Force Relations and Dynamics of Cutting Knife in A Vertical Disc Mobile Wood Chipper - Leonardo El J Pract Technol

31/10/2016
ForceRelationsandDynamicsofCuttingKnifeinaVerticalDiscMobileWoodChipperLeonardoElJPractTechnol
ForceRelationsandDynamicsofCuttingKnifeinaVerticalDiscMobileWoodChipper
SegunR.BELLO1,MusiliuA.ONILUDE2
1DepartmentofAgriculturalEngineeringTechnology,FederalCollegeofAgricultureIshiagu,EbonyiState,
Nigeria*
2DepartmentofAgriculturalandEnvironmentalEngineering,UniversityofIbadan,Nigeria
Email:segemi2002@yahoo.com
*CorrespondingAuthor:Phone:08068576763
Received:15September2010/Accepted:21June2011/Published:25June2011
Abstract
The force relations and dynamics of cutting knife in a vertical disc wood chipper were
investigated. The tool geometry determined include: rake angle (20) Shear angle, (f=
52.15) the mean frictional angle, (t = 5.71). The analysis and comparison of the cutting
forces has shown that the chips separated from the wood are being formed by off cutting,
sincenormalappliedforceNiscompressiveinnature,themagnitudeoftheforcesusedby
theknifeonthewoodisexpectedtoincreaseasthecuttingedgeoftheknifegoesdeeperinto
thewooduntilthevalueoftheresistingforceactingagainstthecutwoodFfisreachedand
exceeded. The evaluated forces acting on the knife and the chip are: F = 3.63Nmm1 N =
34.7Nmm1Fs=27.45Nmm1Fn=31.92Nmm1Ft=8.46Nmm1Fc=33.85Nmm1.The
resultant force acting on the tool face, Pr = 34.89Nmm1. The specific cutting pressure, Pc
andcuttingforceneededtocutthetimber,Fc,are1.79106N/m2and644.84Nrespectively.
The energy consumed in removing a unit volume of material is 69.96kJ/mm3 and the
maximumpowerdevelopedincuttingthechipis3591.77W(4.82hp).Thechipperefficiency
(86.6%)wasevaluatedbythehighestpercentageofacceptedchipsizes.
Keywords
BendingloadCapacityChipperefficiencyChuteCuttingenergyKnifeangle.
Introduction
Acceptable chip size range and uniformity of chip thickness constitute performance challenge for
chippers[1].Amajorchipperperformancechallengeistofindanoptimumcombinationofchippingspeed
and knife cutting angles to produce the preferred compromise between pin chip generation and overtrick
generation.Chipperperformanceshavebeenevaluatedbasedonfactorssuchaschipperinfeedspoutdesigns,
http://lejpt.academicdirect.org/A18/get_htm.php?htm=017_034
1/14
31/10/2016
knife and knife holder designs, knifechip relations and dynamics among others. These factors have been
investigatedbyvariousresearchersinliterature[16].
Differentmethodsofcuttinghavebeenemployedinthewoodproductsindustrydependingontheuse
ofthewoodandpurposeofoperation[2].Inallofthesecuttingmethods,thequalityofsurfaceobtainedasa
resultoftheprocessisaffectedbyfactorsrelatedtotheprocessedmaterial(treespecies,qualityofmaterials,
moisturecontentsofthematerials,etc.).
The performance of a cutting tool or the machinability of a work material can be evaluated by
measuringthecuttingforces.Thereisdifferenceinthecuttingforcesforparallel,andperpendiculartothe
fiberaxis.Thisvariationmakesthestudyaboutforcesdifficultduringmachining.
Several models have been simulated to study parameters/factors that influence the forces acting on
thecutterknife[1,36].Theseparametersincludenumberofcutterknife,cuttingangle,bluntnessofcutters,
etc.andotherfactorsrelatedtothemachinerytechnologicallevel,feedingrate,cuttingspeed,etc.[2].
In [7] it was identified two cutting directions: longitudinal (900) cutting and transversal (9090)
cuttingdirectionswhereannualringsareorthogonaltothelongitudinalsideofthepiece(Figure1).These
cuttingdirectionsobeyedMcKenzies(1960)notation,wherethefirstnumberrepresentstheangleindegrees
between the cutting edge of the tool and the wood grain, and the second indicates the angle in degrees
betweenthecuttingdirectionandthewoodgrain.
Figure1.Orientationofspecimensaccordingtodirectionandcuttingtype(L=longitudinaldirectionR=
radialdirection,andT=tangentialdirection)
The 9090 orthogonal cutting is characterized by producing type I and II failures on the machined
surface, as well as by high parallel cutting forces compare to 900 cutting. In 9090 cutting, the cutting
surface finish is not as important as in the case of 900 cutting. On the other hand, the magnitude of the
parallelforceandtheconfigurationofthecuttingtoolare,inthiscase,extremelyimportant[7].
2/14
31/10/2016
Figure2.Cuttingtoolsusedinthe900cuts(a)and9090(b)
Inthe900cuttingsetting,thepositivenormalcuttingforcesindicatethat,inrelationtothecutting
plane,theknifetendstopressorpenetrateintothespecimen.Atlowerrakeangleslessthan10,thenormal
forcesisfoundtoincreaseasthecuttingthicknessincreasesindicatingthatatsmallanglesthenormalforce
ismoresignificantlyinfluencedbythecuttingthickness.Atincreasedrakeangles,between20and30,the
meannormalforceshowedlittlevariationasthewoodthicknessincreased.In9090orthogonalcuttingthe
mean normal force decreased as cutting thickness and angle increased, going from positive to negative
betweenanglesof30and40[7].
Consideringallangles,thicknesses,juvenileandmaturewoodzones,meancuttingforcesinthe900
cutting direction and the 9090 cutting direction has been reported. In [7] is reported a cutting forces of
24.63Nmm1and35.42Nmm1forthe900cuttingdirectionandthe9090cuttingdirectionrespectively.In
[8] determined a cutting forces for initial and final Pinus taeda woods under the 900 and 9090 cutting
situations,takingintoconsiderationallangles,cuttingthicknesses,andinitialandfinalwoods,andobtained
ameanparallelcuttingforcevaluesof22.3Nmm1for900cutting,and34.7Nmm1for9090cutting.
In[9]wasdeterminedacuttingforcesforthreeeucalyptusspecies(grandis,saligna,andcitriodora).
For the 900 cutting of the grandis species, the mean parallel cutting force at the 10 angle, for all
thicknesses, was 33.2N mm1. [7] determined the cutting force for the species Pinus elliottii, in the 900
cuttingata10angle.Themeanparallelcuttingforcewas27.42Nmm1forcuttingthicknessesof0.2mm
0.4 mm and 0.6 mm. For our Pinus taeda, at the same angle and taking the same thickness into
consideration,themeanparallelforcevaluewas23.23Nmm1.[10]determinedthecuttingforcesforPinus
radiata and found, for the 90 0 cutting in the radial direction, taking all cutting thicknesses into
consideration,ameanparallelforcevalueof41.38Nmm1atthe20angle,and27.88Nmm1atthe30
angle.
ChipperKnife&Mounting/Holder
Althoughchippersvarygreatlyinsize,style,andcapacity,theknivestheyuseareallverysimilar.
Theyarerectangularinshapeandareusually50.8to101.6mm(4to6inches)acrossby101.6to304.8mm
(6to12inches)long.Theyvaryinthicknessfromabout38.1to50.8mm(12inches).Chipperknivesare
madefromhighgradesteel,andusuallycontainaminimumof8%chromiumhardness[12].
Various knife mounting/holder assemblies have been reported in literatures [11, 12]. An improved,
moreconvenientandsimpleknifeholderdesignforthechippereliminatesthecounterknifeandtheknife
holder with the knife mounted directly on the disc plate by bolts and having an adjacent surface extends
outwardfromthechipperdiscatanangleof120degreesfromtheflatsurfacewhichabutsthechipperdisc
[13].
The technical barriers that currently exist in chipping operation include unsuitable chipper cutter
(knife type) and mode of feeding during operation. Previously, there has been no major push to develop
equipmenttoovercomethesetechnicalbarriersintheprocessingoflowvaluewastewood.Currentchipping
and rechipping technologies have served the forest based industries well for many decades however it is
imperativethattheforcedynamicsofthesetechnologiesbewiththeobjectiveofpossiblemodificationsto
3/14
31/10/2016
betterserveandtobemoredirectlyapplicabletotheenduserneeds,eitherinprimaryorsecondaryrecovery
applications.
MaterialsandMethod
Thechoiceofdisctypechipperwasduetotheinherenthighmarketvalueadvantageofgoodquality
chipsproducedfromdiscchippers[14],lowinitialcost,andthesimplicityofthechippingmechanism[15].
DesignConsiderations
The economic benefits of higher quality chips in pulping have intensified the focus on improving
chipperperformance.Theuniformityofchipsizeandthepercentagesofeachchipsizefractionproducedby
achipperaredirectfunctionsofknifecuttingforcesandknifevelocity.Otherchipperdesignfactorsinclude
shaft bending forces, cutting angle and chip geometry. The desire for high quality endproducts, machine
componentreliabilityandhighthroughputisbalancedbythedesignandothertradeoffs.
ChipCuttingAngle:Thelogsapproachtheknivesperpendiculartothegrainata35ospoutangle
relativetothelogaxisinordertocontrolchiplengthwhilechipthicknessremainsarbitrary.Thechiplength
iscontrolledbythedistancebetweentheknifecuttingedgeandthediscplate,i.e.thewidthofthecutting
surface[14].
ChipSize:Thedesireforgoodqualitychipinpulpindustryisastrongfactorinthedesignofchipper
machines.Chipsizeiscontrolledbyknifeangle,logorientationandwoodgraindirection.Therangeofchip
sizesobtainableinchippersinclude25.476.2mm(1to3inches)inlength,12.725.4mm(1/2to1inches)in
width,and(6.2525.4)mm(1inch)thick[15].
DesignEquationsandCalculation
The combination of chipper geometry and wood quality will produce a range of chip lengths and
thicknesseswhichmaybeuniform[16].Withinagivenwoodspecies,thecombinedeffectsofchiplength
setting, spout angle, knife edge angle, and knife velocity are primary parameters modified to optimize the
relationshipbetweenchiplengthandthickness.
Considering the factors governing the machine performance, the following critical factors are
consideredinthedesignofthechipper:
SpecificCuttingForce(Fc)RequiredinCuttingTimber:Thespecificcuttingforcerequiredtocut
timberintochipisevaluatedfromtheanalysisoftheforcesactingonthewoodandtheangleofactions,with
thefollowingassumptions:
1.Anorthogonalcuttingsituationisassumedinordertodeterminethespecificforcesinvolvedincutting.
Forthepurposeofsimplification,thedeadweightofthewoodisassumedinsignificantinrelationtothe
existingforces.
2.Thecoefficientofshearfriction,mistakenas0.1,whichisthesmallestvalueusedinsimulations[17].
3.Anestimatednormalcuttingforce(N)valueof34.7Nmm1at20rakeangle[7,18]isusedfordesign
calculation.
Inthedeterminationofcuttingforces,chipthicknessesetc.,considerationisgiventothedynamicsof
geometryofcutting.ThesimulatedcomponentsoftheknifeandchipgeometryareasshowninFigure3.
4/14
31/10/2016
Figure3.Geometryofcuttinganglesandforcecomponents(wheretheanglenotationsinthefigureare
definedasfollows:=Toolrakeangle.Arakeangleof20oisselectedf=Shearangle)
Arelationshipexistsbetweentheshearangleandtherakeanglegivenbytheexpression:
(1)
2f+t=90
m=Thecoefficientofshearfriction=F/N
t=Meanangleoffrictionbetweenthechipandthetool=tan1(F/N)
t1 =(uncut/undeformedchipthickness).Thisistakenas0.25ofthemaximumwooddiameter.t1is
givenby
t1=hsinf
(2)
t2=Deformedchipthicknessusuallyt2>t1[18].t2isevaluatedbytheexpression
t2=hcos(f)
(3)
b=Sharpnessangle
Actionoftheknifeonthewoodispresentedwiththefollowingforcesystemsanalysisindicatingforces
andanglesasdrawnin(Figure4).Applyingtrigonometry,theforcesactingontheknifeandthechipisgiven
bythefollowingrelationships:
F=Ftcos+Fcsin
(4)
N=FccosFtsin
(5)
Fs=FccosfFtsinf
(6)
(7)
Fn=FcsinfFtcosf
5/14
31/10/2016
Figure4.Knifecuttingforcesandchippingdiagram
Theseforcesactsonthewoodontheperpendicularandparallelaxistothesurfaceoftheknifeand
aredefinedasfollows:
Fc=Forceactinginthedirectionofcutting.
Ft=Thrustforceneededtokeepthetoolintheworkpiece(directionperpendiculartotheworkpiece
surface).
Pr=ResultantforceofFnandFs
F=Frictionforcebetweentoolandchip
N=Normalforcebetweentoolandchip
Fs=Shearforcewithwhichtheknifehastoactinordertocausethecuttingofthefibresinthewood(it
isassumedthatthisforceisperpendiculartothegrain).
Fn=Forcenormaltoshearplane
Experimentally it has been found that the shear angle and the cutting ratio depend upon the work
pieceandtoolmaterialandthecuttingconditions.Severalattemptshavebeenmadetoestablishatheoretical
lawwhichpredictstheshearangle.ErnstandMerchantdevelopedthefirstreasonabletheory.Thisassumed
thattheshearanglewouldtakeupavaluetomaketheworkdoneincuttingminimum[14].Forgivencutting
conditions,theworkdoneisproportionaltoFc,
SpecificCuttingEnergy:Thespecificcuttingenergy,E istheenergyconsumedinremovingaunit
volumeofmaterial.Suchcalculationsarerequiredtodeterminethesizeofthedrivemotor.Thevolumeof
materialremovedisV=hwL,sothespecificcuttingenergycanbewrittenas:
E=FcL/h.w.LJ/m3,N/m2,W.s/m2
(8)
Power Required for Cutting: The power required by each cutting knife was determined using
equation2.
Power,W=EVt/h.
(9)
whereE=therateofmaterialremoval,Vt=Velocityofknifeandh=cuttingtoolefficiency(typicallyinthe
regionof0.7to0.8)
Power Consumed in Cutting: The power consumed by the motor in cutting unit fiber of wood
subdivisionisgivenby
(10)
Allunitsinhorsepower(i.e.,1/33000)1hp=0.746kW
wherePc= Thetotalcuttingpower(Ps+Pf),Ps=Theshearingpowerrequired,Pf=Thefrictionlosses.
Kinetic Energy of the Rotating Disc: In rotation, a sufficient torque is required to keep the disc
spinning at constant angular velocity in the absence of resistive force needed to cut the wood. The disc
inertiaiscalculatedfromtherelation
(11)
I=0.5mR2(kgm2)
KineticEnergyofDisc:Thediscisarigidbodyrotatingaboutalinethroughthecentreofmassand
thuspossessingarotationalkineticenergy(Er)whichissimplythesumofthekineticenergiesofitsmoving
6/14
31/10/2016
parts,andthusitisequalto:
Er=0.5I2=0.5I(v/r)2
(12)
whereEristhekineticenergyinjoules,misthemassinkilograms,isangularvelocity(v/r)=20.94rads
1,risthedistanceofanymassmfromthatline,andvisthespeedinmeterspersecond.
PowerRequiredtoDriveShaft:Powerrequiredtodrivethechippermechanismisgivenby
Pd=F.v=mv3/R
(13)
wherePd=powerrequiredtodrivethechipperdisc,F=centripetalforceactingontheperipheryofthedisc
=mV2/R,m=Totalmassofthechipperunit,R=Radiusofdisc.,V=Discvelocity=pDn,nisgivenbythe
ratioofnbetweenthepulleyandthedisc.
Power required in driving the chipper disc is 14.15kW. According to [20] about 5.22 kW (7 hp) is
requiredtochipaninchofroundwooddiameterduetotheinertiaoftheheavyrotor.Employingthisrelation
thechipperisdesignedtochiproundwoodofapproximately(18.97/7)76.2mm(3inches).
ShaftDesign
Theshaftissubjectedtotwoformsofdirectionalloadings:verticalloadingandhorizontalloading.
TheVerticalloadsresultedfrom:loadsduetoweightofpulleyactingdownward,theappliedtorqueorradial
force,loadsduetoweightofdiscandshaft,andreactionsatthesupports(bearings).TheHorizontalloading
resulted from loads due to tangential force exerted by the pulley and reactions at the supports due to the
tangentialforce.
Alltheseforceswereresolvedbythefollowingequations.
RA=(R2av+R2ah),RA=673.04N
RB=(R2bv+R2bh),RB=673.04N
(14)
TP=(T2t+M2t),TP=478.91N
RA+RB=TP+Wr
Wr=673.04+497.15478.91=298.39N
Figure6.Resultantloadingforcesonshaft
7/14
31/10/2016
Figure5.Shaftprofileanddimensions
BendingMomentEquations
Thebendingforcesateachpointloadisevaluatedbythefollowingmomentequations
(15)
Thefreebodydiagram(FBD),shearforcediagram(SFD)andbendingmomentdiagrams(BMD)are
showninFigure5below.ThemaximumbendingmomentMBmaxasevaluatedfromequation15is+21.25
Nm.Thisoccurswithintheregionofthechipperdisc,WRindicatingtheareaofhighestloadconcentration.
8/14
31/10/2016
Figure5.Forcedistributiondiagramontheshaft(*FBD=FreebodyDiagramSFD=ShearForce
DiagramBMD=BendingMomentDiagram)
Toincreasesafetyinsolidshaft,themaximumbendingmomentMBmaxismultipliedbyafactorof
1.6MBmax=21.251.6=34.00Nm
EquivalentmomentoftheforcesMeqisgivenby[17]
Meq=(T2m+M2Bmax)
(16)
whereTm = Torsional moment in shaft (30.52 Nm, calculated in equation 16) Meq = Equivalent moment
(45.69Nm).
Theshaftdiameterthatwillwithstandtheseloadsiscalculatedfromthemaximumshearstresstheoryandthe
combinedstressequationisusedthus
ds3/16=[(T2mx+M2max)/Sall]
(17)
where Tmax = maximum torsional (twisting) moment MBmax = Maximum bending moment Sall =
Allowabledesignshearstress=3.7921107N/m2ds=shaftdiameter(0.018m)determinedfromequation
(21). If a safety factor of 1.3 is assumed for the design the shaft diameter is 1.5 ds. Any shaft diameter
belowthisvalue(27.0mm)willfailthroughbending.Fromshaftstandardtable,ashaftdiameterof38.1mm
isselectedforsafeshaftdesign.
StrengthinShaft
Strength in shaft is determined to know the limit to which bending will be prevented in the shaft.
Bendingstresseqn.isgivenby
B.S.=Bendingload/Areaofcrosssectionoftheshaft
(18)
whereBendingstress,forsteel=10,000psi(1psi=0.07kg/cm2),Bendingload=weightofshaft+Disc+
torsionalforce+weightofpulley.
Areaofcrosssection=pD2/4.DisthecalculatedDs
9/14
31/10/2016
Rigidity(TorsionalDeflection)inShaft
Angleoftwistinshaftasaresultoftorsionisexpressedbytheexpressionbelowwithanassumption
thattorqueisconstantwithinlimitsofeachshaftstep
(19)
whereqt=Angleoftwistasaresultoftorsion.Thisshouldbewithintheacceptablevaluerangeof0o5o
Mt=CriticaltorqueappliedtotheshaftJti=Polarmomentofinertiaofshaft(cm4)=pds4/32G=Shear
modulusormodulusofrigidity(8.1x1010Nm2forsteel)li=ShaftlengthStiffnessfactorCt=Mt/t
Yieldfactor=1/Ct
(20)
Fortorsionalload,torsionalstressisgivenby
xy=16mt/d3
(21)
Bendingstress
b=mbr/I=32mb/d3
(22)
Axialstressload
a=4Fa/d3
(23)
Stressconcentrationfactoriscalculatedfromtheratioofthemaximumloadstresstotheratedstress
foundintheelasticzones.
=max/ratedand=max/rated,=1
(24)
GeneralMachineDescriptionandFabrication
Thechipperconsistsofachipperdiscassembly,frame,adischousing,aninfeedchuteandanexhaust
or discharge chute. The disc chipper employs a rotary cutting steel disc secured to a shaft and simply
supportedonfrictionbearingstocutwoodintochips.Thecuttingdiscisformedfrommildsteel25.4mm(1)
thick.Thereare3cuttingknives200mminlengthfixedtothecuttingsidesofthediscbolteddirectlytothe
rotatingdisc.
Machine components and shapes were produced from secondary machining operations including
cutting,grinding,andtrimming,drilling,sawing,andturning.Theconditionsoftoolsusedformachininghas
greaterinfluenceoncomponentperformance,henceadequatecarewastakentoestablishandmaintainthe
optimumtoolconditions.
Atthecorrectworkinglevelposition,theheightoftheloweredgeoftheinfeedchuteis1000mm
fromthegroundlevelthehorizontaldistancefromthespoutopeningtotheshortestpartofthechuteouter
edge(below1000mm)fromthegroundis1200mm[21].
The dimensions of the infeed chute are designed to give protection against both upper and lower
limbsfrombeingpulledintothemachine.Itisequallyimportanttoensurethatthechuteislongenoughto
preventhandsreachingthechipperknives.Theloweredgeoftheinfeedchuteselectedforthedesignis600
mmconsideringtheabilityoftheoperatortobendatthehips.Inthisconfiguration,thechipperisfittedwith
aspoutthatapproachesthediscatanangleofabout38to42degreesfromtheverticalplane.
PerformanceTests
10/14
31/10/2016
Severalsamplesofchipswererandomlytakenfromthechippedmaterialatvariouspointsandtime
intervals.Thematerialsweresortedonatableandclassifiedbasedonsumsofaverageofsampledchipsin
accordance with TAPPI 257 Sampling and Preparing Wood for Analysis strategy SCANCM 40:01
classificationreportedby[22].
ResultsandDiscussions
The fabricated machine is as shown in Figure 6 while Table 1 gives the summary of the designed
machinespecifications.Mostavailablecommercialmobilewoodchippershavethesamerangeofdimension
andthespecificationscomparefavourablywithmostcommerciallyavailablemobilediscchippers[21,22].
ToolGeometryandCuttingForces
Basedondesigncalculations,thetoolgeometrydeterminedinclude:theselectedrakeangle,of20o
Shearangle,f=52.15o(calculated)tominimizeworkdoneincuttingThemeanangleoffriction,t=5.71o
(calculated) The chip length, h (calculated) at any given set of knife angle is 24.13mm The average
thickness (t mm) of the chips produced (19.0520.43) mm. The forces acting on the knife and the chip
evaluatedfromequations47are:F=3.63Nmm1N=34.7Nmm1Fs=27.45Nmm1Fn=31.92Nmm1
Ft=8.46Nmm1Fc=33.85Nmm1.Theresultantforceactingonthetool,Pr=34.89Nmm1,ismadeupof
anormalforce,NactingperpendiculartothetoolfaceandFthefrictionforceactingalongtheface.
Figure6.Themobilewoodchipper
Table1.MachineSpecifications
Components
Engine:
InfeedChute:
Discharge
Chute
ChipperDisc:
Knives:
DriveBelts:
Anvil:
Specifications
Atlas3phasedoublewinding15hpsynchronouselectricmotor
Speed:1440rpm,voltage1.2v,frequency50Hz
Chuteopeningatchipperdiscw180mmh150mm/w450mmh360mmatfeedpoint
Dischargechute:providedwithdirectionalflipcover.900mmfromwheel
DiscSize:1100mmx60mm,DiscWeight:86kg,DiscSpeed:540rpm
Threeknivesmadeofhardenedspringsteel.190mmx76mmx10mmdoubleedged,reversibleandre
sharpenable.
Industrial"V"B51/5L540(two)
Madefromhardwearingmetalwitheasyexternaladjustment
11/14
31/10/2016
InfeedRoller:
Chipper
Housing
Chipthrower
FrameSupport:
Landwheels:
Machine
Capacity
38.2mmdiametersteelroller,inbetweentheanvilandtheknives
12mmplatefrontandback,6mmplatedisccover.
Minimumfeedrateapproximately80feetperminute.
Theframeisanetworkofangleironandsquaredpipesweldedtogether.
Wheels15x6.00
76mm(3inch)ratedto3incheswholelog
Theanalysisandcomparisonofthecuttingforceshasshownthatthechipsseparatedfromthewood
arebeingformedbyoffcutting[22],sincenormal(usual)forceNiscompressiveinnature,themagnitudeof
theforcesusedbytheknifeonthewoodisexpectedtoincreaseasthecuttingedgeoftheknifegoesdeeper
into wood up to the moment when the value of the resisting force against wood cutting Ff is reached and
exceeded.Thenthewoodbreakagetakesplaceandtheseparatedpartofwood(chip)isshiftedandcomesoff
therestofthewood.Thisresultisinagreementwiththoseof[22].
Thenominalcuttingstress(specificcuttingpressure),Pcandcuttingforceneededtocutthetimber,
Fc, evaluated are 1.79 106 (N/m2) and 644.84N respectively. The energy consumed in removing a unit
volumeofmaterial(Thespecificcuttingenergy)givenbyequation(10)is69.96kJ/mm3 and themaximum
powerdevelopedincuttingthechipis3591.77W(4.82hp)
PerformanceTest
The ergonomic properties of the machine conform to the set standard A38 standard. The overall
heightofmachineisadequateconsideringthebendingandfeedingofthemachinewiththeaverageheightof
man,1.6m.Outeredgeopeningoftheinfeedchuteisaminimumof41wide39high.Openingatfeed
spoutisdesignedtobeaminimumof14wide12high.Theexternallengthfromfeedspouttoground
levelis85.
The chip classification and mean distribution of chip sizes has been presented by [21]. The chip
particles seen in these samples are broadly characterized as coarse and fibrous in nature. The coarse
characteristic refers to the irregular surface geometry produced by the blunt force reduction action of the
chipping process. The fibrous characteristic refers to the way the particles have separated with the
longitudinal grain of the wood and the frayed ends of each particle. Figure 7 shows the range of physical
characteristicsofchipclassesandsizesproducedbythemachine.
Figure7.Chipsamplesclassified
12/14
31/10/2016
Dominance of one single class might be very difficult to obtain, especially when the chips were
producedfromdelimbedlogsthepresenceofknotsandotherimpuritiesintroducesuchvariance.
Conclusions
This study has identified operating parameters to be considered in developing appropriate size
reductionstrategiesforwoodwasterecovery.Thepotentialeffectoftooldynamicsandcuttingforcesonchip
propertieswasestimatedusingappropriateequationsandassumptions.Thechipsizeclassificationwasused
asabasisforvalidatingtheequationsandformulasemployedinthedesign.
Fromthetestresults,themachineperformeditsdesignedfunctionsandmeetsthecommercialchipper
specifications of producing good quality chips with no dust and less fines. The chipper efficiency was
evaluated by the highest percentage of accepted chip sizes (86.6 %). The disc chipper offers the largest
particlesandthehighestsizeconsistency.Thedustfreechipproducedbythemachineisveryregular,butit
mightprovetoolargeforsomeconversionplants.
References
1. Kline W.A., DeVor R.E., Lindberg J.R., The Prediction of Cutting Forces in End Milling with
ApplicationtoCorneringCuts,Int.J.Mach.ToolDes.Res.,1982,22(1),p.722.
2.SutherlandJ.W.,DeVorR.E.,AnImprovedMethodforCuttingForceandSurfaceErrorPredictionin
FlexibleEndMillingSystems.JournalofEngineeringforIndustry,1986,108,p.269279.
3. LauderbaughL.K.,UlsoyA.G.,DynamicModelingforControloftheMillingProcess,Journalof
EngineeringforIndustry,1988,110,p.367375.
4. MontgomeryD.AltintasY.,Mechanism of Cutting Force and Surface Generation in Dynamic
Milling,JournalofEngineeringforIndustry,1991,113,p.160168.
5. Tlusty J. S.S., An Overview of Modeling and Simulation of the Milling Process, Journal of
EngineeringforIndustry,1991,113,p.169175.
6.WenHsiangLai,ModelingofCuttingForcesinEndMillingOperations,TamkangJournalofScience
andEngineering,2000,3(1),p.1522.
7.GonalvesR.,NriA.C.,Orthogonalcuttingforcesinjuvenileandmaturepinustaedawood,Sci.
Agric.(Piracicaba,Braz.),2005,62(4),p.310318.
8. WoodsonG.E.,KochP.,Tool forces and chip formation in orthogonal cutting of loblolly pine,
Washington:USDA,ForestService,.(ResearchPaperSO,52)1970.
9. NriA.C.,GonalvesR.HernandezR.E.,Foras de corte ortogonal 900 em trs espcies de
madeiradeeucalipto,RevistaBrasileiradeEngenhariaAgrcolaeAmbiental,1999,3,p.239244.
10. Toro W.M., Lara C.M. MacCarte G.V., Estimacion ymodelamiento estadistico para la fuerza
resultante de corte 900 em madera de Pinus radiata. In: congresso iberoamericano de pesquisa e
desenvolvimentodeprodutosflorestais,Curitiba,2002.
11.StringerE.G.,KnifeHolderforWoodChippers.Can.pat.1,262,622,1989,7(7),p.19.4claims.15
p.Cl.2936.Filed:Can.appln.512,65.
12. Kawasaki B.O.M., The effect of cutting speed on the surface quality in wood cutting Model
experiments and simulations by the extended distinct element method. 12th International Wood
MachiningSeminar,1995,p.5662.
13.StringerE.G.,KnifeHolderforWoodChippers.USPat.4712597,1987,15,4claimsFiled:Mar,27,
1986USCl.144/176144/162R
13/14
31/10/2016
14. CWC,WoodWasteSizeReductionTechnologyStudy1997,NISTMEPEnvironmentalprogram(#
CDL973)www.cwc.org(Accessed07/01/2009).
15.TimothyM.Maker,WoodChipHeatingSystems.AGuideforInstitutionalandCommercialBiomass
Installations,RevisedbyBiomassEnergyResourceCenterMontpelier,Vermont,2004.
16.Valby,Theeffectsofchipsizeonmechanicalpulppropertiesandenergyconsumption,TappiJournal,
September,1983,66(9),p.119122.
17.HughJack,Engineerondisc.http://claymore.engineer.gvsu.edu/eod/global/copyrght.html.1993
2001,HughJack.(Accessed30/05/2008).
18.DobrovolskiV.,ZablouskyK.,MakS.,RadchikA.,ErlichL.,MachineElement.ATextbook2ndEd.
MirPub.Moscow,1974.
19.Wikimanual,Gardentools.Woodchipperfromtheopencontenttextbookscollection.Retrievedfrom
http://en.wikibooks.org,2007(Accessed07/01/2009).
20. BrillJ.,Effects of wood and chip quality on TMP properties, International Mechanical Pulping
Conference,proceedings,SPCIStockholm,1985,p.153161.
21. SpinelliR.,HartsoughB.R.,MagagnottiN.TestingMobile Chippers forChip SizeDistribution,
International Journal of Forest Engineering. http://www.lib.unb.ca/Texts/JFE/July05/spinelli.pdf
(Accessed03/08/2008).
22.KawkaW.,IngielewiczH.,WrblewskiT.,ResearchstudiesonthedrumchippersRB800,RB
1300 and other scientific and research works. Typescript. Institute of Papermaking and Printing,
TechnicalUniversityofod,19871997.
14/14

Force Relations and Dynamics of Cutting Knife in A Vertical Disc Mobile Wood Chipper - Leonardo El J Pract Technol

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Force Relations and Dynamics of Cutting Knife in A Vertical Disc Mobile Wood Chipper - Leonardo El J Pract Technol

Uploaded by

Copyright:

Available Formats

31/10/2016

You might also like