Design and Fabrication of Gypsum Board Making Machine

DEBRE TABOR UNIVERSITY
FACULTY OF TECHNOLOGY
DEPARTEMENT OF MECHANICAL ENGINEERING
Design and Fabrication of Gypsum Board
Making Machine
A Thesis Submitted
In the Partial Fulfillment of The Requirements
For the Degree of Bachelor of Science in Mechanical
Engineering
Advisor: Mr. Abera H.
DEBRE TABOR, ETHIOPIA
MAY 2019

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DESIGN AND FABRICATION OF GYPSUM BOARD MAKING MACHINE
Declaration
We hereby declare that the work which is presented in this thesis entitled “Design and Fabrication of
Gypsum Board Making Machine” is original work of our own, has not been presented for a degree
of any other university and that all sources of material used for the thesis have been duly
acknowledged.
__________________________ __________________
SAYID YIMAM (0241/07) date
_____________________________ ___________________
SHEWALEM ASFAW (1287/07)
____________________________ ___________________
NIGAT ASSEFA (0174/07)
____________________________ ____________________
G/TSADIK MESELE (0349/07)
____________________________ _____________________
MELESE MERARA (1323/06)
____________________________ _____________________
MAMARU BELACHEW (1075/07)
____________________________ _____________________
This is to certify that the above declaration made by the candidates is correct to the best of my
knowledge.
__________________________ __________________
Mr. Abera Hunde date

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Acknowledgment
First of all, we would like to thank the almighty of God being with us in all aspects of our life and
for giving us the strength to accomplish this project work.
Secondly, we would like thank a heartfelt gratitude to our advisor Mr. Abera Hunde who contributed
valuable efforts by giving idea, suggestion and the way how to do our work when we did this project.
Thirdly, we would like to thank our special gratitude goes to our evaluators to Mr. Adugna, Yinagar
and Mr. Ramamurthy whose give us insightful suggestion, comment and limitations on the project
have helped us for the successful completion of this project. And also we would like to thank our
Mechanical Engineering student project coordinator Mr. Yusuf A. for his heartful acceptance and
cooperation of our project.
Lastly, but not the least, we also thank and appreciate for our teammates for their cooperation in
providing different necessary things, and also our family has a great role for each step by standing
with us, and everyone who has helped us for better or worse throughout our project time by supporting
in different ways will belongs great appreciation.

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List of Figures
List of Figures Pages
Figure 3. 1 Automatic panel production system ................................................................................. 4
Figure 3. 2 Mixing and baking operation ............................................................................................ 5
Figure 3. 3 Different types of mixer .................................................................................................... 5
Figure 3. 4 Manually gypsum panel making processes ...................................................................... 6
Figure 3- 5 Assembly of the Machine ............................................................................................... 18
Figure 5- 1 Agitator Selection Guide ................................................................................................. 20
Figure 5- 2 Power Diagram of Helical Ribbon Impeller ................................................................... 21
Figure 5- 3 Tank ................................................................................................................................ 26
Figure 5- 4 Motor .............................................................................................................................. 26
Figure 5- 5 reverted gear train speed reducer gear engagement ........................................................ 27
Figure 5- 6 Gear tooth forces ............................................................................................................. 29
Figure 5- 7 belt and pulley ................................................................................................................. 34
Figure 5- 8 Cross section selection chart for Classical Raw Edge Cogged V-Belts ......................... 34
Figure 5- 9 Belt geometry .................................................................................................................. 37
Figure 5- 10 forces on the pulley ....................................................................................................... 41
Figure 5- 11 Forces on the upper shaft .............................................................................................. 43
Figure 5- 12 Forces on the lower shafts ............................................................................................. 46
Figure 5- 13 Gib-head key for coupling ............................................................................................ 47
Figure 5- 14 slider crank mechanisms ............................................................................................... 48
Figure 5- 15 circular slider ................................................................................................................ 50
Figure 5- 16 bed for tank ................................................................................................................... 52
Figure 5- 17 Rollers ........................................................................................................................... 53
Figure 5- 18 bed for glass .................................................................................................................. 54
Figure 5- 19 geometry of holders....................................................................................................... 55
Figure 5- 20 holders .......................................................................................................................... 56

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List of Tables
List of Tables Pages
Table 3- 1 Comparison of Gypsum Board Manufacturing Machines ................................................. 6
Table 5- 1 Structure Parameters of Helical Ribbon and Screw Impeller ........................................... 21
Table 5- 2 Idler correction factor ....................................................................................................... 35
Table 5- 3 Value of correction factor ................................................................................................. 36
Table 5- 4 Value of environmental correction factor......................................................................... 36
Table 5- 5 The value of minimum pulley datum diameter ................................................................ 36
Table 5- 6 Available size for Raw Edge Cogged V-Belts- AX ......................................................... 38
Table 5- 7 Arc of contact and belt length correction factor ............................................................... 39
Table 5- 8 AX-Section Power Rating ............................................................................................... 40
Table 5- 9 N Proportional of Standard for gib-head keys .................................................................. 47
Table 7- 1 Result ……....................................................................................................................... 60
Table 9- 1 Direct cost ........................................................................................................................ 62
Table 9- 2 Indirect cost ...................................................................................................................... 62

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Table of Contents
Contents Pages
Declaration............................................................................................................................................i
Acknowledgment................................................................................................................................ ii
List of Figures.................................................................................................................................... iii
List of Tables......................................................................................................................................iv
Table of Contents.................................................................................................................................v
Abstract............................................................................................................................................ viii
Nomenclature and Abbreviation.........................................................................................................ix
CHAPTER ONE..................................................................................................................................1
1.1. Introduction...........................................................................................................................1
1.1.1 Gypsum powder and board.................................................................................................3
1.1.2. Types of Gypsum Plaster Board........................................................................................3
1.1.3. Gypsum board production line process .............................................................................3
1.3. Statement of the problem..........................................................................................................5
1.4. Objective...................................................................................................................................6
1.4.1 General objective................................................................................................................6
1.4.2 Specific objective ...............................................................................................................6
1.5 Scope of the project ...................................................................................................................7
1.6. Significance of the project ........................................................................................................7
1.7. Advantages and limitations over manual and fully automated machine ..................................7
1.7.1. Advantages ........................................................................................................................7
CHAPTER TWO.................................................................................................................................8
2.1. Literature review.......................................................................................................................8
1.1. Literature gap......................................................................................................................11
CHAPTER THREE ...........................................................................................................................12
3.1. Concept generation.....................................................................................................................12
3.1.1. Gypsum board making machines ....................................................................................12
3.2. Working principle...................................................................................................................16
CHAPTER FOUR..........................................................................................................................17
4.1 Methods and Materials.............................................................................................................17
4.1.1. Primary and Secondary data collection ...........................................................................17
4.1.2. Identification of Fluid property .......................................................................................18

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4.2.1. Mixing equipment selection criteria................................................................................18
4.2.2. Selection of Motor...........................................................................................................18
3.2.3. Selection of Gear Box......................................................................................................19
4.2.4. Design of Belt and Pulley................................................................................................19
4.2.6. Material for Slider Mechanism and Rollers ....................................................................21
4.2.7. Selection of Glass board..................................................................................................21
4.2.8. Selection of Bearing ........................................................................................................21
4.2.9. Materials for Bed of bucket and glass .............................................................................21
4.2.10. Materials of Frame, bars and welding operation ...........................................................22
CHAPTER FIVE ...............................................................................................................................23
5.1. Design analysis...........................................................................................................................23
5.2. Design of parts........................................................................................................................23
5.2.1 Design of mixing equipment ............................................................................................23
5.2.2 Design of gate...................................................................................................................27
5.2.3 Design of silo....................................................................................................................28
5.2.4 Design of blade.................................................................................................................29
4.2.5 Design of tank...................................................................................................................30
5.2.6 Selection electrical motor .................................................................................................30
5.2.7 Selection of gears and analysis of speed reduction ..........................................................31
A, Design of vertical shaft.........................................................................................................31
5.2.8 design of belt and pulley...................................................................................................37
5.2.9 Design of Horizontal shaft for spur and bevel gears ........................................................46
The second shaft ........................................................................................................................48
5.2.10 Design of Key for shaft and pulley.................................................................................50
5.2.11 Design of crank sliding mechanism................................................................................51
5.2.12 Design of circular slider/roller........................................................................................53
5.3.13 Design of bed for bucket or Tank...................................................................................54
5.2.14 Design of Roller..............................................................................................................55
5.2.15 Design of bed for glass ...................................................................................................56
5.2.16 Design of holder bars......................................................................................................58
CHAPTER SIX..................................................................................................................................60
6.1 Fabrication Process..................................................................................................................60
6.1.1 Collecting the necessary materials ...................................................................................60

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6.1.2 Manufacturing of tables....................................................................................................60
6.1.3 Manufacturing of holders .................................................................................................60
6.1.4 Manufacturing of mixing equipment................................................................................60
6.1.5 Manufacturing of rollers and slider crank ........................................................................60
6.1.6 Preparing AC motor, belts and gears................................................................................61
6.1.7 Preparing joints.................................................................................................................61
6.1.8 Assembling .......................................................................................................................61
6.2 Maintenance.............................................................................................................................61
6.2.1 welding .............................................................................................................................61
6.2.2 lubrication.........................................................................................................................61
6.2.3 Substitution.......................................................................................................................61
CHAPTER SEVEN ...........................................................................................................................62
Result and discussion.........................................................................................................................62
7.1 Result .......................................................................................................................................62
7.2 Discussion................................................................................................................................62
CHAPTER EIGHT............................................................................................................................63
Conclusion and Recommendation.....................................................................................................63
8.1 Conclusion ...............................................................................................................................63
8.2 Recommendation .....................................................................................................................63
CHAPTER NINE ..............................................................................................................................64
Cost analysis......................................................................................................................................64
9.1 direct cost.................................................................................................................................64
9.2 Indirect cost..............................................................................................................................64
References......................................................................................................................................66
Part drawing.......................................................................................................................................68
Assembly drawing .............................................................................................................................80

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Abstract
Gypsum board based systems are among those now broadly used, as walls or ceilings in house and
general building construction, fire protection of light-flame wood or steel construction is ubiquitous
and it is principally employed as lining material in light-weight construction, which is a competent
and cost effective technique of providing flexible partitioning assemblies in commercial and
residential buildings.
The project mainly consists of the analysis and design of different parts of the machine and its
accessory. The design starts from the identification of the problem, data collection, material selection,
general considerations and part specifications, part design, working principle of the machine, finally
part and assembly drawing fabrication and testing of the machine.
In this work the machine is consists of three main groups; the first one is power transmitting group
consisting of electric motor, gearbox, belt drives, pulleys, shafts and bearings etc. The second group
consisting of impeller shaft, impeller blades, mixing chamber that carrying a gypsum dough or
chemicals. Finally, the machine has the baking stage of gypsum board or panels by using window
type glass or mirror, and slider crank mechanisms (smoother and remover for transporting system).
The complete product of the gypsum board and operation process was in such kind of environment.
The electricity is supplied to electric motor which runs at 1500 rpm. The desired speed of impeller is
250 rpm and the speed of slider crank is 83.3 rpm. Due to this unwanted speed we used a gearbox
and pulley for speed reduction.
In order to analyze all of the proposed systems effectively, modelling software’s is used. This
modelling software is Solid work, and the designed model is analyzed using ANSYS software
simulation and by experimental setup. All of these tools will be essential in completing a thorough
evaluation and design of the proposed systems.

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Nomenclature and Abbreviation
SHR Single helical ribbon
DHR Double helical ribbon
SCI Single screw with impeller
SPH Smooth particle hydrodynamics
Np Power number
Fr Fraud number
Re Reynolds number
G Gear ratio
M Module
Φ Pressure angle
a Addendum
d Addendum
DP Pitch diameter
Dp Diameter of pinion
Dg Diameter of gear
Wn Normal force
Wr Radial force
Wt Tangential force
Ks Service factor
Ko Service correction factor
Ki Idler correction factor
Ke Environment correction factor
Kc Power rating correction factor
K𝜃 Arc of contact correction factor
Ld Datum length
Pc Correction power rating
Pa Additional power rating
Ps Basic power rating
Pt Input power of motor
μ Fluid viscosity
SR Speed ratio
C Center to center distance
Rm Mean radius
𝛿t Tensile stress

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CHAPTER ONE
1.1. Introduction
Gypsum has been known for centuries and is one of the oldest building materials in the world. The
earliest use of gypsum discovered was in Anatolia around 6000 B.C. Later, in about 3700 B.C. gypsum
was used on the interiors of the great pyramids in Egypt. One of the early uses of gypsum in building
construction appears to have occurred in 3700 B.C. when the Egyptians used gypsum blocks and
plaster applied over woven straw lath in the building of the pyramid of Cheops. As a testimony to the
strength and durability of gypsum, some of this construction is still intact and viewable, including
walls decorated with murals composed of tinted plaster.
Gypsum board (also known as plaster board, wallboard, gypsum panel, sheet rock, or Drywall) is a
panel made of calcium sulfate dehydrate (gypsum) with or without additives and normally pressed
between a facer and a backer (typically thick sheets of paper). It is used to make interior walls and
ceilings. The plaster is mixed with fiber (typically paper and/or fiberglass), plasticizer, foaming agent,
and various additives that can decrease mildew, increase fire resistance, and lower water absorption.
Gypsum building materials are used in all construction types (residential, nonresidential, new or
refurbished), ranging from complex high-tech systems to easy to install products adapted for use by
the general public.
Gypsum board is generic name for a family of panel products that consist of a noncombustible core,
composed of primarily of gypsum and a paper surfacing on the face, back and long edges. This board
often called dry wall, wallboard or plasterboard.it differs from other panel type building products, such
as plywood, hardboard, and fireboard, because of its noncombustible core and paper facers when joints
and fastener heads are covered with a joint compound system, gypsum board creates a continuous
surface suitable for types of interior decoration.
Gypsum board is the premier building material for wall, ceiling and partitioning in residential,
institutional and commercial structure. It used for partitions and the lining of walls, ceilings, roofs and
floors. The properties of gypsum board can be modified to meet specific requirements, such as: fire
resistance, humidity resistance, impact resistance, etc. Provides the foundation of beautiful and high-
quality walls, and can be installed quickly allowing almost immediate decorations.
In the last few years the demand for gypsum board has increased at considerable rate following
infrastructure development works, government housing projects and due to construction of commercial
and residential buildings and industries development. Despite continuous production of gypsum by

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Ethiopian Gypsum works, National Gypsum Share Company and other small-scale producers, the
demand for gypsum board was still on the rise and could not be fulfilled. Due to this shortage, the
government of Ethiopia was forced to import gypsum board through 2011 to 2016.
Although gypsum powder has been produced and used for more than half a century in Ethiopia,
infrastructure development is in its early stage. But, in the last six-seven years, change has been
registered due to and economic growth. As a result of the double-digit economic growth (about 11%
on average), the construction sector has been growing at annual rate of about 20% and the need for
gypsum board is becoming very high from time to time.
The wide gap between demand and supply, the high price of gypsum and conductive investment
environment motivated a number of local and foreign companies to invest in the gypsum industry of
Ethiopia and, some of these companies have already started gypsum production. Nevertheless, due
to the capital-intensive nature of the industry, only few large-scale plants are under construction.
Over the last few decades, synthetic gypsum and production machineries has increasingly been used
in modern building materials in different countries. Most of the synthetic gypsum used is a by-product
of electricity production in coal-fired power plants. During the production of power, a large amount
of flue-gas desulfurization gypsum (FGD) is produced as a result of pollution treatment.
As if these ecological advantages were not enough, gypsum also offers many additional advantages
as a building material due to its superior performance. Prefabricated gypsum boards or blocks of the
raw material allow for faster construction of fire-resistant interior walls and divisions which offer
thermal and sound insulation as well as room moisture balance for increased everyday comfort in
both public and private buildings. All this combines to make gypsum-based building materials ideal
for use in sustainable building construction and renovation projects.
Nowadays gypsum board production machineries have been increased with high qualified products
of boards within a short period of time by avoiding the tiredness of workers using a mechanism of
mixing gypsum powder to obtain high adhesive bond (high strength), baking mechanism on the glass
and extra.
Gypsum board machine with a small-scale size manufacturing is not available on local market. The
workers which a job profession relating with a decoration and ceiling of a house are faced a great
problem and they have decided to do with manpower. The production rate by using this method is
difficult. Instead of this method by using simple operated gypsum board machine is good solution to
achieve a high production rate.

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On this design project, the machine has a semi-automated (operate with collaboration of manual and
automatic mechanism). This machine has primarily focus on reduction of human power requirement
and increase of the production rate per a day. The main significance out of this is to prevent health
related problem that faced on workers, and in addition to this making low cost and it can purchase
each individual person.
1.1.1 Gypsum powder and board
There are two types of gypsum powder is produced;
a) Gypsum Mold (Ceiling);
It used to decorate building construction, It used as a modeling material for tooth restoration, be used
with glass to fabricate a large light weight architectural decoration, be used as a mold material to
fabricate custom body parts for trucks and automobiles.
b) Gypsum Chuck;
It used to paint the walls of construction house, a source of calcium and sulphate, Sulphur for plant
growth, used as a filler and fire retardant in plastic products. The difference between the two is there
setting time and the presence of Na-CMC present only in gypsum chalk. But both take citric acid and
there is micro size difference between the two types of gypsum powders.
1.1.2. Types of Gypsum Plaster Board
Gypsum plaster boards are classified according to their use. Gypsum wall board has a face to which decoration
may be applied. There are five types of gypsum board product that are considered standard. Innovation has
created several new products now available. Standard Gypsum Board:
 Regular core,
 Flexible board,
 Type “X” fire resistant,
  Moisture resistant and
  Plaster baseboard.
Specialty Gypsum Board: Interior ceiling board, Mold & Moisture resistant, Shaft liner, Abuse
resistant and Impact resistant.
1.1.3. Gypsum board production line process
The wet gypsum is dried in a dryer, then calcined to form plaster, hemihydrates of calcium sulphate
(partly water soluble anhydrite) in a calcination unit, and stocked in silos after milling of the calcined
product. Heavy oil is usually used for drying and calcination, and the exhaust gas is released in to air
passing through a scrubber.

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The pulp used as filler is mixed with required amount of water in pulper. In a board forming process,
plaster, filter and water and adhesives under fixed ratios into a mixer, and the slurry leaving the mixer
is sent to forming unit. While the paper for the top and bottom of the gypsum board is supplied is fed
in between the top and the bottom papers moving sandwiched and enveloped by the papers. Setting
of the plaster in the slurry raked place on the belt conveyer of the forming unit along the moving of
the formed gypsum board, and after certain time allowed for setting the board is cut into uniform
size. The setting progresses further on the gypsum board pieces are placed in a drying unit.
In construction, gypsum board or plasterboard and light steel keel are used as non-main wall, which
applied widely to all kinds of industrial and civil architecture. The Paperbacked Gypsum Board
Production Line is a special equipment’s & devices used for producing a kind of new type
construction material, paperbacked gypsum board. The production line is made of sections: -
 Raw Material System,
 Forming System,
 Transportation System,
 Heating
 Drying System,
 Cut to Length System, and
 Taping and Packing System.

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1.3. Statement of the problem
In our country gypsum board manufacturing process is mostly manufactured by using manpower (blue
collar worker) and it is so much tedious and less efficient. In our survey in Hawassa and Debre Tabor
city the average production quantity of a board per a person is not more than 25 units per day. Nowadays
so many very huge technologically advanced gypsum board machines are available, but they need high
initial capital cost ( > $100,000 in global market) and not suitable for small scale production purposes.
Due to this cost and not versatile we have initiate to design and manufacture a medium size gypsum
board panel making machine.

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1.4. Objective
1.4.1 General objective
The main objective of this project is to design and manufacturing gypsum board making machine.
1.4.2 Specific objective
 To design Mixing equipment
 Selection of Motor, Gear Box, Bearing, and Glass with necessary dimensions
 To design Belt and pulley
 To design key, Rollers, Slider crank mechanisms
 To design standing table or bed, frame and bars
 To simulate the final assembly by using SOLIDWORK 2018 and to test the geometrical
structures by ANSYS software.

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1.5 Scope of the project
The range of this design project is from the designing of each parts of the gypsum board making
machine fabrication and testing of the machine and experimental investigation.
1.6. Significance of the project
The main significance of this project is;
 To maximize the production rate per a day.
 To reduce the man power for mixing and baking the board.
 To avoid health problem related to respiratory system due to aerosol of gypsum powder.
 To avoids additional cost of burlap (or jute), for the formation of highly bonding purpose.
1.7. Advantages and limitations over manual and fully automated machine
1.7.1. Advantages
 homogeneous of mixing dough is high.
 Low noise and vibration so no need of vibration isolator.
 Required less maintenance.
 Low cost due to less number of accessories
 It achieves various chemical properties and dilute solution is obtained.
 It is energy efficient.
1.7.2 Limitations
 The frame that was used to prevent the dough from overflowing is dismantled by manually. 
The panel removed from the glass and stow is performed by human power.
 Due to high adhesive property of gypsum dough it’s tedious to clean from the components of the
machines.
 The machine has limited capacity.
 The is designed for particular application (specially for ceiling gypsum panel).

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CHAPTER TWO
2.1. Literature review
(Samrawit Asfaw;) Gypsum board is the premier building material for wall, ceiling and partitioning
in residential, institutional and commercial structures. It is used and preferred everywhere due to its
light weight, less cost and durability and easy to fix property as well as fire and moisture resistant,
and temperature normalization property during cold or hot climate. All these properties make gypsum
product the No 1 choice in the construction industry for finishing purpose. For example, it covers the
interior of more than 97% of new homes constructed in the US and Canada and is used to finish the
interior and sheath the exterior of non-residential structures throughout the world. [1]
(Ahmed Salhi Houari et al.) says about “Mixing of highly viscous fluids” viscous fluids are widely
used in many industrial processes. Obtaining an efficient mixing with high quality of homogenization
at low impeller rotational speeds is a challenging task, due the high power consumption required for
moving the viscous fluid. Among the several stirrers available in industries, the helical ribbon and
screw impellers are efficient for the mixing of highly viscous liquids. These impellers are often
operated in the laminar regime of fluid flows. Depending on the purpose of the mixing operation, the
helical ribbon impeller may be used with one or more helical ribbons mounted on a central shaft,
supported or not by cross-beams. In a stirred tank fermenter, compared the performance of a Rushton
turbine and a double-flight helical ribbon impeller (HRI). They reported that the HRI operating at
moderate conditions (250 rpm) performs better and requires less energy than a double Rushton
turbine operating at an optimum condition (600 rpm). studied numerically the total and local
dispersive mixing performance of double helical ribbons (DHR) and Max blend impellers. [2]
(Edward L. Paul et al.) says about “Hand of Industrial Mixing Science and Practice” that Double
Helical Ribbon (DHR) can achieve a good total circulation throughout the agitated vessel, but it can’t
give a promising local mixing performance via numerical simulations and using the smoothed particle
hydrodynamics (SPH) method, explored the mixing performance of helical ribbon impellers with a
Newtonian fluid. He reported that the addition of an extra ribbon to the SHR doubles the number of
smaller circulation cells of fluid; thereby improving the overall mixing rate. Performance of Helical
Ribbon and Screw Impellers for Mixing Viscous Fluids in Cylindrical Reactors. [3]
(Joanna Karcz;) “An effect of impeller position on dispersion of floating particles in agitated
vessel”, powder flow behavior is highly sensitive to the geometry of the mixer and helical ribbon
blades. The motion of the ribbon blades is generated through the transferrable of momentum from
the impeller to the powder through a combination of impact, centrifugal, frictional, shear, gravity and
inertial forces. Hence, it is difficult to obtain generalized flow pattern for all mixers. Simple mixers

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with one set of ribbon blades located at the bottom of the vessel (e.g. Aromatic-Fielder, Colette Grail,
NiroPellmix, and Zanchetta) create powder flow that move from the bottom of the mixer, out towards
the wall, up the wall and then cascades down towards the Centre of the mixer. [4]
(Azree Othuman Mydin) says on his paper “Gypsum board thermal properties exposed to high
temperature and fire condition” that, Gypsum board partitions and ceiling membranes are possibly
the most common fire resistant construction approach employed in an extensive range of building
types. Very familiar in light frame construction allied with single and multi-family housing, gypsum
board systems are also used in other outsized building types. [5]
(Donald W. Olson) represents on his handbook of “The development of Gypsum board industry in
China Global Gypsum Magazine, CNBM Hangzhou Design and Research Institute, China” states
that Gypsum board finds extensive application in the construction of buildings. The main application
areas include ceiling, wall paneling for thermal insulation and acoustic properties, for partitions and
various other applications when they have produced in high quality by using advanced technologies.
This handbook states that if heating added after digging the panel after baking will enhance the
properties of the ceiling panel and increase the decoration response. [6]
(Kate-Deshmukh N.S.) “Design, Analysis and Testing of shaft mounted speed reducer for coil
winding machine.” say that Shaft mounted speed reducer is a device which is used to reduce speed
of a machine from input speed to the required speed. In this device an internal external gear
arrangement is used for speed reduction. The external gear is engaged with the internal gear but the
external gear is eccentric with the internal gear. Because of such an arrangement reduction of speed
can be achieved as per the requirement. We can change output speed by only changing the eccentric
distance between the external gear and internal gear. [7]
(Kuncewicz F.C. Stelmach et al) says on his paper about “Mechanical Belt drive” Among flexible
machine elements, perhaps V-belt drives have widest industrial application. These belts have trapezoidal
cross section and do not have any joints. Therefore, these belts are manufactured only for certain standard
lengths. To accommodate these belts, the pulleys, have V shaped grooves which makes them relatively
costlier. Multiple groove pulleys are available to accommodate number of belts, when large power
transmission is required. V-belt drives are most recommended for shorter center distances. In comparison
to flat belt drives, these drives are slightly less efficient. V belt can have transmission ratio up to 1:15 and
belt slip is very small. As the belts are endless type, V-belt drives do not suffer from any joint failure and
are quiet in operation. V-belts constitute fabric and cords of cotton, nylon etc. and impregnated with
rubber. [8]

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(Kharagpur) “V- Belt drives among flexible machine elements”, perhaps V-belt drives have widest
industrial application. These belts have trapezoidal cross section and do not have any joints.
Therefore, these belts are manufactured only for certain standard lengths. To accommodate these
belts, the pulleys, have V shaped grooves which makes them relatively costlier. Multiple groove
pulleys are available to accommodate number of belts, when large power transmission is required.
V-belt drives are most recommended for shorter center distances. In comparison to flat belt drives,
these drives are slightly less efficient. V belt can have transmission ratio up to 1:15 and belt slip is
very small. As the belts are endless type, V-belt drives do not suffer from any joint failure and are
quiet in operation. V-belts constitute fabric and cords of cotton, nylon etc. and impregnated with
rubber. [9]
( Eric Brigham et al) “Slider Crank Mechanism for Demonstration and Experimentation MDQ” The
slider-crank mechanism is a particular four-bar linkage configuration that exhibits both linear and
rotational motion simultaneously. This mechanism is frequently utilized in undergraduate
engineering courses to investigate machine kinematics and resulting dynamic forces. The position,
velocity, acceleration and shaking forces generated by a slider-crank mechanism during operation
can be determined analytically. Certain factors are often neglected from analytical calculations,
causing results to differ from experimental data. [10]
(D.K. Nannaware et al).; “Design and Optimization of Roller Conveyor System” A roller conveyor
system is a common piece of mechanical handling equipment that moves materials from one location
to another. Conveyors are especially useful in applications involving the transportation of heavy or
bulky materials. Conveyor systems allow quick and efficient transportation for a wide variety of
materials, which make them very popular in the material handling and packaging industries. There
are a variety of options available for running conveying systems, including the hydraulic, mechanical
and fully automated systems, which are equipped to fit individual needs. [11]
(Mr. Sunil Krishna Nalgeshi) “Design and weight optimization of gravity roller” The FEA is a
numerical procedure for analyzing structures of complicated shapes, which otherwise would be
difficult by analytical method. Analytical solution is a mathematical expression that gives values of
desired unknown quantity at any location in a body or a structure and it is valid for an infinite number
of locations in body or structure. But analytical solution can be obtained only for simple engineering
problems. It is extremely difficult and many a times impossible to obtain exact analytical
mathematical solution for complex engineering problems. In such cases FEM is used which gives
approximate solution. [12]

11
1.1. Literature gap
This project differs from the above literature reviews due to the following reasons;
• Most of the literatures are reviewed on them paper for a single component of the
machine, but in this thesis the combination of all components which reviewed
partly.
• The thesis is not compacted with different sensors and Arduinos to minimize the
initial cost of the machine.
• The geometrical analysis is not tested on with Ansys software for checking purpose
of computational fluid flow.
• The whole thesis has deals on small scale quantity production unlike that of mass
production system.
• The production of the ceiling wall take only a size of 55*110 cm,

12
CHAPTER THREE
3.1. Concept generation
3.1.1. Gypsum board making machines
The gypsum board manufacturing machines in the world has been takes placed in different ways
according to the economic development level and the users of the gypsum panel for construction
around each area. based on these situations the gypsum board or panel production machineries are
classified according to production line, the mixing process of the gypsum powder and ways of the
operational steps of the machines. for this project we have different options and mechanisms of
machines based on their operations to manufacture the gypsum board. this option is listed below;
Option one is Fully Automatic gypsum board manufacturing plants
In this type of gypsum board manufacturing plants, the complete operation of the machine is working
automatically.it starts from the production of gypsum powder and the mixing mechanisms with the
combination of continuous feeding of the dough for baking process sections. Finally heating, cutting,
decorating in different models on the panels and the packaging processes are completely inter
connected automatically. These types of gypsum board plants are produces large amounts of gypsum
boards in the day. However, the plants are more expensive and cost and covers large areas to install
the machines. Since the overall systems of the machines needs huge amount of capital investment,
advanced equipment and experienced workers its difficult to install these types of machines.
Figure 3. 1 Automatic panel production system
Option two is Semi-Automatic gypsum board manufacturing machines.
In semi-automatic gypsum board manufacturing process, some mechanisms are manually by human
power and some are automatic. Based on the mixing mechanism we can classify in to two ways;
a) The mixing mechanism of the gypsum powder is done by motor power which looks like hand
drill structure that is movable and carried by hand. The stirring part is attached at the end of
the mixer machine. This type of mixer stirs small amount of gypsum powder that is not
enough to bake more than one panels or boards. The buckets also small and movable that was
carried by hand. The feeding, baking on the glass is also done by manually by hand human

13
powers. Economically its less but it consumes time and human power and needs more workers
to manufactures more quantities of gypsum boards.
Figure 3. 2 Mixing and baking operation
b) The other types of semi-automatic gypsum board making machine has a mixing mechanism like the first
one but the motor is suspended somewhere around a fixed place and connected with the stirring parts with
the help of belts.it has large bucket used to mix much amount of gypsum powders then it feeds to the baking
station due to gravity flow and some pressures of dough from stirring rotation. Economically it’s less but
takes more than the first mechanisms.it is not consumes more time and human power than the first one and
the baking mechanisms is not manual. Compared to the first it produces more quantities and does not need
more personnel for the manufacturing and operational processes.
Helical ribbon mixer
Dispersion and Double-Helix Mixers are ideal for mixing fine powders, mixtures with solids, and high-
viscosity fluid. In processing plants around the world, ribbon blenders are used to mix hundreds of products,
from fertilizers and plastic resins to flavored coffees and cosmetics. The ribbon blender is among the most
common mixing devices in service today because it is one of the most versatile and cost-efficient mixers ever
created. It was used by comparing them technically based on different criteria and SHR was selected then
made a design for it.
Figure 3. 3 Different types of mixer

14
Figure 3. 4 Manually gypsum panel making processes
Option three is the selected option for the project
For this project semi-automatic gypsum board machine with the mechanism of fixed motors, large
fixed buckets and continuous feeding of gypsum dough for baking section is selected. The reason
that this type of gypsum board manufacturing was selected is due to the conditions listed in the table
be;

15
Table 3- 1 Comparison of Gypsum Board Manufacturing Machines
S/no Types of gypsum board
manufacturing machines
Conditions
related to
high medium less
1 Fully automatic
Cost 
Time
consumption

Space covered 
Man power 
2 Semi-automatic with stir
mechanism is carried by
Hand (movable)
Cost 
Time
consumption

Space covered 
Man power 
Semi-automatic with stir
mechanism is not carried
by hand(fixed)
Cost 
Time
consumption

Space covered 
Man power 
3 Manual operated Cost 
Time
consumption

Space covered 
Man power 

16
3.2. Working principle
The working principles of this machine starts with mixing a gypsum powder with water by using
helical ribbon mixer(arm) in a volume of large cylindrical bucket. This finely mixed dough is dropped
into the glass table. this table used to make the dough in to panel when we apply some external force
on the upper part. the dough is controlled by frame from over flowing on the table stand. after few
minutes the dough is dried and with fine rectangular panel like shapes. after that the dried board is
dismantled or removed from the glass.
Figure 3 - 5 Assembly of the Machine

17
CHAPTER FOUR
4.1 Methods and Materials
4.1.1. Primary and Secondary data collection
Data has collected to maximize product capacity. The increases the quantity of panel products can be achieve
by decreasing time duration for all process and the wastage of dough gypsum due to traditional way of
manufacturing method. Lastly we transform the manual method into semi-automated machine by designing
and manufacturing low cost of material.
We have gathered our primary data by direct contact with a board maker professional and asking the exact data
and by seeing how it working manually and taking the exact size of the gypsum board. The secondary data
source we had took mostly from machine element books like khurmi, Shigley, different journals and internet
website which related with gypsum properties and gypsum making machine.
The methodology for the proposed project work is as shown in flow chart below
Brain storm to solve the proposed problem
Comparative study of different gypsum board machines with helical agitator
study and search alternate sliding crank mechanism
Preparation of detailed design for proposed work
Development of software model of the system
Fabrication
Assembly & Testing
Collection of data through literature available

18
4.1.2. Identification of Fluid property
The design analysis of the whole machine component is based on knowing viscous of the fluid which we have
used for panel production and the power requirement to driving mixing equipment for the purpose of
homogenizing Gypsum powder with water. The main fluid properties parameters are
 Density of gypsum powder & water
 Percentage of ingredient
 Reynold and Froude number of the fluid
4.2 Material selection
4.2.1. Mixing equipment selection criteria
The objective of mixing is homogenization, manifesting itself in a reduction of concentration or temperature
gradients or both simultaneously, within the agitated system. Mixing as the intermingling of two or more
dissimilar portions of a material, resulting in the attainment of a desired level of uniformity, either physical or
chemical, in the final product.
 Agitator rpm (Drive motor / gear box reduction)
 Impeller Flow Number
 Impeller Power number
 Impeller Reynolds Number
 Area of Tank
 Bulk fluid Velocity
 Tank capacity
 Agitator Shaft Power
 Drive motor rating
4.2.2. Selection of Motor
Generalizations, especially for mixers, can misrepresent individual situations, but some features are common
to the largest number of mixers built worldwide. The most common motive force for a mixer is an electric
motor, so a knowledge of standard motor characteristics is useful.
The specification of the motor is based on the above mixing equipment required torque and power obtained
data’s.
 Input power (P)=1.8kw
 Motor speed or frequency(N)=1500 rpm
Result & Data interpretation
Conclusion

19
 Torque 70N-m
3.2.3. Selection of Gear Box
The gearbox is a device which is used to transmit the power from one shaft to the other shaft within
the required gear ratio. But, most of the times space limitation becomes the major problem of system.
Also efficiency of the device is one of the important parameter.
Since we select a motor of 1500rpm we need to reduce its lowest rpm, first select gear ratio, formation
of gear and gear train. Therefore, we select gear ratio of 6:1 for bevel, and 18:1 for spur gear train
(used for sliding mechanism) with the formation of reverted gear train type. The reduction of speed
has taken based on manufacturers manual and recommendation.
a) Material selection for gear and pinion
Before Selection first we need to choose standard material used for the gear pair by their availability,
strength, machining easiness of the material and finally it should be cost wise, therefore: for pinion
AlSl1050 steel with HB =514, heat treatment of quenched and tempered at 205o
C and for gear
AlSl1040 steel with HB = 262, heat treatment of quenched and tempered at 205o
C.
b) Material selection for shaft and bearing
In order to minimize deflection and bending, steel is the logical choices for a shaft because of high
modulus of elasticity. So in this design it’s selected Steel Alloy 1040Mild Steel for the shaft
component.
This are some points that why select stainless steel for ball bearing.
 Having ability to withstand momentary shock load
 Low starting and running friction
 Reliability of service and cleanliness
Note: In Design of gears on speed reducer gear box we check different parameters like safety of the
designed tool, stress, bending moment, different loads and so on are checked.
4.2.4. Design of Belt and Pulley
Among flexible machine elements, perhaps V-belt drives have widest industrial application. These belts have
trapezoidal cross section and do not have any joints. Therefore, these belts are manufactured only for certain
standard lengths.
The V-belt is mostly used in the 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.
a) Material selection for belt
Since the distance between the two pulley is small, require little attention, cheaper, not infest to heat
and the power transmission is small we select the Rubber belt type to achieve good efficiency.

20
b) Material selection for Pulley
The cast materials have low cost, good friction and wear characteristics. The pulleys made of pressed
steel are lighter than cast pulleys, but in many cases they have lower friction and may produce
excessive wear.
Methodology to design belt and pulley is as a following below;
1) Set conditions required in design work a)
Type of machine: agitation purpose
b) Transmission power; It is ideal to use the actual load applied to the belt as the value of the
transmission power, but the rated power of the motor is commonly used for calculation. c)
Running hours in a single day
d) Small pulley speed
e) Speed ratio
2) Set the design power: The value of transmission power used in designing is the power requirement
of the driven machine, if obtained, or the power of driving unit (engine or motor).
Select belt type: Select the belt type in the selection charts below according to design power and
small pulley speed.
3) Select the pulley size:
- Select the small pulley datum diameter larger than the minimum
specified
- Calculate the large pulley datum diameter:
4) Determine the belt length.
6) Determine the required number:
Note: In belt design we must to calculate coefficient of friction between the pulley and belt, centrifugal
tension, and finally the tension on both side (tight and slack side).
4.2.5. materials for shaft and Keys
A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to the
axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable crushing
and shearing stresses.
Material selection for the shaft and key is mild steel having allowable shear and crushing stress taken
as 42 MPa and 70 MPa respectively.
The width and thickness of the gib-head key is directly read on the table depending of shaft diameters
and length of the key is obtained by a formula of:
Estimating of shearing stress and estimating of crushing stress

21
After calculating these two stresses we go to check the feasibility of the design of the key by
comparing FOS. If we get induced shear and crushing stress are less than the permissible stress, the
design of gibe-head key is safe.
4.2.6. Material for Slider Mechanism and Rollers
The slider-crank mechanism is a particular four-bar linkage configuration that exhibits both linear
and rotational motion simultaneously.
Another mechanism that used in this design is the slider-crank mechanism. It is mainly used to
convert rotary motion to translational motion.
The material selection for this slider mechanism component is mild steel due to its strength, easily
machinable, lower cost relative to others metal alloys and the task of the mechanism is not infesting
for high stress.
All kinematic and dynamic force equations are taken from Norton’s Design of Machinery and the
stress are calculated on shearing place and bending stress on pin part.
4.2.7. Selection of Glass board
Here the only required task is measuring (length and width) and cutting of glass with some clearance
of panel board. This glass has used for smoothing the face of the board on one side.
Before starting design of roller, for conveying/rolling purpose, first we should know the load which
exists on the roller. On this design there are three loads are existed. These are load of glass, panel
board, and slider load. So the total weighs applied on roller are;
4.2.8. Selection of Bearing
A bearing is a machine element which support another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while carrying
the load.
4.2.9. Materials for Bed of bucket and glass
Since the load on the bed is distributed load due to the glass, frames, slider and gypsum board or
panel we need to analysis different stresses to know the safety of the bed. This will enhance the
confidence of the design and we able to estimate the equipment life. After finding the total weight
we find to;
The material for both beds (Glass and bucket’s bed’s) are same. The difference is other mechanical
properties like elasticity, allowable stresses, yield strength because the load upload on each bed is
varied.

22
4.2.10. Materials of Frame, bars and welding operation
The need for designed the frame and bar is to obtain a self-supporting structure of the machine for
the vertical loads by resisting vibration of motor and other unaccounted load. This frame has be a
rectangular 4 × 4 cm bar is efficient to withstanding on the ground floor.
4.2.11. Welding and Assembling operation
Finally weld, and tight with bolt if it’s necessary all components of the machine as assemble drawing.

23
CHAPTER FIVE
5.1. Design analysis
The geometry of the overall machine is based on how it should be easy for operation, cost of overall
of the machine, mobility of the machine, and accessibility of materials, which used fabricate the
machine.
These are the part description the designed machine part;
1. Bed: Used to carry every part of the machine and its shape is larger than the remaining parts that
is why it can carry each parts load and absorb vibration due to motor rotation.
2. Silo: Used to store a gypsum powder and it act as feeder for a mixer machine.
3. Shaft: It has circular shape with length and used to transmit power.
4. Carriage: carriage made of sheet metal used to carry bottle and feed the bottle in to inside the
casing.
5. Supports: supports are used as reinforcement to carry the load.
6. Bearings: Used to support the shaft.
7. Motor slider: used for tensioning the belt between the shaft and motor pulleys.
8. Motor: motor is used to give rotational motion to the shaft.
9. Rollers: rollers have circular shape, which used to drive the glass and it is assembled on bed,
which is free from motor, and it is supported by bearings.
10.Gear: is used to transmit, power and by making a gear train we used them for speed reduction.
11.Slider Crank: The slider-crank mechanism is a particular four-bar linkage configuration that
exhibits both linear and rotational motion simultaneously.
5.2. Design of parts
The design analysis of the whole machine component is based on knowing viscous of the fluid and
the power requirement for mixing purpose of Gypsum powder with water. The geometric analysis of
each part is based on the space, cost, easiness of the operation, and availability of materials.
5.2.1 Design of mixing equipment
Fluid property Analysis
Important mechanical features of high viscosity mixers are the low speed and high torque required
to rotate large impellers in viscous fluids.
The percentage ingredient of powder and water in the volume of buckets is assumed to be; 
Powder =12.5kg
 Speed of agitator/stirrer is 250 rpm.

24
 Water = 37.5L, The water content should be more than 3 times of gypsum powder. In US standard
units 1L of water is equal to 0.852kg mass of water is 31.95kg
Specification;
 Density of water
 Density of gypsum powder
After mixing the powder and water, the density of the mixture range from (567-783).so the maximum value
of the density of the dough is assumed to be . Then we obtain the volume of bucket for this
amount of proportion.
……………………………………2
= 100 − 3.5
= 96.44%
Therefore, this amount of percentage of ingredient indicates that the mixture is completely mixed.
I. Power consumption analysis
The agitator power consumption is obtained from the shaft power required to drive an agitator can
be calculated by using the generalized dimensionless equation.
Figure 5- 1 Agitator Selection Guide

25
From the above diagram experimentally given the Reynolds number of dough related to their density
and mass of proportions based on the volume of tank. The values of Reynolds number for bulk fluid
and dough’s ranges from 200 to 400, and 10 to 100 above that it considered as near to solid. Viscosity
and Reynolds number has inversely proportional.
From power diagram the ratio of the inner diameter of the container to the outer impeller diameter is
D/d=0.919 and the ratio of height of impeller to impeller diameter is H/d=0.853.
Table 5- 1 Structure Parameters of Helical Ribbon and Screw Impeller
Parameters
Diameter(mm) Height(mm) Pitch(mm) Reynolds
number
Density
(kg/m³)
Bucket /tanker 465-775 450-700 - - -
Stirrer/impeller 300-670 450-635 115-170 - -
Water - - - 1000
Air - - -
Gypsum powder
(solid)
- - - 2960
Gypsum dough
(bulk fluid)
- - - 783
Figure 5- 2 Power Diagram of Helical Ribbon Impeller

26
The viscosity or viscous drag force of the dough is given by;
But, Power number is given by
But power number also given by this equation
Where D=diameter of tank,
d=diameter of helical ribbon impeller
H=height of impeller=pitch of blades and
k,b,c=are constants for different agitator type, size and bucket or tank geometries then (for helical
ribbon impeller b=1, c=0, k=0.0041)
So, from equation (1) we have V=0.0568m3
and from above table H=575mm=0.575m.
0.
Diameter of stirrer/ impeller size is d=544mm
From power diagram the Diameter of bucket or tank is given by;
Now Reynold’s and fraud number, viscosity of fluid can be calculated;
Where, Fr = Fraud number
Re = Reynolds number
Fluid density
Fluid viscosity
From equation (5) we have a power number;
But shaft power to drive the agitator can be taken from the range between ( 1.3-2.1KW) And it should
be more than calculated power number.so the selected motor has a power
II Design of agitator (stirrer) shaft
 Material: Carbon steel of grades 40C8.
 Ultimate tensile strength: 660Mpa
 Yield strength: 320MPa
 Factor of safety: 2

27
Allowable shear stress
First of all, find the torque acting on the pinion shaft. It is given by
Where P = Power transmitted in watts, and
NP= Speed of the pinion
Based on the viscosity of the dough the limited r0ange of internal diameter of the shaft is 0.55 of
external diameter. For circular hollow shaft, the polar moment of inertia is given by;
,
Now the equation can be written as;
,
𝑑𝑜3−0.55𝑑𝑜3 = 13755.98
0.45𝑑𝑜3 = 137550.98
𝑑𝑜3 = 305668.844 = 67.36𝑚𝑚,
But internal diameter of hollow circular shaft of the agitator is;
𝑑𝑖 = 0.55𝑑𝑜, 𝑑𝑖 = 67.36 × 0.55
= 37𝑚𝑚 , 𝑠𝑎𝑦 40𝑚𝑚
5.2.2 Design of gate
Material; sheet metal
Geometry
Diameter, D=40mm
Length, L=120mm
Area,
= 1.257 × 10−3𝑚2

28
Flow rate analysis
Flow capacity(Q)
𝑄 = 𝑁𝑞 × 𝑁 × 𝐷𝑖3
Where Di=agitator diameter
N=agitator speed
Nq=coefficient of agitator speed, assume=0.00144
𝑄 = 0.00144 × 250 × 0.5443
Area of agitator,
= 0.2324𝑚2
Area of tank
Annular area
𝐴𝑎𝑛𝑛 = At − A = 0.2827 − 0.2324
= 0.04997m2
Rising velocity of dough particles
Bulk fluid velocity
Volume flow rate of the gate
𝑄 = 𝐴𝑟𝑒𝑎 𝑜𝑓𝑔𝑎𝑡𝑒 × 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑
= 1.257 × 10−3 × 4.84
Mass
flow rate
𝑚 = 𝜌 × 𝐴 × 𝑉𝑓
= 783 × 1.257 × 10−3 × 4.84
Here the shooter of tank is releases 4.8 Kg of dough per minute. so that, dough quantity released from
tank for one piece of panel board is need almost one minute.
5.2.3 Design of silo
Material: sheet metal
Geometric analysis
Length=700mm

29
Width=700mm
Height (h1) =350mm
Height(h2) =550mm
Diameter of exit=120mm
Area (A1)
Total area
Area of silo is
gypsum board =4.74Kg. To produce a single gypsum board it needs 10 minutes .in one hour 6 panel
will be produced.in day 96 panel is produced.so totally 455.04Kg of powder is needed. Therefore,
the volume of silo is obtained based on this much of powder. Density of gypsum powder=
Total volume
5.2.4 Design of blade
 Material; High carbon steel of grades 40C8.
 Ultimate tensile strength; 660Mpa
 Yield strength; 320 MPa
 Factor of safety; 2
Blade
Blade thickness
Blade width (w)
m

30
4.2.5 Design of tank
 Material; (mild) Low alloy steel 1040
 Ultimate tensile strength; 520MPa
 Yield strength; 290MPa
Figure 5- 3 Tank
Bucket or Tank outer diameter (
Height of the bucket or tank (h) →
Total volume of tank
Thickness of buckets (t)
5.2.6 Selection electrical motor
The specification of the motor is based on the above obtained data’s.
 Input power (P)=1.8kw
 Motor speed or frequency(N)=1500 rpm
 Torque 70N-m
Figure 5- 4 Motor

31
5.2.7 Selection of gears and analysis of speed reduction
A, Design of vertical shaft
Material; High carbon steel
Ultimate tensile strength; 660MPa
Yield strength; 320MPa
Modulus of elasticity; 210GPa
Diameter of input shaft is obtained from;
𝑑 = 31𝑚𝑚 ≈ 35𝑚𝑚
B, Design of speed reduction on bevel gears
Gear box speed reducer is enclosed system of assembled gear that transmits mechanical energy from
the primary motor to output shaft; it may change also direction torque of mechanical energy. Since
we select a motor of 1500 rpm we need to reduce its lowest rpm, first select gear ratio, formation of
gear and gear train. Therefore, we select gear ratio of 18 with the formation of reverted gear train as
shown below.
Figure 5- 5 Reverted gear train speed reducer gear engagement
In order to achieve the gear ratio of 18 we need to design each gear teeth number and contact length
as follows:
Assumption: Let give a reduction ratio of 3 for the first gear reduction set and 6 for the second
gear reduction set.
Since Nb and Nc rotate at the same speed therefore

32
Substitute Nc in to Nb will give 𝑁𝑎 = 6 × 3 × 𝑁𝑑
1. Bevel gear speed reduction set
Given data; Na =speed of input motor shaft rpm=1500rpm
Assumption Pa=20o
since Pa is pressure angle of 200
gear teeth forms have wider bases and can
transmit greater load, it also reduces the relative sliding velocity.
Let’s check for interference
The smallest number of tooth which will not have interference on the pinion is
Where
G= gear ratio = 6
For full depth teeth, k=1
Pressure angle = ϴ = 200
,
Tp =15.9 ≈ 16 teeth, which is teeth of pinion gear
Therefore, let’s take Ta = teeth which is greater than Np
teeth of gear
Assumption module (m) = 3
So circular pitch (P)
Mathematically
for the pinion (gear on the input shaft)
Dp= diameter of pinion
Dg = diameter of gear
Therefore, contact distance (c)
Gear parameters for the first speed reduction gear set
Module m=3mm
1. addendum (a)
2. Dedendum (b

33
3. Tooth thickness
4. Tooth space = P- tooth thickness = 9 .
5. Fillet radius at root m
6. Face width (B)
7. Outer diameter (Do)
For pinion (Do)p
For gear (Do)g
8. Root diameter (DR
For pinion (DR)p
For gear (DR)
Force analysis on bevel gear
Consider a bevel gear and pinion in mesh. The normal force (WN) on the tooth is perpendicular to
the tooth profile and thus makes an angle equal to the pressure angle (φ) to the pitch circle. Thus
normal force can be resolved into two components, one is the tangential component (WT) and the
other is the radial component (WR). The tangential component (i.e. the tangential tooth load)
produces the bearing reactions while the radial component produces end thrust in the shafts. The
magnitude of the tangential and radial components is as follows;
F is normal to the pitch cone and the resolution of resultant tooth force F into its tangential (torque
.
Figure 5- 6 Gear tooth forces
Where
=radial force φ=pressure
angle (20°
)
a=addendum, =3mm

34
d=Dedendum=3.755mm
DP=pitch diameter=171mm
These forces are considered to act at the mean radius (Rm). we find that
Now the radial force (WR) acting at the mean radius may be further resolved into two components,
WRH and WRV, in the axial and radial directions. Therefore, the axial force acting on the pinion
shaft,
and the radial force acting on the pinion shaft,
These forces are considered to act at the mean radius (Rm). From the geometry we find that
Stress analysis 2. Spur gear speed reduction set
,

35
We know the speed reduction ratio in this gear engagement is 6 where Nc is rpm of first shaft and
Nd is rpm of output shaft
,
NT ), where m =6, k= 1 and ϴ = 14.50
= 15. 9 =16 teeth, we take the pinion teeth
Tc,Tg=number of teeth of pinion and gear respectively.
Speed ratio ,
𝑇𝑑 = 𝑇𝑐 × 6
= 17 × 6
= 102 𝑡𝑒𝑒𝑡ℎ
Take module m=5 for pinion
Diameter of pinion gear
= 90𝑚𝑚
Take module m=2, for gear
Gear parameter
Module =5mm
1. Addendum (a) = m = 5mm
2. Dedendum (b) = 1.25 * m = 6.25 mm
3. Tooth thickness = 1.5708*m = 7.854 mm
4. Tooth space = p – tooth thickness
=15.7 – 7.854 = 7.85mm
5. Filet radius at root = 0.4 *m = 2mm
6. Face width for both gear = m*6 = 30 mm
7. Outer diameter (Do) = d+ 2m
For pinion (do)p = dp +2m = 90 +10 = 100mm
For gear (do)g = dg+ 2m = 210 + 10 = 220mm
8. Root diameter (DR)= d- 2.5*m
For pinion (DR)p = 90 –12.5 = 77mm
For gear (DR)g = 210- 12.5 = 197.5 mm
9. Base circle diameter(Db) = dcosϴ
For pinion (Db)p= 90cos200
= 84.57mm

36
For gear (Db)g =210cos200
= 197.34mm
Force analysis on the Spur gears
Figure Force on the second reduction gear set gear
Hence = 200
r1= 45mm, r2 = 105 mm
Force on gear 1
𝐹21𝑟 = 𝐹21𝑡 𝑡𝑎𝑛∅
= 4.5𝐾𝑁 ∗ 𝑡𝑎𝑛 (14.50)
= 1.2 𝐾𝑁
E, Force on the gear 2

37
𝐹12𝑟 = 𝐹12𝑡𝑡𝑎𝑛14.50
= 4.5𝑡𝑎𝑛14.50
= 1.2𝐾𝑁
= 0.67𝐾𝑁 ∗ 𝑡𝑎𝑛 (200)
= 0.24 𝐾𝑁
Force on the gear 2
= 0.285𝑡𝑎𝑛200
= 0.1𝐾𝑁
5.2.8 design of belt and pulley
For pulley For belt
Material; cast iron Material; Rubber
Figure: ForCe on gear 1 Figure;For
cerce
gear 2

38
Shear stress: 50MPa Yield strength; 2.5MPa Ultimate
tensile strength; 2.5 × 106
𝑁/𝑚2
Figure 5- 7 Belt and pulley
Selection criterion required in design of belt Type of machine and Transmission power
It is ideal to use the actual load applied to the belt as the value of the transmission power, but the
rated power of the motor is commonly used for calculation.
 To calculate the service factor (Ks)
𝐾𝑠 = 𝐾𝑜 + 𝐾𝑖 + 𝐾𝑒
Wherein; Ks: Service factor
Ko: Service correction factor (Table 2-1)
Ki: Idler correction factor (Table 2-2)
Ke: Environment correction factor (Table 2-3)
 How to calculate the design power (Pd)
The value of transmission power used in designing is the power requirement of the driven machine,
is obtained, or the power of driving unit (engine or motor).
Figure 5- 8 Cross section selection chart for Classical Raw Edge Cogged V-Belts
𝑃𝑑 = 𝑃𝑡 × 𝐾𝑠
Wherein; Pd: Design power (kW)
Pt: Transmission power (kW)
Ks: Service factor

39
Wherein, Pt: Transmission power (kW) 1.8Kw
Tq: Torque (N-m) 70 N-m
n: Shaft speed (rpm) 1500rpm 1
PS=0.7355 kW
Table 5- 2 Idler correction factor
Table5-3 Value of correction factor
Table 5- 4 Value of environmental correction factor

40
Select the pulley size
Select the small pulley datum diameter larger than the minimum specified in the Table 2-4.
Inappropriate pulley reduces transmission efficiency and belts' durability significantly.
Table 5- 5 The value of minimum pulley datum diameter
Speed ratio;
The speed ratio from input power to the agitator shaft is 6
large pulley datum diameter
The small diameter is given from above table and belt type for raw edge copped type is 63mm.
Dd; Large pulley datum diameter
Dd; small pulley datum diameter
SR; speed ratio
The belt datum length
Select the standard belt length closest to the Ld' from our lineup table 1.1 belt type
A. 2697
Where;
′: Interim belt datum length (mm)
′: Interim center distance (mm)=1000mm
Dd: Large pulley datum diameter (mm) dd:
Small pulley datum diameter (mm)
Based on the datum length the width 13mm and thickness 9mm of belt is selected from type A cross
section. belt code105 interim length is 2667mm.length designation A64

41
Figure 5- 9 Belt geometry
Table 5-6 Available size for Raw Edge Cogged V-Belts- AX
Center to center distance
𝑏 = 2𝐿𝑑 − (𝐷𝑑 + 𝑑𝑑),
= 2 × 2697 − 𝜋(387 + 63)
= 3980.28𝑚𝑚
= 981.7𝑚𝑚

42
Where
C: Center distance (mm)
Ld: Belt datum length (mm)
Number of belts
Required number of belts (Nb) is determined as follows. Round up the calculation results.
Where
.
From below tables at 0.33 we get = . by interpolation between 0.3 and 0.4 and based on
belt length designation A64, arc of contact factor is obtained. =0.98
From table we have
From AX power rating table based small pulley diameter by interpolation we get the values of basic
and additional power rating, PS=0. 2378, Pa=1.062 Kw.
,
The number of belt is given by;
.
Where ; Nb: Required number of belts Kc: Power rating correction factor
Pd: Design power (kW)=1.8Kw Kθ: Arc of contact correction factor
Pc: Correction power rating (kw) Kl: Belt length correction factor
Ps: Basic power rating (kw) Pa: Additional power rating for speed ratio (kW)
Pt: input power of motors(Kw)

43
Table 5- 7 Arc of contact and belt length correction factor
Table 5-8 AX-Section Power Rating
Contact angles
The velocity of the pulley is obtained from the centrifugal stress or tensile stress in the pulley rim is
given by;
where

44
Coefficient of Friction between Belt and Pulley
According to C.G. Barth, the coefficient of friction (μ) for rubber belts on cast iron pulley, at the
point of slipping, is given by the following relation, i.e.
The following table shows the values of coefficient of friction for various materials of belt and Pulley.
According to this table when the calculate value is little more than listed, we get good coefficient
friction between pulley and belt and we able to reduce slippage
Force analysis
Tension forces at loose and tight side (T2 and T1 ) respectively are calculated.
Figure 5- 10 Forces on the pulley
Angle of rap( ) of pulley is obtained from
Resolving the reactions vertically to the groove, we have
Where
R1 = Normal reactions between belts and sides of the groove.
R = Total reaction in the plane of the groove.
μ = Coefficient of friction between the belt and sides of the groove.
We have an equation for double belt; the ratio of the logarithm of tension forces is given by;

45
,
From power transmitted we have;
Substituting this value in the above equation of (8)
Where; T1=F1 tight side tension
From the above table the value of the groove angle of type A belt and pulley is and the
range of the single belt width and thickness is 13mm and 9mm and 45 and 30mm for belt
respectively. Area of belt,
Mass of belt,
The centrifugal tension of belt is given by,
Maximum tension of belt,
Face width of pulley
Face width of belt
Where, n=number of belt
ef=coefficient values for face width of belt. From table for A type belt (f=10, e=15)
Torque of pulley;
We know that the torque transmitted by the driven or compressor pulley shaft,
=68750mm

46
Since the overhang of the pulley is 1027.5 mm, therefore bending moment on the shaft due to the belt
tensions,
,
Equivalent twisting moment,
,
5.2.9 Design of Horizontal shaft for spur and bevel gears
This shaft is used for carrying both large bevel and small driver spur gears on a single shaft and used
for transmitting power from input driver bevel gear to the output large bevel gear, then this output
power transmitted to spur gears to drive the slider crank mechanisms.
Material; Mild steel AISI: 1090
Ultimate tensile strength; 520Mpa. Factor of safety =4.5
Yield strength; 290Mpa. Bulk modulus = 40 GPa
Modulus of elasticity; 205Gpa Shear modulus = 80 GPa
The first shaft
In this shaft the larger bevel gears and small spur gears are suspended on it. The length of the shaft
is 490mm.
Figure 5- 11 Forces on the upper shaft
Note; All dimensions are in millimeters

47
Yield shear stress
Then rearranging the equation;
Force analysis
Outer diameter of driver and driven bevel gears,57mm and 159mm and face width 18mm
respectively. Density of carbon steel for gear material is Area and volume
,
𝑉1 = 𝐴 × 𝑤 = 2.552 × 10−3 × 0.018 = 4.5932 × 10−5
𝑊1 = 𝑀1 × 𝑔 = 𝜌 × 𝑉1 × 𝑔,
= 7860 × 4.5932 × 10−5 × 9.81
𝑊1 = 3.537𝑁
= 7860 × 3.574 × 10−4 × 9.81
𝑊2 = 27.523𝑁
Outer diameter smaller and larger spur gears, 100mm and 220mm and face width 30mm respectively.
Density of carbon steel for gear material is
Area and Volume;
= 7860 × 2.3562 × 10−4 × 9.81
𝑊1 = 18.145𝑁

48
= 7860 × 1.14 × 10−3 × 9.81
𝑊2 = 87.789𝑁
The reaction forces on the bearing can be calculated by momentum equation
Moment at A;𝑊1 × 0.2 − 𝐹𝐵 × 0.4 + 𝑊2 × 0.44,
𝐹𝐵 = 18.145 × 0.2 + 27.523 × 0.44
𝐹𝐵 = 18.49𝑁,
∑𝐹𝑉 = 0, 𝐹𝐵 + 𝐹𝐴 − 𝑊1 − 𝑊2
𝐹𝐴 = 18.49 − 27.523 − 18.145,
= 27.176 = 27.2𝑁
Moment at A;
The second shaft
This the shaft in which the large spur gear and rotating crank disk is suspended on it. The length of the shaft
is 540mm.the diameter of the gear is 220mm and the diameter of stroke or rotating disk is 300mm.
Due mechanical systems there is some power loss is occurred. New power and torque that transferred
to the second shaft is obtained by;
,
Since they manufactured from the material;

49
Rearranging torque equations yields;
Crank Spur gear
Figure 5- 12 Forces on the lower shafts
Note; All dimensions are in millimeters
Force analysis
Area and volume of rotating crank disk
= 7850 × 2.12 × 10−3 × 9.81
𝑊1 = 163.285𝑁
= 7860 × 1.14 × 10−3 × 9.81
𝑊2 = 87.789𝑁
Moment at B;𝑊1 × 0.54 − 𝐹𝐴 × 0.4 + 𝑊2 × 0.2 = 0,
RA RB

50
𝐹𝐵 = 163.285 × 0.54 + 87.789 × 0.2
𝐹𝐵 = 264.33𝑁,
∑ 𝐹𝑉 = 0,
𝐹𝐵 + 𝐹𝐴 − 𝑊1 − 𝑊2
𝐹𝐴 = −264.33 + 163.285 + 87.789,
𝐹𝐴 = −13.256𝑁
The negative sign indicates that the FA is an upward force and its freely rotates without any effect
on bearings.
5.2.10 Design of Key for shaft and pulley
 Power transmitted = 1.8 KW at 1500rpm.
 Diameter of the shaft = 35mm, from the previous shaft diameter analysis.
 Material for the shaft and key is mild steel having allowable shear and crushing stress taken as
42 MPa and 70 MPa respectively.
Table 5- 9 N Proportional of Standard for gib-head keys
From table 5.9 we find for shaft diameter of 35 mm, width of key w = 11 mm, thickness t = 8 mm.
gibe-head key is used to prevent relative motion.
We know that length of the key in for shaft and pulley;
𝐿 = 1.571𝑑
= 1.571 × 35 = 54.9 ≈ 55𝑚𝑚
Figure 5- 13 Gib-head key for coupling

51
Now let check the induced shear and crushing stress in the key, first let consider shearing of key and
we know that torque transmitted;
Now considering crushing of the key, we know that torque transmitted (T)
As we get the induced shear and crushing stress are less than the permissible stress, therefore the
design of gibe-head key is safe design.
With the same manner of this we find the dimension of key for the shaft the shaft diameter of 56mm.
thickness and width of key is 17mm and 10mm.
5.2.11 Design of crank sliding mechanism
The slider-crank mechanism is a particular four-bar linkage configuration that exhibits both linear
and rotational motion simultaneously. As in the four-bar mechanism, the extended and folded dead
Centre positions are when the crank and the coupler are collinear (coupler link is commonly called
connecting rod in slider-crank mechanisms).
 Material; Mild steel AISI: 1090
 Ultimate tensile strength; 520Mpa,
 Factor of safety=4.5
 Yield strength; 290Mpa,
Figure 5- 14 Slider crank mechanisms

52
Kinematic Analysis
The kinematics of the slider-crank mechanism are evaluated at a rotational speed of 83.33rpm. All of
the following kinematic and dynamic force equations are taken from Norton’s Design of Machinery.
Angular Velocity
ʯ = 83.33 𝑟𝑒𝑣𝑜𝑙𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒
= 8.73 𝑟𝑎𝑑𝑖𝑎𝑛𝑠 𝑝𝑒𝑟 𝑠𝑒𝑐𝑜𝑛𝑑𝑠
Slider Position
,
𝑆(𝜃) = 103.69𝑐𝑚
Slider Velocity
,
Crank Position
𝑆𝑥(𝜃) = 𝑅𝑠𝑖𝑛(𝜃),
= 15𝑠𝑖𝑛21.3 = 5.45𝑐𝑚
𝑆𝑦(𝜃) = 𝑅𝑐𝑜𝑠(𝜃)
= 15𝑐𝑜𝑠21.3 = 14𝑐𝑚
Crank velocity
𝑉𝑥(𝜃) = 𝜔𝑅𝑐𝑜𝑠(𝜃), 𝑎𝑛𝑑 𝑉𝑦(𝜃) = 𝜔𝑅𝑠𝑖𝑛(𝜃),
𝑉𝑥 = 17.97𝑚/𝑠
𝑉𝑦 = 7𝑚/𝑠 Here we get different value on the same input velocity from same shaft, but we take the
highest velocity for design purpose to increase the reliability of the crank mechanism.
Dynamic Force Analysis
Shaking Forces
Shaking force is defined as the sum of all forces acting on the ground plane of the system.
 Ma has a mass*radius product equal to that of the unbalanced crank. Also
 Ma is equal to 2/3 the mass of the connecting rod
 Mb is equal to 1/3 the mass of the connecting rod
Effective mass at crank (Ma), effective mass at connecting rod(Mb) Mass
of connecting rod,
𝑚 = 𝜌 × 𝑉 = 7850 × 1.1 × 0.04 × 0.007

53
= 9.81 × 0.933 = 9.15𝑁
= 9.81 × 0.467 = 4.578𝑁
= 153.15𝑁
𝐹𝑠𝑦(𝜃) = −𝑀𝑎(𝑅𝜔2𝑠𝑖𝑛𝜃)
𝐹𝑠𝑦(𝜃) = −9.15(0.15 × 8.732𝑠𝑖𝑛21.3)
= 38 𝑁
Stress analysis;
. .
= 3480.68𝐾𝑃𝑎 = 3.48𝑀𝑝𝑎
Stress due to design consideration
.
= 115.55𝑀𝑃𝑎
Therefore, the design stress is greater than working stress. It’s safe.
5.2.12 Design of circular slider/roller
Its used to smooth the face of panel by sliding forward and back ward on the glass table.
Material; low carbon steel
Young’s modulus=200GPa
Yield stress=290 MPa
Ultimate stress; 841MPa
Tensile strength=400MPa
Factor of safety=2.5
Geometric analysis
Figure 5- 15 circular slider
Length =570mm
Outer diameter =150mm
Internal diameter =144mm

54
Thickness = 3mm
Area,
Force analysis
Mass of the plate is obtained from its volume and material density and weight of pin of arm.
Density of low carbon steel==7850kg/m^3 and assume pin arm weights 1kg.
.
For each slider, but we have 4 sliders, then we get a total of 58.35 N.
Stress analysis
Yield stresses of the material is given. from that the design stress is given by
The working stress of the plate
. It’s less than 118MPa.its safe.
5.3.13 Design of bed for bucket or Tank
Used to carry the tanker on it.the applied downward load the strength of the material should be
calculated.
Yield stress=247MPa
Factor of safety
Figure 5- 16 bed for tank

55
Geometric analysis
Length=620mm
Width =650mm
Force analysis
The downward load due to bucket, dough and exhaust valves.
Stress analysis
The design stress of carriage is obtained from the relation of
Working
stress of the carriage
therefore, the carriage withstands the load.
5.2.14 Design of Roller
Before starting design of roller, for conveying/rolling purpose, first we should know the load which
exists on the roller. Here they are three loads are occurring on the topside of the roller, load of glass,
panel board, and slider load.
Material – MS
E Mpa,
ρ= 7860 Kg/m3,
Syt = 590 Mpa
Considering uniformly distributed load & FOS = 2
Allowable Stress (σall) = Syt / Fs =590/2=295 Mpa
Load acting on the roller

56
Figure 5- 17 Rollers
Stress analysis Maximum Stress Calculation for given condition
W= 186.28/5= 37.26N (Load act on 5 rollers at a time)
D1= Outer diameter of roller = 61 mm
D2 = Inner diameter of roller = 56 mm
w = Width of roller = 550 mm
y = Distance from neutral axis = 0.061/2 = 0.0305
V= volume = 2.572
Considering uniformly distributed load,
Checking Factor of Safety for design-
,
As Calculated Fs is greater than assumed Fs, Selected Material can be considered as safe.
5.2.15 Design of bed for glass
Yield stress=247MPa

57
Factor of safety=2.3
Figure 5- 18 Bed for glass
Geometric analysis
Length=1200mm
Width=600mm
Area =
Force analysis
Since the load on the bed is distributed load due to the glass, frames, slider and gypsum board or
panel. First its converted to point load along its length.
Geometry of glass; L=1100mm, W=550mm, t=5mm,
Area
Volume
Density;
Load applied on the bed;
Now the reaction forces;
Take moment at A

58
Stress analysis
Due to working;
Due to design criteria;
.
5.2.16 Design of holder bars
Material; Mild steel AISI: 1090
Ultimate tensile strength; 520Mpa. Factor of safety =4.5
Yield strength; 290Mpa. Bulk modulus = 40 GPa
Modulus of elasticity; 205Gpa Shear modulus = 80 GPa
Figure 5- 19 Geometry of holders
The load acting on the bar due by shaft, gears and other components .so these forces are calculated
by taking moment at fixed points
Figure 4- 20 Holders
Forces acting on the bar FA1=163.285N,FA2=87.789, F2B1
=27.523,F2B2=18.145,W3

59
Force analysis at A
Bending moment,
Shaft diameter=45mm
Load W=163.28N
= 38.779𝑁𝑚
= 2.147 × 10−7
= 8.95 × 10−6
Stress analysis
Bending stress
= 4.334𝑀𝑃𝑎
Force analysis at B
Bending moment,
Shaft diameter=45mm
Load W=27.523N
= 6.54𝑁𝑚
= 2.147 × 10−7
= 8.95 × 10−6
Stress analysis
Bending stress
= 0.7307𝑀𝑃𝑎

60
CHAPTER SIX
6.1 Fabrication Process
6.1.1 Collecting the necessary materials
In the design of this machine there are many parts to be included for the effective operation of the
machine. Additionally, it requires many considerations during the operations and Fabrication the
machine. In the Fabrication of this machine first the parts are will be identified and the specifications
will be analyzed. Based on the given specifications and dimensions of the of the parts and based on
design parameters the parts will be manufactured.
6.1.2 Manufacturing of tables
The manufacturing process of table is starting from measuring of its leg of bed on steel frame the it
should cutted by grinder or cutter machines. After that it is welded with bed edge surface to withstand
the load apply on it.
6.1.3 Manufacturing of holders
The holders can be manufactured by cutting the 4x4 RSH steel metal with designed dimension and
welding together. On some parts we use bolts and nuts to join them each other because it’s simple to
dismantle during servicing and maintenance time and for substitution purposes. After joining it was
placed to the necessary application for holding the glass tables, motors, to carry the tank table and
transmission shafts and gears.
6.1.4 Manufacturing of mixing equipment
The mixing equipment’s are tank, agitator and blades. The tank is made from sheet metal by rolling
and make to have a cylindrical shape. Then drilling the gate for dough releasing purposes. The
agitators have blades or impeller for stir the gypsum dough and shafts in which blades are welded on
it.the agitator shaft is connected with pulley by keys.
6.1.5 Manufacturing of rollers and slider crank
The roller fabrication is started with rolling of sheet metals with measured diameter. Then after it
welded on the tip to take the circular shapes by making the closed cylinders. We join the two edges
with bearing to rotate on its axis to move the load from it.
The slider crank has consisted of four bar components. The manufacturing process will start from
cutting the thick metal sheet as disk like shape on that part we weld L-type Ferro bar or arms. This
rod is drilled on at the end for bolt entering purposes. Finally, its connected with connecting rod and
crank.

61
6.1.6 Preparing AC motor, belts and gears
Power producers and transmitter will be selected and prepared. We are purchasing AC electrical
motors, bevel and spur gears, V-belts, bolt and nuts, roller bearings, glass(mirror) etc. After that we
connect them on their right position by different joining mechanisms.
6.1.7 Preparing joints
Joints are used to connect two different parts together in different ways. Either permanently or
temporary method like bolt and nut, keys etc. Maybe we weld together for their good strength
6.1.8 Assembling
The assembling process is starts after all components are completely prepared and arranged well.
Finally, we assemble that we manufactured in the shop and installed for operation its work
6.2 Maintenance
When failure is happened on the parts, the mechanism need to be dismantling parts procedurally until
we find broken part. Then immediate service action is taken and solution will be given for that parts
in different ways. The actions are may be welding the parts, using lubricants and after that if it’s not
possible to use it must be changed the parts.
6.2.1 welding
Welding process is used for metals that are broken or starts crack on the surface. Then it will be used
electron arc welding, mig welding, oxy acetylene gas and etc.
6.2.2 lubrication
The lubrication process is used to avoid the friction and wear created between two moving parts.
grease is used for bevel gear and spur gears between their meshing parts and also on the shafts and
pulleys part. For belt we may use oil lubricants.
6.2.3 Substitution
Substitution process is used after the problem is beyond the above two action can be done. If it’s
impossible to weld the damaged components its necessary to replace the parts instead of broken area.
Also if the parts are not welded like motors, belts and glasses we obliged to replace the components
on the machine.

62
CHAPTER SEVEN
Result and discussion
7.1 Result
The measured and calculated data in the data analysis become synthesized to get perfect safety factor
for our design. The result data that are obtained from the calculations listed in the table below;
Table 7- 1 Result
Sl.
No.
Items Quantity Specification Dimension(mm)
1 Bucket/tank 1 Steel sheet metal Diameter= 600 Depth = 816
2 Motor 1 3-phase AC
electrical stepper
motor
4.5 kg
3 Belt 1 Rubber Length = 2697, width = 13
Thickness = 9
4 Gear 4 Mild steel All data’s are available on chapter 4
5
Key 6 CI
For all shafts Leng = 55 w= 28 t= 16
6
Bearing 24 MS
For B307~bore=35 Do=80
For B405~ bore 25 Do 80
7 Bolt and nuts 20 MS Dmax=15 length=18
8 Pulley 2 CI Dp = 387 B=63, t=35
9 shafts With calculated values
7.2 Discussion
Finally, the result we obtained is so satisfactory and it the best way of prototyping process will lead
as it will easier. Problem-solving task is not an easy as it drafting and we faced a lot of problem even
from data taking stage. Testing feasibility and re doing were one of the complication we faced.
Finally, after all we attained appropriate solution we manufactured the gypsum board making
machine what we need.

63
CHAPTER EIGHT
Conclusion and Recommendation
8.1 Conclusion
The manufacturing of gypsum board machine in our project is a good optional machine that reduces
time, cost, and environmental friendship. We prefer that fabrication in our locally available materials
we really save our time and money greatly and there will be technological transformation in our
community. Thus the machine is prepared by designing and manufacturing the components, and
assembled these components with standard available parts. The machine setup is then tested to ensure
its satisfactory performance. During the testing it is found that, the machine is able to work with
specified rpm and sufficient turbulence is created inside the mixing chamber. The vibrations created
during running condition are much less.
These all results in homogenous mixing of contents in the mixing chamber, which are our main
objectives. The problem is that the machine is able to work in particular range of viscosity and it is
able to handle the limited capacity for which it is previously designed. For given conditions the
performance of machine is found to be satisfactory. In future for large capacity tanks concept of
baffling, sensors and concept of square vessel are also suggested. Finally, there will be recommended
about how the machine is actually fabricated and use in our country.
8.2 Recommendation
It was recommended that the machine draw backs are needs to be improved in the future. the one
who wants to updates his knowledge and experience on some difficulties like gypsum powder feeding
mechanism, amounts of slurry releasing that is perfectly equal with a board being produced and also
the smoothing mechanisms. The optimum level of the machine production rate is limited in time per
quantity in the day. Due to the fact that some mechanisms are manual like board removing after
production is completed from the glass and the drying system is naturally by air.in addition to this
the power transferring mechanisms also consumes more power and little bit cost due to large space
coverage.
This machine was limited by a maximum particle production quantity and size of the material being
produced. Because; the machine is not fully automated in different mechanism and control systems.
Related to safety it is better to use hand gloves, eye glass, shoes, clothes and etc.

Design and Fabrication of Gypsum Board Making Machine

Design and Fabrication of Gypsum Board Making Machine

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