International Journal of Scientific Research and Review ISSN NO: 2279-543X

Formulation of Mathematical Model for Corrugated

paper sheet Machine Using HPFM and Its Design
R.N.Dehankar a, Dr. A.M. Langdeb#
a
Research Scholar & Asstt. Professor, Mechanical Engg. Deptt.,Anjuman College of Engineering &Technology , Nagpur:440001, India
b#
Professor and Head , Mechanical Engg. Deptt., Anjuman College of Engineering, &Technology Nagpur:440001, India
Emails: dehankar3@gmail.com , akashlangde@gmail.com

Abstract: In Present scenario packing of any product is a big task for ruler agriculture product & manufacturing industries
for safety and handling point in view to maintain clean(pollution free) environment. Corrugated paper sheet is better option
in rural areas for packaging purpose both for self-sustenance as well as source of subsidiary income to small farmers &
agricultural labors. There is no such machine is available in rural area for the packaging of agricultural products like
vegetables, grains and fruits etc. At present, no such machines at household level are available using HPFM.

The main theme is to Design a human energized paper corrugation machine for rural sector. The design evolves a new
concept of paper corrugation machine, which eliminates the limitations of packaging which is not available in ruler areas.

In this research, an approximate generalized experimental data based model for paper corrugation machine, has been made
by varying some independent parameters during experimentation, it is clear that one will have to decide what should be the
minimum human energy to be supplied for suitable output of formation of corrugated paper sheet in minimum time, and
also find out what should be the resistive torque offered by the system for the formation of corrugated paper in minimum
time. This is possible if quantitative relationship amongst various dependent and independent variables of the system to be
determined. This relationship would be known as the mathematical model of this mechanical system. It is well known that
such a model for the mechanical system cannot be expressed by applying logic, the only option is to express an experimental
data based model suggested by Hilbert Sc. Hence, it is decided to evaluate an experimental data based model. In this approach
all the independent variables are vary through possible range, a response data gets collected and an analytical relationship
is established for the mechanical system. Once such a relationship is established then the method of optimization can be
applied to deduce the values of independent variables at which the necessary responses can be minimized or maximized.

Keywords: Human Power, Flywheel Motor, Corrugated sheet, Traditional Method, HPFM (human powered flywheel motor)

I. INTRODUCTION
Formation of corrugated sheets can be also undertaken on commercial basis for packaging. The number of small farmers &
agricultural labourers are very large in the rural area and hence they can also produce the bags or boxes made from corrugated
sheets; it is used for packaging of agriculture items. Later they can directly sell their product to customer as per requirement
and get the profit from it without any mediator. The commercial industries require electrical power & hence increase the cost
of processing of formation of corrugated paper sheets. Human powered corrugated sheet machine is environment friendly and
sheets are recycles after use. It will bring Innovation & Mechanization in agricultural packaging industries. Unskilled or
semiskilled workers may also get employment in rural packaging sector. Design of human powered corrugated paper sheet
machine will furthermore help the community by receiving socio-economic benefits.
The basic framework of this unit consists of Human powered flywheel motor unit, torque
transmitting unit and process unit which corrugate the paper.

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II. BACKGROUND OF RESEARCH WORK

A. Traditional Method of Manually paper corrugation:
In the mid-to-late 1800s, in both England and the United States, ruffles or flutes were very popular as
decorations for women’s and children’s clothing, mainly for collars, cuffs and petticoats.
This concept was also adapted to produce unraced corrugated paper to replace plain paper in the cylindrical liners
used to form the shape of top hats worn by gentlemen. The new fluted cylinder was stronger and its flutes provided
cushioning in the sweatband. This process was patented in England in 1856 by Healey and Allen.
Demand for an efficient method to form and Press flutes led to the progress of several different types of fluting
irons. The industries have over 40 patents issued for various fluting irons between 1873 and 1878 in the United
States.

B. Improved methods:
Cardboard packaging is one of the most extensively used forms of packaging of goods. The corrugated sheet is
stiff, strong and light in weight material made up of layers of brown craft paper. These brown craft paper reels
are transported to a corrugation machine, where this paper gets crimped and glued to from corrugated paper
sheet called as single face corrugated board and then this single face corrugated board is cut giving requisite
dimension on the cutting machine. According to requirement by adding another corrugating medium and a
third flat printed liner produces a double wall corrugated board or triple wall corrugated sheets on gluing or
bonding machine called as 3ply, 5ply and 7ply.
Then these cardboards are moved to creasing and cutting machine where extra material is removed and
creasing operation is done (i.e. From where the box get folded). The next operation is slotting operation where
the strip is slotted for stitching and lastly with stitching operation, corrugated box is manufactured.

C. Need of Research
Scope of present research is to establish design data for paper corrugation machine energized by human
powered flywheel motor. The paper corrugation machine concept based on human powered flywheel motor is the
necessity in order to develop the rural area in terms of packaging industry correlated with agriculture industry.
Encourage rural development and self-employment jobs are generated in villages to increase the confidence and
motivation of the peoples related to agriculture field.

III .EXPERIMENTAL SETUP

The experimental setup is shown in the Figures 2. In which shows the following importance unit
I) Energy Unit, ii) Transmission unit, &iii) Processing unit i.e corrugated paper formation unit

FIG 2. DEVELOPED EXPERIMENTAL SETUP FOR CORRUGATED PAPER SHEET MAKING MACHINE

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1.Cycle Unit ,2.sproket,3.Frame,4.Speed Rising Gear Pair, 5.Flywheel,6.Bearing,7.Clutch,8.Two Torque

amplification gear pair, 9.Coupling , 10. Corrugated paper sheet making process Unit.
The objective of the experiment is to gathered information through experimentation for formulation of
mathematical model for making of Corrugated paper sheet processing operations. During the operation for
corrugation process the resistive torque is measured and length of of corrugated sheet in various speed also find
out. Resistive torque T, speed of corrugation rollers Nr and process time tp is measured using DAS.

i) Energy Unit : energy unit consist of the bicycle unit. This is constructed with complete bicycle unit without its
wheels. It is supported by mild steel stand at front side and rear side is supported on main frame. The sprocket
outer diameter is 180 mm, number of teeth are 43 and freewheel outer diameter is 70 mm, number of teeth are 17.

ii) Transmission Unit- This unit comprises of pinion & gear pair II which is fixed and another pinion & gear
pair III is varying with three speed ratios , flywheel, spiral jaw clutch , with power transmission shaft fitted with
flexible coupling engaging with process mechanism shaft known as paper corrugation mechanism .The bicycle
end, is having speed increasing the gear pairs with velocity ratio of 4:1 in order to increase the speed of flywheel
i.e. to store the human energy . For power transmission from flywheel to process unit, a spiral jaw clutch is used
for engagement and disengagement of transmission unit with process mechanism. At the end of power
transmission units, two gear pairs are used, one is with fixed gear ratio of 1:4 where as another with varying gear
ratio of 1:2 ,1:3, 1:4 with totality of vary the processing speed in the range of gear ratio 1:8, 1:12 and 1:16. The
details of different component along with figure are termed below.

iii) Processing Unit (Corrugated Paper Sheet Forming Mechanism)-

Process mechanism mainly consists of following parts
1. Plastic Roller
2. Plain Roller
3. Two Corrugation Roller (Steel & Wood)
4. Tray for Corrugated Sheet

Plastic roller is used to wound the plain paper on it , where as plain roller provide tightening to the paper
and passes through the two corrugated roller to form corrugated paper sheet and that sheet gets
collected on tray which is provided .

1. Plastic Roller
It is the roller provided at the bottom of the process unit. It is made up of plastic with diameter if 65mm
and width of 210 mm .It is mainly used to wound the plain paper on it to provide to the corrugation roller.

2. Plain Roller (Metal and Wood)

This is an idler roller provided below the corrugation roller. The main purpose of this roller is to provide
tightening effect to the plain paper sheet before feed to corrugation roller so that waving of paper to avoided
during feed to corrugation roller.

3. Corrugation Roller (Metal and Wood)

These are the main roller double in quantity, which are made of metal and wood both materials. The
outer diameter is of 90 mm and width of 210mm, pitch of roller 12.5mm whereas depth of roller 7mm . The paper
passes through these two roller feed through plain roller for the formation of corrugated paper sheet.

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Table 4.1: Specifications of Different Parts for Process unit

Sr.No. Description Symbols Machine

1 Outer diameter of corrugation roller (mm) Dr 90

2 Width of Corrugation Roller (mm) Lr 210
3 Pitch of Roller (mm) Pr 12.5
4 Depth of Roller (mm) dr 7
5 Outer Diameter of plain roller (mm) D 90
6 Width of Plain Roller (mm) L 210
7 Diameter of Plastic Roller (mm) Dp 65
8 Width of Plastic Roller (mm) Wp 210
Young modulus of elasticity of steel & wooden Roller (N/mm2)
9 E 200000 &10000
respectively

Fig. 3 CAD Model of Process Unit

III. FORMULATION OF DIMENSIONAL EQUATION FOR CORRUGATED SHEET MAKING BY HPFM

The Buckingham’s Π- Theorem is used for the dimensional analysis of proposed machine after identifying the
dependant and independent variables. The process of dimensional analysis is followed step by step as explained
below:
A. Identification of variables
The term variables are used in a very general sense to apply any physical quantity that undergoes change. If a
physical quantity can be changed independent of the other quantities, then it is an independent variable. If a
physical quantity changes in response to the variation of one or more number of variables, then it is termed as
dependent or response variable. The variables affecting the effectiveness of the phenomenon under consideration
are speed, roller dimensions, material to be processed, elasticity of material , power .The dependent or the response
variables in this case are :-
1) Processing Torque T
2) Speed of corrugated roller Nr
3) Length of corrugated sheet Lq and
3) Processing Time tp.
The various dependant and independent variables involved in the process from the proposed machine are
identified as depicted in table I.

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TABLE I : DEPENDENT AND INDEPENDENT VARIABLE FOR CORRUGATED SHEET MAKING OPERATION
Sr. Variables Unit MLT Dependent/
Independent
2
1 ML T
Resistive torque T N-mm -2
Dependent

2 Processing Time tp Sec. T Dependent

3 Speed of Corrugated Rollers
rps T-1 Dependent
Nr
4 Production Lq (Output-
mm L Dependent
Length of corrugated sheet)
5 Speed of Flywheel Nf rps T-1 Independent
1
6 Time to speedup flywheel tf sec T Independent
7 Length of Corrugated
mm L Independent
Rollers Lr
8 Pitch of Corrugated roller Pr mm L Independent
9 Depth of Corrugated roller
mm L Independent
dr
10 Diameter of Corrugated
mm L Independent
Roller Dr
11 Modulus of elasticity of ML-
N/mm2 1 -2
Independent
Corrugated Rollers E T
12 Thickness of paper t mm L Independent
13 Width of paper w mm L Independent
14 M0L0
Gear ratio G - Independent
T0
15 Kinetic Energy of flywheel ML2T
N-mm -2
Independent
Kf
16 Acceleration due to gravity
mm/sec2 LT-2 Independent
g

B. Dimensional Analysis
Total number of Variables =16
Number of dependent variables = 4
Number of independent variables, n = 12,

t = f (N , t , L , P , d , D , E, t, w, G, k , g)

T = f (N , t , L , P , d , D , E, t, w, G, k , g)

L = f (N , t , L , P , d , D , E, t, w, G, k , g)

N = f (N , t , L , P , d , D , E, t, w, G, k , g)

‘g’, ‘Lr’, E’ and are considered as the repeating variables, therefore m = 3

m = Number of variable relating to fundamental variables.
‘g’ - (LT-2)
‘Lr’- (L)
‘E’- (ML-1T-2)

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Total no. of independent variables = n = 12 therefore

No. of πterms = n – m =12-3 =09
πD1=f1(π1, π2, π 3, π 4,π 5, π 6, π 7, π 8,π 9) =0
First π term ((Speed of Flywheel Nf))
π1= (g)a1 (Lr)b1(E)c1Nf
(M)0(L)0 (T)0 = (LT-2)a1 (L)b1(ML-1T-2)c1 T-1
The values ofa1, b1and c1are computed by equating the powers ofM,L &T on both sides as given below:

For ‘M’ For ‘L’ For ‘T’

M0 = L 0 = a1+ b1- c1+0 T 0 = -2 a1-2c1-1
c1 From eq.of T, 0 = -2 a1-1
substitute the value of a1= -1/2
c1= 0 a1=1 Hence a1=-1/2
0 = -1/2+ b1 subst.in eq. of L to
b1= 1/2 get value of b1.
Substituting the values of a1, b1and c1in the eq. ofπ1term, we have:
π1= (g)-1/2 (Lr)1/2(E)0Nf

Similarly find out other pie terms

π P d D
π = π = π =
g L L L
=t
L
t w π =G π
π = π =
L L K
=
E. L
Dependant dimensionless pi terms are

D1
=
= =
. =

Further to reduce the complexity and to obtain the ease in the behaviour of the system analysis, the pi terms of
independent variables are compact by reduction of variables process as suggested by Schenk Jr. The next table
shows the new pi terms of independent variables in compact form. Thus the total nine pi terms of independent
variables are reduced to six new pi terms as shown in the table under.

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π terms Pi terms equations

( ∗ ∗ )
π1 =

π2 =

π3 =

×
π4 =

π5 =
π6
=

Dimensional Equation for dependent Variable i.e. Process time (tp)

The dependent variable, processing time (tp) can be stated as shown under:

t = f1 (N , t , L , P , d , D , , t, w, G, k , g)
Or
f t , N , t , L , P , d , D , , t, w, G, k , g = 0

Or
πD1 = f1(π1, π2, π3, π4 π5, π6) = 0

π = f P ×d ×D N L t g t. w K
× × × × G ×
L g L L E. L

g
t = f P ×d ×D N L t g t. w K
L × × × × G ×
L g L L E. L

L
t = P ×d ×D N L t g t. w K
g × × × × G ×
L g L L E. L

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Similarly for other Dependent variables

Dimensional Equation for dependent Variable i.e. Processing

time (tp)
t

L
= P ×d ×D N L t g t. w K
g × × × × G ×
L g L L E. L
Dimensional Equation for Response Variable i.e. Resistive
Torque (T)
T

= E. L P ×d ×D N L t g t. w K
× × × × G ×
L g L L E. L

Dimensional Equation for Response Variable i.e. Production

(output-Length of corrugated sheet) (Lq) :

L =L P ×d ×D N L t g t. w K
× × × × G ×
L g L L E. L
Dimensional Equation for Speed of Corrugated roller (Nr)
N

g
= P ×d ×D N L t g t. w K
L × × × × G ×
L g L L E. L

IV. CAD MODEL FOR CORRUGATED SHEET MAKING BY HPFM

A. CAD model are designed in three units
1. Input Process unit
2. Power transmission unit
3. Output process unit.

Fig 5. CAD Model Top view of the corrugated sheet making by HPFM

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B. Mechanical Design of the Machine

The machine has a various parts as per following specification in which the 1/ 4th teeth two spur gear mounted
on each others. When the clutch engaged with process unit Specification of Processing Unit (Corrugated paper
sheet Making Unit):
Table I shows Specifications of Processing unit of corrugated paper sheet making machine

C. Operational step of HPFM corrugated sheet Making Machine

Basically, the machine involves of three sub-systems: (1) energy unit (2) transmission unit & (3) process
mechanism. The energy unit consists of a conventional bicycle mechanism having chain & sprocket mechanism
along with speed rising gear pair, the transmission unit consists of; two speed reducing gear pairs, out of which
one is fixed with gear ratio 1:4 whereas other with varying gear ratio 1:2, 1:3&1:4, hence resultant gear ratios are
1:8, 1:12, 1:16 and used coupling to the process unit through shafts. The arrangement of a human energized paper
corrugation machine
. The energy unit consists of a bicycle mechanism, a pair of speed-increasing gear pair with gear ratio
4:1 G1 and a flywheel to store energy. The transmission unit includes a spiral jaw clutch and the torque
amplification gear pair G2 which is fixed with gear ratio 1:4 and G3 with varying gear ratio (1:2, 1:3 &1:4). The
recommended machine system uses human energy produced by pedaling and stores this energy in a flywheel in
the form of kinetic energy as an energy-input rate suitable to the peddler. Once the storing of suitable energy in
the flywheel, the same can be made available for the run of any process unit (paper Corrugation mechanism) by
making available the energy stored in the flywheel through a spiral jaw clutch and torque-amplification gear ratios
if required.

Thus the flywheel will decelerate contingent on the resisting torque offered by the process mechanism. It indicates
that the peddler does not need to pedal, while the flywheel is supplying energy to the process mechanism. After
engagement of the clutch, there is a transfer of stored kinetic energy from the energy unit and the process
mechanism .The process mechanisms shaft is thus suddenly accelerated and, once reaching its maximum speed,
it is endangered to deceleration. This deceleration is induced by the resistance offered on account of process unit
consist of paper corrugation mechanism. The transmission unit consists of the gear pair G2 and G3 which is
coupled to the process mechanism through coupling. The process mechanism consists of paper corrugation roller
which is connected to transmission unit through shaft and coupling. Because of which the process unit runs and
corrugated paper is form.

Fig 7: Fabricated View of human energized flywheel motor for corrugated paper making machine with location
of sensors

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V. DESIGN OF EXPERIMENTATION
The experimental setup is shown in the Figures 8. In the corrugated paper sheet processing, the objective of the
experiment is to gathered information through experimentation for formulation of Mathematical model for
corrugated paper sheet making processing operations. During forming operation for the measurement resistance
torque, torque without load is measured. And same time the speed of flywheel shaft and speed of process unit
shaft were measured with time.

Fig.8 Display to measure speed, time and torque for corrugated paper sheet machine

D. Experimental Approach
A theoretical approach can be adopted in a case. If known logic can be applied correlating the various dependent
and independent parameters of the system. Though qualitatively, the relationships between the dependent and
independent parameters are known, based on the available literature, the generalized quantitative relationships are
not known sometimes. Hence formulating the quantitative relationship based on the logic is not possible in the
case of complex phenomenon. On account of no possibility of formulation of theoretical model (logic based) one
is left with the only alternative of formulating experimental data based model. Hence, it is proposed to formulate
such a model in the present investigation. The approach adopted for formulating generalized experimental model
suggested by Hilbert Schenck Jr [B-7] is stepwise indicated below.
1. Identification of independent, dependent and extraneous variables.
2. Reduction of independent variables adopting dimensional analysis
3. Test planning comprising of determination of test envelope, test points, test sequence and experimentation
plan.
4. Physical design of an experimental set up.
5. Execution of experimentation.
6. Purification of experimentation data.
7. Formulation of the model.
8. Model optimization.
9. Reliability of the model.
10. ANN simulation of the experimental data.

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VI .CONCLUSION
1. Design, development and fabrication of a new type of corrugated paper sheet making activity by human
powered flywheel motor will work on non conventional energy source.
2. This machine is helps to reduce environmental pollution as the packing bags or cartons made from corrugated
papers, hence environment friendly.
3. In developing countries like India and china where ample human power energy is available along huge
construction business, such human powered flywheel machine systems will help to a great extend to improve the
economical condition and employability of such countries.
4. The test results proved that response variables process time, resistive torque, output length of corrugated sheet
& speed of corrugated roller are significantly influenced by changing important six dimensionless π terms. The
process parameters grouped in π terms were recommended the effective guidelines to the manufacturer for
improving the present operations by changing any one or all from the available process parameters

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