Ag25181192

M. Y. Dakhole, Prof. P.G. Mehar, Prof. V.N. Mujbaile / International Journal of Engineering
Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 2, Issue 5, September- October 2012, pp.181-192
Design And Analysis Of Dedicated Fixture With Chain Conveyor
Arrangement For Multistage Special Purpose Machine
*M. Y. Dakhole, **Prof. P.G. Mehar, ***Prof. V.N. Mujbaile
*M.Tech. (MED), K.D.K. College of Engg., Nagpur
**Asst. Professor, Dept. of Mechanical Engg. K.D.K. College of Engg., Nagpur
***Asst. Professor, Dept. of Mechanical Engg, K.D.K. College of Engg., Nagpur.

ABSTRACT
It is required to fix typical shape engine tractor engine in assembly line. It is very difficult to
components on conveyor while performing fix and clean these components on conveyor. Hence
cleaning operation. In conveyorised multistage automated washing machine with fixture on conveyor
washing machine, to fix these typical shape is highly needed. Hence dedicated fixture for these
components is very difficult. Hence these components and chain conveyor to reach these
components need dedicated fixturing with poke- components at various workstations is designed.
yoke to avoid accidents inside the zone on
conveyor. This project gives feasible solution on 1.3 System legends
conventional roller chain conveyorised The travelling of components from one
arrangement with dedicated moving fixture with station to another should be operation oriented.
conveyor for the tractor components like rear axle Following important legends are considered to design
career, bull gear and shaft of a tractor model. This planning the system as objectives.
arrangement will be widely used for numerous i) To design fixture for auto moving components
cleaning purposes owing to its effectiveness for (Rear axle career, Bull gear and shaft).
high production volume, reliable and durable ii) To design chain and sprocket arrangement with
performance. proper guiding rollers.
iii) To calculate required torque, pulling load, speed
Keywords: Dedicated fixture, chain conveyor, iv) To mount fixture on conveyor by considering
automation, process simulation. movability on forward and return side of
conveyor.
1. Introduction v) To select the sensors.
1.1 Project background vi) To select the material
For an automobile industry it’s very difficult vii) To select the mechanical components like
job to clean the engine component in the assembly bearing, bushes, keys, circlips, etc.
line before assembly of the engine to obtain the
required Millipore value. Hence in automotive, 2 Literature review
aviation, auto ancillaries and other industries 2.1 Fixture
automated washing machines are highly demanded to Fixtures are important in both traditional
save the time, man power and to improve washing manufacturing and modern flexible manufacturing
and drying quality. system (FMS), which directly affect machining
The conventionally using conveyor in quality, productivity and cost of products. The time
production line is worldwide known, but in special spent on designing and fabrication fixtures
purpose machine conveyors are needed with special significantly contributes to the production cycle in
design and parameter for its operational feasibility. In improving current product and developing new
this automated moving fixture arrangement fixturing products.
parameters like V pads, vertical rods, mounting pads, Therefore, great attention has been paid to study of
etc. moves along with chain roller conveyor and fixturing in manufacturing (Thomas and Ghadhi,
reach at multiple station with stop and go operation 1986)[8].
with given speed by gear box.
Speed can be control by VFD (Variable Frequency 2.1.1 Dedicated Fixture
Drive) gear box motor is used in the system, selected Since dedicated fixtures are commonly used
by considering required speed as per the production in mass production, dedicated fixtures design are
rate and number of components to be operated in usually applied the fixture construction is perfectly
machine per shift. designed for specific operation. As part of machining
1.2 Problem statement tooling, the application of dedicated fixture has
In an industry, it is required to clean engine greatly contributed to the development of automated
component rear axle career, bull gear, and shaft of manufacturing system. Therefore dedicated fixture

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designs are specially designed for each specific roller chain is B29. A free-turning roller encircles
operation, with special consideration of fixture each bushing to provide rolling engagement and
structure, auxiliary support, and other operational contact with sprocket teeth. The distance between
properties. Moreover, the operations can be flexing joints in roller chain is the pitch, which is the
conducted quickly and the tolerance requirement can basic designation for different chain sizes. Larger
easily assured in the operation. The problem pitch indicates larger links with higher load ratings.
involving in dedicated fixture application includes Although a small pitch chain carries fewer loads, it
the flexibility and long lead time required to designed offers smoother, quieter operation than a chain of
and fabricate the fixture. When product design larger pitch (Power transmission design)[5]. Figure 3.2
change like the shape and the size changes he shows the schematic of roller chain.
dedicated fixture are usually not longer useful and
scrapped. Today a flexible fixture is desired to a
certain extent in order to design variations of the
products (Taufif Bin Zakaria, 2008)[2]..

2.1.2 Fixture Design Methods:
Jeng and Gill (1997) formulated a fixture
design problem in hierarchical design structure.
Mervyn et al. (2003) presented an internet-enabled
fixture design system by the use of XML file format. Fig.3.1 Schematic of roller chain link (Shoji Naguchi,
Rios et al. (2005) and Alarcon et al. (2010) developed et.al, 2009)[10]
and presented KBE (knowledge based engineering)
application for, modular fixture design. Hunter et al. 3. Design of Fixture
(2006) presented a functional design approach in
3.1 Fixture Design Criteria
which the functional requirements and constraints are The following design criteria must be
considered as an input to the fixture design process. observed during the procedure of fixture design:
Wang and Rong (2008) and Sun and Chen (2007)
 Design specifications
presented the case based reasoning method to provide
 Factory standards
a computer aided fixture design solution. Perremans
(1996) developed an expert system for automatic  Ease of use and safety
fixture design 2.2 Chain Conveyor  Economy
A chain conveyor is a type of conveyor
system for moving material through production lines. 3.2 Fixture locating principle
Chain conveyors utilize a powered continuous chain One of the principal purposes of a fixture is
arrangement, carrying a series of single pendants. to locate the work piece surfaces for performing a
The chain arrangement is driven by a motor, and the different operation. This is usually done with respect
material suspended on the pendants is conveyed. to a number of factors to be considered such as the
Chain conveyors are primarily used to transport reference datum, supporting Surfaces, features those
heavy unit loads, e.g. pallets, grid boxes, and are likely to obstruct the tool movement or access
industrial containers. These conveyors can be single direction, etc. In general, the following Surfaces
or double chain strand in configuration. The load is should be distinguished:
positioned on the chains; the friction pulls the load Active surfaces
forward. Many industry sectors use chain conveyor These are surfaces to be machined, i.e. surfaces
technology in their production lines. The automotive which are subjected to the action of cutting tools.
industry commonly uses chain conveyor systems to Supporting and locating surfaces
convey car parts through paint plants. Chain These are surfaces by means of which the work piece
conveyors also have widespread use in the white and is to be located with respect to set-to-size cutting
brown goods, metal finishing and distribution tools.
industries. Chain conveyors are also used in the Clamping surfaces
painting and coating industry, this allows for easier Clamping surfaces are subjected to the clamping
paint application. The products are attached to an forces for obtaining invariant location. Clamping
above head chain conveyor, keeping products off of surfaces are usually not finish-machined surfaces as
the floor allows for higher productivity levels.[4] clamping marks could damage the finish.
Datum surfaces
2.2.1 Roller chain Datum surfaces are reference surfaces where the
Flexure joints in roller chain contain pins dimensions are to be maintained and measured.
that pivot inside the roller bushings. The pins are Free surfaces
usually press fitted into the pin link plates, and roller Free surfaces are surfaces not involved in the set-up
bushings are press fitted into roller link plates, as for the particular operation.
shown in figure1.The ANSI standard for single pitch (An advance treatise on fixture design)[7]

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- Anticlockwise around Y axis (ACROT-Y)
3.3 Clamping Principles - Clockwise around Z axis (CROT-Z)
3.3.1 Basic Principles of Clamping - Anticlockwise around Z axis (ACROT-Z)
3.3.3.1 Orientation of Locators vis-a-vis Clamping During a set-up, it is necessary to restrict
Force certain degrees of freedom so as to locate and orient
It is necessary in all clamping devices that the active surfaces with respect to the cutting tools.
the clamping forces hold the workpiece in its located Since supporting or restricting surfaces may vary
position and should not cause any positional from the true geometrical shape, especially on rough-
displacement or excessive distortion under the action machined surfaces or cast blanks, it is desirable that
of the clamping forces. Clamping forces should be the workpiece be located with respect to the point
directed towards supporting and locating elements on supports.
overhanging or thin sections of the workpiece. In It’s Important to restrict all the twelve
addition, the force should be transmitted to the rigid degrees of freedom except the three transitional
sections of the body frame of the fixture. Cylindrical degrees of freedom (-X, -Y and -Z) in order to locate
workpieces located in V-blocks can be clamped using the work piece in the fixture. So, nine degrees of
another Vblock, making a 4-point clamping, or freedom of the work piece need to be restricted.
clamped in a 3-jaw chuck, in a 3-point clamping By using the 3-2-1 method as shown below:
configuration. The latter is usually more common, Rest the work piece on three non-collinear points of
especially in turning operations. the bottom surface (XY), and then we will be able to
restrict the +Z,CROT-X, ACROT-X, CROT-
3.3.3.2 Effect of External Forces on the Clamping Y and ACROT-Y degrees of freedom. Now, rest the
Action work piece at two points of side surface (XZ), and
Clamping elements can be classified in you will be able to restrict the +Y and ACROT-Z
accordance with their force-deflection characteristics. degrees of freedom. Now, rest the work piece
There are two broad sub-divisions, viz.: at one point of the adjacent surface (YZ), and you
Type I: clamping elements in which the elastic will be able to restrict the +X and CROT-Z degrees
deformation increases with clamping force, such as of freedom.
screws, levers, cams, etc., So, we can successfully restrict nine
Type II: clamping elements in which the clamping required degrees of freedom by using the 3-2-1
force assumes a constant value independent of the principle of fixture design.
elastic deformation at the contact surfaces such as
fixtures operated with hydraulic or pneumatic 3.5 Design and Development of Fixture
pressures. 3.5.1 Fixture design for Rear Axle Carrier
Within the elastic region, clamping elements The rear axle carrier of tractor for which
based on elastic deformation, i.e.Type I clamps, fixture element is to be designed is as shown in figure
would exhibit a linearly increasing clamping force in 3.2.
proportion to the deformation of the clamping
element, if the workpiece or the locator is assumed to
be rigid. If the workpiece or locator deforms, it will
cause a relaxation of the clamping element and the
clamping force will decrease. A limiting case arises
when the clamping is lost and the force becomes
zero.In Type I1 clamps, the clamping force remains
constant at pre-set values and isindependent of
workpiece and locator deformation. This type of
clamping device istherefore more reliable and would
not relax over time.

3.4 Restrictions on the Degrees of Freedom of a
Workpiece
A workpiece, just like any free solid body, Fig. 3.2 Rear axle Carrier
has twelve degrees of freedom. Dedicated fixture component for the rear
 Six rectilinear displacements along the axle carrier consist of two pairs of resting pads. The
mutually orthogonal co-ordinate axes (+X, - pads are mounted vertically. Pad’s height is
X, +Y, -Y, +Z, -Z) considered by the operation oriented inputs so that
 Six angular displacements with respect to further processes should not affect by fixturing and
the same axes locating the component, since uniformity is to be
- Clockwise around X axis (CROT-X) considered for all components in process of the
- Anticlockwise around X axis (ACROT-X) machine. The resting pads are as shown in figure 3.3.
- Clockwise around Y axis (CROT-Y)

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(1) Locating ring, (2) Hinge block, (3) Hinge
pin
Above designed fixture elements to hold the
rear axle carrier, are then mounted on holding plates
which are fixed on the chain, as shown in figure 3.5.

Fig 3.5. Mounting of fixture elements on mounting
Fig 3.3. UHMW Resting pad plates
The fixture element to locate the rear axle carrier is While executing the cleaning operation on respective
designed by considering the shape and size of the rear workstations, the component, rear axle carrier will be
axle carrier, as shown in figure 3.4 hold by designed fixture as shown in figure 3.6.

Fig 3.6. Holding of rear axle carrier on fixture
elements

3.5.2 Fixture design for Rear Axle Shaft
The rear axle shaft of a tractor engine for
which a holding device i.e. fixture element is to be
designed, is as shown in figure 3.7.

Fig 3.4 . Fixture element for Rear axle carrier

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Quantity required in one fixture set –
V rod – 1 = 2 Nos.
V rod – 2 = 2 Nos.
Maximum weight of –
V rod – 1 = 0.70 kg
V rod – 2 = 0.5 kg
The mounting of V rod – 1 and V rod – 2 on
holding plates and also the holding of shaft on the
designed fixture elements is as shown in figure 3.9
and figure 3.10. The fixture elements i.e. V rods are
fixed on the holding plate by the means of M10 head
socket head cap screw (15 mm).

Fig 3.7. Rear Axle Shaft of Tractor Engine

Dedicated fixture component for the rear
axle carrier consist of two V rods of different height.
The V rods are selected to minimize the area of
contact between rod and shaft. The rods are mounted
vertically on holding plates. V-rod’s height is
considered by the operation oriented inputs so that
further processes should not affect by fixturing and
locating the component, since uniformity is to be
considered for all components in process of the
machine. The V rods (V rod – 1 and V rod – 2) are as
shown in figure 3.8.

Fig. 3.9 Mounting of fixture elements on holding
plates

Fig.3.8. Fixture elements for holding Rear Axle Shaft
(i) V Rod – 1 , (ii) V Rod – 2. Fig. 3.10 Mounting of rear axle shaft on fixture
Material of V Rod 1 and V Rod 2 is AISI 304. elements.

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3.5.3 Fixture Design for Bull Gear As seen above, the different fixture elemnts for rear
Bull gear of the tractor engine to be hold to axle carrier, rear axle shaft and bull gears are
clean before going to assembly section, is as shown designed by considering the geometry of these
in figure 3.11. components. The details of these fixture elements are
as given below.
 Material of fixture elements (except resting
pads) is AISI 304.
 Quantity required for one fixture set –
- UHMW resting pads = 08 nos.
- Fixture elements for rear Axle
Carrier = 02 nos.
- V rod – 1 ( for rear axle shaft) = 02
nos.
Fig 3.11 Bull gears - V rod – 3 (for rear axle shaft) = 02
By considering the geometry of the bull nos.
gears, a fixture element, to hold the gears while - Fixture elements for bull gears = 02
performing the cleaning operations in assembly line nos.
to avoide accidents in conveyor zone, is designed and These designed fixture elements should
drafted as follows. move with chain conveyor. Hence its needed to
mount these fixture elements on chain conveyor. To
mount these fixture elements on chain conveyor, a
holding plate is designed by considering the
geometry and location of fixture elements on chain
conveyor. The holding plate is as shown in figure
3.13.

Fig. 3.13 Detailed View of Fixture elements holding
plate
For one fixture tray, five numbers of holding
plates are required. They are fixed on chain to make a
Fig 3.12 Fixture element to hold Bull gear of tractor fixture tray, as shown in figure 3.14. The holding
(1) Hinge pin, (2) Fixture element rods, (3) plates are mounted on chain conveyor by means of
Hinge block. M8 head socket head cap screw (15 mm). Total 8
numbers of screws are required to mount one holding
The designed fixture element is fixed on the plate.
holding plates. The bull gears will be held by this Details of holding plate:
fixture element so as to avoide movements of gears Material = AISI 304
while performing the cleaning of gears, to avoid Total number per fixture set = 05 nos.
accidents inside the conveyor zone. Weight = 3.3 kg

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From the above figure, it is clear that the minimum
shear stress developed in resting pad is
- 3.4356 Mpa and it can be maximum upto 3.8944
Mpa.
4.2.1 Shear strain
Shear strain developed in the resting pad is as shown
in figure 4.2.

Fig. 4.2 Shear strain developed in resting pad

It can be seen that, the shear strain developed in the
resting pad due to weight of the rear axle carrier
ranges from 5.2861 * 10-8 max to -4.6638 * 10-8.

4.1.2 Equivalent shear stress and equivalent shear
strain
Figure 4.3 shows the equivalent shear stress
developed in resting pad. It is seen that the maximum
equivalent shear stress value is 12.56 Mpa. The
maximum value of equivalent shear stress can be
reduced by providing fillet to the edge where the
maximum equivalent stress is developed. The value
of equivalent shear strain developed ranges from
0.3822 Mpa to 12.5635 Mpa.

Fig. 3.14 Mounting of fixture elements holding plates
on chain conveyor

4. Analysis of Fixture
The static analysis of the designed fixture
elements has been done using analysis software
“Ansys -V11”.
4.1 Static analysis of resting pad
The resting pads, on which the rear axle Fig. 4.3 Equivalent stress developed in resting pad
carrier is to be mounted analysed to find the stresses
and strains developed due to load of component. The Similarly, the figure 4.4 shows the equivalent elastic
shear stress developed in the resting pad is as shown strain developed in resting. It ranges from 1.9807 *
in figure 4.1. 10-9 to 6.5105 * 10-8.

Fig. 4.1 Shear stress developed in resting pad Fig. 4.4 Equivalent elastic strain inresting pad

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The values of stress and strains developed in the
resting pad are summarised as follows.
Equivalent Shear
Object Equivalent Shear
Elastic Elastic
Name Stress Stress
Strain Strain
- -
1.9807e-009
Minimum 382.27 Pa 4.6638e- 3435.6
m/m
008 m/m Pa
6.5105e-008 5.2867e- 3894.4
Maximum 12565 Pa Fig. 4.7 Equivalent strain in V rod
m/m 008 m/m Pa

4.3 Satic analysis of V rod The results of static analysis of V rod are summarised
A ststic analysis is carried out on the fixture as follows.
element for shaft i.e. V rod. It is found that the value
of shear stress ranges from -2.304e5 Pa to 2.2034e5
Pa And the value of shear strain rnages from -
3.1285e-6 to 2.9911e-6, as shown in figure 4.5.

4.4 Static analysis of Gear Fixture elements
The analysis is carried on the gear holding fixture
element. The equivalent stresses developed in the
(I)Shehear stress element is as shown in figure 4.8.

(ii) Shear Strain Fig. 4.8 Equivalent stress developed in gear fixture
Fig. 4.5 Shear stress and Shear Strain developed in rod
Vrod
Similarly, the dirstbution of equivalent strain is as
The equivalent stress and strain distribution in the V shown in figre 4.9.
rod is as shown in figure 4.6. And figure 4.7
respectively.

Fig.4.9 Equivalent strain distrubution in gear fixture.
Fig. 4.6 Equivalent stress developed in V rod

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The result of analysis of gear fixture rod is The result of analysis of holding plate are as follows.
summarised as follows. Shea
Equivale Equiva r
Total Equival Total
Object Equivale Shear nt Object Shear lent Elasti
Deformati ent Deform
Name nt Stress Stress Elastic Name Stress Elastic c
on Stress ation
Strain Strain Strai
- n
Minimu 901.32 4.67e-
3.6142e+0 0. m -
m Pa 009 m/m
06 Pa - 8.9419 2.457
Minim 1725.8
1.8105e e-009 7e- 0. m
um Pa
The fixture are mounted on a holding plate. The +007 Pa m/m 004
holding plate is analysed to find out the validation of m/m
the plate. The shear stress, Equivalent stress, 2.214
2.3007
equivalent strain and deformation of the plate is as Maxi 4.4404e 1.6315e 8e- 3.8722e-
e-004
shown in figure 4.10. mum +007 Pa +007 Pa 004 004 m
m/m
m/m

5. Design of chain conveyor
5.1 Design Calculations of Chain Conveyor
5.1.1 Weight of the components
Table 5.1: Weight of the components to be carried
Total
(i) Shear stress developed in holding plate No. of Wt.
Wt./
Sr. Comp / of
Comp. Comp.
No. Fixture Com
(kg)
tray p
(kg)
Rear
Axle
1 Career 26.4 2 52.8

2 Shaft 22.6 2 45.2

3 Bull Gear 7.8 2 15.6
(II)Equivalent Stress TOTAL 6 113.6

Total weight of components on one fixture tray =
113.6 kg
Maximum number of fixture tray on conveyor at a
time = 06
Total weight of component at a time on conveyor =
113.6 x 6
= 681.6 kg ~ 700 kg.

5.1.2 Weight of fixture elements and other
components on chain conveyor
(iii) Equivalent Strain  Weight of fixture for Rear axle carrier =
1.05 * 2 = 2.10 kg.
 Weight of fixture for shaft
V rod 1 = 0.71 * 2 = 1.42 kg
V rod 2 = 0.72 * 2 = 1.44 kg
 Weight of Gear holding fixture = 0.97 * 2 =
1.94 kg
 Weight of fixture elements holding plate =
3.3 kg.
Total number of holding plates on 1 fixture
tray = 5
(iv)Total deformation Weight of total holding plates = 3.3 * 5 =
Fig. 4.10 Static analysis result of Holding plate. 17.5 kg

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Hence, 1
= × 101.6
8
Total weight of one fixture tray = 24.4 kg
= 12.7 mm
Total number of fixture tray = 6
Centre distance ≤ 80 × pitch
Weight of fixture tray = 24.4 * 6 = 146.4 kg
Hence,
Hence,
Maximum centre distance = 80 × 101.6
 Total weight of fixture elements and other = 8128 mm
components = 681.6 + 146.4 = 828 ˜ 830 kg. = 8.128 m
But due to the space availability, let us consider
5.2 Selection of chain centre distance (C) = 5000 mm = 5 m.
From the catalogue of ANSI roller chain,
Chain no. 64B-1 is selected. The specification of the Length of chain
chain are as follows. N1 + N2 N1 − N2
L = 2C + +( )²
2 4π2 C
Where,
C = Centre distance = 5000 mm
N1 = Number of teeth on driven sprocket = 13
N2 = Number of teeth on driving sprocket = 13
Hence,
Length of chain = 23 m.

Weight of the chain
For the selected chain number 64B - 1, weight of the
chain is 6.5 kg/m
Fig 5.1. Schematic of roller Chain Hence, Weight of the chain = 6.5 × 23
= 149.5 kg
Chani No. 64B -1 ~ 150 kg.
Pitch of the chain (P) = 101.6 mm
Roller diameter, d1 (max) = 63.5 mm Total pulling weight = Weight of chain + Weight of
Width between inner plates, b1 (min) = 60.96 components
Pin diameter, d2 (max) = 39.40 mm = 150 + 830
Pin length, L (max) = 130.00 mm = 980 kg
Inner plate height, h2 (max) = 90.17 mm Maximum pulling weight = Total pulling weight ×
Plate thickness, t (max) = 15.00 mm Coefficient of friction
Weight per meter = 6.5 kg/m In general, for rolling application, the coefficient of
Other input parameter Parameters friction is considered to be 0.2.
Chain speed (v) = 4 m/min Hence,
Select number of teeth on sprocket (z) = 13 Maximum pulling weight = 980 × 0.2
= 196 kg.
5.3 Analytical calculations of Chain Conveyor Let, g = 10 m/s2
 Pitch circle diameter of sprocket Hence,
P Maximum pulling weight = 1960 N.
PCD = π
sin Pulling Torque
z
PCD of sprocket (Dp) = 425 mm = 0.425 Required torque = Maximum pulling weight
m. PCD
×
2
Sprocket outside diameter (Do) = Dp + 0.8 d = 416.5 Nm
Where, d = Roller diameter Final output torque = required torque × Service factor
5 5 Let, Service factor = 1.5
d = × Pitch = × 101.6 = 63.5 mm
8 8
Hence,
Do = 425 + (0.8 × 63.5) = 475.8 mm
Final output torque (T) = 416.5 × 1.5
Inner width i.e. minimum distance between roller link
5 = 624.75 Nm ~ 625 Nm
plate = × Pitch Hence,
8
= 63.5 mm Pulling Torque = 625 Nm.
5
Pin diameter = × Pitc
16 Pitch between components Pc
= Centre distance
31.75 mm =
Number of fixture tray
1
Thickness of link plate = × Pitch
8

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Pitch between components Pc = 833.33mm 6. Result and Conclusion
Time to travel pitch Pc = 13 sec. As discussed above, the dedicated fixtures
60 Pitch are designed to hold the tractor components rear axle
Required RPM = Pc × ×( )
13 z carrier, rear axle shaft and bull gear. the fixture
Where, z = number of teeth = 13 elements are analysed to check the validation of the
Hence, elements. The result of analysis is as follows.
Require RPM = 2.97 rpm 1. Resting Pad
~ 3 RPM Equivalent Shear
Equivalent Shear
Elastic Elastic
Stress Stress
Strain Strain
2πnT -
Horse Power hp = -
45000 1.9807e- 4.6638e-
Minimum 382.27 Pa 3435.6
009 m/m 008
Horse Power hp = 0.26 HP Pa
m/m
π × Torque × RPM 5.2867e-
6.5105e- 3894.4
Required Power kW = Maximum 12565 Pa 008
30000 008 m/m Pa
m/m
Required Power kW = 0.20 kW

Hence, 2. V rod (Fixture element to hold shaft)
Final output Torque (T) = 625 Nm Equivale
Final output RPM (n) = 3 rpm Shear
Equivalent nt Shear
Final output Horsepower (hp) = 0.26 HP Elastic
Stress Elastic Stress
Required kilowatt (kW) = 0.20 kW. Strain
Strain

5.4 Sprocket Parameter calculations -
-
Pitch circle diameter of sprocket, PCD (Dp) = 424.5 Minimu 2.3303e- 3.1285
44.975 Pa 2.3046e+0
m ~ 425 mm m 010 m/m e-006
05 Pa
Top diameter, (Do)max = D + 1.25p – d1 = 488.5 mm m/m
(Do)min= D + p(1-1.6/z)- d1 = 450.59 mm 2.9911
Maximu 1.6844e+0 8.7274e- 2.2034e+0
e-006
m 06 Pa 006 m/m 05 Pa
Hence, let us take top Diameter = 475 mm m/m

Root diameter, Df = D – 2ri 3. Fixture element for gear
Where, ri= roller seating arrangement Equivale
(ri)max = 0.505d1 + 0.069(d1)1/3 = 32.34 mm Total
Equivale Shear nt
(ri)min = 0.505d1 = 32.06 mm Deformati
nt Stress Stress Elastic
Take ri = 32.3 mm on
Strain
-
Hence root diameter = 410.8 mm Minimu 901.32 4.67e-
3.6142e+0 0. m
m Pa 009 m/m
06 Pa
Tooth flank radius
Maximu 7.871e+0 2.0326e+0 4.0782e- 2.8847e-
(re)max = 0.008d1 (z2+180) = 117.3 mm
m 06 Pa 06 Pa 005 m/m 005 m
(re)min = 0.12d1 + (z+2) = 114.3 mm

Take tooth flank radius = 115 mm 4. Holding plate to hold the fixture elements on
Roller seating angle (α) chain conveyor
(α)max = [120 – (900/z)] = 113.080 Shea
(α)min = [140 – (900/z)] = 133.080 Equiva r
Equival Total
Hence take Object Shear lent Elasti
ent Deform
α= 1250 Name Stress Elastic c
Stress ation
Tooth height above the pitch polygon Strain Strai
(ha)max = 0.625p – 0.5d1 + (0.8p/z) = 38 mm n
(ha)min = 0.5(p – d1) = 19.05 mm -
Hence - 8.9419 2.457
Minim 1725.8
ha = 25.4mm 1.8105e e-009 7e- 0. m
um Pa
Tooth width, (bf)max= 0.95b1 = 60.325 +007 Pa m/m 004
~ 60.5mm m/m
Where, b1 = 63.5mm Maxi 4.4404e 1.6315e 2.3007 2.214 3.8722e-
mum +007 Pa +007 Pa e-004 8e- 004 m

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