Analyze and Optimize Design of a blender blade

Chapter 1

INTRODUCTION

Blender is a versatile appliance that is used to mix, grind or emulsify food or other substance. A
stationary blender consists of a blender container with a rotating metal blade at the bottom,
powered by an electric motor that is in the base. This motor drives a pitched blade that chops
items that are put in the blender. The shape of the pitcher and the pitch of the blades create a
vortex or a spiral movement in the fluid which results in uniform consistency in mixing.

A mixer blade is the portion of a tool, weapon, or machine with an edge that is designed to
puncture, chop, slice or scrape surfaces or materials. Blades work by concentrating force on the
cutting edge. Blades are typically made from materials that are harder than those they are to be
used on. Humans have made blades from flaking stones such as flint or obsidian, and from
various metal such as copper, bronze and iron. Modern blades are often made of stainless steel
or ceramic. Steels can be further heat treated to optimize their toughness which allows them to
retain an edge well with use.

Blenders use a 1–2 liters (4–8 cups) blending container made of glass, plastic, stainless steel.
Glass blenders are heavier and more stable. Stainless steel is preferred for its looks, but limits
visibility of the food as it is blended. The container rests upon a base that contains a motor for
turning the blade assembly and has controls on its surface. Most modern blenders offer a
number of possible speeds. Low-powered blenders require the addition of some liquid to
operate correctly. In these blenders, the liquid helps move the solids around the jar, bringing
them in contact with the blades. The blades create a whirlpool effect which moves solids from
top to bottom, ensuring even contact with the blade. This creates a homogeneous mixture.
High-powered blenders are capable of milling grains and crushing ice without such assistance.

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 Fig 1.1: Blender

The individual, and often replaceable, components of a blender are pretty basic and consist of
the following:

• Housing

• Blade

• Jar

• Gasket or seal ring

• Jar base or jar nut

• Lid

In a knee-bone-connected-to-the-shin-bone sort of way, here's how the parts work together.

The base of the blender is the housing, which contains a high-speed, fan-cooled electric motor
as well as the speed controls. The hefty weight of the housing keeps the blender on the counter
during blending. In some models, the blade is permanently attached to the housing, but in most
cases, the blade, gasket and jar base are all separate pieces that fit together and attach to the
jar. The blade sits inside the gasket, which prevents leakage. These two parts fit snugly into the
jar base, which screws onto the jar.

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1.1 Characteristics

Different blenders have different functions and features but product testing indicates that
many blenders, even the less expensive ones, are useful for meeting many consumer needs.
Features which consumers consider when purchasing a blender include the following:

• large visible measurement marks

• ease of use
• low noise during usage
• power usage (typically 300–1000 watts)
• ease of cleaning
• option for quick "pulse" blending

1.2 Objectives

• Re-engineer of existing blades.

• Generate the 3-dimentional computer models

• To design an efficient blade profile for the desired application.

• To perform structural analysis and dynamic analysis.

• Lift and drag - To provide the blender blade with an optimized relationship between lift
and drag which increases efficiency in generating flow with limited consumption of
power which is available in the blending medium.

• To provide the blender blade with increased efficiency in generating flow in order to
homogeneously mix the blending medium using the limited power available.

• Axial flow - To provide a blender blade, which is configured to control the axial flow of
the working medium provided in a blender pitcher.

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 Fig1.2: Vortex and Axial Flow Representation

1.3 Types of blades

Different types of substances demand their respective type, design, and structure of blades–

• Wet Blade

It consists of 4-6 blades wherein the width to length ratio and the thickness is less when
compared to other blades. It is commonly used in homogeneously mixing of liquids.

Fig 1.3: Wet Blade

• Dry Blade

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It consists of 2-4 blades wherein the width to length ratio and the thickness is more
when compared to other blades. It commonly used in converting solid to liquid
substances or solid to powder substances.

Fig 1.4, Fig 1.5: Dry Blade

1.3.3 Chutney grinding blade

It consists of a single blade having 2 ends modified according to the required

constraints. Used with Chutney grinding jar. Ideal for wet and dry Chutneys of Coconut,
Red & Green Pepper, Ginger and Coriander.

Fig 1.6, Fig 1.7: Chutney Grinding Blade

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1.3.4 Mincer Blade

It consists of 2-4 blades. The thickness of blade is more when compared to the rest of
the blade. Used for grating Coconut, Cucumber, crushing Ice, Almond, Cashew Nuts, Dry
Fruits, etc.

Fig 1.8, Fig 1.9: Mincer Blade

1.4 Mechanical operation

A blender consists of a housing, motor, blades, and food container. A fan-cooled electric motor
is secured into the housing by way of vibration dampers, and a small output shaft penetrates
the upper housing and meshes with the blade assembly. Usually, a small rubber washer
provides a seal around the output shaft to prevent liquid from entering the motor. Most
blenders today have multiple speeds. As a typical blender has no gearbox, the multiple speeds
are often implemented using a universal motor with multiple stator windings and/or multi-
tapped stator windings; in a blender with electromechanical controls, the button (or other
electrical switching device or position) for each different speed connects a different stator
winding/tap or combination thereof. Each different combination of energized windings
produces a different torque from the motor, which yields a different equilibrium speed in
balance against the drag (resistance to rotation) of the blade assembly in contact with the
material inside the food container.

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1.5 Applications of blender

Blenders are used both in home and commercial kitchens for various purposes, including to:

• Grind semi-solid ingredients, such as fresh fruits and vegetables, into smooth purées
• Blend ice cream, milk, and sweet sauces to make milkshakes
• Mix and crush ice in cocktails such as the Zombie, piña colada and frozen margarita
• Crush ice and other ingredients in non-alcoholic drinks such as Frappuccino’s and
smoothies
• Emulsify mixtures
• Reduce small solids such as spices and seeds to smaller solids or completely powder or
nut butter
• Blend mixtures of powders, granules, and/or liquids thoroughly
• Help dissolve solids into liquids

Blenders also have a variety of applications in microbiology and food science. In addition to
standard food-type blenders, there is a variety of other configurations of blender for
laboratories.

1.6 Problems

Blenders were developed in 20th century and were widely used for industries and household
purposes. Some of the common problems faced by the blender during the operation are.

• Cavitation – It is an air bubble occurred between the material and the cutter assembly,
causes material which to fail to be blended by the blades, thus disrupting, and reducing
the blend performance

• Lift and drag efficiency are reduced when the blade design is not optimal. The vortex
and the suction force also depend on the blade design.

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 • Blades dull with use and abuse. This is particularly true of acute blades and those made
of soft materials. Dulling usually occurs due to contact between the blade and a hard
substance such as ceramic, stone, bone, glass, or metal.

CHAPTER 2

LITERATURE REVIEW

2.1 Blender blade, Jonathan M, Katz, David J. Kolar, Richard D. Boozer, Michael D. Anton.,
United States Patent Application publication Kartz. Jan. 23, 2004.

This paper describes the detailed geometry of a uniform blade with wing flaps. The geometry of
the blade has a selective orientation of the wing flaps that can provide upwardly directed axial
flow and downwardly directed axial flow. The blender blade includes a body portion having an
upper surface and a lower surface, it includes an aperture with an axis of rotation for the
blender blade. The blender blade is designed in order to control the axial flow of the working
medium provided in a blender pitcher. Therefore, with reference to the blade wing, the amount
and direction of the axial flow of the working medium can be controlled by the wing flap. The
blade provides a configuration for more efficient blending in the blender medium.

2.2 Blender Blade, David J Kolar, Richard D Boozer, Michael Danton.,

United State patent application publication Kolar. May 2004.

The design relates to blender blades configured to decrease drag by decreasing the amount of
impact by the wings of the blender blade on a blending medium, but also gives more lift. The
blender blade has an optimized relationship between lift and drag which increases efficiency in
generating flow with the limited power available in the blending medium. The blade includes a
center portion and wing tips are positioned on the ends of the wings. The wings and the wing
tips include leading edges and trailing edges, where the potion of the leading edges include
beveled edges formed from the bottom surface of the wings and the portion of the leading
edges along the wing tips include beveled edges. The blender blade is capable of
homogeneously mixing liquids and solids in a blending medium.

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2.3 Stirring Knife Assembly Wen-Ching LEE, TAICHUNG CITY, Jan. 27, 2017.

This patented model consists of a knife and a knife shaft assembly incorporated to each other.
The main design motive of this model was to make sure there is even grinding, emulsification,
and proper breakdown of the substances. this is adapted to be installed in a stirring cup
comprising of the knife shaft and its assembly. This consists of various blades of various
characteristics, each comprising of its own independent role when the whole stirring knife
assembly is used in a mixer container. There construction goes by which were in the five blades
of the first knife comprise a horizontal blade, two upwardly inclined blades, and two
downwardly inclined blades, the horizontal blade being parallel to the horizontal surface of the
body, the two upwardly inclined blades inclining upwardly from the horizontal surface of the
body and the two downwardly inclined blades inclining downwardly from the horizontal surface
of the body. According to the claims made by the patented research paper if it works
accordingly, this would be an innovative design which stands out as an allrounder.

2.4 BLENDER/FOOD PROCESSOR BLADE ARRANGEMENT FOR SMALL THROATED BLENDER.,

Moises Behar, Joseph Spencer. AUG 21, 2008.

A blade assembly suited for both blending and food processing in small throat blender jars is
provided. The blade assembly comprises a plurality of blade forms each designed to perform a
specific blending or processing task while simultaneously working together and with the
geometric restrictions of the jar to optimize the assembly’s capability to crush ice, blend or mix
liquids and/or semi-solid materials, and to chop, cut, or slice solid food items without the need
for user interaction to clear compacted items from the blades and/or the walls or bottom of the
jar during its operation. The improved performance also serves the beneficial side effect of
improved bearing and motor life in the blender/food process SO.

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2.5 Food Blender with a Balanced Blade, David J. Kett., St. Joseph FOREIGN PATENT
DOCUMENTS representative, St. Joseph, all of Mich. Jul. 25, 2000.

This is referred from a US patent paper in which it mentions as, a blade is provided for use in a
blender wherein the blade is to rotate about a vertical axis of rotation. The blade is formed with
a central hub portion defining a horizontal plane, and in a preferred arrangement, has four tines
extending outwardly from Said hub portion with each is Spaced at 90 to two adjacent tines to
form two opposed pairs of tines, however, with the tines being arranged angularly metrical to
one another. In order to reduce vibration and torque occasioned by the asymmetrical
arrangement of the tines, each tine in an opposed pair is formed to be balanced to the other
tine with respect to a first product of its mass times a distance of its center of mass from the
center of rotation and with respect to a further product of its mass times a distance of its
center of mass from the axis of rotation and times a distance of its centre of mass from the
horizontal plane. Preferably the magnitude of the products for each tine in an opposed pair
should be within 1% of the magnitude of the products for the other tine in the pair.

2.6 Blender, Gort-Barten, Alex, Crawley, West Sussex., European Patent Office. 16.01.2013
Bulletin 2013/03

A blender comprising a jug adapted to receive a cutter assembly comprising a plurality of

opposed blades, each blade being angled away from the centre of the cutting assembly at a
different from that of the other pairs. The cutter assembly is disposed in a way such that a first
fixing zone is formed below the cutter assembly, a second mixing is above the cutter assembly
and optionally a chopping zone is formed the first and second mixing zones. Domestic and
commercial blenders process and blend a broad range of food and beverage ingredients such as
dairy products However, different ingredients have different blend characteristics. For instance,
some ingredients are easy to blend and blend quickly, while other ingredients or materials are
very hard or lack homogeneity and are very difficult to process and blend. Considering the
claims done by the paper presenter at the end of the paper, this will prove to be an innovative
and refreshing design of the blender if all the claims done work in their favour.

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2.7 Wear tests of steel knife blades, John D. Verhoeven, Alfred H. Pendray, Howard F. Clark.,
Lowa State University. American Bladesmith Society. ELSEVIER B. V 2008.

This study is presented on the relative wear rates of two carbon steels, a Damascus steel and a
stainless steel. Tests were done at hardness values, the stainless steel had slightly superior
cutting performance over the carbon steels. Using the Cutlery and Allied Trades Research
Association (CATRA) of Sheffield England cutting test machine the cutting performance of steel
blades is best carried out at small stroke numbers. These experiments support the view that
stainless steels optimized for hardness and fine carbide distributions have slightly superior
cutting performance than high carbon steels. At a hardness of HRC=61, 52100 steel has a better
cutting performance than 1086 steel and both are generally better than Damascus steel. Tests
were done at hardness values of HRC=41 and 61. At HRC=61 the stainless steel had slightly
superior cutting performance over the carbon steels, while at HRC=41 the Damascus steel had
slightly superior cutting performance

2.8 Dynamics of particle chopping in blenders and food processors, C. M. Rooney, I. M.

Griffiths, C. Brunner, J. Potter, M. Wood-Lee., / Published online: 6 August 2018© The
Author(s) 2018

The models are presented using the idea of chopping at discrete places but then extended to
account for chopping at any point via a continuous model. Comparisons of the predictions from
the various models with experimental data at a fixed time are presented and show that the
models account for much of the behavior. models are thus modified using simple extensions to
account for additional effects and numerical solutions of these models are compared with the
observed data. The theory should provide a useful tool that eliminates the need to perform
costly and time-consuming experiments when understanding how a particular food will be
blended. The behavior of particles in a blender has been examined using a simple model of
chopping. The simple model was modified to account for the debris, which is too small to be
subsequently chopped, being created whenever a particle was chopped.

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2.9 High-Speed Blending Blade for a Food Processing Appliance, Romulus alexandru
gherman, Chicago, IL (US); Timothy J Laroy, Kalamazoo, MI (US); Edith M Wine, Pittsburg, PA
(US). : May 12, 2016.

A high - speed blending blade for a food - processing appliance includes two opposing upwardly
accurate blades , wherein each of the upwardly accurate blades defines a continuously curved
downward top surface , two opposing downwardly accurate blades , wherein each of the
downwardly accurate blades defines a continuously - curved upward top surface , a central
blade portion having a central top surface , wherein the top central surface is co - planar with a
portion of each downward top surface and each upward top surface and a pair of opposing top
blades extending at a predetermined angle from proximate the central top surface.

2.10 Finite Element Analysis for Turbine for turbine blades with contact problems, Yuan-jian
Yang, Liang Yang, Hai-Kun Wang, Shun-Peng Zhu, Hong-Zhong Huang., Article in international
Journal of Turbo and Jet Engines, Jan 2015.

In this paper it establishes three-dimensional finite element model of the blade, then analyses
the strength of the blade, temperature load, centrifugal load, and aerodynamics load. The
paper helps us in understanding finite element stress and strain analysis for a blade. Several
regions of stress concentration, maximum Von Mises stress are acquired which helps in
predicting the life span of the blade.

2.11 Blade Design and optimization of a horizontal axis tidal turbine, Fu-wei Zhu, Lan Ding,
Bin Huang, Ming Bao, Jin-Tao Liu., ELSEVIER-2020.

A device which converts kinetic energy of water into electrical energy is known as Tidal Turbine.
The theory used in this paper is Blade Element Momentum Theory (BEM). Even though there is
an enormous amount of tidal power the actual operation of tidal power plant is not effective
because of its drawbacks in the field of conversion of energy efficiency and the production cost.
The power flow turbine is well discussed in the paper including the chord length and pitch angle
distribution of the blade are optimized by genetic algorithm, so as to optimize the hydraulic
performance. The blade angle is changed with change in the blade pitch angle when there is a

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flow, hence the blade pitch angle must be optimized in respect to the lift and drag ratio of the
airfoils.

2.12 Regression model of the influence of the height of drum mixer blades on the quality of
mixture., Konstantin Fedin, Vladimir Konovalov. E3S Web of Conferences 175, Penza State
Technological University, INTERAGROMASH 2020.

This paper presents how the number and height of blades of a drum mixer influence the quality
of the mixture. The number of blades used does not affect the mixture practically(vary). The
increase or decrease in the height affects the quality of the mixture. The implementation of the
used research made it possible to establish a functional dependence of the influence of the
number of blades and their height on the quality of the mixture. The number of blades did not
affect whereas the height affects the quality of mixture.The increase in the height to 0.175 m
affects the quality of the mixture i.e., increasing the coefficient of variation from 20% to 40%.

2.13 Optimization in work modelling of a mixer, A Chupshev, V Konovalov M Fomina, IOP

Conf. Series: Journal of Physics Faculty of Engineering, Penza State Agrarian University.
VSPID-2017.
The paper presents a list of indicators used to optimize the working process of machines using a
mixer. The shortcomings of the models are indicated and the use of functions variation
corresponding to the theoretical positions is recommended. The impossibility of theoretical
determination (optimum) of the stirrer parameters was revealed. A method for finding rational
valid values of the mixer parameters on the basis of the engine's load was found. The mass of
the prepared portion of the mixture, the quality of the mixture, the duration of mixing, the
productivity of the mixer, the drive power, the specific energy consumption is revealed.

2.14 Design and Analysis of Conical Curved Agitator for Medium Density Fiber Processing
Akash Shriram Hiwrale.Prof. S. J. Parihar., Review International Research Journal of
Engineering and Technology (IRJET). VOL. 5 Issue 11, 2018.

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A blender comprising a jug adapted to receive a cutter assembly comprising a plurality of
opposed blades, each blade being angled away from the center of the cutting assembly at a
different from that of the other pairs. The cutter assembly is disposed in a way such that, in use,
a first fixing zone is formed below the cutter assembly, a second mixing is above the cutter
assembly and optionally a chopping zone is formed the first and second mixing zones. The
blender jug being provided with a fin disposed on an interior of the blender jug. The fine has a
face with a curved cross-section such that a tangent at the apex of the fin substantially points to
the centre of the blender jug. A motor rotates the cutter assembly to create a vortex in the
material within the blender jug.

2.15 Design and Analysis of Agitator Blade of Pressure Vessel for Variable Loads International
Journal of Engineering Research & Technology (IJERT) Shivam Shukla, Subhasini Shukla,
Prashant Bajaj. Vol. 8 Issue 04, April-2019.
This work gives approach for performing stress analysis of an agitator used in pulping process
plant. The analysis is carried out to estimate stress strain and deflection in agitator body. The
conical curved agitator shows better results when compared to other type of agitators from
results it is also found that the conical shaped mixing component on the rotor is feasible to
vertical feeding, mixing material transfer. The structure is validated and concluded as working
in safe mode. It can be optimized by replacing casting by weldment body in conical vessel. Also,
we can increase the production rate by reducing the cost and weight of agitator. It also gives
solution for developing the agitator with curved conical shaped Weldment which is made by
using welding techniques Project gives result and validation on the basis of software tool as well
as mathematical tool along with agitation process of pulping stirrer is also considered which is
mounted on top of the agitator hub.

Chapter 3

Methodology

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3.1 Flowchart

The following methodology was adopted to carry out the project:

3.2 Detailed methodology

• Problem definition.

• Calculate the dimensions of blade profile

• Generate the 3-dimentional computer models

• Prepare finite element model of the 3D computer model

• Pre-process the 3D model for the defined geometry

• Mesh the geometry model and refine the mesh considering sensitive zones for results
accuracy

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• Post process the model for the required evaluation to be carried out

• Determine maximum stress induced in blades.

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Chapter 4
4.1 Material selection and its Properties
The blade component in the blender is function to crushing and mixing the ingredient with a
very fast rotating speed. First, we need to understand the structure of the blade to enable the
blade perform the process like slicing and mincing. We know blade need to be fixed under high
rotational speed operation, therefore the blade must have the high modulus of rigidity to
prevent any distortion during the operation. It is because the shearing force acts on the blade is
very high due to its speed. Since it is rotate in high speed when the food is being dump into the
food container, it will cause an impact acts on the blade that will cause the blade to break or
crack if the blade does not tough enough.
In the selection material many aspects must be considered to ensure the product that we have
made successful in overall aspect. There are some criteria’s that must be considered such as:

 Physical & Mechanical Considerations

 Thermal Considerations

 Chemical Considerations

 Bearing and Wear Considerations

 Cost
To start the material selection of the component, we have to use the various comparison charts
to compare diverse of material that available. In this time around, we use the specific stiffness
to specific strength, strength to cost, strength to toughness, and young modulus to density.
These are primary chart that we use to ensure our selection.
In the specific stiffness to specific strength chart, we can get the result of the material that has
medium specific strength and high specific stiffness. This is an important criterion of stiffness in
our product.
In the strength to cost chart, we need to compromise the cost and the strength that we can
maintain competitive price with the strength for safety.
In the young modulus to density chart, we need to have the mid-range of density to prevent
overweight of product with the high young modulus. High young modulus means that the stress
that the, material can withstand before it’s deformed.
In between strength and toughness, we need to have both for the blades do not fail
prematurely especially face the impact motion of the food encountered by blades.

4.2 Alloy Steel Properties

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Alloy steel is the steel that contain some alloying elements like molybdenum, manganese,
nickel, chromium, vanadium, silicon, and boron. Compare with carbon steel, the properties of
Alloy steels have greater strength, hardness, hot hardness, wear resistance, hardenability, and
Toughness. However, to obtain the require properties, they are needed to be heat treated.
4.3 Stainless Steel Properties
Stainless steel differs from carbon steel by content of chromium in steel. The main different
property of the stainless steel is its corrosion resistance. Carbon steel rusts when exposed to air
and moisture. This iron oxide film is active and accelerates corrosion by forming more iron
oxide. Stainless steels have enough chromium present so that a passive film of chromium oxide
to prevents further corrosion.
Blade material Comparison.
Selected Blade Material – stainless steel
In making blade, we have decided to use stainless steel because of some reason. The most
important is because we need the material that have excellent in corrosion and oxidation
resistance. This is because we deal in making food processor. So that the quality of food is main
idea to ensure the user is safe to use is. Other than that, stainless steel has high wear resistant.
This property is good to have in making the blade because it always sharp in cutting the food.
The impact toughness is also the part that we tend to choose 304 steel since we have rotated in
high speed to cut or slice the food. Stainless steel also has a lot of classification that we can
choose for the production of the blade. Therefore, we have to choose a specific class to ensure
the cost estimation. After we did the research, we decide to choose stainless steel class 304 to
be our material for the production.

Parameters Ultimate Yield Strength Elongation

Tensile Strength
Alloy 620 Mpa 240-290 Mpa 20-24 %
Stainless steel 570 Mpa 440-500 Mpa 15-18 %

Stainless Steel – Grade 304

Fe;<0.08% C; 17.5-20% Cr; 8-11% Ni; <2% Mn; <1% Si; <0.045% P; <0.03% S
These are some of its characteristics:

 Forming and welding properties

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  Corrosion/ oxidation resistance

 Deep drawing quality

 Excellent toughness

 Low temperature properties responding well to hardening by cold working

 Ease of cleaning, ease of fabrication, beauty of appearance.

Percentage Grade 304

C 0.0 - 0.07

Mn 0.0 - 2.0

Si 0.0 - 1.00

P 0.0 - 0.05

S 0.0 - 0.03

Cr 17.50-19.50

Ni 8.00 - 10.50

Fe Balance

N 0.0-0.11
Table 1.2: Chemical Composition for 304 Stainless Steel Alloys

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4.4 Applications of Stainless Steel 304

Stainless steel 304 is typically used in:

• Sinks and splash backs

• Saucepans

• Cutlery and flatware

• Architectural paneling

• Sanitaryware and troughs

• Tubing

• Brewery, dairy, food and pharmaceutical production equipment

• Springs, nuts, bolts and screws

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Chapter 5

Design of Blender Blades

5.Introduction to Software’s

5.1 CATIA (computer-aided three-dimensional interactive application)

CATIA is a multi-platform software suite for computer-aided design (CAD), computer-aided

manufacturing (CAM), computer-aided engineering (CAE), PLM and 3D modelling and
designing.

Since it supports multiple stages of product development from conceptualization, design and
engineering to manufacturing, it is considered a CAx-software and is sometimes referred to as a
3D Product Lifecycle Management software suite. Like most of its competition it facilitates
collaborative engineering through an integrated cloud service and have support to be used
across disciplines including surfacing & shape design, electrical, fluid and electronic systems
design, mechanical engineering and systems engineering.

It is mostly used for its disciplined system, sketching and rendering technology, multi-platform
development, market compliance, engineering insights, and active collaboration. It is used
widely by a variety of industries. These industries are automotive, aerospace, defense and
industrial equipment, plant design, consumer packaged goods, architecture and construction,
process power, petroleum, and other services. The software is ideal for creating solids, surfaces,
assemblies, drawings, fabrication, and analysis. Like Solid works, the program features powerful
parametric modelling and photorealistic rendering tools. However, CATIA offers more advanced
functionality for surfaces and modules for different industries. CATIA is capable of creating
parametric and non-parametric 3D models. The program is compatible with Windows, Solaris,
IRIX and HP-UX. CATIA is available in English, French, German, Italian, Japanese, Chinese,
Korean and Russian. Like most design software, we will need to export the models in STL format
in order to bring them to life with our 3D printer.

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Model edit is practical, making possible to edit a geometry parameter and rerun the program to
have the new parameters ready. CATIA works very well for assemblies too, it makes possible to
easily attach parts and bind specific parameters, also to hide parts that are not desirable for the
analysis. The software is heavy, even with computers designed for heavy-duty loads, resulting in
long wait times to load files and make changes, reducing productivity.

CATIA delivers the unique ability not only to model any product, but to do so in the context of
its real-life behavior: design in the age of experience. Systems architects, engineers, designers,
construction professionals and all contributors can define, imagine and shape the connected
world.

5.2 Solid Works

SolidWorks is a solid modelling computer-aided design (CAD) and computer-aided engineering

(CAE) computer program published by Dassault Systems, that runs primarily on Microsoft
Windows. While it is possible to run SolidWorks on an Intel-based Mac with Windows installed,
the application's developer recommends against this.

SolidWorks is one of the most used CAD programs in professional settings across the globe. As
its 25th birthday approaches, SolidWorks continues to be a widely used and loved CAD option,
considered by many as the industry standard catch-all engineering aid.

Building a model in SolidWorks usually starts with a 2D sketch (although 3D sketches are
available for power users). The sketch consists of geometry such as points, lines, arcs, conics
(except the hyperbola), and splines. Dimensions are added to the sketch to define the size and
location of the geometry. Relations are used to define attributes such as tangency, parallelism,
perpendicularity, and concentricity. The parametric nature of SolidWorks means that the
dimensions and relations drive the geometry, not the other way around. The dimensions in the
sketch can be controlled independently, or by relationships to other parameters inside or
outside the sketch.

In an assembly, the analog to sketch relations are mates. Just as sketch relations define
conditions such as tangency, parallelism, and concentricity with respect to sketch geometry,

22
assembly mates define equivalent relations with respect to the individual parts or components,
allowing the easy construction of assemblies. SolidWorks also includes additional advanced
mating features such as gear and cam follower mates, which allow modelled gear assemblies to
accurately reproduce the rotational movement of an actual gear train.

Finally, drawings can be created either from parts or assemblies. Views are automatically
generated from the solid model, and notes, dimensions and tolerances can then be easily
added to the drawing as needed. The drawing module includes most paper sizes and standards
(ANSI, ISO, DIN, GOST, JIS, BSI and SAC).

Reverse Engineering

Reverse engineering is the process of creating a part drawing by measuring the part to
determine dimensions and attainable tolerances, when no formal specifications exist. Reverse
engineering also can be useful in the redesign process, as well as in the introduction of new
products. In some cases, it may be easier to develop drawings of an existing product and modify
them in a CAD system than create drawings from scratch. The simplest reverse engineering
process is manual measurement and data collection of a physical model's dimensions. In this
process, hand tools such as micrometres, Vernier callipers and gages are used to capture the
critical dimensions needed to generate a part drawing.

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5.3 Drafting of Blender Blades

1. Dry Blender blade

Fig.5.1 Dry Blender Blade

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2. Semi-Liquid Blender Blade

Fig.5.2

Fig.5.3

25
3. Liquid Blender Blade

Fig.5.4

Fig.5.5

26
Fig.5.6

Fig.5.7

27
Fig.5.8

28
4. Semi-Solid Blender Blade

Fig.5.9

Fig5.10

29
Fig.5.11

30
5. High Speed Liquid Blade

Fig.5.12

Fig.5.13

31
Chapter 6
ANALYSIS of the blender blades
Introduction to software

6.1 ANSYS
Ansys, Inc. is an American company based in Canonsburg, Pennsylvania. It develops and
markets CAD/CAM and Multiphysics engineering simulation software for product design,
testing and operation and offers its products and services to customers worldwide.
Ansys was founded in 1970 by John Swanson who sold his interest in the company to
venture capitalists in 1993. Ansys went public on NASDAQ in 1996. In the 2000s, the
company acquired numerous other engineering design companies, obtaining additional
technology for fluid dynamics, electronics design, and physics analysis.
Ansys develops and markets engineering simulation software for use across the product
life cycle. Ansys Mechanical finite element analysis software is used to simulate
computer models of structures, electronics, or machine components for analyzing
strength, toughness, elasticity, temperature distribution, electromagnetism, fluid flow,
and other attributes. Ansys is used to determine how a product will function with
different specifications, without building test products or conducting crash tests. For
example, Ansys software may simulate how a bridge will hold up after years of traffic,
how to best process salmon in a cannery to reduce waste, or how to design a slide that
uses less material without sacrificing safety.
Most Ansys simulations are performed using the Ansys Workbench system, which is one
of the company's main products. Typically, Ansys users break down larger structures
into small components that are each modelled and tested individually. A user may start
by defining the dimensions of an object, and then adding weight, pressure,
temperature, and other physical properties. Finally, the Ansys software simulates and
analyses movement, fatigue, fractures, fluid flow, temperature distribution,
electromagnetic efficiency and other effects over time.

32
6.2 ANSYS MESHING
Creating the most appropriate mesh is the foundation of engineering simulations. Ansys
Meshing appropriately adapts to the type of solutions that will be used in the project and sets
the respective criteria to create the best suited mesh. For a quick analysis or for the new and
infrequent user, a usable mesh can be created in a few short steps. Where possible, Ansys
Meshing automatically takes advantage of the available cores in the computer to use parallel
processing and significantly reduces the time it takes to create a mesh.
•Meshing is a part of the engineering simulation manner where complex geometries and
models are divided into simple elements that can be used as discrete local approximations of
the larger domain.
•Meshing is one of the key components to obtaining accurate results from a FVM model. The
elements in the mesh must take many aspects into account to be able to discretize stress
gradients accurately.
•Typically, the smaller the mesh size, the more accurate the solution as the designs are better
sampled across the physical domains.
•The trade-off is that the higher the accuracy, the larger the simulations become and thus solve
times are extended.

Fig.6.1

33
Static Structural Analysis of Blender Blade
1. High Speed Liquid Blade
a. Meshing

Fig.6.2
b. Rotational Velocity
Input:
Axis of rotation- Z-axis
Speed- 94.245rad/s

Fig.6.3

34
c. Solutions
1. Total Deformation

Fig.6.4

2. Equivalent Elastic Strain

Fig.6.5

35
3. Equivalent Stress

Fig.6.6

4. Maximum Principle Stress

Fig.6.7

36
5. Minimum Principle Strain

Fig.6.8

37
2. Dry Blender Blade
a. Meshing

Fig.6.9
b. Rotational Velocity
Input:
Axis of Rotation-Z-axis
Speed: 94.24rad/s

38
Fig.6.10

39
c. Solutions
1. Total Deformation

Fig.6.11

2. Equivalent Elastic Strain

Fig.6.12

40
3. Equivalent Stress

Fig.6.13

4. Maximum Principle Stress

Fig.6.14

41
5. Minimum Principle Strain

Fig.6.15

42
 3. Semi Liquid blade
a. Meshing

Fig.6.16

a. b. Rotational Velocity
Input:
Axis of Rotation-Z-axis
Speed: 94.24rad/s

43
 Fig.6.17
c. Solutions
1. Total Deformations

Fig.6.18

2. Equivalent Elastic Strain

Fig.6.19

44
45
3. Equivalent Stress

Fig.6.20

4.Maximum Principle Stress

Fig.6.20

46
5.Minimum Principle Stress

Fig.6.21

47
CHAPTER 7

a. OPTIMISED BLADE

b. Draft of the Optimized Blade

Fig.7.1

48
c. Meshing

Fig.7.2

d. Rotational Velocity
Input:
Axis of Rotation-Z-axis
Speed: 94.24rad/s

Fig.7.3

49
 e. Solutions

1. Total Deformation

Fig.7.4

2. Equivalent Elastic Strain

Fig.7.5

50
3. Equivalent Stress

Fig.7.6

4. Maximum Principle Stress

Fig.7.7

51
5. Minimum Principle Stress

Fig.7.8

52
Chapter 8
Experimental Analysis

 The experimental analysis was carried out for the above blades using a 750KW universal
motor blender.
 A constant speed of 2000rpm was maintained during the experiment.
 In our first trial, solid substance pepper of 50g was used for all the 3 blades with an
operation time of 30s.
 In our second trial, milkshake of 200ml was made using all the 3 blades with an
operation time of 90s.
 In our third trial, Chutney of 150g was made using all the 3 blades with an operation
time of 120s.
 In our final trial, Batter of 250g was made using the 3 blades with an operation duration
of 5mins.

Material Blade 1 Blade 2 Blade 3

Pepper (Solid) Not Suitable Suitable Average

Milkshake (Liquid) Suitable Not Suitable Average

Chutney (semi-solid) Average Average Suitable

Batter (Semi-Liquid) Average Average Suitable

Table.8.1

Chapter 9

53
 Results and Discussions
 The results were obtained from static structural analysis and experimental
analysis for all the 3 blades
 The comparison of stress, strain and deformation between 3 blades were
carried out.
The comparisons are shown in table

Solution Optimised blade Blade 1

Total Deformation 0.0028735 mm 0.02587 mm
Equivalent Elastic Strain 2.0698 e-5 2.6332 e-5
Maximum Principal Stress 4.1443 Mpa 5.496 Mpa
Minimum Principal Stress 0.62633 0.53045 Mpa
Equivalent Stress 3.7542 5.0216 Mpa
Table8.2

Solution Optimised blade Blade 2

Total Deformation 0.0028735 mm 0.023922 mm
Equivalent Elastic Strain 2.0698 e-5 1.0224 e-5
Maximum Principal Stress 4.1443 Mpa 2.8035 Mpa
Minimum Principal Stress 0.62633 Mpa 0.70045 Mpa
Equivalent Stress 3.7542 Mpa 2.0345 Mpa
Table.8.3

54
 Solution Optimised blade Blade 3
Total Deformation 0.0028735mm 0.0057906 mm
Equivalent Elastic Strain 2.0698e-5 8.0221 e-6
Maximum Principal Stress 4.1443 Mpa 2.659 Mpa
Minimum Principal Stress 0.62633 Mpa 1.0302 Mpa
Equivalent Stress 3.7542 Mpa 1.593 Mpa
Table.8.4

55
Chapter 10
Conclusion

 As mentioned above, there is an effective change in blade design and also the
characteristics of the blade has been improved.
 The efficiency of lift and drag is improved by modifying the blade, the vortex creation
and suction force is also improved which helps for better cutting, mixing, emulsifying the
substance inside.
 The rpm of the motor plays a major role in this process, due to which we have
considered the technical part which improves the performance of the device.
 By the topics mentioned above, power consumption and time period of the process has
also diminished.
 Static Structural analysis provides us structural behaviour of a component under a
specific boundary and static loading conditions. Visualization of stress distribution can
be seen.
 The stress evaluated through ANSYS workbench is compared with the yield stress of the
material to decide whether the design is safe or not.
 From the above Analysis we can conclude that each blade has its own limitations. Each
blade has its ability to perform according to the substance.

56
 REFERENCES

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 Gort Barten and Alex Crawley, west Sussex “Blender” Published on 16 th January
2013
 Shivam Shukla, Subhasini Shukla, Prashanth Bajaj “– Design and analysis of
agitator blade of Pressure Vessel for variable loads” 4th April 2019.
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 www.researchgate.net/
 www.iosrjournals.org
 Wen-Ching Lee “Stirring knife assembly” Published on 18th May 2015
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 Yuan-jian Yang, Liang Yang, Hai-Kun Wang “Finite element analysis for turbine
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