ACKNOWLEGDEMENT We would like express our gratitude and appreciation to all those who give us the possibility to complete

this report. Special thanks to my supervisor Mr.EN.AIYOU SOLOMON whose help, simulating suggestion and encouragement helped us in all time of designing process and in writing this report

ABSTRACT Idea to develop the milk churner is come from our supervisor that gives a task and a title for this project. This project focuses in design of the mechanical part of machine and systems of milk churner. To achieve objective of this project, this milk churner body structure and mechanical systems needs to concern some other criteria such as strength, safety and ergonomic design. This project flow starts from design and lasts by analyzing the process. Before designing the milk churner we should have to see the products in the market. It is because to study the customer need and to create a new design with new future. Project design will cover for this semester. This is a task of three students do together. This is also one of the opportunities to students to show or to apply their knowledge also skill in using mechanical design software to complete this project. Time management and a good planning also important to make sure the entire plan are in their way. Lastly, discipline needed to complete this project.

INTRODUCTION A milk churner is a portable device consisting of rotational mechanism used to churn the milk. The rotation of the crank shaft which is coupled with another internal shaft by a bevel gear is used to churn the milk. Mechanical milk churner can be either hand operated or power driven. Although a milk churner is a simple and widely used device, the use of any churning device is subjected to certain hazardous. In milk churning application the hazardous are corrosion, dropping, tipping or slipping of a machine or their components during the operation. Proper size, strength, corrosion resistance and stability are the essential requirements of milk churner from safety consideration. The construction of milk churner is shown in figure 1. It consists of a bolt, nut, key, bevel gear, bearing and shaft. Crank shaft rotates, the bearing reduces friction, and the miter bevel gear transmits power to internal shaft. The use of key is to couple the bevel gear with shafts. The use of bolt and nut is to couple the shaft and a rotating bar inside of the churning process.

1. PROJECT SYNOPSIS This third year design project is the part of required subjects to be taken during degree of mechanical engineering course. This is done during the second semester of third year. The design project is also gives the students the individual and group working ability and confidence to complete a task with under less supervision of lecturers. With this, students can learn problem solving skills in areas of designing: analysis, fabrication, and testing as well as learn to do a complete formatted report which is important for future technical writing. Milk churner usually comes in different size and grad since some the products required in different amount of milk that why this machine has been design to churn the milk into different size depend on requirement needed. 2. PROJECT PROBLEM STATEMENT The problem of size of milk churner in the market available, the cost of the machine available in the market are main factors for designing such

economically viable, socially acceptable for that specified area of the design.

3. PROJECT OBJECTIVE There are several objective of this project as follows: 1. To design new milk churner. 2. Small and portable milk churner. 3. Churning into different amount of component.

GENERAL OBJECTIVE Increasing the yield of diary product : the yield products of milk will depend on the amounts of total solids present Improving the safety and hygienic quality of the milk Reduce the time of churning takes

3.1. SPECIFIC OBJECTIVE 1. Expose the real work must be done as a future engineer 2. To learnt how arrange the time and budget 3. To apply all knowledge in this design

PROJECT SCOPE From the title that has been given the development of this project must include how to design the mechanical part of the machine using advanced software like cad, catia and solid work. It is also needs some knowledge and skills to finish the project. There is some other guide must be followed to finish this project. PROJECT BACKGROUND MILK The milk is commonly known as the basic material used in production of butter. Comes with few type and different amount. MILK CHURNER 1. To design milk churner that can churn the milk in different amount. 2. Problem that often faced is that some product required different amount of milk to fulfill the quantity level needed. 3. Through this design user can save time of churning milk and cut the cost to order the required amount of butter. 4. This product may churn the milk with safety and quick over use of conventional way. 5. This product may churn different amount of milk and cost of milk and cut time and cost.

THE CHURNING To succeed in churning the cream has to be at atmosphere between 10 to 14 degree centigrade. Bring it in out of the cold 2 hours before and leave it at room temperature. One of the conditions to succeed in churning. Whatever the cream, use a minimum quantity 5L and maximum 20 liter. Pour the cream in the container and close it in screwing the mechanical system (do not grip too much). Turn the handle in the regular way (but not hurried) to thicken the cream (see on the surface). As a matter of fact, progressively it will be harder and harder to turn the handle. Slow down: the churning is almost finished. When the mechanical system has become harder to turn or slip, the churning is finished. The churning lasts 3 0r 8 minutes according to the quantity of the cream. Recover the butter in pouring out of the contents of the container in glass in a colander (do not keep the whey).

BASIC PRINCIPLES The butter is mainly obtained from milk cream. The cream must be churned. The churning consists of agglomerate the little cells of fat in the cream with amechanical movement : we obtain butter and whey (about 16%). The butter is made up of water (about 16%), fat content (about 82%). In salted butter , the salt content is higher than 3%. In slightly salted butter , the content of salt is between 0.5 and 3%. PROCESS The agitation of a cream, caused by mechanical motion of the device, disrupts the milk fat. The membranes that surrounds are broken down fast, subsequently forming clumps known as butter grain. These butter grains, during the process of churning, fuse with each other and form larger globules. Air bubbles are introduced in these fat globules via the continued mechanical action of the churn. The butter grains are become denser as the fat globules attach to them while the air is forced out of the mixture. This process creates a liquid known as butter milk. With constant churning, the fat globules eventually form sold butter and separates from the butter milk. The butter milk is then dried off and the butter is squeezed to eliminate excess liquid and to form it into a solid mass

CLEANING

Clean the appliances warm under warm water with washing up liquid after each use. The container can be cleaned in dish washer.

THE USE 1.Unscrew the mechanical system appliances. 2.Full the container with milk cream. 3.Close the container screwing the system ( do not grip to much ). 4.Turn the hundle. GENERAL CONSIDERATION 1. The milk churner is manually operated. According to our design the hand force should not exceed. It is required one worker for churning process. A coefficient of 0.9 is assumed in this case to account for reduction in force due to inconvenience. 2. Milk churner is a churning device and subjected to certain hazardous. The average churning speed is limited to 40 rpm because if we apply more than this speed it will cause damage to milk churning machine.

PROBLEM SPECIFICATIONS It is required to design a milk churner for churning milk. It should be general purpose milk churner with Specification: hand driven or manually operated. Capacity: 20 liter. Power: 188 watt. Dynamically balanced made of AISI 304 stainless steel. Suitable for small diaries. For one churning time it takes 18min for 20 liter.

MATERIAL SELECTION 1. The frame of milk churner has simple structure. It should have to be corrosion resistance. Stainless steel of SA182 is selected as a frame material for better corrosion resistance, high ductility, excellent drawing, forming and spinning properties. Stainless steel have 505MPa ultimate tensile strength, 215MPa yield tensile strength, 86GPa shear modulus, 325J charpy impact, 0.29 Poisson ratio ,193-200GPa modulus of elasticity, 70% elongation at the break and density of 8g/cc.

2. The handle is subjected to bending moment and yield strength is the criterion for the selection of handle material. Plain carbon steel of C45 (Syt=380N/mm2) is selected as the handle material. 3. Material selection for bevel gear is commonly carbon steel or alloy steel according with ISO, ASTM, etc. The gears are made of plain carbon steels used for medium duty application 50C8 (Syt=600N/mm2). 4. The keys are subjected to shear and compressive stress. On the basis of strength criterion, plain carbon steel of grade 30C8 (Syt=400N/mm2) is selected for the keys. It is assumed that the compressive yield strength is 150% of the tensile strength. The factor of safety for the keys is taken as 2.5. 5. The bolts are subjected to shear and compressive stress. On the basis of strength criterion, plain carbon steel of grade 30C8 (Syt=400N/mm2) is selected for the bolts. It is assumed that the compressive yield strength is 150% of the tensile strength. The factor of safety for the bolts is taken as 2.5. 6. The shafts are subjected to torsional shear stress. On the basis of strength, plain carbon steel of grade 45C8 (Syt=380N/mm2) is used for shafts. The factor of safety for the shafts is assumed to be 2. 7. There is a relative motion between the bolt and the nut, which results in friction. The friction causes wear at the contacting surfaces. When the same material is used for these components, the surfaces of both components get worn out, requiring replacement. This is undesirable. The size and shape of bolt is costly compared with the nut. Therefore, if at all components is to be replaced due to wear, it should be nut, which is less

costly compared with the bolt. The wear is always restricted to softer surface. Therefore the nut should be made of softer material. This protects the bolt against wear. Cast variety of phosphor bronze of Grade1(Sut=190N/mm2) is selected as the material for nut, phosphor bronze is soft compared with hardened steel. In addition, to this consideration, phosphor bronze has low coefficient of friction, which reduces the torque to overcome friction at the thread surface. It has excellent conformability and machinability. Conformability is the ability of the material to yield and its shape to that of the bolt. Cost is the main limitation of phosphor bronze. 8. The pins are subjected to shear and compressive stresses on the basis of strength criterion, plain carbon steel of grade 30C8 (syt=400N/mm2) is subjected for the pins. The factor of safety for pins taken as 2. It is assumed that the compressive strength is 150% of the yield strength.

DESIGN OF SHAFT Shaft is a rotating machine element which is used to transmit power from one point to another point. It is one of the most common and basic machine elements which are used in a variety of ways in mechanical equipment. It is used with power transmission element like gears, pulleys, flywheels, cranks etc. Shaft Subjected To Simple Torsion According to maximum shear stress theory y =y /2 where y=yield strength y=shear strength n= factor of safety=2 y=380N/mm2 for cu alloy steel y=380/2=190N/mm2 Permissible shear stress =y/2=190/2=95N/mm2 P=Mt where P=power of the causing machine in watt Mt=torsional moment or torque in N-mm N=angular speed of the shaft in rpm. P=400watt N=30rpm

P=(2N Mt)/ 60

Mt=60P/2N =(60*0.4*106)/(2*300) =127.323*103N-mm2 =16Mt/d3 d3=16Mt/ = 16*127.323*103/*95 d=19 mm from standard table d=20 mm can closely selected where d is a diameter of solid shaft in mm

BOLTS Bolt is simply called a bolt or a bolt and nut. The bolt consists of a cylindrical rod with head at one end and threads at the other end. The cylindrical portion between the head and the threads is called shank. Bolts are used under the following conditions: a) The parts that are fastened have medium thickness, b) The parts that are fastened are made of materials, which are too weak to make durable threads. c) The parts are fastened require frequent dismantling and reassembly.

figure 1. hexagonal nut

Figure 2. Hexagonal bolt

DESIGN OF BOLTS Fs=4 P=5KN where Fs is factor of safety P=tensile force of bolted joint subjected

Shear area of 3 bolts = 3*(/4*db2) mm2 For ds up to 40mm, n=3 where ds= diameter of shaft n=number of bolts Therefore, P=3(/4* db2)t Ssy=0.5Syt=0.5(400) = 200N/mm2 t= Ssy/ Fs=200/4 t=50N/mm2 5*103= 3(/4* db2)*(50) db= 6.6mm Check for shearing stress Mt=/4*db2tb*D1/2*n tb= 8*Mt/( *db2* D1/2*n) = Check for crushing stress

Mt=tf*db*sc*D1/2*n sc=2 Mt/ (tf*db*D1*n) sc=

Therefore, from table, standard size of bolts is M8 is selected for our design. Designation Major Pitch Pitch Minor Tensile stress area(mm3) 8.78 14.20 20.10 36.60 58.00

diameter(mm) (mm)

diameter(mm) diameter(mm) dc Dc 3.242 4.134 4.917 6.647 8.376

M4 M5 M6 M8 M10 M12 M16

4 5 6 8 10 12 16

0.70 0.80 1.00 1.25 1.50 1.75 2.00

3.545 4.480 5.350 7.188 9.026 10.863 14.701

3.141 4.019 4.773 6.466 8.160 9.853

10.106 84.30

13.546 13.835 157

DIMENSIONS OF FASTENERS Fasteners such as hexagonal head bolts, screws, washers and nuts are frequently used in all design projects. Their standard dimensions are essential to prepare assembly and detail drawings. In the previous design and standard size such as M16 or M20 is specified. Other dimensions of fasteners are determined by referring the standard table. Thread size d(mm) Pitch, p ds max min k 0.8 5.48 4.52 1 6.48 5.52 4 3.62 4.38 10.89 0.25 10 9.64 1.25 8.58 7.42 5.3 4.92 5.68 14.20 0.4 13 12.57 1.5 10.58 9.42 6.4 5.95 6.85 17.59 0.4 16 15.57 1.75 12.7 11.3 7.5 7.05 7.95 19.85 0.6 18 17.57 2 16.7 15.3 10 9.25 10.75 26.17 0.6 24 23.16 M5 M6 M8 M10 M12 M16

Nom 3.5 min max 3.12 3.88 8.63 0.2 8 7.64

e r s

min min max min

Thread size d Pitch, p dw, min m

M5

M6

M8

M10

M12

M16

0.8 6.9

1 8.7 6.1 4.9 10 9.64 10.89

1.25 11.5 7.9 6.4 13 12.57 14.20

1.5 14.5 9.5 8 16 15.57 17.59

1.75 16.5 12.2 10.4 18 17.57 19.85

2 22 15.9 14.1 24 23.16 26.17

Max 6.9 Min 5.6

Max 8 min 7.64 8.63

Size d (mm)

D (mm)

S (mm)

For bolt or screw size

5.5 6.6 9 11 14 18 22 26 33 39 45 52

10 12.5 17 21 24 30 37 44 56 66 78 92

1 1.6 1.6 2 2.5 3.15 3.15 4 4 5 6 8

M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42 M48

DESIGN OF KEY A key can be defined as a machine element that is used to connect the transmission shaft to rotating machine element like pulley, gear, sprocket or flywheel. A keyed joint consisting of shaft, hub and key.

There are two basic functions of the key. They are: 1. The primary function of key is to transmit the torque from the shaft to the hub of mating element and vice versa. 2. The second function of the key is to prevent relative rotational motion between the shaft and the joined machine element like gear or pulley. Keys are classified into four types 1. Saddle and sunk key; 2. Square key and flat key; 3. Taper key and parallel key; and

4. Key with and without gib-head. For our design, we select square key because it is extensively used in practice. Design for square key b=h=d/4 where b-width of the key (mm) h-height or thickness of the key(mm) l=1.5d l-length of the key (mm) d-diameter of the shaft (mm) Therefore b=25/4=6.25mm l=1.5*25=37.5mm=38mm Force on the key Pk=Mt/ (d/2) =2Mt/d where Pk force on the key Pk= (2*59.524*103 N)/ 25mm = 4.7619kN

DESIGN OF HANDLE The handle is subjected to bending moment. The force exerted by the worker on the handle is given by, F=0.9* 380N/mm2 F= 342N/mm2 The handle is made of steel 30C8 (Syt=380N/mm2). There is no collar friction torque. Therefore, Mb=f*lh=Mt, lh= Mt/F=(59.524*103)Nmm / 342N/mm2=175mm since =32Mb/dh3 dh3=32 Mb/ dh=

BEARING A bearing is a mechanical element that permits relative motion between two parts, such as shaft and the housing, with minimum friction. The functions of the bearing are as follows: 1. The bearing ensures free rotation of the shaft or the axle with minimum friction. 2. The bearing supports the shaft or the axle and holds it in correct position. The bearing takes up the forces acting on the shaft or the axle and transmits them to the frame or the foundation DESIGN OF DEEP GROOVE DOUBLE ROW BALL BEARING L=(60nLdg)/106 where L=life of the bearing in million revolutions. n=rotation of handle Ldg=life of deep groove double row ball bearing. Assumptions n=30rpm Ldg=2000hr. Then, L=(60*30*2000)/(106) L=3.6 million revolution The dynamic load capacity of the bearing is given by, C=FL1/3

Where, C=dynamic load capacity of the bearing F=force exerted by the worker on the handle C=342*(3.6)1/3=524.2N DESIGN OF PIN The number of pin is one. The diameter of the pin is calculated by empirical equations. d1 =0.5d/N1/2 where N is the number of pins d is the diameter of shaft Determine the shear stress in the pins by =8Mt/d12 from previous calculation d=20mm, Mt=95.5*106, N=1 d1=0.5*20/(1)1/2=10mm =8*95.5*106/ (*102)=34,738.7 N/mm2

DESIGN OF MITER BEVEL GEARS CALCULATIONS Assumptions P=400watt NP=40rpm where P= power transmitted by gears NP= speed of pinion gear Pressure angle =200 Mt= (60*106*P (Kw))/ (2NP) = (60*106*0.4)/ (2*40) =95,492.97N-mm tan y= zp/zg=Dp/Dg=1, because miter bevel gears have the number teeth and diameter y= tan-1(1)= 450 rm= [(Dp/2)-(bsiny/2)] but Dp=150mm, b=40mm and Dp=Dg

= [(150/2)-((40sin 450)/2)] rm= 60.86mm FORCE ANALYSIS Pt= Mt/rm= 95,492.97N-mm/60.86mm = 1.5691kN Pr=Pttancosy = 1,569.0596*tan 200*cos450 = 403.82 N

Pa= Pt tan sin y= 1,569.0596*tan 200*cos450 = 403.82 N Where Pt= tangential or useful component (N) Pr= radial component (N) Pa= axial or thrust component (N) y= pitch angle (degrees) =pressure angle (degrees) Dp= diameter of pitch (mm) Dg= diameter of gear (mm) Zp= number of teeth of pinion Zg= number of teeth of gear rm= radius of the pinion at the mid-point along the face width(mm) =Mt= torque transmitted by gears (N-mm) b= face width of the gear (mm)

Material selection of bearing (deep groove double row ball bearing) Sr.No 1 2 3 4 d (mm) 50 50 50 50 D (mm) 70 78 95 110 H (mm) 14 22 31 43 25500 41600 97500 C (mm) Co (mm) 50000 73500 D1 (mm) 52 52 51110 51210 51310 51410 designation

160000 52

159000 250000 52

From the above table, bearing No. 51410 with dynamic load carrying capacity of 159000 is selected for the milk churning machine. The dimensions of the bearing are as follows: d=50mm, H=43mm, D= 110mm, D1=52mm.

SAFETY ASPECT To guard against injury to the workers and prevent damage to machine parts, the following safety measure should be taken. 1. After fabrication, the mechanical milk churner should be tested. In proof test, the milk churner is filled with full of its container with 150% of churning speed. After this test, the milk churner should be functional for full container and 100% churning speed. 2. The milk churner should be provided with a warning. A simple of warning is so as follows: WARNING: DO NOT OVER LOAD THE MILK CHURNER PLACE THE CHURNING MACHINE ON PROPER PLACE 3. Following instruction should be given in the manual or leaflet of milk churner. a) The determination of the speed shall be made assure that is with in the speed rating of the churner. b) Operators shall be instructed in proper use of the milk churner. c) The crank shaft of the churner shall be supported at the support and bearing such that it is stable under load. d) Overload should be avoided. 4. The rated power and speed should be legibly and durably marked in a prominent position on the churner. 5. The deep groove double row ball bearing of the milk churner should be regularly lubricated with grease.

The strength and stability consideration in design are no doubt essential for safety. However, they are not enough to prevent an accident. It is also essential to have personnel involved in the use and operation of the milk churner to be careful in safe operation of the milk churner and its proper use.