Bahir Dar University

Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering
Mechanical Engineering Program

Thesis project on: To Redesign, Adaptation and Manufacturing of Two-Wheel

Metal Polishing Machine.

Prepared By
1. MotbaynorAtnafu
2. YenehabitNigussie
3. ShimelisAdeme

Advisor: -Mr.Wudu Wondmagegn

2019
Bahir Dar Institute of Technology-Bahir Dar University School of Research and Graduate
Studies [Faculty of MED & IED]

THESIS PROJECT

Student:
________________________________________________________________________

Name Signature Date

MotbaynorAtnafu ……………………. …………………….

YenehabitNigussie ……………………… …………………….

ShimelisAdeme ……………………. …………………….

The following graduate faculty members certify that this student has successfully presented the
necessary written thesis proposal and oral presentation of this proposal for partial fulfillment of
the thesis-option requirements for the Degree of Bachelor of Science in [Mechanical Engineering]

Approved: Advisor:
________________________________________________________________________

Name Signature Date

Mr. Wudu Wondmagegn ……………………. …………………….

 Acknowledgment

First of all we would like to praise GOD the almighty for everything done in our life. We greatly
appreciate Bahir Dar Institute Technology for letting us to have this final year project which
helped us to gain theoretical knowledge and practical experience. We would like to express our
sincere to our project advisor Mr. Wudu Wondmagegn for his genuine advice and guidance by
providing necessary information and constructive comments. Thank you all who had direct and
indirect support for this final project report for your kind cooperation and encouragement.
Table of Contents
Acknowledgment ......................................................................................................................................... 3
List of figures ........................................................................................................................................ 6
AbbreviationMeaning ................................................................................................................................... 9
Acronyms .................................................................................................................................................... 10
Abstract ....................................................................................................................................................... 13
Chapter One ................................................................................................................................................ 14
1.1 Introduction ................................................................................................................................. 14
1.2 Back ground of the project ................................................................................................................ 15
1.3 Advantages of polishing machine ..................................................................................................... 15
1.4. Problem statement ............................................................................................................................ 15
1.5 Objective of project........................................................................................................................... 16
1.5.1 Main objective..................................................................................................................... 16
1.5.2 Specific objective ................................................................................................................ 16
1.6 Site Analysis and Inventory .............................................................................................................. 16
1.7 Methodology ..................................................................................................................................... 16
Chapter Two................................................................................................................................................ 18
2.1 Literature Review.............................................................................................................................. 18
2.2 Polishing Mechanization ................................................................................................................... 19
2.3 Methods of defining surface finish ................................................................................................... 19
2.4 Parts of polishing machine and their functions ................................................................................. 20
2.5 Working principle of the machine .................................................................................................... 20
2.6 Factors affecting polisher performance............................................................................................. 21
2.7 Competitive design ..................................................................................................................... 22
Table 2.1 Competitive Design, Their Criteria, Type, Description, Advantage and Disadvantage ..... 22
2.8 Decision matrix ................................................................................................................................. 23
Table 2.2 Given weight to compare based on character ..................................................................... 25
Table 2.3 Selection of shapes of polishing machine components ....................................................... 26
Table 2.4 Selection of variants for each parts of two-wheel polishing machine................................. 27
Table 2.5 Types and selection of bearing ........................................................................................... 27
Chapter Three.............................................................................................................................................. 28
3. Part Design .............................................................................................................................................. 28
3.1 Geometric Analysis ....................................................................................................................... 28
 Fig 3.1 Assembly of two-wheel polisher machine .............................................................................. 28
3.2 Design analysis ..................................................................................................................................... 29
3.2.1 Selection and design criteria .......................................................................................................... 29
3.2.2 Design specification ....................................................................................................................... 30
Table 3.1 Design specification of two-wheel polisher machine ......................................................... 30
3.3 Material selection .............................................................................................................................. 30
3.3.1 Physical properties of material ................................................................................................... 31
Table 3.2 Physical properties of metal ................................................................................................ 31
3.3.2 Mechanical properties of metal .................................................................................................. 31
3.4 Functional structure input ................................................................................................................. 33
Fig 3.2 Functional structure input of two-wheel polisher machine..................................................... 34
Chapter Four ............................................................................................................................................... 34
4. Design part .............................................................................................................................................. 34
4.1 Design of Frame ............................................................................................................................ 34
Fig 4.1 Back side frame ...................................................................................................................... 35
Fig 4.2 Left side frame........................................................................................................................ 35
Fig 4.3 Front frame ............................................................................................................................. 36
Fig 4.4 Middle frame .......................................................................................................................... 37
Fig 4.5 Upper frame 1 ......................................................................................................................... 37
Fig 4.6 Upper frame 2 ......................................................................................................................... 38
Fig 4.7 Overall geometry of frame...................................................................................................... 39
3.5.2 Selection of Pulley and belt ....................................................................................................... 39
Fig 4.8 Two grooved pulley ................................................................................................................ 39
3.5.3 V-belt specification .................................................................................................................... 40
Fig 4.9 Diagram showing two pulleys connected by a belt. ............................................................... 40
Table 4.1 Correction factor (Fa) for industrial service ........................................................................ 41
Table 4.4 length of correction factor .................................................................................................. 44
by......................................................................................................................................................... 44
table 4.5 Arc contact correction factor
..................................................................................................................... 45
Table 4.6 Dimensions of standard v-grooved pulleys ......................................................................... 46
3.5.4 Design of shaft ........................................................................................................................... 52
3.5.5 Selection of anti-friction bearing ........................................................................................ 62
3.5.6 Material selection of Bolt and nut ....................................................................................... 68
 3.5.7 Force and stress analysis of Frame...................................................................................... 69

List of figures
Fig 3. 1 Assembly of two-wheel polisher machine....................................................................... 28
Fig 3. 2 Functional structure input of two-wheel polisher machine ............................................. 34
Fig 3. 3 Back side frame ............................................................................................................... 35
Fig 3. 4 Left side frame ................................................................................................................. 35
Fig 3. 5 Front frame ...................................................................................................................... 36
Fig 3. 6 Middle frame ................................................................................................................... 37
Fig 3. 7 Upper frame 1 .................................................................................................................. 37
Fig 3. 8 Upper frame 2 .................................................................................................................. 38
Fig 3. 9 Overall geometry of frame .............................................................................................. 39
Fig 3. 10 Two grooved pulley ....................................................................................................... 39
Fig 3. 11 Diagram showing two pulleys connected by a belt. ...................................................... 40
Fig 3. 12: Wheel supporter shaft ................................................................................................... 54
Fig 3. 13: Two pulley connected by v-belt ................................................................................... 55
Fig 3. 14 Two grooved pulley supported shaft ............................................................................. 57
Fig 3. 15 One grooved pulley supported shaft with belt (a) front view (b) top view ................... 60
Fig 3. 16 Bearing and housing ...................................................................................................... 64
Fig 3. 17 Standard radial rolling bearing ...................................................................................... 64
Fig 3. 18 Bolt and nut designation ................................................................................................ 69
Fig 3. 19 Free body diagram of frame .......................................................................................... 72
Fig 3. 20 Free body diagram of shaft ............................................................................................ 74
Fig 3. 21 Different types of key seats ........................................................................................... 77
Fig 3. 22 Forces acting on a sunk key. .......................................................................................... 77
Fig 3. 23 Dc motor ........................................................................................................................ 78
Fig 3. 24 Speed controller of motor .............................................................................................. 80
Fig 3. 25 Wheel supporter ............................................................................................................. 82
Fig 3. 26 Two wheel polishing machine ........................................Error! Bookmark not defined.
Fig 3. 27 welding of the frame .......................................................Error! Bookmark not defined.
Fig 3. 28 structure with carrying frame .........................................Error! Bookmark not defined.
Fig 3. 29 Assemble of bearing and shaft........................................Error! Bookmark not defined.
List of Table
Table 2. 1 Competitive Design, Their Criteria, Type, Description, Advantage and Disadvantage.
........................................................................................................Error! Bookmark not defined.
Table 2. 2 given weight to compare based on character. .............................................................. 25

Table 3. 1 design specification of two-wheel polisher machine.. ................................................. 30

Table 3.1.1 physical properties of metal. ...................................................................................... 31
Table 3.1.2 dimension of standard v-grooved pulleys. ................................................................. 41
Table 3.1.3 Dimensions of standard v-grooved pulleys. .............................................................. 41
Table 3..1.4 standard pitch length ................................................................................................. 42
Table 3.1.5 Principal dimension for radial ball bearing.................Error! Bookmark not defined.
Table 3.1.6 Value of Xo and Yo for bearing. ................................Error! Bookmark not defined.
Table 3.1.7 Life of bearing for viral type...................................................................................... 65
Table 3.1.8 Service life of bearing. ............................................................................................... 66
Table 3.1.9 Principal dimension for ball bearing. ..........................Error! Bookmark not defined.
Table 3.1.10 Life of bearing for viral type of Life in revolution. ................................................. 67
Table 3.1.11 values of factor of safety. ......................................................................................... 71
T

No table of figures entries found.

Table 5. 1 Raw material cost..........................................................Error! Bookmark not defined.

Table 5. 2 cost of standard component. .........................................Error! Bookmark not defined.
Table 5. 3 cost summery. ..............................................................Error! Bookmark not defined.
 AbbreviationMeaning
ASME American society of mechanical engineering

WDM Weighted decision matrix

AISI American Iron and Steel Institute

RHS Rectangular hallow sphere

HP Horse power
Acronyms
Symbol Meaning

A Acceleration

C Center distance

D Diameter of shaft

N Speed of belt in rpm

Vr Velocity ratio

Vb Velocity of belt

Wmax Maximum angular speed

Wmin Minimum angular speed

Tc Centrifugal tension

V Velocity

M Mass

T Tension

R Radius

P Power

M Moment

RAH Horizontal Resultant load at grooved pulley A

RBH Horizontal resultant load at grooved B

Rcv Resultant load at point

Te equivalent twisting moment

Me equivalent bending moment

L Rating life

C Basic dynamic load

W Equivalent dynamic load

LH Working hour

𝛒 Density of carbon steel

L Length

A Area

T Thickness

F Force
Greece symbol Meaning

Θ Angle

Ρ Density

𝜇 Coefficient of friction

𝜔 Angular velocity

Ѳ Angle in rad

𝜏𝑚𝑎𝑥 Maximum sheer

 Abstract
The two wheel polishing machine consist of a motor as automatic rather than hand polishing that
operated by human, Polishing is the process of creating a smooth and shiny surface by rubbing it
or using a chemical action, leaving a surface with a significant secular reflection. The two wheel
polishing machine operation is done by mounting an abrasive disk on the tip of shaft The project
documentation has contained the analysis and manufacturing process of two wheel polishing
machine, the main objective, problem statement with its solution and literature review of the
polishing machine is contained in the document, the working principles of the polishing machine
has been provided to answering the question of how it works. The design composed of 1.1KW,
1.5 Horse power and 1440 rpm motor that can use as a source power is mainly transmitted to the
two different size of pulley with the mechanism of V- belt. The belt transfers the incoming
power to the second shaft that make the wheel to rotate, and the machine perform the intended
task, the machine is done by the methods of standard specification with proper design and
selection of components to perform the operation, after such design consideration The design
focused on all the process of conception, visualization, calculation, modification and
specification of details that determine the form of the product. The design has gone under force
analysis, proper material selection, and design evaluation, dimensional optimization,
manufacturing process and cost analysis, so that its performance criterion will not fail in any
sense. The main physical parameters of the design are determined through the appropriate
calculations, and practical considerations with reasonable assumptions. It is discovered that the
design is simple, cheap and can be manufactured with less money available as the team try to
manufacture the prototype by using some manufacture steps like, with consideration of each
component dimension manufacture the part by different method like welding, and assemble the
part. The machine then can save time wasted and money as well as human labor. The total cost
with considering standard raw material, standard components, power and labor cost is estimated
18500 birr. To fulfill the project time is plan from March up to June 2019.
Chapter One
1.1 Introduction
Now a day it is necessary to increase production rate continuously in order to achieve higher
production rates with minimal of human input, there is need to develop innovative machinery to
cater the above needs. Polishing operation is mainly done on the face of the components which
is similar to polishing with the view to improve the surface finish of the components. The
polishing operation is presently done by mounting an abrasive disk on the spindle of a hand
grinder and feeding this rotating disk against the job surface [1].

Polishing is the process of creating a smooth and shiny surface by rubbing it or using a chemical
action, leaving a surface with a significant secular reflection. Polishing is a multistage process.
The first stage starts with a rough polishing and each subsequent stage uses a finer emery paper
of different grades until the desired finish is achieved. In this stage metal removal takes place.
Then in second stage we come across the Fine polishing in which minimal or negligible metal
removal takes place. It is mainly used to remove scratches from the surface of specimen. Finally,
Etching is the operation of revealing micro-structural features (grain boundaries, phases,
precipitates and other micro-structure constituents) of the polished specimen through selective
chemical attack on the surface. A common misconception is that a polished surface has a mirror
bright finish, however most mirror bright finishes are actually buffed.

Polishing is often used to enhance the looks of an item, prevent contamination of instruments, re
move oxidation, create a reflective surface, or prevent corrosion. In metallography and
metallurgy, polishing is used to create a flat, defect-free surface for examination of a metal’s
microstructure under a microscope. Silicon-based polishing pads or a diamond solution can be
used in the polishing process. Polishing stainless steel can also increase the sanitary benefits of
stainless steel.

In the metal Polishing Machine polishing wheel spins at high speed in a plane perpendicular to
the surface to be machined, which ensures the flatness of the surface machined and also the
parallelism of the opposite surfaces of job being machined. The depth of cut is governed by the
sliding motion of cutter carrier in the downward direction whereas the wobbling action achieved
by the combined rotary and eccentric motion of the work table ensures that even machining takes
place all over the surface. To ensure that the complete surface is machined the table slide is
provided.

1.2 Back ground of the project

The project aimed to adapt and build the beginning of sustainable polished metal demonstration
at the first alternative coop. the most Ethiopian factory the final process in metal work is
finishing proses by increasing speed of machine like lathe, milling, grinding and so but all this
machine does not exist extremely good surface finish so after finishing proses to use polishing
machine for creating a smooth and shiny surface by rubbing it. After implementation of this
project, the first beneficiary is Bahir Dar University Technology institute, and then the sponsor
possesses a machine. The sponsor has also gained two-wheel metal polisher machine that can be
used for Varity of factory purpose in the demonstration. The demonstration will not only inform
factor, but also attract customer to the first alternative coop, possible increase sale.

1.3 Advantages of polishing machine

 Flatness guaranteed, Surface machined is necessarily flat.
 No Tool marks on the surface machined.
 Even polishing on surface.
 Less Time consuming, suitable for mass production.
 Dimensional accuracies maintained.
 Surface finish guaranteed.
 Parallelism of surfaces machined is maintained.

1.4. Problem statement

BIT requires a conventional polishing machine that would significantly for high surface finish.
This is with due consideration of the following reasons: -

 Exported polishing machine are too expensive to be purchased in the result a limited
number of polishing machines are available in BIT.
 Manually polishing metals require too much energy and time consuming and the result is
poor surface finishing.
  The problem mainly occurred in Bahir Dar institute of Technology especially Faculty of
Mechanical and industrial engineering Material Science laboratory, to test the grain size
structure, hardness test, tensile strength test that it’s too difficult to obtain a good surface
finish.
 Wastage of time and human labour.

1.5 Objective of project

1.5.1 Main objective
The main objective of this project is to redesign, adaptation and manufacturing of two-wheel
metal polishing machine.

1.5.2 Specific objective

The specific objectives of this project are:
 To design and manufacture different pulleys.
 To design and manufacture different shafts.
 To design and manufacture the two wheels.
 To design V-belts.
 To design and manufacture the frame and the control board.

1.6 Site Analysis and Inventory

The study area of this research is around Bahir Dar University. Existing polishing machine is
very expensive which costs around 650,000 ETB each. This is also exported from foreign
country. And its maintenance cost is also high and difficult to easily maintain. Students are
interested to know and to experiment in the shop/laboratory by using the polisher machine.
Existing alternatives to polish by manual to see grain structure, hardness testing and tensile
strength testing are difficult to obtain for students.

1.7 Methodology

It is a set of activities performed in a project how to convert an idea into a practical product.
Looking at the problem and interpret it with the theoretical knowledge and then identifying the
problem with the help of different books, observation, and interview and by measuring. Then we
will be planning, system level design, detail design, specification and then manufacture.
 Data analysis
 Data collection (literature review)
 Conceptual generation and selection
 Part design
 Geometrical analysis.
 Force analysis.
 Stress analysis.
 3D on Catia software.
 Production process.
 Assembly procedure.
 Wear
 Lubrication
 Friction
 Cost Analysis
Chapter Two
2.1 Literature Review

Probably best known for his fundamental studies of the mechanisms of grinding and polishing
using abrasives and the role of these processes in producing structural changes in surface of
metals [2] in this book they give all the information about polishing with abrasives and their
principles. Various effects of abrasives with their grit size changes are mentioned in the book.

Preparing the polisher machine cooperating with robot. This machine was created for human
health perspective because of polluted air contact during polishing operation. The pollution of air
caused by emulsions released in the air during polishing operation [3] when polishing wheel
rubbing the polishing surface. He was used robotic arms in their machine.

How to select right flap disc direction, Illustrating features of good flap disc and gives the
guideline for selection of flap disc [4] all related terms of flap disc like abrasive grit, grit size,
flap disc material.

Analysis & Control of Vibration in polishing machines about different vibrations caused in the
polishing machine. Using different measuring methods, the vibration of polishing machine can
be controlled [5]. The vibrations are hard to measure; it was witnessed from the formation of
waviness on work piece and polishing wheel. Measured the vibrations by velocity measurement
mode because velocity defined as the rate of displacement per unit time [6]. Vibration was
analyzed by the digital Vibrometer and controlled by damping method. By using different
methodology for reduction of vibration the loss of accuracy and loss of production can be
prevented.

The experiment on metals for measuring roughness of stainless steel after polishing, they do that
experiment on polishing machine and for testing its effectiveness. They use different flap disc
and buffing wheels for polishing purpose with different grades [7].

The mechanical preparation required during polishing in the paper. It is found that a systematic
preparation method is the easiest way to achieve the true structure. The construction of polishing
machine is also mentioned in the paper. The material removal rate (MRR) of different grades is
given in it. In this paper they also describe grinding and polishing method. The paper gives an
idea about fabrication of wet grinding machine (surface). They conclude that with the help of
motor and belt drive system reduced the mechanical efforts of users [6].

2.2 Polishing Mechanization

The term "polishing" is used in the restricted sense generally employed in the plating and metal
finishing industries [7] i.e., as the removal of metal from a surface by means of abrasive particles
attached by adhesive to the surface of wheels or belts. While this operation is normally applied
for the purpose of making the surface smoother, it has been used in the investigation to yield any
desired finish, which in a given case may be rougher than the initial surface, e.g., when cold-
rolled steel is polished with a 90-grain abrasive. The effects of polishing cold-rolled steel upon
the protective value of the coatings, as found in this investigation, are relatively small. The
detailed data obtained in the polishing operations are included because they may be of interest to
persons planning a more detailed study of polishing.

2.3 Methods of defining surface finish

In order to insure that specimens polished according to a given schedule were sufficiently like
each other and sufficiently different from those of another set to lead to reproducible and
significant results [7] it was necessary to employ some objective method for defining the surface
finish. Because all comparable specimens were polished by about the same procedure, except for
the grain size of the abrasive, it was not necessary to select a method that fully defined the
surface. It was sufficient to be able to compare the contours of surfaces similarly produced.
In 1940 the ASME issued a Proposed American Standard, B46, for surface roughness, which
was revised in 1942 as a proposed "American Standard of Surface Roughness, Waviness and
Lay." In it the relevant terms are defined, and a scale of roughness is based on the root mean
square of the height of the irregularities from the nominal surface. Various methods have been
proposed for measuring surface roughness, including
a) Microscopically examination of cross sections,
b) Visual or photographic examination, usually with the aid of a microscope,
c) Measurements of reflectivity, and
d) Tracer methods. Of these, the tracer methods are most readily applied. In these methods,
a fine-pointed stylus is drawn across the surface and its movements are measured or
 recorded. In the Brush Surface Analyzer this is accomplished by means of a tracing pen,
the vertical fluctuations of which are usually magnified much more than the horizontal.

2.4 Parts of polishing machine and their functions

A two-wheel metal polishing machine consists of the following parts [5]
1. Power transmission component
 Shaft: Shaft is rotating machine element which is used to transmit power from one place
to another.
 Pulley: The pulleys are used to transmit power from one shaft to another by means of flat
belts, V-belts or ropes
 Belt drive: The belts are used to transmit power fromone shaft to another by means of
pulleys which rotate at thesame speed or at different speeds.
2. Speed controller: controls the speed of rotating shaft
3. Other component
 Rolling contact bearing: A bearing is a machine element which supports another
moving machine element (known as journal). It permits a relative motion between the
contact surfaces of the members, while carrying the load.
 Frame: are structural design of member that could be hinged to the wall surface, or
fixed (pinion or rolled) to the ground. Frame could have circular, rectangular, square,
L shaped, or U shaped cross section.
 Bolt, nut and washer.

2.5 Working principle of the machine

The mechanism consists of rotating wheel supported by wheel supporter which is attached to the
shaft and the shaft is also consist of bearing and two grooved pulley mounted on it, the rotation is
guided by the belt which need power from motor as a source. The motor used for the two wheel
polishing machine is dc motor of any class of rotary electrical machines that converts direct
current electrical energy into mechanical energy. A DC motor's speed can be controlled over a
wide range, using either a variable supply voltage or by changing the strength of current in its
field windings, so as the machine needed to be controlled the two wheel polishing machine
consists of a dc power controller that manage power as required.
The machine covered with four sided frame, that protect the components from danger and the
bearing from wet that can cause for wear. The motor attached to one side of the frame rather
placing it in to the bottom frame of the machine, because if it placed in to the bottom the motor
fan can be covered and make it out of service. The motor shaft has a pulley at the tip which
allows sticking the belt and rotating it with the help of motor that takes power from electric
source. The belt translates the power from motor to the shaft by the help of two grooved pulleys.
At the tip of this shaft the rotating wheel is attached that perform the main task. The smoothness
of a metal obtained by rubbing the surface with the polishing particles with rotating disk
polishing particle removes small element of the surface and make them smooth in a metal
polishing machine. Polishing wheel spins of high speed in a plane perpendicular to the surface to
the machined.

The 1.1KW, 1.5 horse power and 1440 revolution per minute motor is used and switch on starts
the power transmission that make the shaft to rotate and this shaft from the motor transfer the
power in to the belt by the help of pulley and the pulley has a belt on it to receive the power from
motor shaft and make it sure to transfer in to the second shaft for the rotating wheel. And the
wheel mounted at the ends of the shaft that must be shaped and metal resist material. So the shaft
makes the wheel to rotate as required speed and then it’s possible to place the metal in to the
rotating wheel to have the required smoothness. Flat shaped square or rectangular solid as well as
drilled work piece are polished by this machine and also metals which needed for the study of
grain size structure may also polished by this mechanism.

2.6 Factors affecting polisher performance

The factors which affect the quality and efficiency of threshing are broadly classified in three
groups:
 Material factor: variety of metals, material property
 Machine factor: feeding angle, types of wheel, weight of the motor, diameter of the frame
for wheel sit.
 Operation factor: shaft speed, Feed rate, method of feeding, Machine adjustments.
 2.7 Competitive design
In this research, for the redesign of two-wheel polishing machine, by comparing different types
of criterion that are: -
 Power transmission ways,
 Power source,
 Direction of operation and
 Speed control method

Base on this criterion we take the most advantageous to redesign of two polishing machine in
according to below stated point of view. Comparing them is important to have a good and better
machine than we have in the shop/laboratory.

Table 2.1 Competitive Design, Their Criteria, Type, Description, Advantage and Disadvantage
Criteria Types Description Advantage Disadvantage
Power Belt Driven Transmit power from one Easy to analysis Short period of
transmissio shaft to another by means ,manufacturing time
n of flat belts, V-belts or ,assembly and low
ropes power requirement

Gear Box Transmit power from one Long period of time, Difficult to
shaft to another by assembly ,
combination of gear manufacturing
and maintenance ,
high power
requirement
Methods of Manually The source of power Low cost, Low power
Operation operated operated manually (with No electric power resource
hand or pedal) requirement Many labor force
required
Use Motor The source of power is High speed, high Higher power
electricity or motor energy generate requirement
Direction of Perpendicula The rotating wheel and Easy polished and
operation r work piece perpendicular control ,work piece
face controlled
easily
Parallel The rotating wheel and Difficult to
work piece parallel control
Speed Mechanical The speed of the wheel is Low cost and easy Hazards , difficult
Controller controlled by push and to assemble to control
pull method

Automatic The speed of the wheel is Easy to control , Required skilled

controlled by automatic free from hazard person
speed controller.

From the above different criterion, the best two-wheel metal polishing machine element will
select by using a decision matrix.

2.8 Decision matrix

A decision matrix was used to redesign two wheel polishing machine in the project. The
governing design criteria shown below were used to select the most suitable design:

 The project must have enough technical content to be suitable for a final year project.
 In order to be suitable for a mechanical engineering final year project, it must be relevant
to the subject.
 The project must be useful and of benefit to the desired community.
 Our technical knowledge should be great, which would give us a greater understanding of
that specific area, hopefully leading to a better final design.
 It could be problematic if the raw materials required for testing were not readily available.
 The better the scope for improving the current design, the more beneficial the project will
be.

A weighted decision matrix (WDM) is a simple tool that can be very useful in making complex
decisions, especially in cases where there are many alternatives and many criteria of varying
importance to be considered.
WDMs are often used in design engineering as a qualitative tool to evaluate alternatives. This
page explains how they work in general; other topics will show how they are used in specific
design tasks.

To use a WDM, you need certain information:

 A set of well-defined criteria;

 A set of weights that define the relative importance of the criteria;
 A reference against which comparisons will be made; and
 A well-defined set of alternatives to be ranked.

How you generate these required data will depend on what you want to use the WDM for. In
engineering design, the required data are typically developed during design stages leading up to
concept evaluation.

The decision matrix the following process:

 Define your ideal solution. Spend a few minutes thinking about the ideal solution. How
does it look and feel? Try it on for size. Make a list of the key characteristics for your
ideal solution.
 Set Your Priorities. Which of these characteristics of your ideal solution are the most
important? Assign a weight (percent) to each key characteristic. The weight establishes
your priorities.
 Assign The Points. Evaluate each option and give it a column score for each key
characteristic. You look at each option by itself and rate it according to how it meets your
key characteristics.
 Calculate the weighted scores. Use the Column score and the key characteristic weight
(percent) to calculate a weighted score. This combines the facts from your option with
your priorities for the decision to give you an objective measurement.
 Add up the total scores. Add up the weighted scores to get the total score for each option.
The option with the highest score is closest to your ideal solution.

For this two-wheel polisher machine there is something that might be consider to be the major
character of the machine like, assembly, material handling, cost, efficiency, ease of operation and
maintenance. Each concept was rated out of 100 according to how well it met each of the design
criteria. These scores were then multiplied by the weighting for each criterion and totaled for
each polisher machine to give the overall percentage score shown in table.
The weight is out of 10. Considering the criteria: -
 10 excellent
 7-9 very good
 5-6 good
 <5 poor

Table 2.2 Given weight to compare based on character

Power Speed Controller Methods of operation
transmission
No. Criteria Weight (%) Belt Gear Manual Automatic Manually Use
driven box operated motor
1 Assembly 10 8 5 6 8 5 7
2 Material handling 10 8 6 6 8 6 8
3 Maintenance 10 9 6 8 7 8 7
4 Cost 10 8 5 8 7 8 7
5 Manufacturability 10 8 5 7 6 8 7
6 Labor requirement 10 8 6 6 8 6 8
7 Efficiency 10 8 9 6 8 6 9
8 Durability 10 7 9 6 8 6 8
9 Ease of operation 10 8 7 7 9 6 8
10 Ease of polishing 10 8 7 6 8 5 7
Total sum 100% 80 65 66 77 64 76
Rank 1 2 2 1 2 1
Selection()   
Consider the above criteria. The belt driven two-wheel metal polishing machine that uses
automatic speed controller and operated with the use of motor has been selected.
Select the appropriate component for two-wheel polishing machine
Table 2.3 Selection of shapes of polishing machine components
Solution variant
Pert A B C D
Name
Shaft

Pulley

Belt

Bearing Self-aligning Cylindrical Needle

Ball Ball Roller bearing Roller
Bearing Bearing bearing
Table 2.4 Selection of variants for each parts of two-wheel polishing machine
Selection Solution Variant
Criteria Shaft Pulley Belt
A B C A B C A B

Easy to 4 3 2 4 3 2 3 4
maintenance
Suitability 4 3 3 4 3 2 4 2

Light 2 4 3 5 3 3 4 3
weight

Accuracy 3 3 3 3 4 4 5 3

Easy to
operate - - - 4 3 3 4 3

High
Strength 5 4 3 4 3 3 4 4

Corrosion
Resistance 4 3 2 4 3 2 - -

Reliability
4 3 3 3 3 3 4 3

Power
transmission 4 3 3 3 3 4 5 3

Total 30 26 22 34 28 26 33 25

Rank 1 2 2 1 2 3 1 2

Table 2.5 Types and selection of bearing

Bearing Self-aligning Cylindrical Needle
Type Ball Ball Roller bearing Roller
Bearing Bearing [C] bearing
[A] [B] [D]
Criteria
High speed 4 3 3 3
Low noise/vibration 4 2 2 2
High rigidity 2 3 3 3
Vibration/Shock 2 3 3 2
 resistance
Low starting and 4 1 2 1
running friction
Accuracy to shaft 4 2 4 2
alignment
Total 20 14 17 13
From the above comparison table, the selected shape and types of the component of polishing
machine are listed below.

For shaft: - Solid shaft (shape A) is selected

Pulley: -Single groove pulley (type A) is selected

Belt: -V-belt (shape A) is selected

Bearing: - ball bearing (type A) is selected.

Chapter Three

3. Part Design
3.1 Geometric Analysis

Fig 3.1 Assembly of two-wheel polisher machine

Key

1. Speed controller board

 2. Pocket supporter
3. Shaft
4. Base frame
5. Side frame
6. Motor
7. Motor supporter
8. Two grooved pulley
9. Belt
10. One grooved pulley
11. Pocket
12. Bearing
13. Wheel 1
14. Power controller
15. Wheel 2
16. Speed controller

3.2 Design analysis

3.2.1 Selection and design criteria
General Requirements of Machine Design

 High productivity.
 Ability to produce and provide required accuracy of shape and size and also necessary
surface finish.
 Simplicity of design.
 Safety and convenience of control
 Low Cost.
 Easy of material handling
3.2.2 Design specification
Table 3.1 Design specification of two-wheel polisher machine

Essential feature Desirable feature

 Must be cheap and easy to maintain  Should use standardized parts to

by local people reduce cost and allow easy
 Must be easy to use maintenance
 Must be affordable  Should be adaptable for many
different Situations
 Should be usable by student, teachers
and lab assistant of varying sizes and
fitness levels.

3.3 Material selection

The engineering materials are mainly classified as:
 Metals and their alloys, such as iron, steel, Copper, aluminum, etc.
 Non-metals, such as glass, rubber, plastic, etc.

The selection of a proper material, for engineering purposes, is one of the most difficult
problems for the designer. The best material is one which serves the desired objective at the
minimum cost.
The materials selection and their properties are a great significance for a design engineer.
Therefore, we should be selecting such a material which has properties suitable for each
components of operation the conditions. In addition to this, a design engineer must be familiar
with the effects which the manufacturing processes and heat treatment have on the properties of
the materials. In this project, the selection of a proper material, for engineering purposes is one
of the most difficult problems for designers. There are different factors that we are taking into
consideration to select the material for our design machine parts: -
 Availability of the materials
 Suitability of the materials for the working conditions in service.
 The cost of the material
The important properties, which determine ductility of the material, are physical, chemical and
mechanical properties. so discuss the commonly used engineering materials and their properties
in each component is very important, the following materials, plastic, fabric and cords mounded
in rubber and covered with fabric and rubber, aluminum, carbon steel, and mild steel.

3.3.1 Physical properties of material

The physical properties of the metals include luster, color, size and shape, density, electric,
thermal conductivity and melting point. The following table shows the important physical
properties of some pure metals.

Table 3.2 Physical properties of metal

3.3.2 Mechanical properties of metal

The mechanical properties of the metals are those which are associated with the ability of the
material to resist mechanical forces and load. These mechanical properties of the metal include
strength, stiffness, elasticity, plasticity, ductility, brittleness, malleability, toughness, resilience,
creep and hardness.

Aluminum:
It is white metal produced by electrical processes from its oxide (alumina), which is prepared
from clayey mineral called bauxite.
  Aluminum is a light metal (= 2.7 g/cc); is easily Machin able; has wide variety of surface
finishes; highly reflective to heat and light.
 It is a versatile metal - can be cast, rolled, stamped, drawn, spun, roll-formed, hammered,
extruded and forged into many shapes.
 It can be riveted, welded, brazed, or resin bonded.
 It resists corrosion - no protective coating needed, however it is often anodized to improve
surface finish, appearance.
 Al and its alloys -high strength-to-weight ratio (high specific strength) owing to low
density.
 Such materials are widely used in aerospace and automotive applications where weight
savings are needed for better fuel efficiency and performance.
The aluminum may be alloyed with one or more other elements like copper, magnesium,
manganese, silicon and nickel. The addition of small quantities of alloying elements converts the
soft and weak metal into hard and strong metal, while still retaining its light weight.
Low Carbon Steel (Mild Steel)
 Low carbon steel: It is very low content of alloying elements and small amounts of Mn.
 Most abundant grade of steel is low carbon steel: It is a greatest quantity produced; least
expensive.
 It is not responsive to heat treatment; cold working needed to improve the strength.
 It is a good weld ability and machinability.
 Mild steel widely uses in moisture area because of it highly corrosion resistance, non-
brittle and a strong. As a result, it resists impact load.

Carbon steel

Carbon steels are steels with carbon content up to 2.1% by weight. American Iron and Steel
Institute (AISI) definition of Carbon Steel states: Steel is considered to be carbon steel when: no
minimum content is specified or required for chromium, cobalt, molybdenum, nickel, niobium,
titanium, tungsten, vanadium or zirconium, or any other element to be added to obtain a desired
alloying effect. The specified minimum for copper does not exceed 0.40 percent; or the
maximum content specified for any of the following elements does not exceed the percentages
noted: manganese 1.65, silicon 0.60, copper 0.60. The term "carbon steel" may also be used in
reference to steel which is not stainless steel; in this use carbon steel may include alloy steels. As
the carbon percentage content rises, steel has the ability to become harder and stronger through
heat treating; however, it becomes less ductile. Regardless of the heat treatment, higher carbon
content reduces weld ability. In carbon steels, the higher carbon content lowers the melting point.

V-belt: AV-belt is mostly used in factories and workshops where a great amount of power is to
be transmitted from one pulley to another when the two pulleys are very near to each other.
Made of fabric and cords mounded in rubber and covered with fabric and rubber. This material
has a high strength and has a strong reliability

Pulley: The material of the pulley is aluminum based on the above information, because
aluminum has light in weight, machinability, corrosion resistance is high relative to mild steel,
and carbon steel.

Frame: the material of frame is mild steel based on the above data, because of mild steel which
resist impact load, relative to carbon steel and good weld ability relative to aluminum.

Shaft: The material of shaft is carbon steel on the above data, because of carbon steel, high wear
resistance relative to aluminum and mild steel. It is also hard and strong material.

3.4 Functional structure input

Fig 3.2 Functional structure input of two-wheel polisher machine

Chapter Four

4. Design part
4.1 Design of Frame
Frame are structural design of member that could be hinged to the wall surface, or fixed (pinion
or rolled) to the ground. Frame could have circular, rectangular, square, L shaped, or U shaped
cross section. The law of mechanics applies to one body shown in one free body diagram. Yet
engineering design things with many piece each of which may be though as a body. We would
now like to analyze built of pieces that are connected in a more complex way.

The design of the frame mainly depends on:

 The lifting force these determine the required rigidity
 The determination and size of frame
 The degree of guidance precision
Geometric analyses of frame
1. Geometry of back side frame
 Fig 4.1 Back side frame
Horizontal length = 1000mm
Height =1000mm
Thickness =3mm
Width=40

2. Left side frame

Fig 4.2 Left side frame

Horizontal length each frame =1000mm
Height =1000mm
Space between two vertical frame =400mm
Space between the upper horizontal frame and the middle frame =200mm
Space between the middle frame and the bottom frame=400mm
1. Front frame

Fig 4.3 Front frame

Horizontal distance=1000mm
Height=1000mm
Thickness=3mm
Width =40mm
2. The middle frame
Which frame support the two shaft and welded at the two side frame
 Fig 4.4 Middle frame
Length =920mm
Width =40mm
3. Upper frame 1

Fig 4.5 Upper frame 1

Length=1100mm
Height =200mm
4. Upper frame 2
 Fig 4.6 Upper frame 2
Length =1100mm
Height =100mm
5. Over all geometry of frame
 Fig 4.7 Overall geometry of frame

4.2 Selection of Pulley and belt

Fig 4.8 Two grooved pulley

There are two types of belts are existed in this machine. For the first pulley, power transmit from
motor into shaft one. The second v-belt from the first shaft transfer to second shaft. Shaft one
pulley diameter is larger than other two pulleys

1. Driver pulley

Gives the horse power rating at a maximum pitch diameter of pulleys and the corresponding
speeds. The horsepower rating of the electric motor will therefore determine the diameter of the
driver pulley.

2. Driven pulley

The spindle speed and the spindle of the prime mover are related by the expression.
 N1 D1 =N2 D2 orN1 / N2 =D2 / D1 (1)

i.e., (The speed of driver/the speed of driven) = (Diameter of driven/diameter of driver)

The following factors determined the center distance of pulleys:
 the class of V-belt used;
 the configuration of the machine;
 the space available
However, the two pulleys must be near to each other.

4.3 V-belt specification

For first v-belt

Fig 4.9 Diagram showing two pulleys connected by a belt.

Step 1: - Design of power and identify the cross section

Pd =hp*Fa, (1)

where Fa = Correction factor and hp= horse power

Pd=1.65 hp

=1.5*1.1 or pd =1.1kw *1.1

=1.65hp = 1.21kw

We select the minimum pitch diameter of the pulley and V-belt cross section can be identified by
their top width and depth dimensions.

Minimum pitch diameter of the pulley (dp)=75mm

Top width of belt = 13mm

Depth of belt = 8mm

Table 4.1 Correction factor (Fa) for industrial service
Types of Service Operational hours per day
0-10 10-16 16-24
Light Duty:-Agitator-Blowers-Centrifugal pumps-fans (up to 7.5 1.1 1.2 1.3
KW) and compressors.
Medium Duty:-Compressors fans (above 7.5 KW) line shafts- m 1.2 1.3 1.4
achine tools presses and positive displacement pumps.
Heavy Duty:- Conveyors –buckets elevators and hammers. 1.3 1.4 1.5
By using the identification chart, we can select the belt type from table of stated on a text book of
machine design by R.S KHURMI and J.K GUPTA for the types including width, range, diameter,
thickness and weight of belt.We have selected the v-belt that is belt type A

Table 4.2 Dimension of standard v-grooved pulleys

We have selected the v-belt that is belt type A

Step 2: - Determine V-belt length

L = 2C + 1.57(D1 + D2 ) (2)

C = Centre distance

D1 = diameter of pulley on motor

D2 =consider diameter of pulley on shaft

Centre distance (AB) = 500mm

D1 = 75mm

D2 = 125mm

L = 2 ∗ 500 + 1.57(125 + 75)

L = 1314mm

From standard pitch length v-belts according to IS 2494-1974

L1331mm is the length of belt

Table 4.3 Standard pitch length

Step 3: - Velocity ratio of belt drive

It is the ratio between the velocity of the driver and the follower or driven. It expresses as

N1 = 1440rpm (speed of driver in rpm)

N2 = speed of driven in rpm

 Length of the belt that pass over the driver in
minute =D1 D1 (3)

Length of the belt that pass over the driven in minute

=D2 N2 (4)
N1 D2 (5)
Step 4 :-Then the velocity ratio Vr = N2 = D1

Based on the above formula

N2 75
=
1440 125
1440 ∗ 75
N2 = = 864rpm
125
Velocity ratio
1440
(Vr)= = 1. 67
864
D2N2 (6)
The velocity of belt (Vb)= 60

(125) ∗ 864
Vb = = 5.655 m⁄s
60
The maximum angular speed (7)

( ωmax) = 2Nmax
60

ωmax1 = 21440
60
= 150.8 rad⁄s

And the
minimum angular speed (ωmin1 ) =
2Nmin (8)
60

ωmin = 2864
60
= 90.5 rad⁄s

Step 5 :-determine the rated power per belt

4.375
Pr = dp ∗ Nm [1.769 − − 3.081 ∗ 10−4 (dp ∗ Nm)2
dp
(9)
1
− 0.3658 log(dp ∗ Nm)] + 4.3772 (1 − )
ksr
 4.372
𝑝𝑟 = 2.953 ∗ 1.44 [1.769 − − 3.081 ∗ 10−4 (2.953 ∗ 1.44)2
2.953
1
− 0.3658 log(2.953 ∗ 1.44)] + 4.3772 (1 − )
1.084

pr = 0.5641hp

Step 6 :-Angle of contact or lap

𝐷𝑝 − 𝑑𝑝 125 − 75
= = 0.1
𝑐 500

 = 180 − 2 (10)

= 180 − 2(2.87)

= 174. 30


= 174. 30 ∗
180

= 3.04rad

Table 4.4 length of correction factor

by select length of correction factor from table

Fl = 0.99

 = 1740
Table 4.5 Arc contact correction factor

By select the arc contact correction factor from table

Fa = 1.13

Step 7:-To calculate the number of belts (Vn)

Vn = pd/pr*Fa*Fl

Vn = 1.65hp/0.5641hp ∗ 1.13 ∗ 0.99 = 2.6

Step 8:-Calculate the face width (B) of the pulley from table V- belt type A

We take from table e=15 and f= 10, then

B = (n-1) e +2f

B = (2.6-1)15+20

B= 44mm
Table 4.6 Dimensions of standard v-grooved pulleys

Step 9:-Calculate Tension of V-belt

 The tension on tight side will be greater than the slack side
 We know that mass of the belt per meter length
kg⁄ (9)
m = Area ∗ density in m3
Therefore, the centrifugal tension (Tc)

Tc = m ∗ v 2 (10)

Note: The cross section area of each belt is 336mm2 the coefficient of friction between the pulley and
the belt () = 0.30 which are recommended for this project, the density of belting is 1140𝑘𝑔/𝑚3 , and
allowable stress 1.75 Mpa to be expected to give a belt life of about 15 years.

Therefore, calculate mass of belt, centrifugal tension (Tc) based on the above data

m =A∗g∗l (11)

kg⁄
mass = 336 ∗ 10−6 ∗ 1331 ∗ 1140 = 0.518 m

Tc = m ∗ v 2 , where v= velocity of belt

Tc = 0.518 ∗ 5.655 = 2.933N

And maximum tension in the belt

T = stress ∗ area =  ∗ A (12)

= 336 ∗ 1.75 ∗ 106 = 588N

After that tension in the tight side of the belt

T1 = T − Tc (13)

T1 = 588 − 2.933 = 585.1N

75
R1= radius of motor pulley= = 37.5
2

125
R2= radius of shaft pulley= = 62.5
2

C= Centre distance between the two pulleys (14)

D2 − D1 125 − 75
sin  = = = 0.05
2C 2 ∗ 500

 = sin−1 (0.05) = 2.870

To calculate tension, we use the following formula.

T1 (15)
2.3 log (T2) = cosecβ, cosecβ =1/sinβ ,

from table β= 38/2

585.1
2.3 log ( ) = 0.3(3.04)(3.072)
T2

585.1
2.3log ( ) = 2.802
T2

log 585.1
= 1.22(taking antilog 16.66)
T2

585.1
T2 = = 35.12N
16.66

The effective turning (driving) force at the circumference of the follower is the difference
between the two tensions (i.e. T1-T2)

585.1 − 35.12 = 549.98N

For Second V-belt: - Between two shafts

Power transmit from shaft one to shaft two.

Step 1: - Identify the cross section.

The belt type is A (the same as belt 1)

Step 2: - Determine V-Belt length

L = 2C + 1.57(D1 + D2) (16)

Where C= Centre distance=300mm

D1 = 125mm

D2 = 80mm (Consideration)

L = 2 ∗ 300 + 1.57(125 + 80)

L = 921.85mm

From the standard: type A

L = 925mm

Step 3: - velocity ratio of the belt drive

In this case

N1 = 864rpm (Speed of driver in belt two)

N2 = speed of driver in rpm

N2⁄ = d1⁄ = N2⁄ 125⁄

N1 d2 864 = 80

N2 = 125 ∗ 864⁄80 = 1350rpm

N1 864
Velocity ratio(Vr) = = = 0.64
N2 1350

D2N2
Velocity of belt(Vb) =
60
 (80)(1350)
Vb = = 5.655 m⁄s
60

2Nmax (17)
The maximum angular speed (ω2 ) =
60

2(1350)
= = 141.4 rad⁄sec
60

2Nmin (18)
The minimum angular speed(ω2 ) =
60

2(864)
= = 90.5 rad⁄sec
60

Step 4:- determine the rated power per belt

4.375
Pr = dp ∗ Nm [1.769 − − 3.081 ∗ 10−4 (dp ∗ Nm)2
dp
(19)
1
− 0.3658 log(dp ∗ Nm)] + 4.3772 (1 − )
ksr

4.372
𝑝𝑟 = 2.953 ∗ 0.864 [1.769 − − 3.081 ∗ 10−4 (2.953 ∗ 0.864)2
2.953
1
− 0.3658 log(2.953 ∗ 0.864)] + 4.3772 (1 − )
1.084

pr = 0.688hp

C = center distance between two pulley

D2 − D1 80 − 125 (20)
sin  = | |=| | = 0.075
2C 2(300)

 = sin−1 (0.075) = 4.30

Step 5:- Angle of contact or lap

𝐷𝑝 − 𝑑𝑝 125 − 80
= = 0.15
𝑐 300

 = 180 − 2 = 180 − 2(4.3) = 171.40 ~ 1690

 
 = 169 ∗ = 2.95rad
180

by select length of correction factor from table 4.4

Fl = 0.97

 = 1690

By select the arc contact correction factor from table 4.5

Fa = 1.13

Step 6:- To calculate the number of belts (Vn)

Vn = pd/pr*Fa*Fl

Vn = 1.65hp/0.688hp ∗ 1.13 ∗ 0.97 = 2.2

Step 7:- Calculate the face width (B) of the pulley from table V- belt type A

We take from table 4.6 e=15 and f= 10, then

B = (n-1)e +2f

B = (2.2-1)15+20

B = 38mm

Step 8:- To calculate Tension for V-belt

NOTE:- A=336mm2 g=1140kg/m3

=0.3 =1.75Mpa

To be expected to give a belt life of about 15 years therefore calculate mass of belt

m=A∗g∗L (21)

m = 336 ∗ 10−6 ∗ 1140 ∗ 925

m = 0.354 kg
Centrifugal tension (Tc based on above data)

Tc = m ∗ v 2 , (22)

where v = velocity of belt

Tc = 0.354 ∗ 5.655 = 2N

And maximum tension in the belt

T = stress ∗ Area =  ∗ A (23)

= 336 ∗ 10−6 ∗ 1.75 = 588N

After that tension in the tight side of the best

T1 = T − Tc = 588 − 2 = 586N

To calculate tension based on the following formulation

T (24)
2.3 log (T1 ) = cosecβ
2

586
2.3 log ( ) = (0.3)(2.95)(3.072)
T2

586
2.3log ( ) = 2.72
T2

log 586
= 1.1826(taking antilog 15.2265)
T2

586
T2 = = 38.5 N
15.2265

The effective turning (driving) force at the circumference of the follower is the difference
between the two tensions (i.e. T1-T2)

586 − 38.5 = 547.5N

A little consideration will show that when the speed of belt increases, the centrifugal force also
increases which tries to pull the belt away from the pulley. This will result in the decrease of
power transmitted by the belt. It has been found that for the efficient transmission of power.

The coefficient of friction between the belt and the pulley depends upon the following factors:
 The material of belt;
 The material of pulley;
 The slip of belt; and
 The speed of belt.

4.4 Design of shaft

A shaft is the component of a mechanical device that transmits rotational motion and power. It is
integral to any mechanical system in which power is transmitted from a prime mover, such as an
electric motor or an engine, to other rotating parts of the system.

A shaft is a rotating or stationary member, usually of circular cross-section having such elements
as gears, belt, pulleys, flywheels, cranks, sprockets and other power transmission elements
mounted on it. Shafts are either solid or hollow.

Shaft Design Procedure

Because of the simultaneous occurrence of tensional shear and normal stress due to bending, the
stress analysis of a shaft virtually always involves the use of a combined stress approach. The
recommended approach for shaft design and analysis is the distortion energy theory of failure.
Vertical shear stresses and direct normal stresses due to axial loads may also occur. On very
short shafts or on portions of shafts where no bending or torsion occurs, such stresses may be
dominant.

Procedure:
1. Determine the rotational speed of the shaft.
2. Determine the power or the torque to be transmitted by the shaft.
3. Determine the design of the power-transmitting components or other devices that will be
mounted on the shaft, and specify the required location of each device.
4. Specify the location of bearings to support the shaft. Normally only one bearings are used to
support in one shaft. The reactions on bearings supporting radial loads are assumed to act at the
midpoint of the bearings.
Bearings should be placed on either side of the power-transmitting elements if possible to
provide stable support for the shaft and to produce reasonably well-balanced loading of the
bearings.
5. Propose the general form of the geometry for the shaft, considering how each element on the
shaft will be held in position axially and how power transmission from each element to the shaft
is to take place.
6. Determine the magnitude of torque that the shaft sees at all points.
 It is recommended that a torque diagram be prepared.
7. Determine the forces that are exerted on the shaft, both radially and axially.
8. Resolve the radial forces into components in perpendicular directions, usually vertically and
Horizontally.
9. Solve for the reactions on all support bearings in each plane.
10. Produce the complete shearing force and bending moment diagrams to determine the
distribution of bending moments in the shaft.
11. Select the material from which the shaft will be made, and specify its condition: cold-drawn,
heat-treated, etc.
 Plain carbon or alloy steels with medium carbon content are typical, such as AISI 1040,
4140, 4340, 4660, 5150, 6150, and 8650.
 Good ductility with percent elongation above about 12% is recommended.
 Determine the ultimate strength, yield strength, and percent elongation of the selected
material.
Material selection for shaft
There are different materials are used for shaft, but the material used for shafts should have the
following properties: -
 It should have high strength
 It should have good machinability
 It should have low notch sensibility
 It should have good heat treatment properties
So the material used for ordinary shaft is Plain carbon or alloy steels with medium carbon
content are typical, such as AISI 1040, 4140, 4340, 4660, 5150, 6150, and 8650.
A. Shaft one
Which is a vertical shaft and two grooved pulley attach at the tip of shaft and conect to moter by
v-belt then translate a speed in to the second shaft.

Fig 4.10: Wheel supporter shaft

T1 = 585N

T2= 35.12N

T3 = 586N

T4 = 38.5N

Where:

T1= Tension in the tight side of the belt on pulley A.

T2 = Tension in the slack side of the belt on pulley B.

T3 = Tension in the tight side of the belt on pulley A.

T4 = Tension in the slack side of the belt on pulley B.

𝑟 62.5 (25)
𝑡𝑎𝑛𝛾 = = = 7.125°
𝑐 500
 Fig 4.11: Two pulley connected by v-belt
Where:

RAH1= horizontal Resultant load at grooved pulley A

RAV1=vertical resultant load at grooved pulley A

RAH1 = T1cos𝛾 = 585𝑐os7.125° = 580.5𝑁

RAH2 = T2𝑐𝑜𝑠𝛾 = 35.12cos7.125° = 34.85

Horizontal load acting on shaft A.

RAH = RAH1 + RAH2 (26)

= 580.5 + 34.85

= 615.35N

Vertical load acting on shaft A.

RAV = RAV1 + RAV2 (27)

= T1sin𝛾 + T2 sin𝛾

= (585 + 35.12) sin7.125

= 76.92𝑁

At pulley two

𝑟 62.5 (28)
𝑡𝑎𝑛 𝛾 = = = 0.21
𝑐 300
𝛾 = 11.77°

Horizontal load acting on a shaft A by pulley B.

RBH= RBH3 + RBH4 (29)

Where:

RBH=horizontal resultant load at grooved B

RBH3=horizontal resultant load at grooved B by T3

= T3cos𝛾2 + T4cos𝛾2

= (586 + 38.5N) cos11.77°

=611.4N

Vertical load acting on shaft A by pulley B.

RBv = T3sin𝛾2 + T4sin𝛾2 (30)

= (586 + 38.5N) sin11.77°

=127.4N

Change the direction for analysis

 Fig 4.12: Two grooved pulley supported shaft
First of all, consider` the vertical loading at A and B.

Rcv = RAH + RBH (31)

Where:

Rcv=resultant load at point C

= 615.35 + 611.4

= 1226.75N

Bending moment at point A(BM at A )

MAV = RCV * 0.3 (32)

= 1223.55*0.3

= 368N

Bending moment at B the same value.

RCH = RAV + RBV (33)

= 76.92 + 126.7

= 203.62Nm

Bending moment at C.

BMc= RCH* 0.3 (34)

= 203.62* 0.3

= 61.1Nm

Resultant B .M at C

HA = √𝑀𝐴𝑉 + BMc (35)

= √(368)2 + (61.1)2
= 373Nm

MA = MB

M = MA + MB

368+203.62

= 571.62Nm

T = (T1 - T2) R (36)

= (RAH1 – RAH2) R

= (580.5 – 38.5)0.0625

=33.88Nm

Let, we know that the equivalent twisting moment Teq

Te = √𝑀2 + 𝑇 2 (37)

= √(571.62)2 + (38.5)2

=572.9 * 103 𝑁𝑚𝑚

We also know that the equivalent twisting moment.

𝜋
Te = 16 * 𝜏*𝑑 3 (38)

𝜋
572.9* 103 = 16 * 𝜏*𝑑 3

𝜋
572.9 * 103 =16 * 135*𝑑3

572.9* 103 =26.51𝑑3

d = 27.85mm

Again we know the equivalent bending moment

 1 (39)
Me = 2 (𝑀 + √𝑀2 + 𝑇 2 )

1
= 2 (571.62 + 572.9 )

Me = 572.26*103 Nmm

𝜋
Me = 32*𝜎𝑏 ∗ 𝑑 3 (40)

Where: 𝜎𝑏 = 360 𝑁⁄𝑚

𝜋
572.26 *103 = 32*360*𝑑3

572.26*103 = 35.34* 𝑑 3

d= 25.3mm

Taking larger of the two value

d= 27.85mm or 30 mm

Figure 4.13: shear force and bending moment diagram

B. Shaft two
 (a) (b)

Fig 4.14: One grooved pulley supported shaft with belt (a) front view (b) top view
𝑟 40 (41)
tan𝛾 = 𝑐 = 300

𝛾 = 7.59°

Horizontal load acting on shaft B.

RAH3 = T3cos𝛾=586cos7.59°

= 580.87N

RAH4 = T4cos𝛾=38.5cos7.59°

=38.2N

RAH = RAH3 + RAH4 (42)

=619.1N

Vertical load acting on shaft B.

RAV3 = T3sin𝛾 = 586sin7.59°

=77.4N

RAV4 =T4sin𝛾38.5sin7.59°
= 5.085N

RAV=RAV3 +RAV4

= 82.5N

T= (RAH3-RAH4)R (43)

= (580.87-38.2)0.04

= 21.7Nm

First of all, consider the vertical load at C pulley.

RDV=RAH

RDV=619.1N

B.M at pulley C

B.M at AV= RDV*0.3

=185.73Nm

Now consider the horizontal load.

RDH=RAV

RDH=82.5N

B.M=82.5*0.3

B.M=24.75Nm

M=√𝑀𝐴𝑉 2 + 𝑀𝐴𝐻 2 (44)

=√185.732 + 24.752

=187.4Nm

Let, we know that the equivalent twisting moment Teq

Teq=√𝑀2 + 𝑇 2 (45)

= √187.42 + 24.752

=189*103 Nmm

We also know that the equivalent twisting moment (Teq)

𝜋
Teq=16*𝜏*𝑑 3 (46)

𝜋
189*103 =16*135*𝑑3

d= 19.25mm

Again we know that the equivalent bending moment.

1 1 (47)
Me=2 (𝑀 + √𝑀2 + 𝑇 2 = 2 (M+Te)

1
Me= 2 (187.4 + 189)

Me = 188.2Nm

𝜋
Me=32*𝛿𝑏 ∗ 𝑑3

𝜋
188.2*103 = 32 (360)*𝑑3

d= 17.5mm

Taking larger of the two value

d=19.25mm say 20mm

4.5 Selection of anti-friction bearing

The prime factors in bearing selection are total system reliability for its design life and the cost
effectiveness. To achieve such reliability, the bearings must be of the proper type and size. The
selection process must consider all factors which will affect bearing performance and cost. These
factors include:
  Magnitude and direction of loads
 Speed of rotation
 Required life
 Available Space
 Lubrication
 Shaft and housing designs
 Alignment
 Adjustment
 Temperature
 Environment
It is impossible to select any one of these factors as being the most critical. All must be
considering in every bearing application. and the bearing also roller types by comparing the rest of its
types as to show the outstanding adevantagoues roller contact bearing over the rest are:

 Low starting and running friction except at very high speed.

 The ability to withstand momentary shock loads.
 Accuracy of shaft alignment.
 Low cost of maintenance as less lubrication is required while in service.
 Small overall dimensions.
 Reliability of service.
 Easy to mount and erect.
 Cleanliness.
 Fig 4.15: Bearing and housing
Standard designation of ball bearing

Fig 4.16: Standard radial rolling bearing

Given data from the above analysis

For shaft

Speed of rotation in shaft1 N=864rpm

Torque=38.5Nm

ωmax1=150.8 𝑟𝑎𝑑⁄𝑠𝑒𝑐
Service factor Km=1.5 for moderate load , Km = gradually applied or steady load of rotating
shaft.
Table R.S KHURMI and J.K GUPTA the recommended value of Km and Kt.

Table 3.2 Principal dimension for radial ball bearing [13]

Bearing no Bore Outside diameter in mm Width in mm

206 30 62 16
306 30 72 19
406 30 90 23
And the value of Xo and Yo for bearing show below in the table.

Table 3.3 Value of Xo and Yo for bearing [13]

Type of bearing Single raw bearing

Radial contact groove ball Xo Yo
bearing 0.6 0.5

There for bearing no 206 to select principal dimension

Bore diameter (db.) =30mm

Width =16m

Outer diameter (do) =62mm

Table 3.4 Life of bearing for viral type [13]

Bearing no Single bearing
206 Static Dynamic
10kN 15.3KN

Table 3.5 Service life of bearing [13]

Application of bearing Life of bearing in hour

Machines requires to work with high 100,000-200,000
degree of reliability 24 hour per day
𝑐
L=(𝑤)𝑘 *106 revolution or

where

L= rating life

C=basic dynamic load

W=equivalent dynamic load

10
K=3 for ball bearing and for rollers
3

Life in revolution

L=60*N*LH revolution (48)

Where LH=working hour

N=864rpm

LH= 100,000

=60*864*100,000

=5.184*109 revolution
Dynamic load (w)

1
L (49)
C=w(106 )K

C=15.3KN for table above

5.184∗109 1
15.3*103 =w( )3
106

W=880.83N

For the second shaft

Principal dimension for radial ball bearing show below

Table 3.6 Principal dimension for ball bearing [13]

Bearing no Bore Outside diameter Width

204 20 47 14
304 20 52 14
404 20 72 19
And the value of Xo and Yo for bearing is the same value than the first shaft.

Bearing no 204=diameter=20mm

Width = 14mm

Outside diameter = 47

Table 3.7 Life of bearing for viral type of Life in revolution

Bearing no Single bearing

204 Static Dynamic
6.55 10

L=60*N*LH (50)

Where
N=1350rpm

LH=100,000 hour

L= 60*1350*100,000

=8.1*10^9 revolution

Dynamic load (w)

1
L (51)
C=w ( 6)
k
10

C=10KN

8.1∗10^9 1
10*103 =w ( )3
106

W=499.43N

4.6 Material selection of Bolt and nut

Fastener material selection

There is no one fastener material that is right for every environment. Selecting the right fastener
material from the vast array of materials available can be appearing to be a daunting task.
Careful consideration may need to be given to strength, temperature, corrosion, vibration,
fatigues and many other variables. However, with some basic knowledge and understanding, a
well thought out evaluation can be made.
 Fig 4.17: Bolt and nut designation
Classification of bolting material

Since bolting material does not come in contact with fluid, its material compatibility with fluid is
not important. The selection of bolt material is determined based on service conditions and it is
wasteful to specify expensive alloys when carbon steel material is entirely suitable. It is
important for bolting material to have good tensile stress.

As per ASME B16.5, bolting material has beendivided into three categories as follows:

A. High strength bolting:

Bolting materials having allowable stresses not less than those for ASTM A193 grade B7 are
listed as high strength bolts. ASME B16.5 Table 1B is enclosed for reference.

These and other materials of comparable strength may be used in any flanged joint.

B. Intermediate strength bolting:

Bolting materials listed as intermediate strength, and other bolting of comparable strength, may
be used in any flanged joint, provided the user verifies their ability to seat the selected gasket and
maintain a sealed joint under expected operating conditions.

C. Low strength bolting:

Bolting materials having not more than 30 ksi specified minimum yield strength are listed as low
strength. Selected from standard medium carbon steel AISI 1030, 1035, 1038 and 1541 and
ASTM A325, ASTM A449.

From the above point of view, select M8*1.5 for cover

M12*1.5 for bearing

4.7 Force and stress analysis of Frame

Frame are structural design of member that could be hinged to the wall surface, or fixed (pinion
or rolled) to the ground. Frame could have circular, rectangular, square, L shaped, or U shaped
cross section. The law of mechanics applies to one body shown in one free body diagram. Yet
engineering design things with many piece each of which may be though as a body. we would
now like to analyze built of pieces that are connected in a more complex way.
The design of the frame mainly depends on:
 The lifting force these determine the required rigidity
 The determination and size of frame
 The degree of guidance precision
In engineering practice, the machine parts are subjected to various forces which may be due to
either one or more of the following:
1. Energy transmitted,
2. Weight of machine,
3. Frictional resistances,
4. Inertia of reciprocating parts,
5. Change of temperature, and
6. Lack of balance of moving parts.
When some external system of forces or loads act on a body, the internal forces (equal
andopposite) are set up at various sections of the body, which resist the external forces. This
internal force per unit area at any section of the body is known as unit stress or simply a stress. It
is denoted by a Greek letter sigma (σ). Mathematically,
Stress, σ = P/A (52)

Where P = Force or load acting on a body, and

A = Cross-sectional area of the body.
In S.I. units, the stress is usually expressed in Pascal (Pa) such that 1 Pa = 1 N/m2. In actual
practice, we use bigger units of stress i.e. Mega Pascal (MPa) and Gigapascal (GPa), such that
1 MPa = 1 × 106 N/m2 = 1 N/mm2
And 1 GPa = 1 × 109 N/m2 = 1 kN/mm2
In case of ductile materials e.g. mild steel, where the yield point is clearly defined, the factor of
safety is needed based upon the yield point stress. In such cases,
Factor of safety is the ratio of Yield point stress and Working or design stress
In case of brittle materials e.g. cast iron, the yield point is not well defined as for ductile
materials.
Therefore, the factor of safety for brittle materials is based on ultimate stress.
∴Factor of safety is the ratio of Ultimate stress and Working or design stress
 This relation may also be used for ductile materials.
The above relations for factor of safety are for static loading.
The selection of a proper factor of safety to be used in designing any machine
componentdepends upon a number of considerations, such as the material, mode of manufacture,
type of stress, general service conditions and shape of the parts. Before selecting a proper factor
of safety, a designengineer should consider the following points:
 The reliability of the properties of the material and change of these properties
duringservice;
 The reliability of test results and accuracy of application of these results to actual
machineparts;
 The reliability of applied load;
 The certainty as to exact mode of failure;
 The extent of simplifying assumptions;
 The extent of localizedstresses;
 The extent of initial stresses set up during manufacture;
 The extent of loss of life if failure occurs; and
 The extent of loss of property if failure occurs.
Each of the above factors must be carefully considered and evaluated. The high factor of
safetyresults in unnecessary risk of failure. We take the value of factor of safety 3 because the
machine need great take care due to its vibration that can result hazard. The values of factor of
safety based on ultimate strength fordifferent materials and type of load are given in the
following table:

Table 3.8 values of factor of safety

Material selection for the frame
The material selected for the frame is A36 steel, because it has high toughness, it is wieldable
and it’s have high corrosion resistance A36 steel is available in market with low cost.
A36 steel the following properties
 Yield strength 250Mpa
 Ultimate tensile strength 400mpa
 Yong modules 200.6mpa
 Density of carbon steel =7800kg/m3
 From this data, stress design become
σ
σd = f.s=400/2.5=160mpa (53)

1. Motor supporter frame

In this frame the only existing lode is motor lode so let as analysis

Fig 4.18: Free body diagram of frame

Force analysis for frame
Wm=Wm = Mm ∗ g (54)

Where:
Wm =weight of motor
Mm= mass of motor =12kg (physical measured)
Wm=12*10=120N
ƩFy=0, Ay+By-Wm=0 (55)

Ay+By=120N
ƩMA=0, -Wm*50+By*100=0
By=60N
Substitute to By value for equation (57)
Ay=60N
Stress analysis of the frame
Stress induced in the horizontal frame is axial stress and bending stress
To calculate axial stress:-
σ = P/A (56)

A= l∗w (57)

L=1000mm
W = 40*40mm
t=3mm
Where:
p=axial load
A=area of frame
L=length of frame
t=thickness of frame
A=1000*40=40,000mm2
σ=120/40,000=0.003N/mm2
By using maximum principal stress theory
Axial stress less than allowable stress so the dimension we assume are safe
To calculate bending stress:-
σb = MbY/I (58)

Where: Mb=bending moment

Y=centroid distance(Y= w/2=20)
I = moment of inertia hollow rectangular section
Ixx = BH3/12 -bh3/12 = 40*403/12 -34*343/12 (59)

Iyy = HB3/12 - hb3/12 = 40*403/12 -34*343/12

I = 101972mm4
b = 120N*20mm/101972mm4
b = 0.0235N/mm3
By using bending stress theory, the frame design is safe because bending stress is less
2. Two shaft exerted frame

Fig 4.19: Free body diagram of shaft

Weight of shaft one with pulley and bearing
MP (Mass of pulley) = 0.75kg (physical measured)
Mb (Mass of bearing) =0.5kg (physical measured)
Length of shaft =400mm
D1 (diameter of shaft one) =30mm
D2 (diameter of shaft two) =20mm
m=ρ∗v (60)

v= A∗l (61)

Shaft 1:
ms1 = ρπr 2 ∗ l (62)

Where: m=mass of shaft one

𝛒=density of carbon steel
V=volume
A=area
L=length of shaft one
A = ρπr 2 l
Ms1=7800*3.14*0.0152*0.4
Ms1=2.2kg
Wp1 = (ms1 + mp + mb)g (63)

Wp1= (2.2+0.75+0.5) *10

Wp1=34.5N
Wp2 = ms2 + mp + mb) ∗ g
A = ρπr 2 l (64)

Ms2=7800*3.14*0.012*0.4
Ms2=0.98kg
Wp2= (0.98+0.75+0.5) *10
Wp2=22.3N
ƩFy=0: CY-wp1-wp2+Dy=0 (65)

Cy+Dy = 56.8N
ƩMc=0: -wp1*511-wp2*811+Dy*1000=0
-34.5*511-22.3*811+Dy*1000=0
Dy = 35.7N
CY = 21.1N
Stress analysis
L = 1200mm
T = 3mm
B = 40, σ = P/A, A = l ∗ b
σ =56.8/48000 =0.0012N/mm2
By using maximum principal stress theory; axial stress less than allowable stress so the
dimension we assume is safe

4.8 Design of key and key ways

In order to allow the pulley, transmit its rotational power to the shaft effectively and without any
slipping, key is used for the pulley in our design. In our design profile rectangular keys are used
as they are most common used key in industry as well as due to a lower cost required. Profile
rectangular keys can insure that the shaft and pulley inter lock each other in all direction, which
is better to prevent the pulley from moving in any direction. A key is also a mechanical element
inserted between the shafts and bearing hub to connect these together in order to prevent related
motion between them. It is always inserted parallel to the axis of the shaft. Key also used as a
temporary fastening and shearing stresses to achieve the bearing of crushing and shearing load
on the key, the preferable material that we select for key is mild steel.
A36 mild steel the following properties: -
 The permissible shear strength for mild steel is 56Mpa
 The permissible crushing strength for mild steel is 112Mpa
 Yield strength 250Mpa
 Ultimate tensile strength 400mpa
From the standard key and key way dimensions we can get the height, width hub dimension
based on shaft diameter.
 Fig 4.20: Different types of key seats

Fig 4.21: Forces acting on a sunken key.

From the table 1.1 of a text book of machine design by R.S KHURMI ANS J.K GUPTA we can
select the width and height of the key based on the diameter of the shaft.

W = 8mm
H = 7mm
Where: T = torque transmits by the shaft
F = tangential force
D = diameter of shaft
L = length of key
T = thickness of key
Hub dimension
For pulley w = 8+0.18=8.18 and h=7-0.18 = 6.82mm
Required length of key on pulley
Lp = 4𝑇𝑒 ∗ 𝑅𝑐𝑣/(𝜎𝑢 ∗ 𝑑𝑠 ∗ 𝑤) (66)

Lp = 4*572.9*1226.75/400*30*8
Lp = 29.28mm
Stress analysis
Shear stress in key
𝜎𝑠ℎ = 𝑇𝑒/(𝑤𝑝 ∗ 𝐿𝑝 ∗ 𝑟𝑠) (67)

= 572.9*103/ (8*29.15*15)
= 163.78Mpa
Compressive stress in key
𝜎𝑐 = 𝑇𝑝/(0.5ℎ ∗ 𝐿𝑝 ∗ 𝑟𝑠 (68)

σc = 572.9*103/(3.5*29.15*15)
=374.4Mpa
Force from compressive stress
F (69)
σc =
0.5h ∗ L

F = σc ∗ 0.5h ∗ L (70)

F = 7.654 KN
Area from key =8*7=56mm2
σ1=F/A= 136.7Mpa
Therefore, it is recommending that for key σ1 ≤ σsh ≤ σc the key is safe

4.9 Selection of Motor

Fig 4.22: motor

The 1.1KW, 1.5 horse power and 1440 revolution per minute motor is used for the rotating the
two shaft by using power transmission material. And the wheel mounted at the ends of the shaft.
Because of this rotating the tool used for polishing is flap disk with 80 and 120 grade. Flat
shaped square or rectangular solid as well as drilled work piece are polished by this machine.
A DC motor is any of a class of rotary electrical machines that converts direct current electrical
energy into mechanical energy. The most common types rely on the forces produced by
magnetic fields. Nearly all types of DC motors have some internal mechanism, either
electromechanical or electronic, to periodically change the direction of current flow in part of the
motor.

DC motors were the first type widely used, since they could be powered from existing direct-
current lighting power distribution systems. A DC motor's speed can be controlled over a wide
range, using either a variable supply voltage or by changing the strength of current in its field
windings. Small DC motors are used in tools, toys, and appliances. The universal motor can
operate on direct current but is a lightweight motor used for portable power tools and appliances.
Larger DC motors are used in propulsion of electric vehicles, elevator and hoists, or in drives for
steel rolling mills. The advent of power electronics has made replacement of DC motors with AC
motors possible in many applications.

The motor we need for the two-wheel polisher machine is Marathon Electric-model number
0905t17fh65171 0.5-1.5HP 4 poles 1440RPM 90SD TEFC 230/460 volts single phase – catalog
number R396A.

4.10 Selection of speed controller of dc motor

 Fig 4.23 Speed controller of motor
Speed controllers receive supply voltages and provide signals to motor drives that are interfaced
to motors. They are used to start, stop, and run motors in programmed manner. Motor controllers
can be used to gradually start or increase the speed of a motor, increase torque, or reverse
rotational direction of the motor. They can also be used to reduce cost by using smaller wire and
reduced amperage devices to control the motor. Controllers are used due to the demands of the
operating system, installation requirements, or to increase motor efficiency.
There are two basic types of controllers: electronic and electromechanical.
 Electronic units are very sophisticated and include features such as soft starting and
variable frequency drives. Electronic units can be programmed to respond to system
inputs and pre-set running conditions.
 Electromechanical units make use of electromagnetic contractors or relays to stop, start,
and reverse the motors direction.
Motor controller components include a power supply, amplifier, user interface, and position
control circuitry, so we select the same speed controller of dc motor as it’s a redesign of two
wheel polishing machine which is found in the shop as we try to show in fig 3.24.
i. Selection criteria
The following specifications are essential to select motor speed controllers.
a) Electrical specifications
b) Operating parameters
c) Features
a. Electrical specifications
Electrical rating includes:
 Maximum output voltage is the voltage that the device outputs. This output must match
the system’s processes.
 Rated power is the maximum power to be used with the motor.
 Continues output current is the term used to describe the current which a device will
carry continuously in air without exceeding temperature limits.
 Peak output current is the capacity current output for a short period of time.
b. Operating parameters
Operating parameters include specification for
  Setup and control describes how the controller is operated by the user.
 Manual controls such as
Knobs
DIP switches
Jumper
Potentiometers
 Computer controlled or aided, including:
Joystick
Digital control panel
Computer interface
 Configurations for motor controllers include several mounting styles. Most devices
mount on a:
Chassis
DIN rail
Panel
 Rack
 Wall
 Printed circuit board
c. Features
Motor speed controllers are available with several different features options.
 Soft start is controlled circuitry, which allows the motor to ramp up to full speed over
time. This is often a safety feature for motors moving large or delicate loads, and as a
preventive measure for excessive current draw.
 Braking
 Dynamic braking is the method of the braking in which the power supply is
disconnected from the motor windings. The motor then essentially becomes a
generator and the power (heat) is dissipated through a resistor shunt across the
windings.
 Injection braking is applicable for AC motors only. The AC power is
disconnected and the DC power is “injected” into the windings. This creates a
magnetic field opposing the motor rotation and slowing or stopping the motor.
  Regenerative braking is similar to dynamic braking. The motor is removed from
the power generated from the rotating motor is sent back to the supply. The
generated power can be used to recharge a battery that supplies the power to the
system.

4.11 Wheel supporter

The wheel supporter is manufactured in the shop from the available material as the polisher
machine needs to rotate the wheel which perform the main function, rotate and make the object
or metal to have a good surface finishing.
The wheel removes unnecessary metals from the surface, like as examples in the shop polisher
machine is an important machine to analyze the grain structure of metal or steel and after
obtaining of a good surface finished metal then the grain size will be clear and seen in the screen.

Fig 4.24: Wheel supporter with shaft

5. RESULT AND DISCUSSION

Table 3.23 result and discussion
Number Component Specification Dimension

1. Frame Length 1100mm

Back side frame
Height 1000mm

Thickness 40mm

Width 40mm

Left side frame Length 1000mm

 Height 1000mm

Front frame Height 1000mm

Thickness 40mm

Width 40mm

Middle frame Length 1020mm

Width 40mm

Upper frame 1 Length 1100mm

Height 200mm

Upper frame 2 Length 1100mm

Height 100mm

2. V-belt Width 10mm

Depth 6mm

Center of distance 50mm

Length 1458mm

3. Shaft 1 Length 400mm

Diameter 30mm

Shaft 2 Length 400mm

Diameter 20mm

4. Radial ball bearing Bearing number 204

Bore diameter 30mm

Outside diameter 62mm

 Width 16mm

5. Bolt and nut For bearing M8*15

For cover M12*15

6. Key and keyway width 8mm

Shaft
Height 7mm

Pulley Width 8.81mm

Height 6.82mm

7. Motor Horse power 1.1

Revolution per 1500

minute