has the following additional advantage such as:-
 The V-belt drive gives compactness due to the small distance between centers of pulleys.
 The drive is positive, because the slip between the belt and the pulley groove is
negligible.
 Since the V-belts are made endless and there is no joint trouble, therefore the drive is
smooth.
 Higher velocity ratio up to 7 to 8 the maximum being 10
 It Provide long life 3 to 5 years & it easily installed and removed
 Possibility of using with small center distance and quiet and low i maintenance
 Provide shock absorption between driver and driven shaft.
 The V-belt may be operated in either direction, with tight side of the belt at the top or
bottom. The center line may be horizontal, vertical or inclined.
A profile of the v belt is shown below:

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Fig 3.13 cross-sections of V-belt and V-grooved pulley

Belt design analysis

Known values

Engine power = 6Hp (4476w)

Input rotational speed, 𝑁1 =3600rpm

Output revolution of eccentric shaft, 𝑁2 =6000 vpm

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

Design power =power transmitted * service factor

𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = 4476 × 1.5 = 1615𝑤

𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = 6.714𝑘𝑤

𝑁1 3600 3
𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑑 𝑡𝑕𝑒 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

There for the pitch diameter

Now

𝑓𝑜𝑟𝑚𝑜𝑠𝑡 𝑒𝑐𝑜𝑛𝑜𝑚𝑖𝑐 𝑑𝑖𝑟𝑣𝑒 𝑉 = 45 𝑚 𝑠

45 × 60
𝐷1 = = 𝟐𝟑𝟖. 𝟖𝒎𝒎 𝒔𝒂𝒚 𝟐𝟒𝟎𝒎𝒎
𝜋 × 3600

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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

𝜋𝑛1 𝐷1 𝜋 × 0.24 × 3600


𝑉1 = = = 𝟒𝟓. 𝟐𝟏 𝒎 𝒔
60 60
Select a suitable center of distance

Now

𝐶 > 𝐷1 < +𝐷2 𝑎𝑛𝑑 𝐶 < 𝐷2

That is C should be between 240mm and 3(340+141)mm

Between 240 and 1143mm

Also 𝐶𝑚𝑖𝑛 = (𝐷1 + 𝐷2 ) + 3t

t = height of belt section from TABLE 3.9 the value 11mm.

𝐶𝑚𝑖𝑚 = 0.5 240 + 141 + 3 × 11 = 𝟐𝟐𝟑. 𝟓𝒎𝒎

Let us take C =400mm

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

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(𝐷1 + 𝐷2 )2 (0.24 − 0.1411)2
𝑞= = = 𝟎. 𝟎𝟎𝟏𝟐𝟐𝟓
8 8

𝐶 = 0.20413 0.204132 + 0.001225=0.40523 = 405.23mm

Determine the angle of contact on the smaller pulley.

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

𝜇 = 0.3 𝑓𝑜𝑟 𝑟𝑢𝑏𝑏𝑒𝑟 𝑓𝑎𝑏𝑟𝑖𝑐 𝑜𝑛 𝐶𝐼𝑝𝑢𝑙𝑙𝑦 𝑎𝑛𝑑 𝛽 = 𝑔𝑟𝑜𝑣𝑒 𝑎𝑛𝑔𝑙𝑒 38𝑜


0.3
Therefore 𝜇𝑒 = 3.3255 = 𝟎. 𝟗𝟗𝟐

𝐹1
= e0.992×2.896 = 14.4𝑓𝑜𝑟𝑒4 𝑡𝑕𝑒𝑟𝑒𝑓𝑜𝑟𝑒 F1 = 𝟏𝟒. 𝟒𝟒𝐅𝟐
𝐹2
F1 – F2 = 148.487N

148.487
𝐹2 = = 𝟏𝟏. 𝟎𝟒𝟖𝑵
13.44
𝐹1 = 𝟏𝟓𝟗. 𝟓𝟑𝟓𝟏𝑵

Now let as find number of belt by relation

𝐹1
𝑍≥
(𝑓𝑡 − 𝜌𝑣 2 )𝐴𝐶1 𝐶2

1 1
𝑤𝑕𝑒𝑟𝑒, 𝑍 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑒𝑙𝑡, & 𝑏𝑒𝑙𝑡 𝑠𝑡𝑟𝑒𝑛𝑔𝑡𝑕(𝑓𝑡 ) = 𝑡𝑜 𝑜𝑓 6.5𝑡𝑜10.5 𝑀𝑃𝑎
6 8
𝑓𝑡 = 1.5𝑀𝑃𝑎 = 1.5𝑁/𝑚𝑚2

𝜌𝑣 2 = 1400𝐾𝑔/𝑚3 ∗ (45.216𝑚/𝑠𝑒𝑐)2 = 2.86𝑀𝑃𝑎

𝜌𝑣 2 = 2.86𝑁/𝑚𝑚2

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Now from 𝐓𝐀𝐁𝐋𝐄 𝟑. 𝟏𝟎 the area section of B belt 1.4𝑐𝑚2 = 140𝑚𝑚2

𝐶1 = 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒 ≅ 0.98

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

𝐶2 = 𝑏𝑒𝑙𝑡 𝑙𝑒𝑛𝑔𝑡𝑕 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 0.9

159.535
𝑍=
(1.5 − 2.86) ∗ 140 ∗ 0.98 ∗ 0.9

∴ Z = 𝟎. 𝟗𝟒𝟗 𝐬𝐚𝐲 "𝟏" 𝐛𝐞𝐥𝐭 𝐢𝐬 𝐫𝐞𝐪𝐮𝐢𝐫𝐞𝐝

3.6 Design of the eccentric rotary shaft


The eccentric rotary shaft has two bearing support, eccentric mass and the smaller pulley that
transmits the power from the engine.

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

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Vibratory plate compactor 2007

Fig. 3.14 3D view of eccentric rotary shaft with its bearing and pulley

3.6.1. Design of shaft


Known values:
 Centrifugal force = 25000N

Distributed force = 25000N/0.13m=192307N/m


Free body diagram (FBD) of this shaft will be, free body diagram (FBD) of this shaft will be,

Fig. 3.15 free body diagram of eccentric rotary shaft

Let’s find the reaction forces,

Σ𝐹𝑌 = 0

𝑅𝐴𝑁 + 𝑅𝐵 = 25000𝑁 + 170𝑁 = 25170𝐾𝑁 … … … . . 𝑒𝑞𝑛 (1)

Σ𝑀𝐴 = 0

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Vibratory plate compactor 2007
2500𝑁 − 0.085𝑚 − 0.17𝑅𝐵 + 0.2 × 170𝑁𝑚 = 0 , 𝑡𝑕𝑒𝑛 𝑅𝐵 = 𝟏𝟐𝟕𝟐𝟎𝑵

By substituting in to equ (1)

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

Σ𝐹𝑌 = 0 , 𝑉1=𝑅𝐴 = 12450𝑁

ΣM1 = 0 , R A X so M1@X = 0 and M1@X = 0.02 = 249 Nm


II. Section CD

Σ𝐹𝑌 = 0 ,12450 − 𝑉2 − 192307𝑁𝑚 𝑥 − 0.02 = 0

𝑉2 = −19230𝑥 + 13296.14𝑁 , 𝑠𝑜 𝑉2@𝑋 = 0.02 = 12450𝑁 , 𝑎𝑛𝑑 𝑉2@𝑥 = 0.085𝑚 = −49.95𝑁

Σ𝑀2 = 0 , 𝑀2 − 12450𝑥 + 96153.5 𝑥 − 0.02 = 0

𝑠𝑜, 𝑀2@𝑥 = 0.02𝑚 = 249𝑚 𝑎𝑛𝑑 𝑀2@𝑋 = 0.15𝑚 = 𝟐𝟒𝟐. 𝟓𝑵𝒎

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Vibratory plate compactor 2007

III. Section DB

Σ𝐹𝑌 = 0

−𝑉3 + 12450𝑁 − 25000𝑁 = 0

𝑉3 = −12550𝑁

Σ𝑀3 = 0

𝑀3 − 12450𝑥 + 25000 𝑥 − 0.085 = 0

𝑀3@𝑋=0.15= 242.5𝑁𝑚 𝑎𝑛𝑑 𝑀3@𝑥=0.17 = −𝟖. 𝟓𝑵𝒎

IV. Section BE

Σ𝐹𝑌 = 0

𝑉4 + 12450𝑁 − 25000𝑁 + 2720𝑁 = 0

𝑉4 = 170𝑁

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Vibratory plate compactor 2007
Σ𝑀4 = 0

𝑀4 − 12450𝑥 + 25000 𝑥 − 0.085 − 12720(𝑥 − 0.17)

𝑀4 = 170𝑥 − 37.40

𝑀4@𝑋 =0.17 = −8.5𝑁𝑚 𝑎𝑛𝑑 𝑀4@𝑋=0.22 = 0

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

We know the equivalent twisting moment

𝑇𝑒 = 𝑀2 + 𝑇 2

Torque transmitted by the belt is,

𝑇 = 𝑇1 + 𝑇2 × 𝑅

𝑇 = 159𝑁 − 11𝑁 × 70.5 = 10.434𝑁𝑚

Where, 𝑇1 = tension in tight side & T2 = tention in the slack sid𝑒 of the belt

The equivalent twisting moment

𝑇𝑒 = 2492 + 10.4342 = 249.219𝑁𝑚

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.

𝐾𝑎 = 𝑎𝑆𝑢𝑡 𝑏 from 𝐓𝐀𝐁𝐋𝐄 𝟑. 𝟏𝟏 a = 4.51 and b = 0.265

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Vibratory plate compactor 2007
𝑘𝑎 = 4.51 × 723−0.265 = 0.79

Let as guess 𝑘𝑎 = 0.9

𝑆𝑒 𝑡 = 0.5𝑆𝑢𝑡 = 0.5 × 723 = 361.5𝑀𝑝𝑎

𝑆𝑒 = 𝐾𝑎 𝐾𝑏 𝐾𝑐 𝐾𝑑 𝐾𝑒 𝐾𝑓 𝑆𝑢𝑡 𝑡

𝐾𝑐 𝐾𝑑 𝐾𝑒 𝐾𝑓 = 1

𝑆𝑒 = 0.9 × 0.79 × 0.5 × 723 = 257𝑀𝑝𝑎

𝐾𝑓 = 1.7 𝑎𝑛𝑑 𝐾𝑓𝑠 = 1.5

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

3.6.2. Selection and design of bearing

Fig3.17 Bearing Profile

Selection of radial ball bearings

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

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 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

 The bearing is subjected to radial load 𝑅𝑏 = 12720𝑁


 Catalogue life of bearings 𝐿𝑐 = 5000𝑕𝑟𝑠 [www.globalspec.com]

Analysis

The following procedure can be followed:


The equivalent load coming on the bearing is calculated the above value this equation does not
account for any shock or impact force and temperature condition which bearing my express.
Incorporating these two factors, the design load F is calculated from the equivalent load P as
follows

𝐹 = 𝑃 × 𝐾𝑎 × 𝐾𝑡

Where

 𝐾𝑎 = 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑒𝑟 𝑜𝑟 𝑠𝑒𝑟𝑣𝑖𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟


 𝐾𝑎 = 𝑕𝑒𝑎𝑣𝑦 𝑠𝑕𝑜𝑐𝑘 𝑙𝑜𝑎𝑑 = 2.5 … … . 𝐟𝐫𝐨𝐦 𝐓𝐀𝐁𝐋𝐄 𝟑. 𝟏𝟏
 𝐾𝑡 = 𝑡𝑒𝑚𝑝𝑟𝑒𝑎𝑡𝑢𝑟𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = 1.5 … . 𝐟𝐫𝐨𝐦 𝐓𝐀𝐁𝐋𝐄 𝟑. 𝟏𝟐

𝐹 = 12720 × 2.5 × 1.05 = 𝟑𝟑𝟑𝟗𝟎𝑵

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
𝑡𝑕𝑒 𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑙𝑖𝑓𝑒 = 8 × 300 × 5𝑦𝑒𝑎𝑟 = 12000𝑕𝑟
𝑑𝑎𝑦 𝑦𝑒𝑎𝑟
The catalog life of bearing 𝑕𝑟𝑠 = 5000𝑕𝑟

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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 = 5000𝑕𝑟𝑠
𝐿𝑑 1 1200 1
𝑙𝑖𝑓𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = ( )3 = ( )3 = 2.5
𝐿𝐶 500

The rotational speed of bearing 𝑟𝑒𝑣 𝑚𝑖𝑛

𝑛𝑑 = 6000𝑣𝑝𝑚

Catalogue rotational speed 𝑟𝑒𝑣 𝑚𝑖𝑛

𝑛𝑐 = 5000𝑟𝑝𝑚 ................... TABLE M

6000 1
𝐾𝑆 = ( )3 = 1.06
5000
Design radial load

𝐶𝑅 = 33390 × 2.5 × 1.06 = 𝟖𝟖𝟒𝟖𝟑. 𝟓𝑵

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

 Bore diameter = 55mm


 Outside diameter = 140mm
 Dynamic load C =99500N
 Width B = 33mm
 Bearing mass M = 2.3kg

The function of a lubricant in ball and roller bearings are:-

 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

Determine factor of safety

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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

𝐾𝑡 = 1.6 … … … … … … . . 𝐹𝑅𝑂𝑀 𝑇𝐴𝐵𝐿𝐸

𝑞𝑠 = 0.8 … … … … … 𝑓𝑜𝑟 𝑡𝑕𝑒𝑖𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑐𝑜𝑛𝑠𝑒𝑛𝑡𝑎𝑟𝑎𝑡𝑜𝑖𝑛 𝑓𝑎𝑐𝑡𝑜𝑟


𝐾𝑓 = 1 + 𝑞 𝑞𝑡 − = 1 + 0.8 1.6 − 1 = 1.48

K ts = 1.2 and qs = 0.8

𝐾𝑓𝑠 = 1 + 𝑞𝑠 𝐾𝑡𝑠 − 1 = 1.16

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

𝐾𝑏 = 1.5𝑑 −0.157 = 𝑓𝑜𝑟 51 ≤ 𝑑 ≤ 254𝑚𝑚 = 1.51 × 55−0.157 = 0.81

𝑆𝑒 = 𝐾𝑎 𝐾𝑏 𝑆 𝑡 𝑢 = 0.79 × 0.5 × 723𝑀𝑝𝑎 = 231𝑀𝑝𝑎

Eccentric mass dimension analysis

Known values,

 Rotational speed of the eccentric shaft, 𝜔 = 6000 𝑟𝑝𝑚


 Centrifugal force, 𝐹 = 25000𝑁

Assumption eccentricity of the unbalanced mass (e) = 0.020m

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.

Therefore, from the diagram below,


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Vibratory plate compactor 2007

𝑒= (2 ∗ 10−2 )2 + (2 ∗ 10−2 )2 = 2 2 ∗ 10−2 𝑚

𝐹𝑜 = 𝒎𝑒𝜔2

2𝜋 ∗ 6000 2
25000𝑁 = 𝒎 × 2 2 + 2 ∗ 10−2 𝑚 × ( )
60
𝒎 = 3.17𝐾𝑔 … … … … … … 𝑎𝑛𝑠

The volume eccentric mass:

𝑚 3.17𝐾𝑔
𝑉= = = 0.000403𝑚3
𝜌 7860 𝐾𝑔
𝑚3

The area shaded region in the fig. below


𝑉 0.000403 𝑚 3
𝐴𝑒𝑐𝑐 = = = 0.0031𝑚2
𝐿 0.13𝑚

𝐴𝑒𝑐𝑐 = 𝐴2 − 𝐴1

Centroid from the y axis

Σ𝐴𝑌
𝑦=
Σ𝐴

Centroid from the x axis

Σ𝐴𝑥
𝑥=
Σ𝐴

The outer radius of eccentric mass is

Σ𝐴1𝑦1 + Σ𝐴1𝑦2 −𝐴1 𝑦1 + 𝐴2 𝑦2


𝑦+𝑒= =
Σ𝐴1 + Σ𝐴2 𝐴𝑒𝑐𝑐

−0.275 × 0.024 + 𝜇𝑟2 3


0.0475 = = 𝑟2 = 43.6𝑚𝑚
0.0031

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Fig 3.18 Cross sectional view of the eccentric shaft with its eccentric mass and shaft centers

3.7 Design of key


A keyway is a slot or recess in a shaft and hub of the pulley to accommodate a key. A key is a
piece of mild steel inserted between the shaft and hub or boss of the pulley to connect these
together in order to prevent relative motion between them. It is always inserted parallel to the
axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable

Material selection

From: TABLE 3.6

For ductile cast iron A536-84, Grade 60-40-18


 Yielding strength, 𝛿𝑦 =276 Mpa
 Ultimate strength, 𝛿𝑢 =414Mpa
 Elastic modulus, E = 152 GPa
𝐾𝑔
 Density, 𝜌 = 7428 𝑚3
Known value
 Shaft revolution 6000 vpm
 Shaft diameter 52 mm ( 2.05 In)
 Engine power 6 Hp ( 4476w)

Figure 3.19 Rectangular Keyway Profiles

By using shaft diameter

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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 = 0.577𝑠𝑦 × 69𝑀𝑝𝑎 = 39.8𝑀𝑝𝑎


𝐹
Failure by shear across the area ab will create a stress of 𝜏 = 𝑡𝑙 substituting the strength divided
by the factor of safety for τ gives

𝑠𝑠𝑦 𝐹 414.195
= =
𝑛 𝑡𝑙 12.7𝑙
39.8 × 106 414.195
= = 𝟎. 𝟎𝟎𝟑𝟑𝟒𝒎
4 0.0105𝑙
l =0.00334m

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3.8 Design and selection of isolators


Isolators are made from a wide variety of resilient media having diverse characteristics. Each
type of isolator has characteristic properties and is particularly suited to certain specialized
applications. To make the best use of available isolators, the designer should understand the
basic properties of each type

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

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.

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Fig. 3.20 Flex- Bolt sandwich rubber Mounts

Features and Benefits:


 Economical.
 Compact and lightweight.
 Easy to install.
 Maintenance-free.
 Three size groups: small, medium and large.
 Unitized construction.

The main purpose of these isolators is protecting the supported mass from the vibratory
disturbances of the supporting structure as we see below:

Fig. 3.21 Free Body Diagram of Vibration Response of the Ground

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:

 Mass of the engine and other accessories = 60 Kg


 Minimum working rotational speed (N) = 5000rpm/83.33Hz
Desired isolation: 95%, I = 0.95
Assumption; Number of isolators (n) = 4

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Fig. 3.22Typical transmissibility curve for an isolated system

Where 𝑓𝑑 = disturbance frequency and 𝑓𝑛 = isolation system natural frequency.

Fig. 3.23 Family of transmissibility curves for a single degree of freedom system.

Transmissibility (force/force or motion/motion):


1+𝑟 2 4𝑧 2 1
|T |= ≅ 𝑓𝑜𝑟 𝑟 > 1𝑎𝑛𝑑 𝑠𝑚𝑎𝑙𝑙 𝑧
(1+𝑟 2 )2 +4𝑧 2 𝑟 2 (𝑟 1 −1)

Where; z = damping ratio .


Isolation pads made of damping material such as cork, natural rubber, and neoprene can be used
for this purpose. Natural rubber has damping ratios of 0.05.

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
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 Properties:

1. All |T | curves coincide at r = 2 for all z


2. Isolation region: r > 2
3. In isolation region:|T | decreases with r (i.e., better isolation at higher frequencies)
|T | Increases with z (i.e., better isolation at lower damping).

 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 = m ∗ (2𝜋𝑓𝑛 )2 =60kg∗ (2𝜋 ∗ 18.17𝐻𝑧 )2 =783.30N/mm

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

𝑘𝑖𝑛𝑑𝑖𝑣𝑖𝑑𝑢𝑎𝑙 = 195.83𝑁/𝑚𝑚 We approximate it to the higher value.

Therefore the natural rubber is:

 Type 1, J-5425-15,
 art dimension (A=79.2mm,B=31.8mm,C=76.2mm,D=31.8mm )

Fig. 3.24 Geometrical dimensions of the rubber


Amplitude of the vibratory plate compactor

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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.

Known values are:

 Centrifugal force =25KN= 5620.22lbs


 Frequency=6000vpm
 Effective vibratory mass (100kg-60kg) = 40kg = 88.185lb
768 ∗5620 .22𝑙𝑏𝑠
Amplitude= 6000 2 = 0.1239 𝑖𝑛 = 3.104𝑚𝑚
(𝜋∗ ) ∗88.185𝑙𝑏𝑠
30

Which is approximately equal with the value used in compaction analysis?

3.9 Design of fasteners


A fastener is any device used to connect or join two or more components. Literally hundreds of
fastener types and variations are available. The most common are threaded fasteners referred to
by many names, among them bolts, screws, nuts, studs, lag screws, and set screws. A screw is a
threaded fastener designed to be inserted through a hole in one member to be joined and into a
threaded hole in the mating member

Fig. 3.25 Hexagonal-head bolt

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

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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

From Table “3.16” material property

 Steel (low or medium carbon) Property class 4.6


 Minimum proof strength = 225 MPa
 Minimum tensile strength = 400 MPa
 Minimum yield strength = 240 MPa
 Modulus of elasticity = 210 GPa
 Minimum proof strength = 225MPa

Known values

Total force (F) = 25KN

Assumption

Number bolt (n) = 4

Factor of safety (f.s) = 2.5

Due to tensile load:


𝛿𝑦 𝐹
= where, F= total force 𝐴𝑡 =area
𝑓∗𝑠 𝑛 ∗𝐴 𝑡

25∗10 3 𝑁∗2.5
𝑟2 = = 2.072∗ 10−5 𝑚2
4∗𝜋∗240∗10 6 𝑝𝑎

r = 4.55∗ 10−3 m, 𝑑𝑚 =2r=9.10∗ 10−3 𝑚 ≈ 10𝑚𝑚

Due to Shear force;


𝜏 𝐹 𝐹 0.8∗𝛿 𝑦
= 𝑛 ∗𝐴 = 𝜋 ∗𝑑 𝑐 2
=
𝑓.𝑠 𝑐 𝑛∗ 𝑓.𝑠
4

4∗25∗10 3 N∗2.5
𝑑𝑐 2 =4∗π∗0.8∗240 ∗10 6 =1.036∗ 1𝑂−4 𝑚2

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Vibratory plate compactor 2007
𝑑𝑐 = 0.01018m≈ 11𝑚𝑚

𝑑𝑐 = d-1.226869p so, d= 11mm+1.226869∗ 2 = 13.454𝑚𝑚 ≈ 14𝑚𝑚

Therefore the hexagonal cap screw is: M14

3.10 Design of plates

3.10.1. Design of base plate


Allowances should be made for the effects of vibratory forces.
Material selection for the plates and washer
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.
From: TABLE “3.6”
For ductile cast iron A536-84, Grade 60-40-18
 Yielding strength, 𝛿𝑌 =276Mpa
 Ultimate strength, 𝛿𝑢 =414Mpa
 Elastic modulus, E = 152 GPa
 Density ( 𝜌) = 7480 Kg/𝑚3
 Compressive strength range 3 to 5 times ultimate strength

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

Volume (V) of the plate is;


m 30𝑘𝑔
V= ρ =7489 𝑘𝑔 /𝑚 3 = 4.011∗ 𝟏𝟎−𝟑 𝒎𝟑

Therefore its thickness (t) will be;

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.

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Vibratory plate compactor 2007
Let’s take the smaller value of the compressive strength,

𝛿𝑐𝑦 = 3𝛿𝑢 =3∗ 414𝑀𝑝𝑎=1242Mpa

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.

3.10.2. Design of exciter assembly side covers


Material selection from: TABLE 3.6

For ductile cast iron A536-84, Grade 60-40-18

Yielding strength, 𝛿𝑦 =276Mpa

Ultimate strength, 𝛿𝑢 =414Mpa

Elastic modulus, E = 152 GPa

Known values

Diameter of the bolt = M10

Force on each bolt = 2083.3N

Fig. 3.26 bearing of bolt on members or bearing of members on bolt

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:-

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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

Bearing in members, all bolts active:


𝐹 F δ
𝛿 = 𝐴 = t.d = ny
d

2083.33N∗2
t= = 0.001509m≈2mm
0.01m∗276∗10 6 pa

3.11 Part Drawings

Eccentric rotary shaft with its bearing and pulley

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Vibratory plate compactor 2007

Base plate

Shaft housing

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Vibratory plate compactor 2007

Handle

Belt cover

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Vibratory plate compactor 2007

Fuel tank

Shaft

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Vibratory plate compactor 2007

Tensional Helical spring

Pressure-cone frustum member model for a cap screw

Centrifugal clutch

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Vibratory plate compactor 2007
3.11. 1 3D Modeling of vibratory plate compacter

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Vibratory plate compactor 2007
3.12 Designed parameter summery

NO Designed Quanti Parameter


component ties
1 Belt 1 𝐷1 − 240𝑚𝑚
𝐷2 = 141𝑚𝑚
L = 1415mm
2 Bolt 8 r = 10mm
𝑑𝑐 = 14𝑚𝑚
3 Ball 2 d= 55mm
bearing D = 140mm
4 Bass plate 1 L = 500mm
W = 400mm
𝑡 = 15mm
5 Eccentric 1 L = 220mm
rotary shaft 𝑑 = 52mm
6 Side cover 1 𝑡 = 2mm
7 Helical 4 𝑐=6
spring 𝑑 = 19.50𝑚𝑚
𝐿𝐹 = 25𝑚𝑚
𝑃 = 8.35𝑚𝑚
8 Clutch 1
9 Key 1 W=12.7m
L=9.5mm

10 Isolators 4 A=79.2mm,B=
31.8mm,C=76.
2mm,D=31

3.13 Table

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Vibratory plate compactor 2007

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Vibratory plate compactor 2007

First iteration estimates for stress concentration factors 𝑘𝑡 and 𝑘𝑡𝑠

Warning: these factors are only estimates for use when actual dimensions are not yet determined.
do not use these once actual dimensions are available.

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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 -

Sled runner key seat 1.7 - -

Retaining ring 5.0 3.0 5.0


groove

Missing values in the table are not readily available

Table 3.12 stress concentration factors

Material Approx damping factor 𝒄 𝒄𝒄 𝑻𝒎𝒂𝒙 (approx)


Steel spring 0.005 100
Elastomers 0.005 100
Natural rubbers 0.05 10
Neoprene 0.05 10
Butyl 0.12 4.0
Barry hi damp 0.15 3.5
Barry it 0.11 4.5
Barry universal 0.08 6.0
Friction damped springs 0.33 1.5
Metal mesh 0.12 4.0
Air damping 0.17 3.0
Felt and cork 0.06 8.0

Table 3.13 Damping factors for materials commonly used for isolators

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Vibratory plate compactor 2007
Properties Natural rubber Neoprene Hi-Damp Barry LT
silicone compound
Adhesion to metal Excellent Excellent Good Very good

Tensile strength Excellent Excellent Good Excellent

Tear resistance Good Good Fair Good

Compression set Good Fair Fair Goo d


resistance
Damping 0.05 0.05 0.15 0.17
factor,𝒄 𝒄𝒄 (approx)
Operating 200F 200F 300F 200F
temperature(max)
Stiffness 10× 10× <2× 2×
increase(@-65F)
Oil resistance Poor Good Fair Fair

Ozone resistance Poor Good Excellent Fair

Resistance to Poor Very good Excellent Good


sunlight aging
Resistance to heat Fair Good Excellent Good
aging
Cost Low Low H igh Moderate

Table 3.14 Relative properties of elastomers used as the resilient media

Shear Compression Part dimensions

Part Type Elastomer Maximum Spring Maximum Spring A B C D


number static rate static rate
load(N) kc(N/mm) load(N) kc(N/m)

J542515 1 NR 409 39 2669 219 79.2 31.8 76.2 31.8


J5425275 4 NR 489 46 3203 245 79.2 13.5 76.2 13.5
J54251 1 NR 698 80 4537 379 79.2 31.8 76.2 31.8
J5425123 4 NR 732 133 7428 722 79.2 13.5 57.2 13.5
J5425276 1 NR 933 149 6850 617 79.2 31.68 57.2 31.8
J542527 2 NR 1050 114 9074 482 79.2 13.5 76.2 38.1
J5425169 1 NR 777 142 4893 700 79.2 31.8 76.2 38.1

Table 3.15 Standard elastomers of-flex-bolt small and medium sandwich mounts

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Vibratory plate compactor 2007

Metric mechanical property classes for steel bolts, screws and studs

Property Size Minimum Minimum Minimum Material Head


class range proof tensile yield marking
inclusive strength,Mpa strength,Mpa strength,Mpa
4.6 M5-M36 225 400 240 Low or 4.6
medium
carbon
4.8 M1.6- 310 420 340 Low or 4.8
M16 medium
carbon
5.8 M5-M24 380 520 420 Low or 5.8
medium
carbon
8.8 M16- 600 830 660 Medium 8.8
M36 carbon,Q&T
9.8 M1.6- 650 900 220 Medium 98
M16 carbon,Q&T
10.9 M5-M16 830 1040 940 Low carbon 10.9
mar tensile
Q&T
12.9 M1.6- 920 1220 1100 Alloy ,Q&T 12.9
M36

The thread length for bolts and cup screw is;

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.

Minimum strengths are strength exceeded by 99 percent of fasteners.

Table 3.16 Dimensions with pitch series

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Vibratory plate compactor 2007

Chapter Four: Conclusion and Recommendation

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.

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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.

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Vibratory plate compactor 2007

Reference

[1]. Shigley’s Mechanical Engineering Design, Eighth Edition Budynas−Nisbett

[2]. Machine elements in mechanical design, Fourth Edition Robert L. Mott, RE University of
Dayton

[3]. Engineering vibration

[4]. Light equipment manufactures bureau (LEMB)

[5]. Soil compaction handbook

[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

[8]. www.globalspec.com SKF specification of bearing

[9].Mechanical vibration

10 .Machine by Sharma

11 .Text book of mechanical vibration

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