GOVERNMENT COLLEGE OF ENGINEERING TIRUNELVELI

DESIGN PROJECT

DESIGN OF SCREW CONVEYOR

GUIDED BY Mrs.SUPRIYA (AP, GCE)

DONE BY RAJESH M 13MEED1511 950813408011

Screw flight development

We selected sectional flight screw The outside diameter of screw The inside diameter of the screw Development of outside diameter A =( =( A = 1004.87mm ) ( ) ) ( ) = 304.8mm =101.16mm

Development of inside diameter B =( =( B = 441.33mm ) ( ) ) ( )

The developed inside radius of the flight will be

= 1.2769 r = 220.667mm

Conveyor length =1m+ 2*pitch For one meter length = 1000+ 2(304.8) =1609.6mm No. of flights = = 5 flights Thickness of flight Material = 6.35mm

= Mild steel(ms)

Calculation of various loads acting on screw conveyor: 1. Load due to coal Coal bulk density = 61 * 16.018 = 977.098 kg/m3

Let V = volume in which coal loads acts downwards (i.e. on the center pipe)

V = [(width of trough) * (height of end plate above center pipe)] (0.5* volume of hollow pipe)

Width of trough = 330.2mm = 0.3302m

Height of end plate above center pipe = 196.85mm = 0.19685m Volume of hollow pipe = 0.785[(101.16)2 (88.9)2] = 1.899*106 mm3 = 1.8918*10-4 m3 V = (0.3302*0.19685) (0.5*1.8918*10-4) = 0.06499 9.459*10-4 = 0.0648 m3

We know that Bulk density = Mass / volume Mass = 0.0648 * 980.941 = 63.56kg The weight of coal = 63.56*10 W1= 635N

2. Load due to flights Volume of one flight = 3.142/4 * (D0*D0 Di*Di) thickness = 0.784(0.3048*0.3048 0.1016*0.1016)* 0.00635 = 0.785(0.0929 -0.01032) * 0.00635 = 4.11640*10-4m3 Mass of flight = 5 * density * volume = 5*7800*4.1164*10-4 = 16 kg/m W2 Adding 1 & 2 Total UDL on 1m length = 635+160 = 795 N/m Taking 50% overload to be on safer side UDL = 1192.5 N/m = 160 N/m

Load fluctuations may come due to dynamic loading Therefore increasing UDL say = 1200 N/m

3. Load due to each solid shaft a) Drive end shaft diameter = 76.2mm = 0.7853*0.0762*0.0762*0.508 = 0.7853*2.94967*10-3 = 2.3163*10-3 m3

Density

= Mass / volume Mass = 2.3163*10-3 * 7800 = 18 kg W3 = 180 N

b) Coupling shaft diameter = 76.2mm = 0.784*0.0762*0.0762*0.20955 = 9.55*104m3 Mass = 7800*9.55*10-4 = 7.45kg W4 4. Load due to hollow pipe Mass = volume * density = 0.785(0.10162 -0.08892)*7800 = 14.81kg Taking 60% overload to be on safer side M = 23.696kg Considering this also as UDL of 240 N/m Total UDL = 1200+240 = 1440N/m = 74.5 N

Bearing selection (End bearing) We select SKF 6216 deep groove ball bearing is selected based on the shaft diameter 76.2mm from the PSG data book The static load C0 = 4550kgf

The dynamic load C = 5700kgf Maximum permissible speed (rpm) = 5000rpm Assume life required to be 10,000hrs 90% probability of survival Life in million revolution = L*60*N/ 1000000 = 10000*60*53.29/1000000 = 31.974 million revolution The equivalent load P Where X = radial factor Y = Thrust factor S = Service factor Fa/ Co = 635/4550 = 0.1395 From the PSG data book e = 0.31 Fa/Fr= 635/345 = 1.840 > e The radial factor X = 0.56 Thrust factor Y = 1.4 = [X.Fr+Y.Fa]*S

P = [0.56(345) +1.4(635)]*1.2 = (193.2+88.9)*1.2 = 1298.64N = 129.86kgf The ratio c/p in the graph from PSG data book C/P = 3.36 C= 3.36*1298.64 = 4363.43 N = 436.34 kgf The bearing SKF6216 is selected because in our case dynamic capacity is 436.34kgf.It be lesser than permissible dynamic capacity. So, bearing is very well safe. Deflection calculation: The deflection of the screw is given by D= Where W -Total weight of screw in pounds L - Screw length inches E - Modulus of elasticity I - Moment of inertia (in)4

Here w =189 lbs L = 132 in E = 29,000,000 for low carbon steel I = 4.788in4

For schedule 40 pipe =

= 0.040 in = 1.1016mm

It is lesser than the allowable deflection 6.35mm. For schedule 80 pipe

= 0.0310in =0.787mm As comparing the both schedule 40 & 80 pipe, the deflection is less than allowable deflection 6.35mm

Torque calculation: Torque acting on the screw conveyor is given by the relation = 63025 * motor horse power / N (rpm of the screw) = 63025* 3 / 54 = 3501.38 lbs. in = 3501.38*4.44*2.54 T = 395.60*103 N.mm

From the CEMA correspond to shaft diameter 3 = 76.2 mm. The calculated torque is less than the maximum allowable torque 15435 lbs. in under 2 bolts in shear and bearing. Based upon the torque ratings as per CEMA the following dimension are selected to transfer the torque in safer. The screw flight diameter = 12 = 304.8 mm

The shaft diameter Pipe outer diameter Inner diameter Selection of hanger

= 3 = 76.2mm = 4 = 101.6mm = 3 = 76.2mm

Corresponding to bearing material and characteristics We select 99A hanger. It is designed for maximum support and its slim design minimizes obstruction of material flow.

Corresponding to screw diameter 12 the dimension of the hanger bearing A= 330.2mm B= 177.8mm C= 76.2mm D = 431.8mm E=50.8mm F=101.6mm G=25.4mm H (Bolt Size) = 12.7mm K=9.525mm Selection of Motor and gear box Based upon the horsepower calculation, we select 3hp, 415v, 3;50 Hz A/C squirrel cage induction motor is selected from Hindustan electric motor catalogue. The speed of motor = 1425 rpm The speed of conveyor = 57 rpm Service factor = 1.2 The output torque of the conveyor = 374.93 N-m The step ratio = 25 Based upon the step ratio & input horse power the size 43 three stage inline helical gear unit is selected for screw conveyor.

Dimension of shafts and coupling bolt

Standard End Shaft

Based on shaft dia 76.2mm C=25.4mm D=76.2mm F=25.4mm G= 44.45mm H (bolt size) = 19.05mm M= 25.4mm N=7.93mm Z= 152.4mm

Drive shaft

Hanger end shaft

Based on shaft diameter 76.2mm, the hanger end shaft is selected F=203.2mm G=76.2mm H (bolt) = 19.05mm L= 25.4mm M = 76.2mm N =25.4mm Coupling shaft

Troughs and covers We selected U trough formed flange A= 330.2mm B=177.8mm C=50.8mm D=431.8mm

The dimension of cover D=431.8mm G=15.8mm Inlet and discharge spout

The dimensions are B= 254mm C=203.2mm D=228.6mm K =4.76mm

Saddles and feet

Flange feet

Trough ends

EXPLODED VIEW OF SCREW CONVEYOR

1. Screw 2. Drive shaft 3. Coupling shaft 4. End (tail) shaft 5. Covers 16. Cover clamps

6. Hanger 7. Hanger bearing 8. Discharge 9. Flange foot 10. End bearing 17.Inlet

11. Shaft seal 12. End plates 13. Internal collars 14.Coupling bolt 15. Bolt pads 18. U-Trough