Concrete Pipe Making Machine

DESIGN OF CONCRETE PIPE MAKING MACHINE
BY: Abel Dagne

Abrahaley Kahsay
Adissu Kahsay
A thesis submitted in partial fulfillment of the requirements for the award of

Bachelor of Science Degree in Mechanical Engineering
SCHOOL OF MECHANICAL AND INDUSRRIAL ENGINEERING
ETHIOPIAN INSTITUTE OF TECHNOLOGY-MEKELLE
MEKELLE UNIVERSITY
ADVISOR: INS. BESUFEKAD GETACHEW

LECTURER, MECHANICAL ENGINEERING DEPARTMENT
DATE: 06/JUNE/2016
Design of Concrete Pipe Making Machine
Acknowledgment
There are really no words to express our special thanks towards our advisor INS. Besufekad
who had helped us a lot with his knowledge and giving practical examples of different
mechanisms from the beginning to the end. Secondly, we would like to thank our friends and
dorm mates for giving as ideas towards the partial fulfillment of B.Sc. degree in mechanical
engineering.
We are also greatly thankful to all our classmates who provide us special supports & advices
during trouble & critical times. Last but not least, all praise is due to the Almighty God for
granting us the power, courage and wisdom to finish our study.
i
EIT-M Mechanical Engineering JUNE 2016
Abstract
This project deals with the design concepts, performance and brief design analysis of a concrete
pipe making machine which is a new machine for manufacturing of Concrete pipes (tubes) to
be designed by taking consideration of vibrating table for compressing and giving final shape of
product. The layout of the machine will be a vertical stand, and it's design will be reasonable,
reliable and simple to operate. All the design analysis is calculated manually based on different
machine design books. Material selection, for each part, is also considered as the pre-request task
for the design analysis. At the end part of the design, detail (part) and assembled drawings are
drawn using solid work software’s.
ii
Table of Contents
Acknowledgment ........................................................................................................................................... i
Abstract ......................................................................................................................................................... ii
List of figure ................................................................................................................................................. vi
Abbreviation .............................................................................................................................................. viii
Chapter One .................................................................................................................................................. 1
Introduction .................................................................................................................................................. 1
1.1 Background and justification .............................................................................................................. 1
1.2 Problem statement ............................................................................................................................. 4
1.3Objectives ............................................................................................................................................ 6
1.3.1General objective .......................................................................................................................... 6
1.3.2Specific objectives ......................................................................................................................... 6
1.4Scope of the study ............................................................................................................................... 6
1.5Expected out comes ............................................................................................................................. 6
1.6Study methodology .............................................................................................................................. 7
1.7Design procedures ............................................................................................................................... 7
Chapter two .................................................................................................................................................. 9
Literature review....................................................................................................................................... 9
2.1. Introduction ....................................................................................................................................... 9
Chapter Three ............................................................................................................................................. 15
3.1. Conceptual Design ........................................................................................................................... 15
Concept-2 ............................................................................................................................................ 16
Concept-5 ............................................................................................................................................ 19
3.2. Concept selection............................................................................................................................. 20
Chapter Four ............................................................................................................................................... 21
4. Design Analysis.................................................................................................................................... 21
4.1. Design of the frame work (molding parts) ................................................................................... 21
4.2. Motor selection for the reciprocating pressing head .................................................................. 25
4.3. Design of four bar mechanism ..................................................................................................... 27
iii
4.10. Thickness design of the dies (molding cylinders) ....................................................................... 35

4.11. Weight of the cylinder (outer die) ............................................................................................. 36
4.12. Design of the horizontal beam on which the outer die is mounted .......................................... 37
4.13. Design of hydraulic cylinders for the outer die .......................................................................... 43
4.14. Design of Piston rod diameter ................................................................................................... 45
4.15. Calculating the total applied force on the piston of the cylinder .............................................. 48
4.16. Working pressure of the hydraulic cylinder ............................................................................... 49
4.17. Flow rate in the cylinder ............................................................................................................ 50
4.18. Power inside the cylinder........................................................................................................... 50
4.19. Calculating the thickness of the cylinder ................................................................................... 50
4.20. Barrel weight calculation ........................................................................................................... 55
4.21. Design of vertical sliding column for the outer die .................................................................... 55
4.22. Weight calculation of the sliding column of the outer die ........................................................ 60
4.23. Design of the lower shaping ring ............................................................................................... 61
4.24. Design of the lower horizontal beam......................................................................................... 63
4.25. Weight calculation of the beam ................................................................................................. 69
4.26. Design of the lower hydraulic cylinders ..................................................................................... 69
4.27. Flow rate in the oil cylinder Q .................................................................................................... 75
4.28. Power analysis on the piston P .................................................................................................. 75
4.29. Weight of the Barrel................................................................................................................... 78
4.30. Design of the vertical frame ....................................................................................................... 80
4.31. Weight calculation of the vertical frame ................................................................................... 84
4.33. Design of spring.............................................................................................................................. 90
4.34. Design of the upper table .............................................................................................................. 92
4.35. Design of the lower vibrating table................................................................................................ 95
4.36. Design of hydraulic cylinder for the pressing head........................................................................ 98
4.37. Force applied on the piston of pressing head.............................................................................. 100
4.38. Stiffness of the returning spring .................................................................................................. 100
4.39. Thickness design of the cylinder .................................................................................................. 101
4.40. Design of belt conveyor ............................................................................................................... 102
4.41. Design of shaft for the conveyor.................................................................................................. 105
4.42. Bolt design........................................................................................................................................ 119
iv
CHAPTER FIVE ........................................................................................................................................... 121

Conclusion and recommendation ............................................................................................................. 121
5.1. Conclusion ...................................................................................................................................... 121
5.2. Recommendation........................................................................................................................... 122
References ............................................................................................................................................ 123
PART DRAWING AND ASSEMBLE .......................................................................................................... 124
v
List of figure
Figure 1concrete pipe ...................................................................................................................... 1
Figure 2 horizontal concrete pipe making machine ........................................................................ 3
Figure 3vertical concrete making machine ..................................................................................... 3
Figure 4design procedures .............................................................................................................. 7
Figure 5, concrete feeding conveyor ............................................................................................... 9
Figure 7central vibrating ............................................................................................................... 10
Figure 6head pressing machine ..................................................................................................... 10
Figure 8, machine base frame ....................................................................................................... 11
Figure 9, steel pipe mould ............................................................................................................. 12
Figure 10 hoist tools...................................................................................................................... 13
Figure 11oil pump ......................................................................................................................... 14
Figure 12 2D concept one ............................................................................................................. 15
Figure 13 2D concept2 .................................................................................................................. 16
Figure14, 2D concept three ........................................................................................................... 17
Figure15, 2D concept four ............................................................................................................ 18
Figure16, 2D concept five............................................................................................................. 19
Figure17, horizontal beam on which the outer die is mounted ..................................................... 37
Figure 18general concepts on Euler’s buckling formula .............................................................. 42
Figure 19hydraulic cylinder .......................................................................................................... 43
Figure20, flange - flange end hydraulic cylinder .......................................................................... 44
vi
Abbreviation
rh = head radius
σY = yield strength
Th = torque applied at the pressing head
σt = tensile strength
t =die thickness
E = modulus of elasticity
Wc = weight of the hallow cylinder
σc = compression stress
Wh = weight of cylinder head
τs = shear stress
g = gravity
Pmax = maximum lateral pressure
lr = l1 = effective rod length
γc = specific weight of concrete
σc = circumferential stress at radius r
h = height of concrete tube
P = working pressure of the cylinder at its
PL = lateral pressure of fresh concrete inner radius,
d = outer diameter of the internal molding din = inner diameter of the concrete tube
cylinder
m = mass of unbalance mass
PL = lateral pressure of fresh concrete
w = frequency of vibration
d = outer diameter of the internal molding
e = eccentricity,
cylinder
Fv = vertical force x = amplitude, e = 4cm = 0.04m
Ac = area of compaction na = number of active coils.
PH = hydraulic pressing pressure of the σu = ultimate strength

head
QT = the total pump flow rate
ωh = head angular speed in rad/sec
Hp = pressure head
viii
Chapter One
Introduction
1.1 Background and justification
Cement and concrete pipes are widely used on various industrial construction projects. The
tubular products are widely used in electrical conduits, agricultural irrigation, urban water supply
and drainage. The construction of pipes and underground conduits dates back thousands of years
and is one of the earliest forms of civil engineering construction.
Figure1 Figure 1concrete pipe
Concrete Pipe Making Machines is the ideal equipment to manufacture concrete and cement
pipes with different sizes and shapes. The machine can produce different sizes of tubular (pipe)
products such as connection tubes, small tubes and large tubes with oval, tapered, rectangular,
square or round shapes as preferred by the manufacturer; by using sand, gravel, stone chips, fly
ash and slag mixed with appropriate amount of cement.
1
The tubular products made by the machine must have the following advantages:
 Good initial strength
 average wall thickness,
 smooth inner and outer wall
 good impermeability
 high compressive strength
 low cost
 firm and reliable tie-in convenient construction
 High efficiency and release the mold immediately to maintenance etc..
There are a lot of technologies to produce pipes of different shape and size including spun
technology, center core vibration, and packer head etc. Until now spun technology is dominating
in most of the industries to produce the concrete pipe which works on the principle by
incorporating mechanism of outer core rotation in horizontal centrifugal machine. This machine
operates on high speed RPM where concrete is feed into the rotating mold. But this
manufacturing operation is time consuming and efficiency is very low, in addition physical
strength of the product quality is not good and thickness is not uniformly distributed. Presently,
Vertical Vibration Casting Concrete pipe Making Machine is one of the most advanced concrete
pipes making technology in the world which integrate the technology of Mechanical, electric,
Hydraulic, and the Automatics. This machine is easy to operate, much higher efficiency, and
full-automatic. It can be used to produce the concrete pipe from DN600-3600mm, length 2-3
meter, and range from reinforced Concrete pipe, Steel Jacking pipes.
=> So we are going to design a vertical vibrating casting concrete pipe making machine in as our
project, and the design will be reasonable, reliable and simple to operate.
Some images of the machines
Horizontal concrete pipe making machine
2
Figure 2 horizontal concrete pipe making machine

Vertical concrete pipe making machine
Figure3, vertical concrete making machine
3
1.2 Problem statement

Owing to the fact that concrete pipes have vast range of advantages on various infra-structural
and industrial construction projects, such as electrical conduits, agricultural irrigation, urban
water supply and drainage, the demand for concrete pipe, the need to increase output and
productivity with uniformity of concrete particle distribution are continuing to grow
dramatically, and this is the reason why equipment manufacturers are interested to produce high
quality pipe with faster rate. Therefore new machine with improved new manufacturing method
is necessary to develop to cope of the requirement of pipe manufacturing company. Moreover,
with the large losses of foreign currency and the need of business creativity, locally designed
concrete pipe making machines are found very important with the current infrastructural
activities of our country. Owing to these facts, this research is focused to develop effective and
more feasible molding machine which able to manufacture cement and concrete pipes. To
complete this research task engineering designs are done with systematic planning, following the
scientific and practical ideas to meet the stated objectives.
Problems we have observed:
Defect of manually made concrete pipe
4
Fully manually making of concrete pipe
5
1.3Objectives
1.3.1General objective
The general objective of this project is to design a concrete pipe making machine that is flexible
for different sizes and shapes.
1.3.2Specific objectives
The specific objectives of the project are:-
 To design the outer and inner molding dies (cylinders)
 To design the hydraulic systems for up and down ward movements of the molding
cylinders
 To design the belt, shafts and bearings
 To design the structure(frame) of the machine
 To select the appropriate pump and hydraulic motor
1.4Scope of the study

 The scope of this study concerns only on the design analysis of a concrete pipe making
machine including its detail and assembled drawings.
1.5Expected out comes

 High production efficiency
 Less pipe mould: usually 2 sets can meet the need
 Improved dimensional accuracy of products
 Enhanced manufacturing time
 Full use of material, no waste
 The noise will low during the production, which is within the standard allowed limit
 Save the space and easy handle
6
1.6Study methodology
 Reading different machine design books
 By discussing and sharing ideas
 Using internet sources
 Using mechanical soft ware’s like CATIA and solid work
1.7Design procedures
Figure 4 design procedures
7
1.8. Design specifications
Design specifications are the requirements or the set of terminologies which are used to develop
the final approach of a system. They can be classified into physical, structural, functional and
cost requirements. Considering those requirement targets, the designed machine must fulfill the
following requirements
 Homogenous compaction of material

 No cosmetic cracking at surface
 No leakage
 Able to produce product varieties
 Can be easily operated
 Low cost
8
Chapter two
Literature review
2.1. Introduction
Concrete Culvert Pipe Making Machine
Presently, Vertical Vibration Casting Concrete Culvert Pipe Making Machine is one of the most
advanced Concrete pipes making technology in the world which integrate the technology of
Mechanical, electric, Hydraulic, and the Automatics. This machine is easy to operate, much
higher efficiency, and full - automatic. It can be used to produce the concrete pipe from DN600-
3600mm, length 2-3 meter, and range from reinforced Concrete pipe, Steel Jacking pipes.
1) Concrete feeding conveyor,
Figure 5. Concrete feeding conveyor
This conveyor is droved by Variable Frequency motor, rubber belt, easy to maintain and operate.
The unique variable speed control system promises the concrete feeding continuous, stable, easy
to control. Widely feeding within the working diameter, one feeding conveyor can be used for
the two positions Concrete Culvert Pipe Making Machine (Vertical Vibration Casting Type).
9
2) Head Pressing machine,
Figure 6headFigure
pressing
6 machine
It is a movable gantry frame with automatic hydraulic pressing for left and right direction, also
up and down direction. It is used to form the pipe end joint, to make accurate and solid end joint.
It is full-automatic Vertical Vibration Casting Concrete Pipe Machinery.
3) Central Vibrator,
Figure 7central vibrating

This vibrator is installed in the inner pipe mould, consists of four independent sections, sealing
reliably. Special designed for the concrete pipes. All the bearings are imported, and use the
special Oil Air Lubrication Technology, which helps the vibrator cooling even running at high
10
speed, under heavy load. The fast speed we design is 4600 rpm the vibrating force, and
frequency is adjustable for different product. There is a unique design of the locking system, it is
very easy to disassemble and assemble the vibrator when change the inner mould for different
pipe specification. Our vibrator is with longer using life, and good performance, easy to
maintain, it is the critical part of the whole machine.
4) Machine Base Frame,
Figure 8, machine base frame

The entire machine frame is made by high strength steel, using the Carbon Dioxide arc welding.
It is used to support the inner mould, vibrator, and the electric motor driving system. Including
inner mould base, motor seat, major bearing seat, and damping vibration device, with simple
structure, much lower failure rate.
5) Hydraulic System, Cooling System,
We choose the top quality hydraulic system in China, based on the advanced hydraulic control
technology, also equipped with displayer of oil temperature, oil level, alarm device, also the heat
radiation, and filter device. Because of the vibrator is running at very high speed, and under
heavy load, it will be easy to get hot. Then the cooling system is very important, which will
decide the whole vibrator life and working performance. Also with the oil temperature, oil
11
pressure etc. alarm protection, these will guarantee the whole pipe machine running safe, and
stably.
6) Steel pipe Mould,
Figure 9, steel pipe mould

Figure 9
We are capable to design the steel pipe mould according to client’ ASTM, BS, or any other
countries concrete pipe standards.
A whole pipe mould will include:
a.) outer mould 1 pc
b.) inner mould 1 pc
c.) Press head Bracket 1 pc
d.) Base Ring pallet 1 pc
e.) Spigot Forming Ring 1 Pc
12
7) Hoist tools
Figure10
Figure 10 hoist tools
The tools are special in design, used to transport the pipe mould, range for all diameters matched
with the machine.
8) Electric Control System.
Ourselves Control system is with programmable PLC system, automatic memory function, and
touch screen 10.5 inch. All the electric parts are Schneider, we also design the limited position
switches to protect the whole machine, besides, each operation between the machine running will
be locked in case of wrong operation. Our control system is the fruit of our over ten years of
efforts, very easy to learn, and use. Only one worker is enough to operate.
13
9) Oil Pump
Figure 11oil pump
 Concrete Pipes products made by Vertical Vibration Concrete Culvert Pipe Making
Machine
14
Chapter Three
3.1. Conceptual Design

In order to develop the high quality pipe, systematic procedure is followed, having generated
ideas and concepts, the next necessary step is to evaluate them and select the best concept. One
method of evaluation is the use of tabular matrices. These consist of a series of criteria against
which the concepts must be marked. The importance of the criteria can be weighted, if
appropriate, and the most suitable concept is identified as the one with the highest overall mark.
Here, below concepts are generated and their model is shown via AutoCAD
Concept -1
Figure 12 2D concept one
Concept 1 shows the model of machine having vibration base to give the vibration energy on the
freshly inserted concrete. Vibration table is equipped with motor which is able to change the
desired amplitudes, frequencies, and vibration during change in pipe size. Therefore, it is
important to keep the concrete mixture in constant proportion regardless of the pipe sizes.
Rotation is carried by the electric motors mounted at the top to provide more compaction and
shaping of concrete. Inner die system is movable in up down motion during shaping of pipe.
15
Concept-2
Figure13, 2D model of concept two
The positioning of the pipe is vertical mount system where the vibration is given from the base
which is alike to the vibration as mentioned in concept 1. This machine is able to provide not
only vibration but also rotation. Outer die is fixed in the vibration table and inner die is movable
which can move by means of rotation of shaft coupled with electric motor mounted at the top. In
the inner die there are slots to couple the shaft with inner die so that when the shaft rotates the
torque is transmitted to the inner die. So the product is speculated to perform better than existing
products till now.
16
Concept-3
Figure14, 2D model of concept three

This model consists of fixed inner die and vertically movable outer die as molding parts of the
machine. It also consists pressing head operated by motor to have combination of reciprocating
and hydraulic pressing motions for removing air voids , uniformly distribution of the concrete
particles and consolidation in the optimum manner so as to get smooth surface finish that ensure
no permeability from the inner part of sewage pipe and compact quality product. The up down
motion of outer die and upward motion of the formed concrete tube are provided by hydraulic
mechanism whereas the fluid is pressurized by the combination of hydraulic pump and electric
motor.
17
Concept-4
Figure15, 2D model of concept four
The vibration system for the concrete pipe making machine utilizes a precisely manufactured
inner core that contains spiral shaped screw to generate pressure in the concrete of the inner
mold. This setup consists of vibration table where preferably arranged electric vibrators are
mounted at the frame of table. Vibration table is designed in the way that different size of pipe
can be manufactured in the same table. To manufacture different sized pipe, only the changeable
part is the upper plate of vibration table. The outer die and spigot end is fixed on the table at the
first step then inner part is moved to its position and concrete is fed into the inner zone. Core
starts to move in upward direction by compacting concrete. The core part can be adjusted to slide
up and down from the small clearance hole at the center of table
18
Concept-5
Figure16, 2D model of concept five

This machine serves to cast pipes of concrete in horizontal pattern. Machine includes inner mold
part, outer mold part. The inner core is displaced in horizontal axis after the production of pipe
and outer die, finished pipe along with spigot end are taken to next place for storage. After the
solidification of concrete, outer cover is taken to another place and finished pipe is taken out
from die. Manufacturing steps of this embodiment is concrete is fed from the upper part of the
die where there are holes to inject the pressurized concrete. Several holes are made to reduce the
manufacturing time and for uniformity of concrete flow throughout the pipe cavity. Tiny air
holes are also made at the upper part to remove the trapped air inside the cavity.
19
3.2. Concept selection

Concept selection is the activity in which the generated concepts are analyzed and sequentially
eliminated to identify the best concepts. A reference design is existing machine which is
considered as the datum. Selection criteria are generated based on design requirements, which
includes the customers’ requirements and designers’ intentions. For purpose of concept selection,
the weight of the criteria can be determined subjectively by team consensus or through a
designer’s rational intent. A percentage is normally used to assign the weight.
Table 1 concept selection table
Concepts
Concept 1 Concept 2 Concept 3 Concept 4 Concept 5
Selection weight Rating Weighted Rating Weighted Rating Weighted Rating Weighted Rating Weighted
score score score score score
criteria
Productivity 18% 2 3.6 5 9.0 5 9.0 3 5.4 3 5.4
variety
Safety 20% 4 4.0 4 8.0 4 8.0 4 8.0 4 8.0
Easy in 13% 3 2.6 4 5.2 3 3.9 3 3.9 5 6.5
manufacturing
Uniform density 16% 3 3.2 3 4.8 6 9.6 4 6.4 4 6.4
product
Easy of handling 13% 4 5.2 3 3.9 3 3.9 3 3.9 5 6.5
Durable product 20% 3 6.0 3 6.0 5 10.0 3 6.0 4 8.0
Total score 2.46 3.69 4.44 3.36 4.08
Rank 5 3 1 4 2
Continue No No Yes No No
20
Chapter Four
4. Design Analysis
4.1. Design of the frame work (molding parts)

A, determining the maximum lateral pressure (𝑃𝑚𝑎𝑥 ) of concrete
1, from Rodin’s models
𝑃𝑚𝑎𝑥 = 𝛾𝑐 h, for external vibrated concrete
Where, 𝑃𝑚𝑎𝑥 = maximum lateral pressure
𝛾𝑐 = specific weight of concrete
h = height of concrete tube
𝐾𝑁
= 24𝑚3 × 1.5m = 36kpa
2, From ACI models
30𝐶𝑤 kpa ≤ 𝑃𝑚𝑎𝑥 ≤ 150𝐶𝑤 CC,
30kpa< 36kpa < 150kp
Since the lateral pressure is in the range, it is acceptable.
3. From German standard model
𝑃𝑚𝑎𝑥 =18 +14R for fluid mixture
Where, R = feed rate
36kpa = 18 + 14R
36−18
R= = 1.286m/h
14
4. From CIRIA models, the minimum size of the tub is;

21
𝑃𝑚𝑎𝑥 = 𝑃𝐿 = 14.37 + 0.094d + 3.14R
Where, 𝑃𝐿 = lateral pressure of fresh concrete
d = outer diameter of the internal molding cylinder
36−14.37−3.14𝑅
d= 0.094
d = 187.149mm ≈188mm
The minimum outer diameter of the internal molding cylinder is 188mm.
4, from Hoffman model
𝑃𝐿 ∅
𝜆= = 𝑡𝑎𝑛2 (45 - 2 ), 20° ≤ ∅ ≤ 30° let take ∅ = 20°
𝑃𝑣
Where, 𝜆 = compaction ratio of the fresh concrete
∅ = friction angle
𝑃𝑣 = vertical pressure
𝜆 = 0.49
𝐿𝑃 36𝑘𝑝𝑎
𝑃𝑣 =0.49 = 0.49
= 73.47kpa
𝐹𝑣 = 𝑃𝑣 × 𝐴𝑐
Where, 𝐹𝑣 = vertical force
𝐴𝑐 = area of compaction
𝜋(𝐷 2 −𝑑2 ) 𝜋(7502 − 6002 )

𝐴𝑐 = = = 0.159𝑚2
4 4
𝐹𝑣 = 73.47Kpa × 0.159𝑚2 = 11.68KN
The compaction factor, 𝑓𝑐 for the normal range is = 0.8- 0.92
22
0.8+0.92
Let us take 𝑓𝑐 = = 0.86
2
𝜌𝑐𝑏 𝑏𝑒𝑓𝑜𝑟𝑒 𝑐𝑜𝑚𝑝𝑎𝑐𝑡𝑖𝑜𝑛 𝛾

𝑓𝑐 = = 𝛾𝑏𝑐
𝜌𝑐𝑓 𝑎𝑓𝑡𝑒𝑟 𝑐𝑜𝑚𝑝𝑎𝑐𝑡𝑒𝑑 𝑓𝑐
𝜌𝑐𝑏
𝑓𝑐 = = 0.86
𝜌𝑐𝑓
Where, 𝜌𝑐𝑏 = density of concrete before compaction
𝜌𝑐𝑓 = density of concrete after fully compaction
𝜌
𝑐𝑏 2400𝑘𝑔⁄𝑚3 𝛾𝑏𝑐
𝜌𝑐𝑓 = 0.86 =
0.86 𝛾𝑓
Where, 𝛾𝑏𝑐 = specific weight of concrete before compaction
𝛾𝑓 = specific weight of concrete after fully compaction
= 2790.7𝑘𝑔⁄𝑚3
𝛾𝑓𝑐 = 27.907𝐾𝑁⁄𝑚3
𝐹𝑏𝑐 = 𝛾𝑏𝑐 × V = 24𝐾𝑁⁄𝑚3 × V, where, 𝐹𝑏𝑐 = force of concrete before compaction
V = volume of concrete
𝛾𝑏𝑐 = specific weight of concrete before compaction
𝜋𝐷 2
But V = 4
× 1.4𝑚
𝜋
= 4 (𝐷2 - 𝑑2 ) ×1.4m
𝜋
( 0.752 - 0.62 )× 1.4m
4
= 0.2255𝑚3
𝐹𝑏𝑐 = 5.341KN
𝐹𝑎𝑐 = 27.907 × V = 6.211KN
23
𝐹𝑐 = 𝐹𝑎𝑐 - 𝐹𝑏𝑐 = 6.211 – 5.341
W here, 𝐹𝑎𝑐 = force of concrete after compaction
𝐹𝑐 = force of compaction
𝐹𝑐 = 0.8695KN ≈ 870N
𝐹𝑐 870𝑁
𝑃𝑐 = = 0.159𝑀2 = 5.472Kpa
𝐴
Where, 𝑃𝑐 = pressure of compaction
The pressing head of hydraulic force 𝐹𝐻 must be greater than or equal to the compaction force of
the fresh wet concrete, 𝐹𝑐 or its pressure 𝑃𝑐 .
i.e. 𝐹𝐻 ≥870N or 𝑃𝐻 ≥ 5.472Kpa
Where, 𝐹𝐻 = hydraulic pressing force of the shaping head
𝑃𝐻 = hydraulic pressing pressure of the head
N.B; the force for reciprocating movement of the pressing head must be greater than the friction
force of the top surface of the concrete.
Assuming the coefficient of friction of the concrete, 𝜇𝑠 = 0.3, the friction force is given by;
𝐹𝑟 = 𝜇w = 𝜇𝐹𝑐
= 0.3× 𝐹𝑟ℎ 870N = 261N
𝐹𝑟ℎ = 𝐹𝑎𝑝𝑝 > 𝐹𝑟 =261N
Where, 𝐹𝑟 = friction force
𝜇 = coefficient of friction of the concrete
W = weight of compaction
𝐹𝑟ℎ = force or reciprocating head
24
𝐹𝑎𝑝𝑝 = applied force on the head to overcome the rotational friction and to
accelerate it centrifugally.
4.2. Motor selection for the reciprocating pressing head

The motor is the source of power for the mechanical reciprocating shaping head.
Analysis of the power of the motor (𝑃𝑚 )
𝑃𝑟ℎ = 𝐹𝑟ℎ × 𝑣ℎ
𝑣ℎ 2
𝐹𝑅 = 𝐹𝑎𝑝 - 𝐹𝑟 = ma = m × 𝑟ℎ
Where, 𝐹𝑅 = resultant force = centrifugal force
𝑃𝑟ℎ = head reciprocating power
𝑣ℎ = head reciprocating speed
a = centrifugal acceleration of the shaping head
m = mass
𝑟ℎ = radius of the pressing (shaping) head
𝐹𝑟 = 𝜇𝐹𝑐 = 0.3 × 870N = 261N
For, 𝐹𝑅 > 0, let, 𝐹𝑅 = 80N
𝐹𝑎𝑝 = 𝐹𝑟𝑒ℎ
𝐹𝑎𝑝 = 𝐹𝑅 + 𝐹𝑟 = 80N + 261N = 341N = TTE
An addition of resistance factor ranged from 10% − 15% the TTE (𝐹𝑎𝑝 ), accounts for the
frictional losses between joints, linkages and motor bearings must be assumed to ensure
acceptable motor performance.
Let us take 15% which is the maximum
TTE = 𝐹𝑎𝑝 = 1.15 × 341 =392.12N
25
V 2
𝐹𝑅 = ma = m 𝑟h > 0
ℎ
𝐹𝑅 𝑟ℎ 𝐹𝑐
𝑉ℎ = √ , but m =
𝑚 𝑔
870𝑁
m = 9.81𝑚⁄𝑠2 = 88.685kg
80𝑁 ×0.375
𝑉ℎ = √ = 0.582𝑚⁄𝑠 ≈ 0.6𝑚⁄𝑠
88.685
𝑉ℎ
𝜔ℎ = =1.6𝑟𝑎𝑑⁄𝑠𝑒𝑐 where, 𝜔ℎ = head angular speed in rad/sec
𝑟ℎ
𝑟ℎ = head radius
2𝜋 𝑁ℎ
𝜔ℎ = where, 𝑁ℎ = speed of the pressing head in rpm
60
60 𝜔ℎ
𝑁ℎ = = 15.28rpm
2𝜋
𝑃𝑟𝑒ℎ = 𝐹𝑟𝑒ℎ × 𝑣ℎ = TTE× 𝑉ℎ
26
4.3. Design of four bar mechanism
Assumptions
𝐿1 = 460mm 𝐿3 = 500mm
𝐿2 = 100mm 𝐿4 = 300mm
Where 𝐿1 = frame
𝐿2 = driver
𝐿3 = connecting rod
𝐿4 = driven
𝐿2 + 𝐿3 < 𝐿1 + 𝐿4
100 + 500 < 460 + 300
600 < 760mm
27
If the sum of the length of the longest and shortest link is less than or equal to the sum of the
lengths of the other two links, then four bar mechanism will operate as crank – rocker.
4.4. Transmission angle
The angle 𝛾 between links two and one in four is called transmission angle.
To find 𝛾𝑚𝑖𝑛 (minimum transmission angle) from cosine law:
(𝐿1 − 𝐿2 )2 = 𝐿3 2 + 𝐿4 2 − 2𝐿3 𝐿4 cos 𝛾𝑚𝑖𝑛
((𝐿3 2 +𝐿4 2 )−(𝐿1 −𝐿2 )2 )

𝛾𝑚𝑖𝑛 = cos −1 = cos −1 0.7
2𝐿3 𝐿4
𝛾𝑚𝑖𝑛 = 45.46°
4.5. Maximum transmission angle 𝜸𝒎𝒂𝒙
(𝐿1 + 𝐿2 )2 = 𝐿3 2 + 𝐿4 2 − 2𝐿3 𝐿4 cos 𝛾𝑚𝑎𝑥
((𝐿3 2 +𝐿4 2 )−(𝐿1 +𝐿2 )2 )

γmax = cos −1 2𝐿3 𝐿4
γmax = cos −1 0.088
γmax = 85.4°
28
𝛾 = (45.46°, 85.4°)
5002 = 3002 + 5602 − 2 × 560 × 300 cos 𝛼
(3002 +5602 )−5002

𝛼 = cos −1( )
2×560×300
𝛼 = cos −1 0.46 = 62.6°
𝜃 = 180° − 2𝛼 = 54.8°
𝜃 = the angle of rotation of the pressing head.
𝑇ℎ = TTE× 𝑆, S = r𝜃
TTE = 392.12
𝑇ℎ = TTE× r𝜃, where 𝜃 = the angle of rotation of the pressing head
TTE = total tractive effort of the pressing head
r = 375mm radius of the head
𝑇ℎ = torque applied at the pressing head
54.8°
𝑇ℎ = 392.12×0.375× 180° 𝜋 = 140.64Nm
Assume
𝜔𝐵 = angular velocity of the driven
𝜔𝐵 = 0.54rad/s
𝑉𝐵 = tangential velocity of the driven
VB = ωB × r = 375mm×0.54rad/s
= 160mm/sec
29
Z = √(1002 + 4602 ) − (2 × 100 × 460 cos 30 = cos −1 ( 0.66)
Z = 376.73mm
(5002 +3002 )−376.752 )

β = cos−1 ( ) = cos−1 ( 0.66)
2×500×300
β = 48.685°
sin 𝛽×300
sin 𝛼1 = 376.73
𝛼1 = sin−1(0.6) = 36.87
sin 30×100
sin 𝛼2 = 376.75
50
𝛼2 = sin−1 (376.75) = 7.63°
4.6. Velocity analysis using victor mathematics
𝑉𝐵 = 𝑉𝐴 + 𝑊3 ×R, Where, 𝑉𝐴 = tangential velocity of driver
𝑉𝐵 = tangential velocity of driven
R = length of connecting rod (𝐿3 )
𝑉𝐵 cos 11.63 − 𝑉𝐵 sin 11.63 = 𝑉𝐴 cos 60𝑖 − 𝑉𝐴 sin 60𝑗 + ( 𝑊3 ×R)j
𝑉𝐵 = 160mm/sec
Summing the i components
600cos 11.63 = 𝑉𝐴 cos 60
𝑉𝐴 = 313mm/sec
𝑉𝐴
𝜔𝐴 = = 3.13rad/sec
𝑟
30
𝜔𝐴 ×60
𝑁𝐴 = = 30rpm
2𝜋
Torque of the driver (T)
𝐿1 ×𝑇ℎ 100×140.64𝑁𝑚
T= =
𝐿4 300
T = 46.6Nm
Power required for the driver
P = T×𝜔𝐴
P = 46.6Nm×3.13 = 143w = 0.5hp
4.7. Motor selection
𝜂𝑚 = 95%, where 𝜂𝑚 = motor efficiency
𝑃
𝑃𝑚 = 𝜂 , where 𝑃𝑚 = power required from the motor
𝑚
143
= 0.95 = 150w = 0.2hp
N = 30rpm
Therefore, having power of 0.2hp=1/5 hp and 30 rpm a gear motor is selected from table 2
below.
31
Table 2 concept selection table
32
4.8. Design of links and pins of the four bar mechanism
Material selection
Mild steel ASTMA36
𝜎𝑌 =250mpa 𝑇𝐶 = 125mpa
𝜎𝑡 = 400mpa E = 200Gpa
𝜎𝑐 = 407mpa
The link is rectangular section of thickness t and width w.
Assume
𝜎
w = 8t 𝜎𝑎𝑙𝑙 = 4𝑐 = 100mpa
F.s = 4
Link is under compression
𝐹 𝐹
𝜎𝑐 = 𝑤×𝑡 = 8𝑡 2
𝑇ℎ 140.64𝑁𝑚
F= =
𝐿3 300𝑚𝑚
F = 468.8N
𝐹 468.8
t = √8×𝜎 = √8×100×106
𝑎𝑙𝑙
t ≈ 2mm
33
w ≈ 20mm
Both the link and pin are made of the same material. Force applied at the link is F= 468.8N.
𝜏𝑠 = 125mpa
125𝑚𝑝𝑎
𝜏𝑎𝑙𝑙 = = 31.25mpa
4
𝐹 𝐹
𝜏𝑎𝑙𝑙 = 𝐴 = 𝜋𝑑4
4
4×𝐹
D=√ = 4.37mm
𝜋×31.25×106
d = 5mm
34
4.10. Thickness design of the dies (molding cylinders)

Material
Steel with material properties of;
𝑔
𝜌 =7.85 ⁄𝑐𝑚3
𝜎𝑦 = 207mpa
E = 210Gpa
Limitation point
Assuming F.s = 2
𝜎𝑦 207𝑚𝑝𝑎
𝜎𝑎𝑙𝑙 = F.s = = 103.5mpa
2
𝜎𝑦
𝜏𝑎𝑙𝑙 = 2𝐹.𝑠 = 51.75mpa
From the equation of Hoop stress the thickness can be found as follow;
𝑃𝐷 𝑃𝑟
𝜎ℎ𝑜𝑜𝑝 = = where, 𝑃 = concrete lateral pressure
2𝑡 𝑡
t =die thickness
𝑃𝐷
𝜎ℎ𝑜𝑜𝑝 = ≤ 𝜎𝑎𝑙𝑙
2𝑡
𝑃𝐷 36×103 𝑝𝑎 ×0.75𝑚
t ≥ 2𝜎 = = 0.13mm
𝑎𝑙𝑙 2 ×103,5 × 106 𝑝𝑎
t ≥ 0.13mm ≈ 3mm for safety
35
4.11. Weight of the cylinder (outer die)
𝑊𝑇 = 𝑊𝑐 + 𝑊ℎ where, 𝑊𝑇 = total weight of the cylinder
𝑊𝑐 = weight of the hallow cylinder
𝑊ℎ = weight of cylinder head
= (𝑉𝑐 × 𝜌𝑠𝑡𝑒𝑒𝑙 +(𝑉ℎ × 𝜌𝑠𝑡𝑒𝑒𝑙 )) g where, 𝑉𝑐 = volume of cylinder
𝑉ℎ = volume of the head
𝜌𝑠𝑡𝑒𝑒𝑙 = steel density
g = gravity
𝜋 (𝐷 2 − 𝑑2 )ℎ
𝑉𝑐 = 4
(7562 − 7502 )1.5

=𝜋 = 0.01064𝑚3
4
𝜋 (𝐷ℎ 2 − 𝐷𝑐 2 )𝑡 𝜋(8062 − 7562 )× 3mm

𝑉ℎ = = =
4 4
= 1.84× 10−4 𝑚3
m = 7850𝑘𝑔⁄𝑚3(0.01064 + 1.84× 10−4) 𝑚3
= 850kg → w = 850N
𝑚𝑐 = 𝑉𝑐 × 𝜌 = 83.5655kg
𝑤𝑐 = 𝑚𝑐 × g = 835.655N
36
𝑚ℎ = 𝑉ℎ × 𝜌 = 1.446kg
𝑤ℎ = 14.45N
4.12. Design of the horizontal beam on which the outer die is mounted
Sketch of the beam
Figure17, horizontal beam on which the outer die is mounted

When we distribute each weight on the horizontal mounting structure,
𝑤
𝜔𝑐 = 𝐷𝑐 where, 𝜔𝑐 = load distribution of the head on the cylinder
𝑐
37
𝐷𝑐 = diameter of cylinder
835.655𝑁
= = 1.1054𝐾𝑁⁄𝑚
0.756𝑚
𝑤ℎ 14.45𝑁
𝜔ℎ = 𝐷 = (0.806−0.756)𝑚 = 289𝑁⁄𝑚 where, 𝐷ℎ = diameter of the head
ℎ− 𝐷𝑐
Free body diagram
Reactions
𝐴𝑦 = 425N = 𝐹𝑦
Shear force
𝑉𝑚𝑎𝑥 = 425N
Maximum bending moment
38
𝑚𝑚𝑎𝑥 = 100Nm @ x= 478mm
Ansysis analysis of the beam
39
40
41
General concepts on Euler’s buckling formula
Figure 18general concepts on Euler’s buckling formula
42
4.13. Design of hydraulic cylinders for the outer die
Figure 19hydraulic cylinder
Material
Steel-mild with mechanical properties of
E = 220Gpa
G = 140.25Gpa
𝜎𝑦 = 207mpa
𝜌 = 7.86𝑔⁄𝑐 3
𝜀 = 0.28
43
Sketch of fixed – fixed (flange – flange) end hydraulic cylinder
Figure20, flange - flange end hydraulic cylinder
Assumption
 𝐿2 = 2m = 𝐿𝑐 = = length of the cylinder

 𝐿1 = 1.95m = 𝐿𝑟 = rod length
 f.s = 3 = factor of safety
 𝑛𝑐 = 2 = No of cylinders
𝑤𝑇
 𝑤𝑇 = 1KN = = 500N
𝑛𝑐
 No of cylinders = 𝑛𝑐 = 2
 Single acting 2 cylinders
 Fixed – fixed boundary conditions
 𝑉𝑝 = 0.5m/s 𝜇𝑐 = 0.3
 𝑡𝑝 = 5mm 𝜇𝑝 = 0.1
44
Limitation points
𝜎𝑎𝑙𝑙 = 𝑓.𝑠 = = 69mpa
3
𝜎𝑎𝑙𝑙 69𝑚𝑝𝑎
𝜏𝑎𝑙𝑙 = = = 34.5mpa
2 2
Points to be done
 Safe dimensional design of the;

 Piston rod
 Piston
 Hallow cylinder
 Checking the rod for buckling
 Determine the force to lift the rod at 0.5m/s
 Calculating the flow rate inside the cylinder
 Determining the working pressure of the cylinder
 Determining the power required to lift the load
4.14. Design of Piston rod diameter

𝜋 2 𝐸𝐼
k= 𝑊𝐿 ×f.s = ,
𝐿2
k= 𝑊𝐿 ×f.s = 3× 1KN = 3KN

𝐾
But 𝑛 = 1.5KN where, K = buckling load
𝑐
𝑊𝐿 = load weight = 1000N

𝑛𝑐 = number of cylinders = 2
𝐾 𝜋 2 𝐸𝐼 𝜋 2 𝐸𝐼 𝜋𝑑𝑟 4
= ,k= 2 𝑛𝑐 , but I =
𝑛𝑐 𝐿2 𝐿1 64
𝐿𝑟
𝑙𝑟 = = 0.975m,
2
Where; 𝑙𝑟 = 𝑙1 = effective rod length
𝐿𝑟 = 𝐿1 = length of the rod
𝑑𝑟 = rod diameter
45
I = second moment of inertia of the rod
2𝜋3 𝐸𝑑4
k= 64𝑙𝑟 2
4 32𝑘𝑙𝑟 2 4 32×3000𝑁×(0.975)2
𝑑𝑟 = √ = √𝜋3 ×220×109𝑁⁄𝑚𝑚2
𝜋3 𝐸
𝑑𝑟 = 10.755mm,
So from the preferred standard table for cylinder bore and rod diameter, the suitable value for
the rod is, 𝑑𝑟 ≈ 20mm. And the corresponding piston diameter for 𝑑𝑟 = 20mm is 𝑑𝑝 = 40mm.
∴ 𝑑𝑟 = 20mm and 𝑑𝑝 = 40mm
Checking the rod for buckling
𝐿𝑟 𝑃𝑐𝑟
𝑙𝑟 = = 1.95m/2 = 0.975m Assuming ≥ 4, the critical load is given as follow.
2 𝑝𝑎
4𝜋 2 𝐸𝐼 4𝑊𝐿
𝑃𝑐𝑟 = ≥ , where 𝑃𝑐𝑟 = critical load
𝑙𝑟 2 𝑛𝑐
𝑊𝐿 = load weight
𝑊𝐿
𝑝𝑎 = actual load = = 500N
2
46
𝜋𝑑𝑟 4 𝜋(20𝑚𝑚)2
𝐼𝑟 = = = 7.854× 104 𝑚𝑚4
64 64
𝐿𝑟 = (1950mm)2 = 3.8× 106 𝑚𝑚2
4×𝜋 2 ×220mpa ×7.854×103 𝑚𝑚4

𝑃𝑐𝑟 = = 18KN
3.8×106 𝑚𝑚2
𝑃𝑐𝑟 ≥ 4𝑝𝑎 = 4× 500N
18KN > 2KN……… therefore the rod is safe for buckling.
Critical stress of the rod
𝜋2𝐸
𝜎𝑐𝑟 = 𝐿 ≥ 𝜎𝑐 , where 𝑟𝑔 = radius of gyration
( 𝑟 )2
𝑟𝑔
𝐼
𝑟𝑔 = √ 𝑚𝑖𝑛
𝐴 𝑅
𝜋𝑑2 𝜋(20𝑚𝑚)2
𝐴𝑅 = = = 314.16𝑚𝑚2
4 4
𝜋20𝑚𝑚4
= 𝐼𝑚𝑖𝑛 = = 7853.982𝑚𝑚4
64
7853.982𝑚𝑚4
𝑟𝑔 = √ = 5mm
314.16𝑚𝑚2
𝜋2𝐸 𝜋 2 ×220×103 𝑚𝑝𝑎

𝜎𝑐𝑟 = 𝐿 == 1950𝑚𝑚 2 = 14.31mpa
( 𝑟 )2 (
5𝑚𝑚
)
𝑟𝑔
Checking the piston rod for compression stress
𝜎𝑐 ≤ 𝜎𝑐𝑟 and 𝜎𝑎𝑙𝑙
𝑊𝐿 1000𝑁
𝜎𝑐 = 𝑛 = 2×314.16𝑚𝑚2 = 1.59mpa
𝑐 𝐴𝑅
Since 1.59mpa < 𝜎𝑐𝑟 = 14.31mpa and 𝜎𝑎𝑙𝑙 = 69mpa, the rod is safe for compression stress.
47
4.15. Calculating the total applied force on the piston of the cylinder
For 𝑑𝑟 = 20mm, 𝑑𝑝 = 40mm
N.B; piston diameter = bore diameter of the cylinder
𝐹𝑅 = 𝐹𝑎𝑝𝑝 - 𝐹𝑟 - 𝑊𝐿 - 𝑊𝑃&𝑟 = ma,
Where 𝐹𝑅 = net force
𝐹𝑎𝑝𝑝 = total applied force on the piston to overcome the friction forces, weight and to move
the load with 0.5m/s
𝐹𝑟 = total friction force due to the concrete and piston
𝑊𝑃&𝑟 = 𝑊𝑃 +𝑊𝑟
𝜋(402 − 202 )𝑚𝑚2

4
𝜋(𝐷𝑝 2 − 𝑑𝑟 2 )𝜌𝑔×𝑡
𝑊𝑃 = = 72.67× 5× 10−3 𝑚
4
= 0.363N
𝜋𝑑𝑟 2 𝐿𝜌𝑔 𝜋(20𝑚𝑚)2 ×1.95𝑚×𝜌𝑔

𝑊𝑟 = =
4 4
= 47.24N
𝑊𝑃&𝑟 = 0.63N + 47.24N = 47.6N for one cylinder
𝑊𝑃&𝑟 for 𝑛𝑐 = 2 = 47.6N × 2 = 95.2N
𝑊𝑇 = 𝑊1 + 𝑊𝑃&𝑟 × 2
1000N +47.6N×2 = 1096N
𝐹𝑟 = 𝑊𝑇 × 𝜇𝐶 +𝑊𝑇 𝜇𝑃 = 𝑊𝑇 (𝜇𝐶 + 𝜇𝑃 )
= 438.9N
48
𝑊𝑇1 ×𝑎 𝑉2− 𝑈2 𝑉2
𝐹𝑅 = , but a = = 2𝐿
𝑔 2𝑆 𝑟
(0.5𝑚/𝑠)2
= = 0.6641𝑚⁄𝑠 2
2×1.95𝑚
𝐹𝑅 = 7.16N
𝐹𝑎𝑝𝑝 = 𝐹𝑅 +𝐹𝑟 +𝑊𝑇
7.1562N +438.4N + 1095.2N = 1.54KN, but, since there are 2 number if cylinders, the force
applied for each cylinder is;
𝐹𝑎𝑝𝑝 𝐹𝑎𝑝𝑝
=
𝑐𝑦 𝑛𝑐
1.54𝐾𝑁
= 0.77KN = 770N
2
4.16. Working pressure of the hydraulic cylinder
Assuming the dynamic truss;
𝐹𝑅 = 0.9P× 𝐴𝑝 , the working pressure of the cylinder is
𝐹
𝐷 𝐹𝑎𝑝
P = 0.9𝐴 = 0.9𝐴
𝑝 𝑝 𝑛𝑐
𝐹𝑎𝑝 1.542𝐾𝑁
𝐹𝐷 = =
𝑛𝑐 2
= 770N
𝜋𝐷𝑝 2 𝜋(40𝑚𝑚)2
𝐴𝑝 = =
4 4
= 1.256637× 103 𝑚𝑚2
770𝑁
P = 0.9×1.256637×103 𝑚𝑚2 = 0.505mpa = 6.81bar < 𝜎𝑎𝑙𝑙 = 69mpa
49
4.17. Flow rate in the cylinder

𝜋𝐷𝑃 2
Q = 𝑉𝑝 𝐴𝑝 , but, 𝐴𝑝 = 4
𝐴𝑝 = 1.256637× 103 𝑚𝑚2
1.256637×103 𝑚𝑚2 ×0.5𝑚/𝑠

Q= = 6.2832× 10−4 𝑚3 ⁄𝑠
106
4.18. Power inside the cylinder
P = Q× 𝑝 = 6.2832× 10−4 𝑚3 ⁄𝑠 × 6.81 × 105 𝑁⁄𝑚2
= 427.886W
For the two cylinders,
𝑃𝑇 = 𝑛𝑐 × 𝑃
2× 427.886W = 855.772W
4.19. Calculating the thickness of the cylinder
We can calculate the thickness of the cylinder using Lame’s equations as follow;
𝑏
𝜎𝑟 = 𝑟 2 - a
𝑏
𝜎𝑐 = 𝑟 2 + a where 𝜎𝑟 = radial stress
𝜎𝑐 = circumferential stress at radius r
a & b are constants
𝑏
𝜎𝑐 (𝑟𝑖𝑛 ) = + a ≤ 𝜎𝑎𝑙𝑙 , where, 𝜎𝑐 (𝑟𝑖𝑛 ) = circumferential stress at the inner radius of the
𝑟𝑖𝑛 2
cylinder.
𝑏
𝜎𝑐 (𝑟𝑖𝑛=20𝑚𝑚 ) = 202 + a ≤ 𝜎𝑎𝑙𝑙
50
Let 𝜎𝑐 = 𝜎𝑎𝑙𝑙 at 𝑟𝑖𝑛 = 20mm
𝑏
= (20𝑚𝑚)2 + a = 69mpa
𝑏
= 400𝑚𝑚2 + a = 69mpa……………………. 1 and
𝑏
𝜎𝑟 (𝑟𝑖𝑛 ) = 𝑟 2
– a = P, where, 𝜎𝑟 = radial stress inside the cylinder at its inner radius
𝑖𝑛
P = working pressure of the cylinder at its inner radius,
𝑟𝑖𝑛 = 20mm
𝑏
𝜎𝑟 = 𝑟 2
–a=P
𝑖𝑛
𝑏
= (20𝑚𝑚)2 - a = 6.81bar
𝑏
= 400𝑚𝑚2 - a = 6.81bar……………………2
Then now add equation 1 and 2
𝑏
= 400𝑚𝑚2 + a = 69𝑁⁄𝑚𝑚2 ……………………. 1
𝑏
= 400𝑚𝑚2 - a = 0.681𝑁⁄𝑚𝑚2 ……………………2
2𝑏
= 400𝑚𝑚2 = 69.681𝑁⁄𝑚𝑚2
2b = 69.681𝑁⁄𝑚𝑚2 × 400𝑚𝑚2
b = 13.94KN
Substitute the value of b into equation two
𝑏
- a = 0.681𝑁⁄𝑚𝑚2
400𝑚𝑚2
51
13.94𝐾𝑁
- a = 0.681𝑁⁄𝑚𝑚2
400𝑚𝑚2
13.94𝐾𝑁
a = 400𝑚𝑚2 - 0.681𝑁⁄𝑚𝑚2 = (34.85 – 0.681) mpa
a = 34.17𝑁⁄𝑚𝑚2
Now let us substitute the value of a and b into the Lame’s equations
𝑏
𝜎𝑐 = 𝑟 2 + a
13.94𝐾𝑁
𝜎𝑐 = + 34.17mpa and
𝑟2
𝑏
𝜎𝑟 = 𝑟 2 – a
13.94𝐾𝑁
𝜎𝑟 = – 34.17mpa
𝑟2
Note that the cylinder must be strong enough to absorve all the stress such that the stress at the
outer surface of the barrel must be zero.
𝑏
i.e. 𝜎𝑐 (𝑟𝑜 ) = – a = 0, where, 𝜎𝑐 (𝑟𝑜 ) = radial stress at the outer radius of the cylinder
𝑟𝑜 2
𝑟𝑜 = outer radius of the cylinder
13.94𝐾𝑁
𝜎𝑐 (𝑟𝑜 ) = – 34.17mpa = 0
𝑟𝑜 2
13.94𝐾𝑁
= 34.17𝑁⁄𝑚𝑚2
𝑟𝑜 2
13.94𝐾𝑁
𝑟𝑜 = √34.17𝑁⁄𝑚𝑚2 = 20.25mm≈ 21mm
𝐷𝑜 = 2𝑟𝑜 = 2×21mm
𝐷𝑜 = 42mm
52
𝐷𝑜 −𝐷𝑝 42−40
t= =
2 2
t = 1mm
But, since the cylinder is assumed to be thick cylinder for hydraulic purposes;
𝑟 𝑟
≤ 10, t ≥
𝑡 10
21
t≥ = t ≥ 2.1mm, let t = 3.5mm
10
So, 𝐷𝑜 = 𝐷𝑝 + 2t = 40 + 7mm
𝐷𝑜
𝐷𝑜 = 47mm and 𝑟𝑜 = 2
𝐷𝑜 = 47mm and 𝑟𝑜 = 23.5mm
Then, know let us check the total length L for buckling
L=𝐿𝑟𝑜𝑑 +𝐿𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
= 1.95m + 2m = 3.95m
4𝜋 2 𝐸𝐼
𝑃𝑐𝑟 = 𝐿2 ×𝑍
𝐿1 𝐿2 1 1 𝐿 2𝜋𝐿1
Z= + + (𝑙 - 𝑙 ) × 2𝜋 sin( )
𝑙1 𝑙2 2 1 𝐿
Where 𝐿1 = visible length of the piston rod
𝐿2 = length of the cylinder
𝑃𝑐𝑟 𝜋𝑃𝐷 2
≥ 4, 𝑝𝑎 =
𝑝𝑎 4
𝜋𝑑𝑟 4 𝜋(𝐷𝑜 4 − 𝐷𝑝 4 )
𝐼𝑟 = And 𝐼𝑐 =
64 64
I = 𝐼𝑟 + 𝐼𝑐
53
𝐿1 1.95𝑚
𝑙1 = = = 0.975m
2 2
𝐿2 2𝑚
𝑙2 = = = 1m
2 2
𝐿 𝐿2 1 1 𝐿 2𝜋𝐿1
Z = 𝑙1 + + (𝑙 - 𝑙 ) × 2𝜋 𝑠𝑖𝑛( )
1 𝑙2 2 1 𝐿
𝐿 𝐿 1 1 𝐿 2𝜋𝐿𝑟
= 𝑙 𝑟 + 𝑙 𝑐 + (𝑙 - 𝑙 ) × 2𝜋 𝑠𝑖𝑛(
𝑟 𝑐 𝑐 𝑟 𝐿
1.95 2 1 3.95 2𝜋×1.95

= 0.975 +1 + (1 - 0.975) × (
2𝜋 3.75
= 4 – 0.017 = 3.983
4𝜋 2 𝐸𝐼
𝑃𝑐𝑟 = 𝐿2 ×𝑍
𝜋𝑑𝑟 4
𝐼𝑟 ≤ = 7.854× 103 𝑚𝑚4
64
𝜋(𝐷𝑜 4 − 𝐷𝑝 4 )
𝐼𝑐 = = 113.8671× 103 𝑚𝑚3
64
𝐼𝑐 > 𝐼𝑟 Which indicates that the cylinder has higher resistance to bending or buckling.
I = 𝐼𝑟 + 𝐼𝑐
= 7.854× 103 𝑚𝑚4 +113.8671× 103 𝑚𝑚3 = 121.7211× 103 𝑚𝑚3
4𝜋 2 𝐸𝐼
𝑃𝑐𝑟 = ≥ 4𝑝𝑎
𝐿2 ×𝑍
4×𝜋 2 ×220×103 𝑁⁄𝑚𝑚2 ×121.7211×103 𝑚𝑚3

= 16.94KN ≈ 17KN
(3950𝑚𝑚2 )×4
𝑊𝑇 1.142𝐾𝑁
𝑊𝐿 = = = 571N
2 2
𝑃𝑐𝑟
𝑃𝑐𝑟 = 17KN > 571N, or ≥4
𝑝𝑎
17KN ≥ 4× 571𝑁
54
17KN > 2.284KN, the total length is safe for buckling.
4.20. Barrel weight calculation
WBare = Whcy + Woil
𝜋
Whcy = 4 (472 − 402 )×2m× 7860 × 9.81
= 73.76N = 74N
𝜋
Woil = 𝑉𝑏 × 𝜌𝑜𝑖𝑙 × 𝑔 = 4 (𝑑𝑝 2 )× 𝐿𝑠𝑏𝑜𝑥 𝜌𝑔
𝜋
= 4 × 402 × 1950 × 900 × 9.81
= 21.635N ≈22
WBore =Whcy + Woil
= 47N + 22N = 96N, but for two barrels (hydraulic cylinder)
2WBore = 192N
4.21. Design of vertical sliding column for the outer die
Given
𝑊𝐿 = 500N
Material
Steel with mechanical properties of;
 E = 200Gpa
 𝜎𝑦 = 250mpa
 𝜌 = 7850𝑘𝑔⁄𝑚3
Assumptions
55
 L = 3.6m
 F.s = 2.5
 Fixed – free end for xy plane
X = 2 ≈ 2.1
 Fixed – fixed end for xz plane
X = 0.5 ≈ 0.65
 C – shape rectangular cross – section area
Required
𝑎
a, ratio of corresponding to the most efficient design against buckling
𝑏
b, design the most efficient cross – section for the column

Limitation points
𝜎𝑎𝑙𝑙 = 𝐹.𝑠 = = 100mpa
2.5
𝜎𝑦 250
𝜏𝑎𝑙𝑙 = 2𝐹.𝑠 = 2×2.5 = 50mpa
Analysis
𝑎
a, ratio of analysis
𝑏
The most efficient design occurs when resistance to the buckling is equal in both planes
(xy and xz planes). And this occurs when the Cylinderness ratios (𝜆 ) are equal in both
planes.
Buckling in xy – plane
Assumptions is fixed – fixed end X= 2
𝐼𝑍
𝑟𝑧 2 = where 𝑟𝑧 = radius of gyration for xy – plane
𝐴
56
1 𝑏 3𝑎 3
𝐼𝑍 = 12(b𝑎3 − 2 ( ) )
4
1 27b𝑎3
= 12(b𝑎3 − 128
1 101b𝑎3 101b𝑎3
= 12( )=
128 1536
101b𝑎3
𝐼𝑍 = 1536
𝑏 3𝑎
A = ba− 2 × 4
3𝑏𝑎 5𝑏𝑎
= ba − =
8 8
5ba
A 8
IZ 101ba3 5ba
rz 2 = = ÷
A 1536 8
101ba3 8 101𝑎2
= × 5ba =
1536 960
101
rz = a√960
Cylinderness ratio of xy – plane

Le,z KL
λz = = , where, λz = Cylinderness ratio in the z direction
rz rz
K = end constant
K = 2 for fixed – fixed, but the recommended value for design is K = 2.1
2.1𝐿
λz = a 101
√
960
Assumptions fixed – fixed end k = 0.5
Iy 5ba
ry = A , but A = 8
1 3 3a b 3
Iy = (ab − ( ) )
12 4 2
1 3ab3
= 12 (ab3 - )
32
29ab3
Iy = 384
Iy 29ab3 8
ry 2 = = × 5ba
A 384
29
ry = b√240
57
Cylinderness ratio for the the xy – plane

Le,y KL
λy = =
ry ry
K = 0.5 for the fixed – fixed end, but the recommended value for design is 0.65
KL
λy = ry
0.65L
λy = 29
b√
240
Most efficient design

λz = λy
2.1L 0.65L
a 101
= 29
√ b√
960 240
29 101
2.1√ 0.65√
240 960
=
a 𝑏
29
𝑎 2.1√
240
=
𝑏 101
0.65√
960
𝑎 0.73
= 0.211 = 3.46
𝑏
𝑎
= 3.46 is the most efficient design ratio against buckling for the vertical sliding
𝑏
structure of the outer die.

Design the most efficient cross – section
𝑎
From the ratio 𝑏 = 3.46,
a = 3.46b, so it is clear that 𝐼𝑧 > 𝐼𝑦

101b𝑎3 29ab3
i.e. 𝐼𝑍 = > Iy =
1536 384
Therefore we have to design the column based on the smaller moment of inertia which is
29ab3
Iy = .
384
𝑃𝑐𝑟 = 𝑊𝐿 × 𝐹. 𝑠 = 500N× 2.5

= 1.25KN
0.65L 0.65×3600𝑚𝑚
λy = =
29 𝑏×0.347611
b√
240
6.317𝑚𝑚×103
λy = 𝑏
58
𝑃𝑐𝑟 1.25𝐾𝑁
𝜎𝑐𝑟 = = 𝑏𝑎
𝐴 5
8
10×103
= , but a = 3.46b
5𝑏𝑎
10×103
𝜎𝑐𝑟 = 5×3.46𝑏×𝑏
578.035𝑁
𝜎𝑐𝑟 = ………………… 1
𝑏2
𝜋2 𝐸 𝜋2 𝐸
And 𝜎𝑐𝑟 = 2 = 𝐿
λ ( 𝑒 )2
𝑟
𝜋2 ×200×103 𝑁⁄𝑚𝑚2
𝜎𝑐𝑟 = 6.317×103𝑚𝑚 2
( )
𝑏
𝜋 2 ×200×103 𝑁⁄𝑚𝑚2 ×𝑏2

= 39.9045×106 𝑚𝑚2
𝜎𝑐𝑟 = 0.049466𝑏 2 𝑁 ⁄𝑚𝑚4 ………………………… 2
Then now equate equation 1 and 2
578.035𝑁
𝜎𝑐𝑟 = = 0.049466𝑏 2 𝑁⁄𝑚𝑚4
𝑏2
578.035𝑁
𝑏4 = = 4
49.466×10−3𝑁⁄𝑚𝑚
4
b = √11.6855 × 103 𝑚𝑚4
𝑏
= 10.397≈ 11mm for strength = 5.5mm
2
𝑏
But = 3.46
𝑎
a = 3.46b = 3.466× 10.397
= 35.97362≈ 36mm
3 3×52
And 4a = = 39mm
4
59
4.22. Weight calculation of the sliding column of the outer die
Given Required
5𝑎𝑏
A= , a= 36mm and b= 11mm V=?
8
L = 3600mm m =?
𝜌 = 7.85𝑔⁄𝑐𝑚3 = 7850𝑘𝑔⁄𝑚3 w =?
Solution analysis
V = AL
5𝑎𝑏 5×36×11𝑚𝑚2
A= =A=
8 8
A = 247.5𝑚𝑚2
V = 247.5𝑚𝑚2 × 3600mm
= 891× 103 𝑚𝑚2 = 8.91× 10−4 𝑚3
m = 𝜌 × 𝑉 = 78508.91× 10−4 𝑚3
m = 6.99kg ≈ 7kg
w = mg = 7kg × 9.81𝑚⁄𝑠 2
w = 68.67N ≈ 69N
For the two columns
𝑊𝑇 = 2w = 138N
60
4.23. Design of the lower shaping ring
Definition; the lower shaping ring is a metal used to support the concrete tube and the outer die
to internally shape the concrete tub. This internal shape of the tube makes easy the concrete tube
for interconnecting and joining with other consecutive tubes.
Material selection
Steel – milld
𝜌 = 7.86𝑔⁄𝑐𝑚3
E = 220Gpa
𝜎𝑦 = 207mpa
Given Assumption
𝐷𝑖𝑛 = 600mm f.s = 2
𝐷𝑜 = 750mm t = 5mm
Design consideration
𝜎𝑎𝑙𝑙 = 𝐹.𝑠 = 2
𝜎𝑎𝑙𝑙 = 103.5mpa
61
Dimension design of the metal ring
Weight design of the ring
Assuming when the metal ring is straightened and chanced to flat the following hollow circular
cylinder will be created by assuming uniform well thickness.
𝐷𝑟𝑝 = 750mm + 2(3 +3.5 + 50)
= 750 + 113 = 863mm
𝑑𝑖𝑛 = 600mm
𝜋 ( 𝐷𝑟𝑝 2 −𝑑𝑖𝑛 2 )×𝑡

V= 4
= 1.057× 10−3 𝑚3
m = V𝜌 = 1.057× 10−3 𝑚3 ×786𝑘𝑔⁄𝑚3
= 8.313kg
Wr = mg = 81.555N
Checking the ring for compression stress
Let us design the ring based on the weight of the concrete, then it will also safe for the outer die
weight.
62
𝑊𝑐 4𝑊
𝜎𝑐 = = 𝜋(𝐷2 −𝑑2𝑐)𝑚𝑚2 ≤ 𝜎𝑎𝑙𝑙
𝐴𝑐
4×5.2425×103 𝑁
= 32.963kpa
𝜋(7502 −6002 )𝑚𝑚2
𝜎𝑐 ≤ 𝜎𝑎𝑙𝑙
32.963kpa <103.5mpa, the ring is safe for compression.
4.24. Design of the lower horizontal beam
Definition; the lower horizontal beam is the structure used to carry the total load of the molded
concrete, pipe, the outer die with its supporting upper horizontal beam and its two sliding vertical
columns, the weight of the two hydraulic cylinders and the lower shaper ring metal when the
molded (formed) concrete is raised up from inner die for taking away purpose.
Given
𝑤𝑐𝑛𝑐 = 5.43KN, 𝑤𝑐𝑛𝑐 = concrete weight
𝑊𝐿1 = 1KN = load applied on the upper hydraulic cylinders
𝑊𝑝,𝑟 = 2×47.6N = piston and rod weight
𝑊𝑐𝑙𝑛 = 2×69N = weight of the upper sliding column
𝑊𝑟𝑛𝑔 = 81.555N = weight of the ring metal
𝑊𝐵𝑎𝑟𝑟𝑒𝑙 = 2×96N = weight of the barrel and its oil
Required
a, total load on the beam 𝑊𝑇2
b, maximum bending moment and stress of the beam
c, dimension design of the beam
63
d, weight calculation of the beam
Material selection
Steel with material properties of;
E = 200Gpa
𝜎𝑦 = 207mpa
𝜌 = 7.85𝑔⁄𝑐𝑚3
F.s = 2
Analysis
a, calculation of distributed and concentrated loads and total weight on the beam
𝑊𝑇 = 2×𝑊𝑐𝑦𝑛 + 2𝑊𝑏𝑎 +2𝑊𝑝,𝑟 +𝑊𝑐𝑜𝑛 +𝑊𝑟𝑛𝑔 +𝑊𝐿1
𝑊𝑐𝑜𝑛 = mg =𝜌𝑉𝑔
= 5.43KN
𝑊𝑇 = 2×69N +2×96N +2×47.6N + 5.43KN +1KN + 81.555N
𝑊𝑇 = 6.937KN
Concentrated loads
𝑊𝑇1 = 𝑊𝐿1 +2𝑊𝑝,𝑟 + 2𝑊𝑏𝑎
= 1000N +2×47.6N + 2×96N
= 1.2872N
𝑊𝑇1
= 643.6N
2
64
Distributed loads
𝑊𝑐𝑙𝑛
𝑊𝑐𝑙𝑛 = 69N and 𝜔𝑐𝑙𝑛 = 𝑎
69𝑁
𝜔𝑐𝑙𝑛 = 0.036 = 1.92KN/m
𝑊𝑐𝑜𝑛
𝑊𝑐𝑜𝑛 = 5.43KN and 𝜔𝑐𝑜𝑛 = 𝐷𝑖𝑛
5.43𝐾𝑁
= 750×10−3 𝑚 = 7.24KN/m
𝑊𝑟𝑛𝑔
𝑊𝑟𝑛𝑔 = 81.555N and 𝜔𝑟𝑛𝑔 =
𝐷𝑟𝑛𝑔
81.555N
= 763×10−3 𝑚 =106.881N/m
Support reactions
The two hydraulic cylinders are the supporting reactions of the beam.
i.e 𝑅𝐵 and 𝑅1 .
b. F.B.D of the beam
65
Using Ansysis program
66
𝑅𝐵 = 𝑅1 = 3.4685KN
𝑅𝐵 = 𝑅2 = 3.4685KN
M.B.M = 𝑀𝑚𝑎𝑥 = 969.9Nm and 𝑉𝑚𝑎𝑥 = 3.4KN
C, dimension design of the beam (lower beam)
Definition- the dimension of the lower beam will be safely designed based on the maximum
bending moment.
Analysis
Assume the cross – sectional area is a solid rectangular dimensioned as follow.
Assume w = 3t
67
𝑡𝑤 3 𝑤𝑡 3
𝐼𝑥𝑥 = and 𝐼𝑦𝑦 = , but 𝐼𝑦𝑦 < 𝐼𝑥𝑥 , because w > t.
12 12
So, we design the beam based the smaller resistance of moment inertia which is;
𝑤𝑡 3
𝐼𝑦𝑦 = 12
𝑀𝑦 𝑡
𝜎𝑏 = , but y = 2
𝐼
𝑡
𝑀 6𝑀𝑡
2
𝜎𝑏 = 𝑤𝑡3
= 3𝑡 4
12
2𝑀
𝜎𝑏 = ≤ 𝜎𝑎𝑙𝑙
𝑡3
2𝑀
𝑡3 ≥ 𝜎
𝑎𝑙𝑙
3 2×969.9𝑁𝑚
t ≥ √103.5×106 𝑁⁄𝑚2
t ≥ 26.5627mm, let t = 30mm
w = 3t = 3×30mm = 90mm
Where, 𝑑𝑖𝑛 = inner diameter of the concrete tube = 600mm
𝐷𝑏 = thickness diameter on the hole of the = 668mm
𝐷𝑜 = diameter on the beam
𝐷𝑜,𝑏 = outer diameter of the beam
H = one side of the square center part of the beam = 763mm
68
4.25. Weight calculation of the beam
𝑊𝑏 = 𝑚 𝑇 g
𝑚 𝑇 = 𝑚1 +𝑚2 +𝑚3 +2𝑚4
𝑚 𝑇 = 𝜌 (𝑉1+𝑉2+𝑉3+2𝑉4)
𝑚 𝑇 = 𝜌(𝐴1 ℎ1 + 𝐴2 ℎ2 + 𝐴3 ℎ3 + 2𝐴𝐴 ℎ4 )
𝜋(𝐷𝑏 2 −𝑑𝑏 2 )𝑚𝑚2 ×𝜌×45

𝑚1 = 𝐴1 ℎ1 = 4
𝑚1 = 23.9222kg
𝜋(𝐷𝑜,𝑏 2 −𝑑𝑏 2 )ℎ2 𝜌

𝑚2 = 4
𝜋(6932 −6682 )×30𝜌

= 6.29331kg
4
𝜋𝑑𝑏 2 ℎ𝜌
𝑚3 = 𝐻 2 h𝜌− = 70.515kg
4
𝑚4 = 2×w×L×t×𝜌
= 2(90×30×232.5) × 𝜌 = 9.8557kg
𝑚 𝑇 = 110.5834kg
𝑊𝑏 = mg = 1.085KN
4.26. Design of the lower hydraulic cylinders
Definition; the lower hydraulic cylinders are the two cylinders which are used to support and lift
for the total load (weight) in the concrete pipe making machine. The working fluid of the
cylinders is oil.
69
Givens
𝑊𝐿1 = 1KN
𝑊𝑐𝑦 = 287.2N
𝑊𝑐𝑜𝑛 = 5.43KN
𝑊𝑟𝑛𝑔 = 81.555N
𝑊𝑐𝑙𝑛 = 69×2N = 138N
𝑊𝑏 = 1.085KN
Assumptions
𝐿𝑠𝑡𝑟𝑜𝑐𝑘 = 1.5m, F.s = 3
𝐿𝑐𝑦 = 1550mm = 1.55m
Number of cylinders, 𝑛𝑐 = 2
 Single acting 2 cylinders

 Fixed – fixed boundary conditions
𝑉𝑝 = 0.5m/s = piston speed
𝑡𝑝 = 10mm = piston thickness
𝜇𝑝 = 0.1 = friction coefficient in the piston and barrel
𝜇𝑏 = 0.027 roller friction coefficient
𝑛𝑟 = 6 = number of rollers
Material
Steel-mild with mechanical properties of
70
E = 220Gpa
G = 140.25Gpa
𝜎𝑦 = 250mpa
𝜌 = 7.86𝑔⁄𝑐 3
𝜀 = 0.28
Design considerations
𝜎𝑦
𝜎𝑎𝑙𝑙 = 𝐹.𝑠 = 83.33mpa
𝜎𝑎𝑙𝑙
𝜏𝑎𝑙𝑙 = = 41.67mpa
2
Analysis
Required; safe design of the following against buckling and other stresses.
a, 𝑊𝐿2 = 𝑊𝑇
b, 𝑑𝑟𝑜𝑑 , 𝐷𝑝
c, P,Q and p
a, determination of total load on each cylinders
𝑛𝑐 = 2cylinders
𝑊𝐿 = 𝑊𝑇 = 𝑊𝑐𝑜𝑛 + 𝑊𝑐𝑙𝑛 +𝑊𝑇1 + 𝑊𝑟𝑛𝑔 + 𝑊𝑏
𝑊𝐿 = 1287.2N + 138N + 5430N + 81.55N + 1085N = 8.022KN
𝑊𝐿 = 4.01KN/cy
Design of Rod and piston diameter
𝑊𝐿 𝑊𝐿 8.022KN
= =
𝑐𝑦 𝑛𝑐 2
71
𝑊𝐿
= 4.011KN
𝑐𝑦
𝐿𝑟𝑜𝑑 = 1.5m
𝜋 2 𝐸𝐼
𝑊𝑐𝑟 = 𝑊𝐿 ×F.s = ≥ 𝑊𝐿
𝑙𝑒𝑞 2
𝑊𝑐𝑟 = 4.011×3 = 12.033KN
𝑙𝑒𝑞 = equivalent rod length
𝑙𝑒𝑞 = k×L, K= 0.5 for fixed – fixed end, but the recommended value for design is k = 0.65.
𝑙𝑒𝑞 = 0.65L = 0.65×1.5m
𝑙𝑒𝑞 = 0.975m
𝜋𝑑𝑟 4
I= 64
𝜋2 𝐸𝐼
𝑊𝑐𝑟 = ≥𝑊𝐿
𝑙𝑒𝑞 2
𝜋2 𝐸𝜋𝑑𝑟 4
𝑊𝑐𝑟 =
64𝑙𝑒𝑞 2
64𝑙𝑒𝑞 2 ×𝑊𝑐𝑟
𝑑𝑟 4 = 𝜋 3 ×𝐸
4 2 3 2
64𝑙𝑒𝑞 ×𝑊𝑐𝑟 4 64×12.033×10 ×(0.975)
𝑑𝑟 = √ 𝜋3 ×𝐸 = √ 𝜋3 ×200×109 𝑁⁄𝑚2
𝑑𝑟 = 18.54mm, but the suitable value from preferred standard table is 20mm and the
corresponding piston diameter from the table is 40mm.
𝑑𝑟 = 20mm
𝐷𝑝 = 40mm
𝜋2 𝐸
𝜎𝑐𝑟 = 𝐿
( )2
𝑟
72
𝐼
r = √ 𝑚𝑖𝑛
𝐴 𝑅
𝜋𝑑𝑟 4
= 𝐼𝑚𝑖𝑛 = 64
𝜋20𝑚𝑚4
= = 7853.982𝑚𝑚4
64
𝜋𝑑2 𝜋(20𝑚𝑚)2
𝐴𝑅 = = = 314.16𝑚𝑚2
4 4
7853.982𝑚𝑚4
r= √ = 5mm
314.16𝑚𝑚2
Cylinderness ratio
L 1500𝑚𝑚
λ= = = 300
r 5𝑚𝑚
𝜋2𝐸 𝜋 2 ×200×103 𝑁⁄𝑚𝑚2

𝜎𝑐𝑟 = 2 =
λ 3002
𝜎𝑐𝑟 = 21.93mpa
Checking the rod for compression stress
𝑊𝐿 4.022KN
𝜎𝑐 = = 314.16𝑚𝑚2
𝐴𝑅
= 12.8mpa
𝜎𝑐𝑟 ≤𝜎𝑐𝑟 and 𝜎𝑎𝑙𝑙
12.8mpa < 21.93mpa and 83.33mpa, the rod is safe for compression stress.
c, calculation of applied force on the piston (Fapp )
FR = Fapp - Fr - Wf = ma
Fapp = FR + Wf +Fr
Wf ×a 𝑉2− 𝑈2 𝑉2
FR = , but a = = 2𝐿
g 2𝑆
73
(0.5𝑚/𝑠)2
= = 0.08334𝑚⁄𝑠 2
2×1.5𝑚
Wf = 𝑊𝐿2 + 𝑊𝑃,𝑟2 , where Wf = weight load on the fluid
Fr = friction force due to roller and piston friction
𝑊𝑃,𝑟2 = 𝑊𝑝2 +𝑊𝑟2
𝜋
= ρg4 (𝐷𝑝 2 𝑡 + 𝑑𝑟 2 𝐿)
𝜋
= ρg 4 (402 × 10 + 202 × 1500𝑚𝑚3
= 37.4257N
Wf = 4.011KN +37.4257N = 4.05KN
Wf ×a 4.05KN×0.08334𝑚⁄𝑠2
FR = =
g 9.81𝑚⁄𝑠2
= 34.41N
Fr = 𝜇𝑟 × Wf +𝜇𝑝× Wf , 𝜇𝑟 = 𝜇𝑝 = 0.02
Wf (𝜇𝑟 + 𝜇𝑝 ), but since we have 6 rollers
Fr = Wf (6𝜇𝑟 + 𝜇𝑝 )
Fr = Wf (7𝜇𝑝 ), since 𝜇𝑟 = 𝜇𝑝
= 7×0.02×4.05KN = 567N
Fapp = FR + Wf +Fr
= 34.41KN + 4.05KN + 567N = 4.651KN
d, working pressure of the cylinder, P
𝐹𝑎𝑝𝑝
P= ≤ 𝜎𝑎𝑙𝑙
𝐴𝑝
74
𝜋𝐷𝑝 2 𝜋(40𝑚𝑚)2
𝐴𝑝 = =
4 4
= 1.256637× 103 𝑚𝑚2
4.651KN
P = 1.256637×103 𝑚𝑚2 = 3.7mpa
P ≤ 𝜎𝑎𝑙𝑙
3.7mpa ≤ 83.33mpa
∴ the cylinder is safe under its working pressure.
4.27. Flow rate in the oil cylinder Q

𝜋𝐷𝑃 2
Q = 𝑉𝑝 𝐴𝑝 , but, 𝐴𝑝 = 4
Ap = 1.256637× 103 mm2
1.256637×103 mm2 ×0.5m/s

Q= = 6.2832× 10−4 m3 ⁄s
106
4.28. Power analysis on the piston P
P = Q× 𝑝 = 6.2832× 10−4 𝑚3 ⁄𝑠 × 3.7𝑚𝑝𝑎
= 2.325kw
Thickness design of the barrel (cylinder)
We can calculate the thickness of the cylinder using Lame’s equations as follow;
𝑏
𝜎𝑟 = 𝑟 2 - a
𝑏
𝜎𝑐 = 𝑟 2 + a where 𝜎𝑟 = radial stress
𝜎𝑐 = circumferential stress at radius r
a & b are constants
75
b
σc = r 2
+ a ≤ σall
in
Let σc = σall = 83.333mpa
b
σc = r 2 + a = 83.333mpa, but rin = piston diameter
in
b
+ a = 83.333mpa…………………..1
rp 2
𝑏
And 𝜎𝑟 = 𝑟 2 – a = p
𝑝
𝑏
– a = 3.7mpa…………………2
𝑟𝑝 2
Equate equation 1 and equation 2 simultaneously;
𝑏
+ a = 83.333mpa
𝑟𝑝 2
𝑏
– a = 3.7mpa
𝑟𝑝 2
2𝑏
= 87.033mpa
𝑟𝑝 2
b = 87.033𝑁⁄𝑚𝑚2 × (20𝑚𝑚2 )
= 17.4066KN
Substitute the value of b into equation 2 or 1
𝑏
– a = 3.7mpa
𝑟𝑝 2
𝑏
a= −3.7mpa
𝑟𝑝 2
a = 39.816mpa
Now, let us substitute the value of a and b into the Lame’s equations;
76
𝑏 17.4066KN
𝜎𝑐 = 𝑟 2 + a = +39.816mpa
𝑟2
𝑏 17.4066KN
𝜎𝑟 = 𝑟 2 – a = −39.816mpa
𝑟2
Note that cylinder must be strong enough to absorb all the stress such that the stress at the outer
surface of the barrel must be zero.
𝑏
–a=0
𝑟𝑜 2
𝑏 𝑏
= a, from this 𝑟𝑜 = √𝑎
𝑟𝑜 2
17.4066KN
𝑟𝑜 = √39.816mpa = 20.91mm ≈21mm
𝐷𝑜 = 2𝑟𝑜 = 42mm
t = 𝑟𝑜 −𝑟𝑝 = 21−20mm = 1mm
But since the cylinder is assumed to be thick cylinder for hydraulic purposes,
𝑟 𝑟
≤ 10 from this t ≥10
𝑡
21𝑚𝑚
t≥ 10
t ≥ 2.1mm
Let t = 5mm
So, 𝐷𝑜 = 𝐷𝑜 +2t
40 + 10 = 50mm
77
4.29. Weight of the Barrel
Wb = Wcy + Woil
𝜌𝑠𝑡𝑒𝑒𝑙 g (𝑉𝑏 ) + (𝑉𝑜𝑖𝑙 )g 𝜌𝑜𝑖𝑙
𝜋
𝑉𝑐𝑦 = 4 (𝐷𝑜 2 − 𝐷𝑝 2 ) × 𝐿
𝜋
𝑉𝑐𝑦 = 4 (50𝑚𝑚2 − 40𝑚𝑚2 ) × 1.5𝑚
= 1.0603×10−3 𝑚3
𝜋
𝑉𝑜𝑖𝑙 = 4 ×𝐷𝑝 2 × 𝐿 = 1.885×10−3 𝑚3
Wb = 𝜌𝑏 g (𝑉𝑏 ) + (𝑉𝑜𝑖𝑙 )g 𝜌𝑜𝑖𝑙
𝜌𝑜𝑖𝑙 = 900𝑘𝑔⁄𝑚3
Wcy = g𝜌𝑠𝑡𝑒𝑒𝑙 ×𝑉𝑐𝑦
= g×7860𝑘𝑔⁄𝑚3×1.0603×10−3 𝑚3
Wcy = 98.4N
Woil = g×𝜌𝑜𝑖𝑙 × 𝑉𝑜𝑖𝑙
= g×900𝑘𝑔⁄𝑚3 ×1.885×10−3 𝑚3
Woil = 16.643N
Wb = 98.4N+16.643N
Wb = 98.4N
The total weight of one hydraulic cylinder is,
78
WT,cy = Wpr + Wbarrel = 37.4257N + 98.4N
= 135.825N ≈ 136N
Summary results
𝑑𝑟𝑜𝑑 = 20mm
𝐷𝑝 = 40mm, 𝑡𝑝 = 10mm
𝑡𝑐𝑦 = 5mm, 𝐷𝑐𝑦 = 50mm
𝑊𝑐𝑟 = 3𝑊𝐿
p = 3.7mpa
P = 2.325kw
𝐿𝑠𝑡𝑟𝑜𝑘𝑒 = 1.5m
Power delivered to the load
𝑊𝐿 ×𝐿 𝑤𝑜𝑟𝑘 𝑜𝑛 𝑡ℎ𝑒 𝑙𝑜𝑎𝑑 𝑉2 0.5𝑚/𝑠2

𝑃𝐿 = = , but t = = 0.08334𝑚⁄𝑠2
𝑡 𝑡 𝑎
= 3secs
4.011𝐾𝑁×1.5𝑚
𝑃𝐿 = = 2.055kw
3𝑠𝑒𝑐𝑠
Efficiency of the cylinder
𝑝𝑜𝑤𝑒𝑟 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑙𝑜𝑎𝑑

𝜂𝑐𝑦 = 𝑝𝑜𝑤𝑒𝑟 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟×100%
𝑃
𝜂𝑐𝑦 = 𝑝 𝐿 ×100%
𝑐𝑦
2.055kw
𝜂𝑐𝑦 = 2.325kw ×100% = 86.26%
79
4.30. Design of the vertical frame
Definition the vertical frame is the structure on which the total load of the concrete pipe making
machine slides. The vertical frames are two in number and are designed as rectangular columns.
Given
𝑊𝐿2 = 8.022KN
Assumptions
 L = 3m
 F.s = 2.5
 Single acting 2 cylinders
 Fixed – fixed boundary conditions
Materials
Steel with mechanical properties of
E = 220Gpa
𝜎𝑦 = 250mpa
𝜌 = 7.85𝑔⁄𝑐 3
Required
𝑊
a. ratio of corresponding to the most efficient design against buckling
𝑡
80
b. design the most efficient cross – section for the column (vertical frame)
c. total column weight
Design consideration
𝜎𝑎𝑙𝑙 = 𝐹.𝑠 = 2.5
𝜎𝑎𝑙𝑙 = 100mpa
𝜏𝑎𝑙𝑙 = 2𝐹.𝑠 = 5
𝜏𝑎𝑙𝑙 = 50mpa
Analysis
𝑊
a, ratio of design
𝑡
The most efficient design occurs when the resistance to the buckling is equal in both planes (xy
and xz – planes) and this occurs when the Cylinderness ration (λ) in both planes are equal.
𝐼
𝑟𝑧 2 = 𝐴𝑍, 𝐼𝑍 for
1 𝑡 𝑊
𝐼𝑍 = 12(𝑡𝑤 3 −5 ( 5 )3
1 3𝑡𝑤 3
= 12(𝑡𝑤 3 − 625
1 622𝑡𝑤 3
= 12( )
625
311𝑡𝑤 3
𝐼𝑍 = 6×625
𝑤 𝑡
A = wt−3 ( 5 × 5)
22𝑤𝑡
A= 25
81
311𝑡𝑤 3 22𝑤𝑡
𝑟𝑧 2 = ÷
6×625 25
311𝑡𝑤 3 25
= × 22𝑤𝑡
6×625
311𝑡𝑤 2
r = √6×25×22 =
311
r = w√3300
Cylinderness ratio of xy – plane, (λ)
𝑙𝑒,𝑧
𝜆= = K×L
𝑟𝑧
K = 2 for fixed – free ends, but the recommended value for design is k = 2.1
2.1𝐿
𝜆𝑧 = 311
w√
3300
2.1𝐿
𝜆𝑧 = 311
w√
3300
𝐼𝑦 22𝑤𝑡
𝑟𝑦 2 = ,A=
𝐴 25
311𝑤𝑡 3
𝐼𝑦 = 6×625
311
𝑟𝑦 = t√3300
2.1𝐿
𝜆𝑦 = 311
t√
3300
Most efficient design
𝜆𝑧 = 𝜆𝑦
82
2.1𝐿 2.1𝐿
311
= 311
w√ t√
3300 3300
2.1 2.1
= =
𝑤 𝑡
𝑤
= 1 that means w = t
𝑡
b, design of the most efficient cross – section
Since w = t, 𝐼𝑦 = 𝐼𝑧
𝑊𝐿×𝐹.𝑠 8.022𝐾𝑁×2.5
𝑃𝑐𝑟 = =
𝑛𝑐𝑜𝑙 2
= 10.0275KN
𝑃𝑐𝑟 25×10.25𝐾𝑁
𝜎𝑐𝑟 = =
𝐴 22𝑡 2
11.648𝐾𝑁
𝜎𝑐𝑟 = ………………….1
𝑡2
And also
𝜋2 𝐸
𝜎𝑐𝑟 = 𝜆2
2.1𝐿 2.1×3𝑚
𝜆= 311
= 0.307×𝑡 = 20.522m/t
t√
3300
𝜋2 𝐸
𝜎𝑐𝑟 = 20.522m 2
( )
𝑡
𝜋 2 ×200×109 𝑁⁄𝑚2 ×𝑡 2
𝜎𝑐𝑟 = 421.1525𝑚2
𝜎𝑐𝑟 = 4.68695× 𝑡 2 × 109 𝑁⁄𝑚4 ……………………2
Then now, equate equation 1 and 2
11.648𝐾𝑁
= 4.68695× 𝑡 2 × 109 𝑁⁄𝑚4
𝑡2
83
4 11.648𝐾𝑁
t = √4.68695×109 𝑁⁄𝑚4
t ≥ 39.7mm, let t = 50mm
w = t = 5omm
𝑡 𝑤
= = 10mm
5 5
𝑡
Note that 5 = 10mm is the width of the metal roller which roller on the vertical frame. As a result
the cross – sectional area is dimensioned as follow.
4.31. Weight calculation of the vertical frame
𝑊𝑓𝑟 = ρgV =ρgAL
22𝑤𝑡
= ρg × 𝐿, 𝜌𝑠𝑡𝑒𝑒𝑙 = 8750𝑘𝑔⁄𝑚3
25
𝜌𝑔×22𝑡 2 𝐿
𝑊𝑓𝑟 = ,t=w
25
𝜌𝑔×22(50𝑚𝑚)2 1.5𝑚𝑚
𝑊𝑓𝑟 = = 254.13N
25
Since we have two column frames, the total frame weight is;
84
𝑊𝑇𝑓 = 2×254.13N = 508.26N
4.32. Design of vibration table
As well as researching the different types of suspension, many different sources of vibration
were found, Sources of vibration such as using a rotating shaft with an eccentricity or using
cams. Both options allow for adjustable vibration amplitudes. The rotation of an eccentric mass
was the most common source of vibration seen. This design is easy to fabricate, has minimal
wear, and can be relatively easy to adjust. Alternatively, cams will provide constant amplitude of
vibration, regardless of load (unlike a design using an eccentricity). However, cams will be
difficult to machine because according to the ASTM handbook for concrete vibration table
design, vibration amplitudes should range from 0.3 to 0.4 mm at a frequency of 3900±200 RPM.
Also, our low torque motor will be unable to lift the heavy loads required of it. Therefore, the
most viable source of vibration is the rotating eccentricity. Steel was almost exclusively used in
the construction of vibration tables. We feel that steel is the best option for our design as well,
due to its durability, relatively low cost, rigidity, and high availability. Steel is also a very
forgiving metal to weld, unlike aluminum, which usually requires a heat treatment process after
welding.
We select electric motor vibration table due to:
 The forces generated by the rotating unbalances are transmitted directly to the table
without dependence upon a reactionary force against a heavy base or rigid ground
connection.
 The cost of mechanical exciter is less compared to other exciters.
 There are no leakage problems as in hydraulic exciters.
85
Model of vibrator
FBD
86
The equation of motion will be
M𝑥̈ +𝑘𝑒𝑞 x = m𝜔2 esin 𝜔𝑡……………………….1
This is linear second order forced vibration due to unbalance mass.
x (t) = xsin 𝜔𝑡
𝑥̈ = -𝜔2 x sin 𝜔𝑡
Subtitling equation in to equation one
- M𝜔2 xsin 𝜔𝑡+𝑘𝑒𝑞 x = m𝜔2 esin 𝜔𝑡
M𝜔2 xsin 𝜔𝑡+𝑘𝑒𝑞 xsin 𝜔𝑡 = m𝜔2 esin 𝜔𝑡
𝑘𝑒𝑞 x− M𝜔2 x = m𝜔2 e
x (𝑘𝑒𝑞 − M𝜔2 ) = m𝜔2 e
m𝜔 2 e
x= ……………………..2
(𝑘𝑒𝑞 − M𝜔2
Where M = total mass excluding the mass of unbalanced
M = total mass of lower spring lifts+iner die mass +mass of table
M = 8.02KN+718N+416𝑁
M = 9.154KN……… total weight.

87
M = 934kg is total mass excluding the unbalance mass.
Assumption
Impact force or centrifugal force due to the unbalance mass is 1.1 of the total mass.
𝑓𝑜 = 1.1𝑊𝑇 = 1.1×934kg×9.8, where 𝑓𝑜 = impact (centrifugal)
𝑊𝑇 = total weight
𝑓𝑜 = 10KN
𝑓𝑜 = m𝜔2 e, where,
m = mass of unbalance mass
w = frequency of vibration
e = eccentricity,
x = amplitude, e = 4cm = 0.04m
Specification
From concrete vibration table the frequency and amplitude is;
Frequency = 3600±200rpm
Amplitude = 0.3 to 0.4mm
𝑓𝑜 = m𝜔2 e, w = 3800rpm
2𝜋×3800
= 𝑟𝑎𝑑⁄𝑠𝑒𝑐 = 398𝑟𝑎𝑑⁄𝑠𝑒𝑐
60
10× 103 𝑁 = m×0.04m×3982 𝑟𝑎𝑑⁄𝑠𝑒𝑐
m = 1.6kg, unbalanced mass with eccentricity.
88
m𝜔 2 e
x = (𝑘 , x = 0.4m
𝑒𝑞 − M𝜔2
m𝜔 2 e 𝜔
x=𝑘 2
, r=𝜔
𝑒𝑞 (1 − 𝑟 ) 𝑛
𝑘𝑒𝑞
𝜔𝑛 = √ 𝑀
m𝜔 2 e
x=𝑘 2)
, r = frequency ratio
𝑒𝑞 (1 − 𝑟
𝑘𝑒𝑞 1
𝜔𝑛 = √ 𝑀 = √𝑀 × √𝑘𝑒𝑞
𝜔𝑛 = 0.33× √𝑘𝑒𝑞
m𝜔 2 e
x= 𝜔 2
𝑘𝑒𝑞 (1 – ( ) )
𝜔𝑛
Substituting values of variables in the equations and the equivalent stiffness of the spring will be
obtained
1.6×3982 ×4cm
0.4×10−3mm = ω 2
keq (1 – ( ) )
ωn
1.6×3982 ×4cm
0.4×10−3mm = (ω2 )
keq (1 –
(0.33×√keq )2
1.6×3982 ×4cm
0.4×10−3mm = (3982)
keq (1 –
(0.33×√keq )2
10.13×106
k eq −145.46× 106 = 0.4
k eq = 170.79× 106 𝑁⁄𝑚
keq 170.79×106 𝑁⁄𝑚

k= = ,
4 4
89
Where
k = stiffness of each spring
k = 42.696× 106 𝑁⁄𝑚
4.33. Design of spring
Material selection
G = 80Gpa
E = 210Gpa and we know that;
k = 42.696× 106 𝑁⁄𝑚
𝑡𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 9.154×103 𝑁

F= = where F = axial load of spring
4 4
F = 2.258KN
Assumption
 Square ground end

 Average service
C = 5 = spring index
𝐹 2.258KN
𝛿 = 𝑘 = 42.696×106 𝑁⁄𝑚
𝛿 = 0.054mm, deflection of the spring due to impact load (centrifugal load of rotating unbalance
mass which is the amplitude of vibration.
x = 0.4m
𝛿𝑚𝑎𝑥 = 𝛿 + x = 0.054mm + 0.4 = 0.454mm
90
𝛿𝑚𝑎𝑥 = 0.454mm, maximum deflection of the spring.
8𝐹𝐶
𝜏 = k×𝜋𝑑2 , but k = 𝑘𝑠 × 𝑘𝑐
Where 𝑘𝑠 = stiffness factor due to shear
𝑘𝑐 = stiffness concentration due to curvature
K = wahils stress factor in order to consider the effect of both direct shear
as well as curvature of the wire.
4𝑐−1 0.615
k = 4𝑐−4 + 𝑐
k = 1.1875+0.123 = 1.3105
F = 2.288KN
𝑘×8𝑤𝑐 1.3105×8×2.288×103 ×5
d=√ =(√ )
𝜋𝜏 𝜋×315×106
d = 11mm
D = cd = 5×11 = 55mm
8𝑤𝑐 3 ×𝑛
𝛿𝑚𝑎𝑥 = , where n = number of coils.
𝐺×𝑑
𝛿𝑚𝑎𝑥 ×𝐺×𝑑 0.454×10−3 ×80×109 ×11×10−3

n= =
8𝑤𝑐 3 8×2.288×103 ×53
n≈1
𝑛𝑎 = number of active coils.
n′ = n + 2 for squared and ground end
n′ = 3
91
𝐿𝑠 = r′× 𝑑 = 3× 11 = 33mm = solid length
𝐿𝐹 = 𝐿𝑠 +𝛿𝑚𝑎𝑥 + ( n′−1) × 1𝑚𝑚
𝐿𝐹 = 33mm + 0.454mm + (3-1) ×1mm
𝐿𝐹 = 35.5mm = free length of the spring
Weight of the inner die,𝒘𝒅
wd = 𝑤𝑐𝑦 + 𝑤ℎ𝑐
𝜋(𝑑𝑜 2 −𝑑𝑖𝑛 2 )
𝑤𝑐𝑦 =𝜌𝑔 ,𝜌𝑠𝑡𝑒𝑒𝑙 = 7850𝑘𝑔⁄𝑚3
4
𝜋(6002 −5942
𝜌𝑔 = 693.273N
4
𝜋(𝐷𝑐ℎ 2 −𝑑𝑜 2 )𝑡
𝑤ℎ𝑐 = , 𝐷𝑐ℎ = diameter of cylinder head
4
𝜋(7052 −6002 )×3𝑚𝑚

𝜌𝑔 = 24.863N
4
𝑊𝑏𝑖 = 693.273 + 24.863 = 718.086N ≈ 718.1N
4.34. Design of the upper table

𝑊𝑇 8.022𝐾𝑁
𝑊𝑡 = =
675𝑚𝑚 675𝑚𝑚
= 12.95KN/m
𝑊𝑡(𝑥) = 12.95KN/m
𝑅𝐴𝑦 = 4.6206KN
𝑅𝑐𝑦 = 4.6206KN
92
𝑉max(𝑥) = 4.6206KN @ x = 0.035and 0.705m
M.B.M
𝑀max(𝑥) = 822Nm @ x = 0.3675m
Thickness design of the table

𝑀𝑦
𝜎𝑏 =
𝐼
Assume the cross – sectional area is rectangle as follows
𝑤𝑡 3 𝑡𝑤 3
𝐼𝑥𝑥 = and 𝐼𝑦𝑦 =
𝑡2 𝑡
But since w > t, 𝐼𝑦𝑦 > 𝐼𝑥𝑥
𝑤𝑡 3
So, considering 𝐼𝑥𝑥 =
𝑡2
𝑀𝑦 𝑡
𝜎𝑏 = ,y=
𝐼 2
𝑀𝑦
𝜎𝑏 = ≤ 𝜎𝑎𝑙𝑙
𝐼
𝜎𝑎𝑙𝑙 = = = 82.8mpa
𝐹.𝑠 2.5
93
𝑡
𝑀 6𝑀
2
𝜎𝑏 = 𝑤𝑡3
= ≤ 𝜎𝑎𝑙𝑙
𝑤𝑡 2
𝑡2
6𝑀
𝑡2 ≥
𝑤𝜎𝑎𝑙𝑙
4932×103 𝑚𝑚2
t≥√ , t ≥ 9.39 ≈ 10mm
55890
Weight of the table
𝑊𝑡 = b × 𝑤 × 𝑡 × 𝜌𝑔 − 𝑑𝑖𝑛 2 t× 𝜌𝑔
Weight calculation of the upper vibrating table
𝑊𝑡𝑎 = 𝑊𝐴1 +𝑊𝐴2
= 𝜌𝑔(𝐴1 − 𝐴2 )𝑡
94
= 𝜌𝑔(7352 − 2002 )×10𝑚𝑚3 = 385.22N
Weight total on the spring
𝑊𝑠𝑝 = 𝑊𝑑 + 𝑊𝐿2 + 𝑊𝑧
= 2𝑅𝐴𝑦 + 𝑊𝑧
2× 4.6206KN + 385.22N = 9.63KN
4.35. Design of the lower vibrating table
Reactions analysis
∑ 𝐹𝑦 = 0
𝑅𝐴 + 𝑅𝐸 = 2×4.82KN−𝑤𝑚
𝑅𝐴 + 𝑅𝐸 = 9.63KN + 500N
𝑅𝐴 + 𝑅𝐸 = 10.13KN…………….1
∑ 𝑀𝐴 = 0
95
-30× 4.82 − 367.5𝑚𝑚 × 500𝑁 − 705𝑚𝑚 × 4.82𝐾𝑁 + 735𝑚𝑚𝑅𝐸 = 0
𝑅𝐸 = 5.07KN
Then, 𝑅𝐴 = 10.13KN −5.07KN = 5.07KN
Then the F.B.D is;
Ansysis analysis of the vibrating table
96
97
4.36. Design of hydraulic cylinder for the pressing head
Given material
𝐹𝐶 = 870N steel
V = 0.6m/s E = 220Gpa and 𝜎𝑦 = 207mpa
Assumptions
 𝐿𝑟 = 500mm
 F.s = 3
 Fixed – fixed ends
 Single acting spring returnable cylinder
 𝑡𝑝 = 5mm
Required
 dr , Dp
 p = delivered to the load
 P = delivered to the piston
 Q, t cy and Do
 ηcy
 LT = Lc + Lstrock
Analysis
Euler’s column buckling formula
π2 EI
wcr = ≥ F. s × wapp
l2
Let wcr = F. s × wapp
3× 870N = 2610N
98
l = KL, K = 0.5 for fixed – fixed end and k recomended for design is 0.65
l = 0.65L = 0.325m
πdr 2
I= 64
π2 EI π3 Edr 4
wcr = =
l2 64l2
4 64wcr l2 4 64×2610N×(0.325m)2
dr = √ =√
π3 E π3 ×220×109 N⁄m2
= 7.13mm, but the suitable value from the preferred standard table of rod and piston diameter is
20mm and the corresponding piston diameter is 40mm.
∴ dr = 20mm and Dp = 40mm
Weight of the piston and rod
𝑤𝑝𝑟 = 𝑤𝑝 + 𝑤𝑟
𝜋𝜌𝑔(𝐷𝑝 2 𝑡+𝑑𝑟 2 𝐿)
= 4
πρg(402 ×5+202 500)

= = 12.6
4
πρoil g(Dp 2 L)
woil = 4
πρoil g(402 ×500)

woil = 4
woil = 5.55N
wpr = wp + wr + wo
12.6 + 5.55N = 18.15N
99
4.37. Force applied on the piston of pressing head
FC = Fap − Fr + wpr
Fr = μ(FC + 𝑤𝑝𝑟 ) = μ𝐹𝑣
Let μ = 0.3 and Fv = (870 + 18.15N)
Fr = 0.3(870 + 18.15N) = 266.445N
Fap = FC + Fr − wpr
= 870 + 266.445 − 18.15N = 1.1183KN
4.38. Stiffness of the returning spring
Fr = 𝐹𝑠𝑝 = kx, x =𝐿𝑠𝑡𝑟𝑜𝑐𝑘 = 500mm
𝐹𝑠𝑝
k= , 𝐹𝑠𝑝 = Fr = 266.445N
𝑥
266.45𝑁
k= = 532.89N/m
0.5𝑚
Note k increases as the stroke length decreases.
Working pressure of the cylinder
Fap 𝜋×(402 )𝑚𝑚

p= , 𝐴𝑝 = = 1.2566371× 10−3 𝑚2
𝐴𝑝 4
1.1183KN
P = 1.2566371×10−3 𝑚2 = 8.9bar
Flow rate and power analysis
Q = 𝐴𝑝 𝑉 = 1.2566371× 10−3 𝑚2 × 0.6𝑚/𝑠
= 7.54× 10−4 m3
100
a. Power delivered to the piston, 𝒑𝒑 ;
𝑝𝑝 = PQ = 8.9bar×7.54× 10−4 𝑚3
= 671.06w
b. Power delivered to the load
L
P = FC × t = FC × V
P = 870𝑁 ×0.6m/s = 522w
Efficiency of the cylinder
p
ηcy = p × 100%
p
522𝑤
= 671.06 × 100% = 77.79%
4.39. Thickness design of the cylinder
From design of pressure vessels,
Dp p
σh = ≤ σall……………………….1
2t
𝐷𝑝
𝜎𝑟 = ≤ 𝜏𝑎𝑙𝑙 …………….2
4𝑡
Using equation 1
𝐷𝑝 𝑝 𝜎𝑦
t≥ , 𝜎𝑎𝑙𝑙 = = 69mpa
2𝑡 𝐹.𝑠
40𝑚𝑚×8.9𝑏𝑎𝑟
t≥
2×69𝑚𝑝𝑎
𝑟
t ≥0.258, but ≤ 10
𝑡
101
𝑟
t≥ for thick cylinder
10
20
t≥ =2
10
t ≥ 2, let t = 3mm
4.40. Design of belt conveyor
Material selection
Flat leather belt
𝜎𝑢 = (21 – 35) mpa
𝜎𝑎𝑙𝑙 = 2.8mpa
𝑓1 = 0.45 coefficient of friction between the belt and concrete.
Wear strip material
Stainless steel
𝑓2 = 0.5 coefficient of friction between the belt and wear strip
𝜌1 = 2400𝑘𝑔⁄𝑚3 = density of concrete
𝜌2 = 1000 𝑘𝑔⁄𝑚3 = density of belt material
𝑓3 = 0.25 = coefficient of friction between the belt and pulley
Assumption
 The concrete flows over the belt from the hopper create a rectangular shape of
accumulated concrete.
 Width of belt 200mm
 Height of accumulation 100mm
102
Let’s calculate force required at the belt which is the belt pull (T)
T = g[(M +w)× 𝐿𝐻 × 𝐾1
Where g = 9.81m/s gravitational acceleration
M = mass of concrete per concrete
𝐿𝐻 = c = center distance between pulleys
𝐾1 = coefficient of friction between strip and belt
Mass of product (concrete) to be conveyed
M = 𝜌 × 𝑉, Where V = volume
Volume of rectangular shape is
V = 𝐿𝐻 × 𝑤 × ℎ, where w = width of the belt
h = height of concrete accumulation
V = 0.7× 0.2 × 0.1 = 14 × 10−3
M = 𝜌 × 𝑉 = (2400× 14 × 10−3 )𝑘𝑔
M = 33.6kg = mass of concrete.
Mass of belt (w)
w=𝜌×𝑉
V = L× 𝑤 × 𝑡, where L = length of belt
Assumption
c = 700mm
w = 200mm
103
t = 10mm
𝐷1 = 𝐷2 = 88mm
2
L = 2c + 𝜋(2D)
2(2×0.088)
L = 2× 0.7 + = 1.5m
𝜋
V = 1.5×0.2×0.01 = 3× 10−3 𝑚3
w = 𝜌 × 𝑉 = 1000×3× 10−3 𝑚3
= 3kg = weight of belt
T = g[(M +w)× 𝐿𝐻 × 𝐾1 , 𝐿𝐻 = c
T = 9.81[(33.6 +3) ×0.7×0.5
T = 125.6N
Stress induced to the belt is equal to
𝐹 125.6𝑁
𝜎 = 𝐴 = 0.2×0.01 = 0.628mpa
𝜎 = 0.628mpa = stress induced to the belt
Because of 𝜎𝑎𝑙𝑙 is greater than stress induced it is safe.
𝜎 < 𝜎𝑎𝑙𝑙
0.628 < 2.8mpa, therefore it is safe.
Power observation of the conveyor and desired motor speed
Assume belt speed
V = 25m/min or V = 0.42m/sec
104
𝜋𝐷𝑁
V= 60
𝑉×60 0.42××60
N= =
𝜋𝐷 𝜋0.088
= 91rpm
𝑝𝑏 = T× 𝑉 = power required to drive the belt
0.42𝑚
𝑝𝑏 = 125.6× = 52.75𝑤
𝑠𝑒𝑐
𝑝𝑚 = motor power selection should be considered
𝑝𝑚 = 2𝑝𝑏 = 2× 52.75 = 105w
P = 105w = motor required to drive the belt
Motor selection
N = 91rpm
105
P = 1/7ℎ𝑝 = 746w = 0.142ℎ𝑝
∴ Form table 2 above gear motor MTGP parallel shaft gear motor selected.
4.41. Design of shaft for the conveyor

Material selection
Stainless steels SISI 430
Tensile strength 𝜎𝑡 =517 Mpa
Yield strength= 276 Mpa
Assumption
F.s = 4
Neglecting mass of shaft and pulley applied load is torsion only.
105
2𝜋𝑁
P = T𝜔, 𝜔 = 60
2×𝜋91
= = 9.53rad/sec
60
𝑝
T=𝜔
105𝑤
T = 9.53rad/sec = 11Nm
3 16𝑇 3 16×11
d = √𝜋𝜏 = √𝜋×34.5×106
𝑎𝑙𝑙
d = 15mm
4.42. Bearing selection
 High carbon chromium steel
ball bearing
Analysis
ω𝑅= Radial load
T 11Nm
wR = d/2 = 15mm/2
𝑤𝑅 = 1.466KN
𝐿
C = 𝑤𝑅 × (106 )1/𝐾
L = 60× 𝑁 × 𝐿𝐻
K = 3 for ball bearing
106
𝐿𝐻 = is 5year 10hours per day
𝐿𝐻 = 5× 365 × 10 = 1.825 = 1.825× 104 hours
L = 60×91×1.825× 104 hours
L = 99.645× 106 rev
𝟑 𝟗𝟗.𝟔𝟒𝟓×𝟏𝟎𝟔 𝐫𝐞𝐯
C = 1.466× 𝟏𝟎𝟑 × √( )
𝟏𝟎𝟔
C = 6.8KN
Table 3 indian standard for ball bearing selection
According to IS (Indian standard) from table above
IS 302 single row deep grove ball bearing is selected.
bore = 15mm
107
∴ w = 13mm
Outer diameter = 42mm
Standard dimension of the hydraulic cylinders
108
Table 4 pump selection
109
Table 5 pipe selection
A. Dimensioning for the upper hydraulic cylinder
Given
𝑤𝐿 = 500N
V = 0.5m/s
𝐿𝑠 = 1.95m = 76.772inch
Results
3
𝑑𝑟 = 20mm Q = 0.00062832𝑚 ⁄𝑠
𝐷𝑝 = 40mm 𝑝𝑝 = 427.886w
𝐷𝑜 = 47mm 𝑝𝐿 = 𝑊𝐿 × 𝑉 = 250w
110
𝐹𝑎𝑝 = 770N 𝜂 = 58.43%
P = 6.81bar
Required
a. I and 𝐿𝑐
b. 𝑑𝑡 , 𝑑𝑜,𝑡
c. Vt
Solution
a. Standard inlet, I and closed length of the hydraulic cylinder, 𝑳𝒄 for the upper cylinders.
Using table as guide;
I = ¾ inch = 20mm
𝐿𝑐 = 𝐿𝑠 + x, based on equation III for 𝐿𝑠 ≥ 50𝑖𝑛
x1 = 7.5inch = 20mm
𝐿𝑠𝑡𝑟𝑜𝑐𝑘 −50
x2 = = 68mm
10
𝐿𝑐 = 1950 + 146.05 +68mm = 2.209mm
And I = 3/4inch = 20mm
b. Standard pipe dimensions for the upper cylinders
For I = 3/4inch = 20mm, 𝑑𝑡 = I = 20mm and 𝑑𝑜 = 26.67mm from the standard pipe table.
c. Speed of the oil in the pipe
Qcy = Qt = Q
Ap × VP = At × Vt = 6.283× 10−4
111
Ap 𝐷𝑃 2
Vt = VP = VP
At 𝑑𝑡 2
402
Vt = 202 × 0.5m/s = 2m/5
B. Dimensioning for the lower (mould riser) hydraulic cylinders
Given Design result
𝐿𝑠𝑡𝑟𝑜𝑐𝑘 = 𝐿𝑠 = 1.5mm 𝑑𝑟 = 20mm
VP = 0.5m/s 𝐷𝑝 = 40mm
𝑤𝐿 = 4.01KN 𝐷𝑜 = 47mm
Required 𝐹𝑎𝑝 = 4.651KN
a. I and 𝐿𝑐 P = 3.7mpa
b. 𝑑𝑡 and 𝑑𝑜,𝑡 Q = 6.283× 10−4
c. Vt P = 2.325kw
Solution
a. Standard inlet, I and closed length, 𝑳𝒄 for the lower hydraulic cylinder
I = 3/4inch = 20mm
𝐿𝑐 = 𝐿𝑠 + x1 + x2 based on equation three for 𝐿𝑐 ≥ 50𝑖𝑛
x1 = 5.75inch = 146.05mm
𝐿𝑐 −50
x2 = = 23mm
10
𝐿𝑐 = 1500 + 146.05 + 23 = 1.669mm
b. Standard pipe dimensions for the hydraulic dimensions

112
For I = 3/4inch = 20mm
𝑑𝑡 = 20mm from the table
𝑑𝑜,𝑡 = 26.67mm from the table
C. Speed of the oil in the tube
Qcy = Qt = Q
Ap × VP = At × Vt
Ap 𝐷𝑃 2
Vt = VP = VP
At 𝑑𝑡 2
402
Vt = 202 × 0.5m/s = 2m/5
Power of the pump delivered to the cylinder
P = 2.325KW
For 2 cylinder
P = 2×2.325 = 4.65KW
C. Dimensioning for the pressing head (shaping) hydraulic cylinders
Given Design results
𝑤𝐿 = 870N 𝑑𝑟 = 20mm
𝐿𝑠 = 500mm 𝐷𝑝 = 40mm
VP = 0.6m/s 𝐷𝑜 = 47mm
Required Q = 7.54× 10−4 𝑚3 ⁄𝑠
113
a. I and N p = 8.9bar
b.𝑑𝑡 , 𝑑𝑜,𝑡 P = 671.06/2 = 335.53w
c.Vt 𝐹𝑎𝑝 = 1.1183KN/2 = 559.15KN
Solution
a. Standard inlet, I and closed length of the hydraulic cylinder for the pressing head.
I = ¾ inch = 20mm
𝐿𝑐 = 𝐿𝑠 +x based on equation one for 𝐿𝑠 ≤ 35𝑖𝑛
𝐿𝑐 = 500 + 146.05 = 646.05mm
b. standard pipe dimension for the pressing cylinder ( from the table)
For I = 3/4inch = 200mm
𝑑𝑡 = 20mm
𝑑𝑜,𝑡 = 26.67mm
c. Speed of the oil in the pipe
Qcy = Qt = Q
Ap × VP = At × Vt
Ap 𝐷𝑃 2
Vt = VP = VP
At 𝑑𝑡 2
402
Vt = 202 × 0.6m/s = 2.4m/5
Total flow rate
114
𝑄𝑇 = 2(𝑄𝑐𝑦1 + 𝑄𝑐𝑦2 +𝑄𝑐𝑦3
𝑄𝑇 = (𝑄𝑐𝑦𝑢 + 𝑄𝑐𝑦𝐿 + 𝑄𝑐𝑦𝑃 )
2(6.2832 +6.2832 + 7.84)× 10−4 𝑚3 ⁄𝑠
𝑄𝑇 = 40.21310−4 𝑚3 ⁄𝑠
Where 𝑄𝑇 = the total pump flow rate
Pump total power

𝑝𝑇 = 𝑝1 + 𝑝2 +𝑝3
= 𝑝𝑐𝑦𝑢 + 𝑝𝑐𝑦𝑙 +𝑝𝑐𝑦𝑝
= 2 (335.53w + 427.886w + 2.325× 103 w)

= 6.177kw ≈ 6.2kw
Total pump head
𝑃 𝑃𝑇
𝐻𝑝 = 𝛾𝑄𝐻 = 𝜌
𝑜𝑖𝑙 𝑔𝑄𝑇
Take 𝜌𝑜𝑖𝑙 = 0.9𝑔⁄𝑐𝑚3 = 900𝑘𝑔⁄𝑚3

6.2kw
𝐻𝑝 = 900𝑘𝑔⁄𝑚3 ×40.21310−4 𝑚3 ⁄𝑠×9.81𝑚3 ⁄𝑠
= 174.628m
Pump – motor selection
Design results
𝑃𝑇 = 6.2Kw
𝑝𝑇 = 1.572mpa
𝑄𝑇 = 40.213× 10−3 𝑚3 ⁄𝑠
𝐻𝑇 = 171m
Required
Proper pump and motor selection for the design values
Solution
115
Table 6 pump selection by its head
Possible pumps results for the head, 𝐻𝑇 = 171m are

 Multistage centrifugal pumps
 Piston pumps
 Screw pumps
Table 7 pump selection by its capacity
116
Possible pumps results for the design flow rate, 𝑄𝑇 = 40.213× 10−3 𝑚3 ⁄𝑠 are;
 One stage centrifugal pumps

 Piston pumps
 Screw pumps
 Vortex pumps
Possible pumps which are common for both the design 𝐻𝑇 = 171m, and 𝑄𝑇 = 40.213×
10−3 𝑚3 ⁄𝑠 are;
 Piston pumps
 Screw pumps
𝑃𝑇 = 6.2kw = P1 + P2 + P3
= 2(335.53w + 427.886w + 2.325103 w)

= 6.2kw
Note; 6.2kw is the total power of the motor to actuate the three pairs of cylinders all at
once. But since each pair is operated at different consecutive times (pressing → rising the
mould → rising the outer die), we have to select the pump motor based on the largest
power of the design result which is the mold rising power.
i.e 𝑃2 = 2(2.325kw) = 4.65KW
For the design flow rate and head, the corresponding pump – motor selection is given as
follows.
117
Sketch of the fluid power (hydraulic) system assembly
N.B:- the hydraulic cylinder in the sketch is in vertical stand in our design as the circuit shown
below;
118
4.42. Bolt design

Given
w = 2× 5.07𝐾𝑁= 10.14KN
Material
Steel carbon with mechanical properties of;
E = 200Gpa
𝜎𝑦 = 350 mpa
𝜌 = 7.879𝑔⁄𝑐𝑚3
𝜀 = 0.29
𝜎𝑧 = 420mpa
Assumptions
 F.s = 3.5mm
 n=4
 removable fastening non- replated black finish
a) 𝑑𝑟, 𝑑𝑚 , 𝑑𝑜 ,p
b) 𝑇ightening torque
Solution
𝜎𝑦 350𝑀𝑝𝑎
𝜎𝑎𝑙𝑙= 𝐹.𝑠= =100Mpa
3.5
𝜎𝑦
𝜏𝑎𝑙𝑙 =2 𝐹.𝑠=50mpa
4𝐾𝑁
𝜎𝑧 = ≤ 𝜎𝑎𝑙𝑙
𝑛𝜋𝑑𝑟 2
4×10140𝑁
𝑑𝑟 = √4×𝜋×1000
𝑑𝑟 = 6mm
a) But from standard table for 𝑑𝑟, =6mm,the correct values are:
𝑑𝑜 =8mm
119
𝑝 = 1.25
𝑑𝑟 = 𝑑𝑜 -p =8-1.25=6.75
𝑑𝑚 = 𝑑𝑜 -p/2
=8mm
𝑏)Tighening torque
𝑇 = 14.82 𝑁𝑚 𝑓𝑟𝑜𝑚 𝑚𝑜𝑏𝑖𝑙𝑒 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑜𝑟 𝑎𝑝𝑝𝑙𝑖𝑐𝑡𝑖𝑜𝑛(𝑚𝑒𝑐ℎ. 𝑒𝑛𝑔 𝑜𝑛𝑒)
120
CHAPTER FIVE
Conclusion and recommendation

5.1. Conclusion
The concrete pipe making machine is designed to be easy, productive, efficient, reliable,
durable and flexible for making different size of concrete pipes with the following
extreme size intervals.
 𝑑𝑚𝑖𝑛 = 188mm
 𝑑𝑚𝑎𝑥 = 600mm
 𝑡𝑚𝑎𝑥 = 75mm
 𝐿𝑚𝑎𝑥 = 1.5mm
Due to its vertical stand, the machine consumes small surface area and provides easy
product handling.
Since the machine is automatically operated, it will save time and lower consumption. So
it will produce 12 concrete pipes per hour (12pipes/hour) by consuming about 6.5kw
power. When we compare the productivity of this machine with the manually concrete
production we observed, which produces 6 pipes per day (6pipes/day), it is 48 times the
productivity of the manual production.
i.e. the machine productivity = 48 × manual productivity.
So, we conclude that the machine will solve the concrete pipes production requirements
with good quality, fast productivity and low power consumption.
121
5.2. Recommendation
We want to recommend the following points about the machine;

 The machine must be manufactured based on its design considerations and design
analysis if it is needed to do the required work effectively.
 The machine should not be loaded beyond its design limitations for safe and long
life functionality of the machine.
 Generally the machine should be manufactured and operated properly
122
References
1. Cecil Jensen & Jay D.Helsel, Engineering drawing and design, 5th edition, McGraw-Hill,
1996, New York.
2. Joseph Edward Shigley& Charles R.Mische, Mechanical Engineering design, 5th edition,
McGraw – Hill, 1989, New York.
3. Robert C.Juvinal& Kurt M.Marshek, Fundamentals of machine components design, 3rd
edition, John wiley, 1999, New York.
4. R.S. Khurmi& J K Gupta, A Text book of machine design, Eurasia, 2002, New Delhi.
5. http://www.engineeringtoolbox.com/ansi-stainless-steel-pipes-d_247.htm
6. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-
ISSN: 2320-334X, Volume 12, Issue 3 Ver. I (May. - Jun. 2015), PP 15-22
www.iosrjournals.org
123
PART DRAWING AND ASSEMBLE
Assembly drawing
124
125
126

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Concrete Pipe Making Machine

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DESIGN OF CONCRETE PIPE MAKING MACHINE

BY: Abel Dagne

A thesis submitted in partial fulfillment of the requirements for the award of

SCHOOL OF MECHANICAL AND INDUSRRIAL ENGINEERING

ETHIOPIAN INSTITUTE OF TECHNOLOGY-MEKELLE

ADVISOR: INS. BESUFEKAD GETACHEW

4.10. Thickness design of the dies (molding cylinders) ....................................................................... 35

CHAPTER FIVE ........................................................................................................................................... 121

Fv = vertical force x = amplitude, e = 4cm = 0.04m

Ac = area of compaction na = number of active coils.

PH = hydraulic pressing pressure of the σu = ultimate strength

Figure1 Figure 1concrete pipe

 Good initial strength

 average wall thickness,

 smooth inner and outer wall

 high compressive strength

 firm and reliable tie-in convenient construction

 High efficiency and release the mold immediately to maintenance etc..

Some images of the machines

Horizontal concrete pipe making machine

Figure 2 horizontal concrete pipe making machine

Figure3, vertical concrete making machine

1.2 Problem statement

Problems we have observed:

Defect of manually made concrete pipe

Fully manually making of concrete pipe

 To design the outer and inner molding dies (cylinders)

 To design the belt, shafts and bearings

 To design the structure(frame) of the machine

 To select the appropriate pump and hydraulic motor

1.4Scope of the study

1.5Expected out comes

 Less pipe mould: usually 2 sets can meet the need

 Improved dimensional accuracy of products

 Enhanced manufacturing time

 Full use of material, no waste

 Save the space and easy handle

 By discussing and sharing ideas

 Using internet sources

 Using mechanical soft ware’s like CATIA and solid work

Figure 4 design procedures

1.8. Design specifications

 Homogenous compaction of material

1) Concrete feeding conveyor,

Figure 5. Concrete feeding conveyor

2) Head Pressing machine,

Figure 7central vibrating

4) Machine Base Frame,

Figure 8, machine base frame

5) Hydraulic System, Cooling System,

6) Steel pipe Mould,

Figure 9, steel pipe mould

A whole pipe mould will include:

a.) outer mould 1 pc

b.) inner mould 1 pc

c.) Press head Bracket 1 pc

d.) Base Ring pallet 1 pc

e.) Spigot Forming Ring 1 Pc

8) Electric Control System.

Figure 11oil pump

3.1. Conceptual Design

Figure 12 2D concept one

Figure13, 2D model of concept two