ARBA MINCH UNIVERSITY

ARBA MINCH INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING

A REPORT ON INTERNSHIP WORK AT TANA BELES

SUGER FACTORY

By:

BELACHEW WORKNEH ID: NSR/436/12

OCTOBER , 2023 G.C

ARBAMINCH , ETHIOPIA

1
ACKNOWLEDGEMENT

I
 EXECUTIVE SUMMERY
Generally during the internship period from Tana Beles sugar factory project, I have seen
different activities with good understanding. Especially ,I have got better understanding about
the working principle of sugar industry or the general work flow of sugar factory starting
from Weight Bridge up to the end of the process that I have got refine sugar and molasses
with in corporated power plant as power and steam source. That means sugar cane carried by
trailerand weighted by weight bridges then by un-loader add this sugar cane to feeding tables,
this feeding table transport to cane carrier. Cane carrier feeds to shredder for cutting cane,
after this by using belt conveyor the row sugar transform in to diffuser/juice extraction
section/ from this section raw sugar converted to juice and bagass, but the bagas part is feed
to mill house. In millhouse the remaining juice/press juice/ are returned in to the
primary juice produced from diffuser, in addition to this bagasse part is separated and
feed to boiler by using belt conveyor in order to generate power and steam for processing
refined sugar. The press juice and the juice that is produced from diffuser are mixed together
and pumped to the clarification section. In this section there are different heaters, lime
addition tank, SRI (short retention time), and also other different part of this section, but the
major processes are takes place from this section, this means mud and juice are separated
from vacuum filter from this to produce filtrate and filter cake/juice free mud/ then filtrate
going to the FFE/falling film evaporator/ after this place 68 % sugar or syrup are produced,
then the syrup pumped to process house. From here there are different parts such as over-
head tank ,batch- pan ,green receiver, continuous pan ,mas secuite receiver ,centrifugal
machine. After this process clear liquor is pumped in to clarification for further
clarification. This clear liquor then pumped refinery section and it has its own over- head
tank ,batch –pan, green receiver and also hot water tank and cold water tank in addition to
this it has refinery sugar and run -off, so this refinery going to sugar grinder to produce
refined sugar but the run off is going to the molasses section. By this internship time, I had
improved different kinds of skills. Like, practical skills ,upgrading theoretical
knowledge ,improving interpersonal communication skill ,improve team work skiil , to
improve leadership and to understanding about work ethics .

II
Table of Contents
ACKNOWLEDGEMENT ......................................................................................................... I
EXECUTIVE SUMMERY ....................................................................................................... II
LIST OF FIGUER..................................................................................................................... V
LIST OF TABLES ................................................................................................................. VII
ABBREVIATION................................................................................................................. VIII
CHAPTER ONE ........................................................................................................................ 1
INTRODUCTION ..................................................................................................................... 1
1.1 CAMPANY BACKGROUND AND OVERVIEWS ............................................................ 1
1.1.1 Historical Background ............................................................................................... 1
1.1.2 Mission ,values & vision of Tana beles suger factory .............................................. 2
1.1.3 Its main products and services. .................................................................................. 3
1.2 ORGANIZATION STRUCTURE OF THE COMPANY ..................................................... 4
CHAPTER TWO .................................................................................................................... 5
WORK RESPONSIBILITY AND ASSIGNMENTS ................................................................ 5
2.1 TASK 1 UNDERSTANDING AND OVERVOEW OF EXTRACTION PLANT .............. 5
2.2 BOILER PLANT ................................................................................................................. 12
2.3 PROCESS HOUSE ............................................................................................................. 16
2.4 WORK SHOP AND FABRICATION .............................................................................. 19
2.5 WORK FLOWS OF TANA BELES SUGAR FACTORY ................................................. 20
CHAPTER THREE ................................................................................................................. 21
TECHNICAL ASPECT OF THE INTERNSHIP .................................................................... 21
3.1 OBJECTIVES OF THE INTERNSHIP ............................................................................... 21
3.1.1 General Objective .................................................................................................... 21
3.1.2 Specific Objective.................................................................................................... 21
3.2 Methods and Procedures While Working ............................................................................ 22
3.2.1 Methods used for Working in Tana beles sugar factory ......................................... 22
3.2.2 Procedures That We Followed While Performing a Task ....................................... 22
3.3 Technical tasks/products ...................................................................................................... 22
3.4 KNOWLEDGE AND ACQUAINTANCES ACQUIRED .................................................. 23
3.4.1 Improving Practical Skills ....................................................................................... 23
3.4.2. Improving theoretical knowledge ........................................................................... 23
3.4.3. Improving interpersonal communication................................................................ 24
3.4.4. Improving team skills ............................................................................................. 24

III
 3.4.5. Improving leadership skill ...................................................................................... 24
3.4.6. Understanding about work ethics and related issues .............................................. 25
3.4.7 Entrepreneurship skill .............................................................................................. 25
3.5 PROBLEMS ENCOUNTERED DURING THE INTERNSHIP PERIOD ......................... 26
CHAPTER FOUR .................................................................................................................... 28
DESIGN OF TRIPLE MECHANICAL MACHINE .............................................................. 28
4.1 INTRODUCTION ............................................................................................................... 28
4.2 PROBLEM STATEMENT .................................................................................................. 28
4.3 OBJECTIVE OF THE PROJECT........................................................................................ 28
4.3.1 Main objective ......................................................................................................... 28
4.3.2 Specific objective .................................................................................................... 28
4.4 METHODES &MATERIAL ............................................................................................... 29
4.4.1 Methodology............................................................................................................ 29
4.4.2 Materials .................................................................................................................. 29
4.5 DETAIL DESIGN AND ANALYSIS ................................................................................. 29
4.5.1Design of pulley........................................................................................................ 29
4.5.2 Selection of belt ....................................................................................................... 31
4.5.3 Design of bevel gear ................................................................................................ 33
4.5.4 Selection of grinder wheel ....................................................................................... 36
4.6.5 Selection of hacksaw blade...................................................................................... 36
4.6.6 Design of shaft ......................................................................................................... 37
4.5.7 Design of key ........................................................................................................... 38
4.5.8 Design of vertical column........................................................................................ 39
4.6 WORKING PRINCIPLE ..................................................................................................... 40
CHAPTER FIVE ..................................................................................................................... 41
CONCLUSION AND RECOMMENDATION ....................................................................... 41
5.1 CONCLUSION .................................................................................................................... 41
5.2 RECOMMENDATION ....................................................................................................... 42
REFFERENCE ........................................................................................................................ 42
APPENDEX............................................................................................................................. 43
PART DRAWING ..................................................................................................................... 43
ASSEMBLY DRAWING .......................................................................................................... 46

IV
 LIST OF FIGUER
Figure 1 Organization structure of the company ...................................................................... 4

Figure 2 Feeding table ............................................................................................................... 6

figure 3 Cane washing system ................................................................................................... 7

Figure 4 .Shredder ...................................................................................................................... 9

Figure 5 Dffuser ....................................................................................................................... 11

Figure 6 general arrangement of mill roller ............................................................................. 12

Figure 7 Sectional View of a Fire Tube Boiler ...................................................................... 12

Figure 8 Simple Diagram of Water Tube Boiler ..................................................................... 13

Figure 9 Overall component of boiler ...................................................................................... 13

Figure 10 Water feed pump ................................................................................................... 14

Figure 11 De-aerator ................................................................................................................ 15

Figure 12 Economizer ............................................................................................................. 15

Figure 13 top section of shell and tube heater ........................................................................ 18

figure 14 Work flows of tana beles sugar factory .................................................................... 20

Figure 15 open belt .................................................................................................................. 32

Figure 16 Pulley ....................................................................................................................... 43

Figure 17 Belt .......................................................................................................................... 44

Figure 18 Bevel gear ................................................................................................................ 44

Figure 19 Grinding wheel ........................................................................................................ 44

Figure 20 Hack saw ................................................................................................................. 45

Figure 21 Shaft ......................................................................................................................... 45

Figure 22 Rectangular sunk key .............................................................................................. 45

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Figure 23 Triple mechanical machine...................................................................................... 46

VI
 LIST OF TABLES
Table 1 Materials of each components .................................................................................... 29

Table 2 dimension of standard v- grooved pulley according to IS2494-1974 ......................... 30

Table 3 Dimension of standard v-belts according to IS2494-1974 ......................................... 32

Table 4shaft material................................................................................................................ 37

VII
 ABBREVIATION
Tp Pinion teeth
Dg Gear diameter
Tg Gear teeth
T1 Tension in the tight side of the belt
T2 Tension in the slack side of the belt
𝜎𝑎𝑙𝑙 Allowable strength
𝜎𝑐𝑎𝑙𝑙 Allowable compressive strength
𝜌 Density of the material
𝜎𝑢 Ultimate stress
R Radius
D Diameter
C Basic dynamic load rating
𝜎𝑒𝑠 Endurance limit
K Load-stress factor
Q Ratio factor
Wt Tangential load
Dynamic load
Wl Wear load
𝛿 Deformation
Z Section modulus
T Torque transmitted by the shaft,
F Tangential force acting at the
circumference of the shaft
D Diameter of shaft,
L Length of key
T Thickness of key

VIII
IX
 CHAPTER ONE
INTRODUCTION

1.1 CAMPANY BACKGROUND AND OVERVIEWS

1.1.1 Historical Background
Tana Beles Sugar Factory One is located at Amhara Regional State, Jawi District of Awi
Zone. It is one of the three factories planned to be built under Tana Beles Sugar Development
Project which was established in 2010. The Factory is found at a distance of 650 kilometers
from Addis Ababa as well as 225 kilo meters from the Regional Capital Bahir Dar via Gilgel
Beles` tarmac road. When the project was incepted it was planned to have sugarcane
developed on 75 thousand hectares of land that would supply sugarcane to the three factories
envisioned to be built. Ethiopian Sugar Industry Group (by then Sugar Corporation) had
agreed in 2011 with Metals and Engineering Corporation (METEC) to construct the factory
with in eighteen months. However, as the factory was delayed for more than seven years, the
agreement with METEC was terminated in 2018 by the decision of the government.
The factory with a capacity of crushing 12 thousand tons of sugarcane a day is supposed to
have sugarcane to be developed on 25 thousand hectares of land initially. In December 2019
an agreement was signed with China CAMCE Engineering Co., Ltd. (CAMCE)/ to complete
the remaining construction and other related works of the factory. The government has made
available domestic as well as foreign currency worth of 95 million dollar for the purpose.
Accordingly, CAMCE, despite the challenge of Covid-19, has made tremendous effort to
complete the construction work and thereby enable the factory began trial production in June
2021.The Factory, at last, was inaugurated officially on June 6, 2021 by H.E Prime Minister
Abiy Ahmed (Ph.D).Tana Beles Sugar Factory One, entering operation in its full gear as per
its design, produces refined sugar and 45 megawatts electricity of which it uses 16 megawatt
for its own operational purposes and sends the remaining 29 megawatt for the national power
grid generating income to the factory.
Owning the ethanol plant in the future, it will also have the capacity of producing higher
volume of ethanol. Tana Beles Sugar Factory is one among the five sugar factories which
have become autonomous by the Council of Ministers Regulation Number 495/2022.
 Irrigation Infrastructure Construction

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Irrigation water for the factory`s sugarcane production is diverted from Beles River. The
project generally has 30 km long weir which conducts 60 cubic meter water per second
including controller; silt remover with main, medium as well as small canal construction
completed and giving service. With the exception of few fields most of agriculture field of
the factory uses overhead sprinkler for irrigation. So far around 16 thousand 146 hectare land
is irrigated from the 40 thousand hectare land which is needed for the factory`s sugarcane
development.
 Sugarcane Development
Till June 2022 about 13 thousand 147 hectare land is covered with sugarcane. As factory
construction was delayed so much from the scheduled time, the field with very old sugarcane
is over turned and changed to rattan and 4 thousand 374 hectare land is being taken care of
while sugarcane grown on 3 thousand 893 hectare is ready to be supplied to the factory,This
sugarcane is being supplied to Tana Beles Sugar Factory One on its transition from trial
production to regular production.
 Co-Products
The Factory is producing co-products in line with sugarcane cultivation. So far cultivating
banana on 24.5 hectare, mango on 23 hectare, orange on 80 hectare, papaya on 2.6 hectare,
guava on 0.44 hectare and avocado on 0.42 hectare has been achieved.
 Housing
One thousand 703 residential and 16 service giving houses have been built and most of them
are giving service.

1.1.2 Mission ,values & vision of Tana beles suger factory

 Mission
 To prepare full functioned 12000 TCD sugar production factory
 To transfer functional plant to its client sugar corporation
 Vision
 To produce skilled man power
 To enhance technology transfer for our country
 To produce refined sugar for our country
 To produce electric power from bagasse and use for sugar process andsend to national
grid
 Values
 Sense of ownership.

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  Result oriented and cost effective attitude.
 Good governance.
 Virtuous work.
 Customer oriented.
1.1.3 Its main products and services.
Today Sugar cane is considered as one of the best converters of solar energy into biomass and
sugar. It is a rich source of food (sucrose and syrup), fiber (cellulose), and fodder (green
leaves and tops of cane plant, bagasse, and molasses and to some extent press mud), fuel and
chemical. But tana beles sugar factory is not run yet for the future start to produce the above
listed and the following main products.
 raw sugar
 refined sugar
 Molasses
 Electricity

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 1.2 ORGANIZATION STRUCTURE OF THE COMPANY

General Manager

Factory depute manager Agriculture depute manager Service depute manager

Technical manager Operation manager

Three coordinators

Mechanical Maintenance T.L Electrical & Instrumentation T.L Workshop T.L

Senior Mechanical Senior Senior Mechanical

Engineering (Ex.plant) Mechanical .Engineering Engineering ( process plant)
(boiler plant)

Figure 1 Organization structure of the company

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 CHAPTER TWO
WORK RESPONSIBILITY AND ASSIGNMENTS

During our three month internship program, I have been working in different plants of the
company. We have been working in the following four major plants:
1. Extraction plant
2. Boiler plant
3. Process house
4. Workshop and fabrication

2.1 TASK 1 UNDERSTANDING AND OVERVOEW OF EXTRACTION PLANT

The common parts of extraction plant
A .Weigh bridge
Measuring the mass of cane delivered is an important operation because of cane payment
implications. This is generally done on a weighbridge or large platform scale when the cane
is delivered by trailer. During weighment, it is usually necessary to take two weighment for
accomplish a complete single weighment. If the total weight of vehicle after loading material
is known, then the weight of empty vehicle should be known to calculate the net weight of
material, which is finally required. During loading of material first weighment is done to take
the weight of empty vehicle and second weighment is taken to find out total weight of loaded
vehicle. The net weight is calculated internally by the WEIGHBRIDGE SOFTWARE W S41,
which is the required weight of loaded material. During unloading of material first
weighment is taken to find out total weight of loaded vehicle and second weighment is done
to take the weight of empty vehicle.
 Main components of weigh bridge
a) Sensor and its cable line
b) Plate form scale
c) Soft ware program
B. Cane un-loader
Cane Un-loader is equipment that feed the cane into the feeding table for which motions are
controlled and operated by the operator from the un-loader cabin and unloaded cane in a short
time. The cane loaded truck is parked on the platform for unloading the cane into feeding
table. Truck tippler operator starts the hydraulic pump which operates upon double acting
hydraulic cylinder and platform so as to cause tilting of platform along with truck. This

5
results in the slippage of cane from the truck. For the protection of truck and preventing
against falling into the feeding table holding bracket is hold from side.
C.Feedingtable
Sugar Mills generally handle loose cane/cane bundles which often have one or more
horizontal or inclined cane tables. The cane/cane bundles are unloaded on feeder tables and
further conveyed for cane preparation .One or more feeder tables will feed cane to the main
cane carrier. The operator requires stopping or starting feeder table depending on the required
uniform feed at mill. The table has 8 strands of chain system to drag the cane to
discharge .The feeder table is designed to suit length of truck or trailer. It consists of a system
of chains dragging the cane. The angle of inclination of table varies from horizontal up to 45
and varies depending on the requirements at plant layout. Steeper slopes are recommended
where cane washing system is fitted to facilitate for easy drainage of washed water. On the
steeper tables slats with cleats are used to propel the cane up .The chain links are made of
high strength material and hardness to reduce abrasion wear due to mud sand and other
material. The cleats are attached to chain for gripping the cane and a fair amount of spillage
on the underside of the head shaft.

Figure 2 Feeding table

 Main components of feeder table

a) Chain,152.4 mm pitch; breaking strength 80 ton
b) Slats, Side Plates & Chutes
c) Head end sprocket (14 teeth,152.4mm pitch)
d) Tail end sprocket(14 teeth 152.4mm pitch)
e) Drive and tail end shaft

6
 f) Cast steel or fabricated sprocket wheels with machine cut teeth.
g) Couplings and rubber bushes.
h) Bearing
i) Electric motor
j) planetary gear box (MODEL- P4-38)Eddy current coupling / VFD
k) Operator Cabin at a suitable Height.
D .Cane washing system
The cane from fields is delivered with excessive amounts of soil, rocks and thrash. The wash
water is sprayed onto the cane as it is conveyed up the feeder table .Cane washing system is
provided on top of the feeder table near head end of feeder table conveyor. The water is
sprayed at high pressure on to the cane before the cane is dropped on to the cane carrier .Two
numbers of high pressure pumps (working pumps) are used to lift the water from storage
sump. The water is pumped to the header at top of the feeder table. The header has many
nozzles in series and spray water in jet form on the cane to get cane free of mud ,sand, rocks
and tramped iron etc. One pump is kept as standby and used whenever the main working
pumps are under maintenance .The water drained out from feeder table is collected into
another sump made opposite to storage sump. The water from the sump collecting the water
is discharged though two pumps (working pumps) for irrigation purpose or sent to water
purification. Additional two pumps are provided as stand by to be used if the main working
pumps are under maintenance.

figure 3 Cane washing system

 Main component for cane washing system
a) Pressure pump and motor

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 b) Storage sump
c) Header nozzles
d) Juice valves
Cane Carrier
The cane carrier is steel slat conveyor. The width of the carrier is usually the same as width
of the mill rolls. The steel slats are bolted to 4 strands of conveyor chains. The steel slats are
overlapping and so are slightly wider than chain pitch. The roller chains are used to reduce
friction because of heavy loads and relatively long conveyors. The return flight of the carrier
is supported at intervals on idlers .For uniform cane preparation generally two carding drums
are installed on cane carrier
 Main component of cane carrier
a) Slope plates, inclined plates
b) Runners, Idlers
c) Drive & tail end shaft
d) Chains & Sprockets
e) Slats
f) Reduction Gear box
g) Motor
F .Equalizer
Cane equalizer is provided on the cane carrier conveyor and between feeder table and carding
drum .The purpose of equalizer is to align the cane on carrier before it is fed to carding drum
and subsequently to shredder. A drum having hard faced curved plates are fitted
circumferentially to achieve this purpose. This has also a checkless chamber on top of the
drum to temporarily hold excess cane coming from feeder table .The equalizer hollow shaft
same length as of cane carrier. The hollow shaft is connected to motor through a gear box and
couplings. The direction of rotation of the equalizer is in the opposite direction to the cane
carrier travel. This facilitates the pressing of cane heap in the form of a bed and fed to pusher
of the shredder.
 Main components
a) Shaft, Fins
b) Bearing
c) Seal, ring
d) Motor
e) Gear box

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 f) Coupling
G. Shredder
Shredder is provided at the head of the main cane carrier conveyor. The purpose of cane
shredder is to cut the cane in to small pieces and fiberize the cane .The shredder has a shaft
on which hubs are attached. At the end of the hub swing hammers are assembled. The
hammer tip is made of carbide and hard. The carbide tips are bolted to the swing arm and can
be replaced in case of breakage or worn out. The cane passes from the top end on to the
shredder and gets fiberized. The rotating hammer cut the cane against the anvil. The fiberized
cane is dropped on to the belt conveyor and sent for further processing.

Figure 4 .Shredder
 Main components
a) Hammer carbide tips
b) Anvil plate
c) Swing arm pin
d) Motor
e) Bearing, Coupling
H. Belt Conveyor
Sugar cane belt conveyor is designed to handle prepared cane fibers described above from
shredder to diffuser. Impact rollers are fitted near the tail end of the belt conveyor to support
the belt against falling prepared cane from shredder. The rotary brush scrapper is provided at
the head end of the conveyor belt to clean the external surface of the belt and the internal
segmented ‗V‘ type scrapper is provided at the tail end side to clean the inside surface of the
belt. On the intermediate position equalizer is provided to spread the prepared cane evenly on
the belt. An overhead electromagnetic separator is provided on the belt conveyor after
equalizer to remove tramped iron and other iron materials. Under the belt of the overhead

9
magnetic separator non magnetic rollers are fitted to improve magnetic effect .Take up pulley
type vertically gravity tension (by counter weight) is provided below the return line belt to
maintain proper tension of the belt during operation. A cane weigher is provided below the
conveyor belt after overhead magnetic separator. It weighs mass flowing on the belt and
senses the prepared cane flow.
 Main Components
a) Impact idle
b) Internal scrappers
c) Equalizer
d) Take up pulley
e) Counter weight
f) Sand pit
g) Bend pulley
h) Belt weight
i) Snub pulley
j) Head pulley
k) External scrapper
I. Diffuser
The housing of the diffuser is of welded steel construction. It is from 35 meters to 52 meters
long; the cross section is rectangular and diffusers of different capacities are made in different
widths. The conveyor grids and screens are supported by two outboard type roller chains with
a pitch of about 3 feet. These chains are supported at the extreme ends by sprockets. At the
driven end, the sprockets are coupled through a gearwheel and pinion to a variable speed
hydraulic drive or electric gear motor drive. The conveyor itself is made or articulated frames
to which the screens are fixed. The screens and frames are rigidly attached to corresponding
links of the two chains. These chains are fitted with self-lubricating bushings. The rollers ride
on parallel rails. The return rails are completely exposed underneath the housing, giving full
visibility and accessibility to the screens. The thickness of the bed varies from 1.5 meters to 2
meters. The space between the two conveyor spans is occupied by a large tank with a sloping
bottom split into individual hoppers by means of vertical plates. These vertical plates have
horizontal slots, at specified levels, through which the juice overflows to the next hopper. At
the end of the conveyor, there is a revolving scraper to even out the flow of bagasse which
falls in an outlet hopper. This hopper is provided with a conveyor for removing the bagasse.
The diffuser is equipped with lifting screws in the press water feedback area.

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 Figure 5 Dffuser

Milling House
The prepared cane then enters the roller mills to squeeze out and separate the juice from the
bagasse. The juice is extracted from the fibered cane by squeezing order high pressure. The
wear of the roller occurs due to corrosion of metal by the acid, friction between scrapper and
trash plate to the roller passage. There are three rollers called feed, top and delivery rollers
meshed to extract the juice from the fibered cane, tana beles Sugar Factory has four mills in
milling plant having the following number of roller.
a) First mill has six rollers
b) Second mill has four rollers
c) Third mill has four rollers
d) Fourth mill has six rollers

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 Figure 6 general arrangement of mill roller

2.2 BOILER PLANT

Boiler plant is one of the four (4) main plants located in the Tana beles suger factory . It is
used to produce steam used in the else plants. Boiler plant is a huge plant that use water,
Bagasse and air as an input to produce the steam as an output. In sugar industry boiler is the
heart because of that with in boiler dry steam was generated for the purpose of electricity and
exhaust steam is used in Sulphur burners, centrifugal machines, evaporators, heaters, pans,
receivers and dryer for various operation.
Classification of boiler
 There are mainly two categories of boiler.
 Fire tube boiler
 Water tube boiler
 Fire tube boiler

Fire tube boiler is long steel tubes through which hot gasses from a furnace pass and around
which the water to be converted in to steam.

Figure 7 Sectional View of a Fire Tube Boiler

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  Water tube boiler

The water passing through the tubes and the hot gasses passing outside the tubes, these
boilers can be of single or multiple drum type and can be built to any steam capacity and
pressure, have higher efficiency than fire tube boilers.it has high capital cost and used for
high pressure high capacity steam boiler.

Figure 8 Simple Diagram of Water Tube Boiler

 Major components of water tube boiler

a) Grate f) Economizer
b) Forced drought fan g ) Bank tubes
c) ID fan h) Water feed pump
d) SA fan i) Mechanical dust collector
e) De-aerator j ) Super heater

Figure 9 Overall component of boiler

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Water Feed Pump
The Pump for feeding water to a Boiler is a multi-stage centrifugal pump having number of
impellers mounted on a drive shaft in series with the help of diffuser. All the impellers are
connected in series, so that the liquid discharged with increased pressure from one impeller,
passes through the connected passage to the inlet of the next impeller and so on, till the
discharge from last impeller passage into the delivery pipe.

Figure 10 Water feed pump

De-aerator
The de-aerator is an important feed-water system component which is used to remove the
dissolved gases like oxygen and carbon dioxide in the feed water through the de- aerator
vents. The presence of those gases in the feed-water which will enter in boiler or steam
generator can causes a rapid corrosion in the tubes. So the de-aerator dissolves the gases, by
reducing the partial pressure of the liquid and Rising the temperature of the solution up to the
saturation temperature. After the feed water is sprayed and heated up to (104-105) ᵒC, it is
stored with in the de-aerator tank. If the water in de-aerator storage tank level increases, then
the pressure in the de- aerator increases which affects the inlet steam flow by reducing its
temperature.

14
 Figure 11 De-aerator
Economizer
Economizer is a heat recovery system, usually installed near and at the back side of boiler. It
is mainly used to increase the temperature of the feed water delivered from the de-aerator
flowing through out it by opening the economizer air vent. Heat is transferred to the water
inside from flue gas flowing over the economizer throughout the air heater.

Figure 12 Economizer
Super heater
Super heater is used to increase the temperature of steam above its saturation temperature or
point. After the temperature of steam was increased above its saturation point dry steam will
produced. The temperature becomes lower due less air supply and moisture in steam.

Grate
Grate is a part of boiler in which bagasse is burnt. The bagasse is burned by means of forced
drought fan and spread out through the overall surface of the grate using turbulence fan. The

15
ash inside the grate is washed out and removed from the grate through ash conveyor because
it reduces the efficiency of steam generating unit and its working atmosphere.
Forced Drought Fan (FD)
To bring the air effectively in to contact with fuel and to remove the products of combustion
from the boiler, some pressure difference is required, this is called draught. The Forced Draft
system uses a fan to deliver the air to the furnace, forcing combustion products to flow
through the unit and up the stack for the purpose of burning. In a forced draught system, a fan
is installed near or at the base of the boiler to force the air through the boiler combustion bed
and other passages through the furnace, flues, air preheater and economizer.
Induced Draft Fan (ID)
The function of ID fan is to suck flue gases from furnace and pushes them to stack. ID fans
are installed above the flues, between the Boiler and chimney at its base. It produces higher
draft up-to 600 mm water column and it helps to spray fuel inside the furnace and crate
suitable cyclone inside the furnace. Here the furnace is kept at a slight negative pressure
below the atmospheric pressure so that combustion air flows through the system.
Secondary Air Fan (SA)
In this system a fan is located at or near the sides of the furnaces. The discharge of this fan is
connected to the body of the boiler with multiple nozzles that direct air to the inside
combustion chamber to create turbulence in the flue gas.
Mechanical dust collector
Mechanical dust collector is the equipment installed next to the id fan for the purpose of
environmental pollution control/protection by removing dusts and ash from the flue gas..
Bagasse Feeding System
Bagasse is the solid fibrous material which leaves the delivery opening of the last of the
tandem, after extraction of the juice.
Inside the furnace which is the surface between the grate and the wall of tubes bagasse is
required to burn with a fuel inside the furnace. For satisfactory boiler bagasse must be fed
reliably at high rates into narrow enclosed chutes, keeping them full without choking or
generating excessive dust. Many factories have installed magnets on the bagasse supplies to
boilers in order to protect against tramp iron damage to boiler feeders or moving grates.

2.3 PROCESS HOUSE

This plant is the largest and complex plant in which the following process takes place to
produce white sugar.

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 a) Juice weighting e. Crystallization
b) Heating of juice
c) Clarification of juice
d) Evaporation of juice
Juice Weighting
Mixed juice is normally weighed or measured. If the juice is measured samples of each
measuring tank is taken to obtain an average density of the measured juice and find the
correct specific gravity. The volume of the juice is converted to weight by multiplying it by
its specific gravity. Imbibition water is also weighed or measured. When it is measured, its
volume is also converted to weight multiplying by its specific gravity.
Under normal conditions, the factor relating cane, imbibition water and mixed juice is
bagasse. Hence the weight of bagasse is calculated through the difference.

Bagasse = Cane + Imbibition Water - Mixed juice.

The main purpose of mixed juice weighing is to determine the weight of bagasse supplied to
boiler plant, to determine the milling plant extraction, to determine the boiling house
recovery.

Juice Heater
Juice heating is excited in a number of vessels called juice heaters or pre-heaters. The main
purpose of heating juice or the juice heater is Heat destroys micro-organisms and enzymes
preventing loss of sucrose by microbiological activity. Heat accelerates the reaction rate
between the juice acids and the lime which will be subsequently added. The steam is able to
transfer heat to the juice through the metal surface of the tube.
This causes the temperature reduction of the steam. This reduction is possible only if a certain
amount of steam condenses. If there is no condensation of steam, there is no heat transfer
from steam to juice. Therefore, superheated steam cannot be used for heating, because it has
to lose the superheat first before it can start condensing.

Types of heater
There two main types of heaters exchangers, Shell and Tube type (vertical and horizontal)
and plate heat exchanger heaters. Shell and Tube type is a juice heater consists of a series of
tubes which contain fluid that must be either heated or cooled. They are typically used for
high pressure application greater than 30bar and 260oc. The condensate should leave the
heater through the outlet above the lower tube plate on the side opposite to the steam inlet

17
above ¼ of the length down from the top of the heater and non-condensed gas should leave
through the vent line opened to the atmosphere. In Tana beles Sugar Factory they use this
type of heat exchangers on the evaporators and heaters.
A. Frist heater: - In the first heater juice should be heated at temperature of 75oc to 85oc.The
purpose of heating at this stage is; to kill bacteria and to facilitate a chemical reaction
foregoing processes.
B. Second heater:-After the three components i.e. the juice, lime and sulfur dioxide are mixed
in a required proportion turns back to the second heating room .in this room then mixed
components are heated at the temperature of 95ᵒc to 105ᵒc.
C. Third heater: - In this room the juice is heated at the temperature of 115oc to facilitate
evaporation.

Figure 13 top section of shell and tube heater

Juice Clarification
Depending on the type of final product to be produced, there are different methods of juice
clarification. Here in case of Tana beles suger only the sulphitation process is applied.

 Advantage of sulphitation
 Fast boiling of massecuite
 Fast crystallization of sucrose.
 Marked improvement of sugar color.
 Disadvantage of sulphitation
 Higher ash content of sugar.
 Great expense cost for Sulphur and its generation equipment.
Dorr clarification

18
It is a large vessel which consists of four supper imposed compartments with feed chamber at
the top and each forming a complete clarifier independent of the other.
It is provided with a central hollow shaft, rotating very slowly and movers the scraper at the
speed of 12rev/hr approximately. During each compartments of the door clarifier the muddy
and clear juices are going to be separated and screened on juice screener. The clean juice is
sent to the third heater and its mud in addition to dry bagasse is also screened through a rotary
vacuum vessel. There are two each 28 feet diameter and 321,725 liters’ capacity Dorr
clarifiers here in Tana beles Sugar Factory for separation of muddy juice from clear juice

2.4 WORK SHOP AND FABRICATION

1. Bending machine
Bending means deforming a flat sheet along a straight line to form the required angle various
sections like angles, channels V-shape etc., are formed by bending, which may then be used
for fabrication of steel structures. A machine can be used to deform a sheet or plate to hollow
shapes of constant (i.e. cylindrical, elliptical) or varying cross sections like cone frustum.
2. Rolling machine
Rolling is a metal forming process in which straight length is transformed into a curved
length.
3. Shearing machine
A machine with blades or rotary discs for cutting sheets and plates. It is usually used cutting
rough shapes out of medium sized piece of sheets metals.
4.Drilling machine
It is a device used to make holes in a hard surface. The most common machining operations
performed on a drill press are drilling, reaming, tapping, counter boring, counter sinking, and
spot facing
Radial drilling machine
Drilling machine is to make circular holes on the components with the help of drill bites. But,
the purpose of the radial drilling machine is used to drill the holes in the given radial distance
and this will be used, when the component size is large in terms of height. When the
compotes are large, it cannot fit its structure in the machine vice. Therefore, the component
has to be pleased on the ground and the radial arm of the drilling machine has to be rotated
w.r.t the component to do the operation.
5.Milling machine

19
It is a machine tool used to rotate single or multiple cutting edges and removes metal when
work is feed against a rotating cutter. Milling machines are one of the essential machines in
any modern machine shop They are capable of machining flat or contoured surfaces, slots,
grooves, recesses threads, gears, spirals and other configurations.
Plain milling machine
The table feeding is done either by hand or power. The plain milling machine having a
horizontal spindle is also called as a horizontal handle milling machine. The table may be fed
as longitudinal, cross, or vertical directions.

2.5 WORK FLOWS OF TANA BELES SUGAR FACTORY

Cane Weigh bridge Cane un-loader Feeding table

Belt Conveyor Shredder

MCC Cane washer

Diffuser
Heater Clarification Evaporation

Mill house Centrifugal Batch pan &

centrifugal Pan House
pan

Bagass Sugar Molasses

Furnace Scriber Cheminie

figure 14 Work flows of tana beles sugar factory

20
 CHAPTER THREE
TECHNICAL ASPECT OF THE INTERNSHIP
Internship training delivers have various important outcomes. In addition to improve our
abilities of converting various theoretical knowledge into their real application in practical
world, it also delivers a number of additional benefits like Improving practical skills,
improving theoretical knowledge, improving team playing skills, improving interpersonal
communication skill, improving leadership skill, benefit in terms of gaining entrepreneurship
skill and understanding about work ethics.

3.1 OBJECTIVES OF THE INTERNSHIP

Internship program is a method of letting the students to assume themselves as potentially
responsible workman for a particular work by assigning them to actively participate in
production control as well as maintenance in industrial company. Such trends help us to have
valuable work experience. Internship programs are also potentially valuable to the company.
In this internship, we could observe what the outside industrial world looks like more than we
knew when we were at university. we learned or took many theoretically lessons even
difficult to understand theoretically. So, in this internship, we will get good opportunity to
solve these difficulties. Because those things which were theoretically difficult to understand,
were not hard to understand when we learned practically.

3.1.1 General Objective

The main objective of the internship program is an enabling a student in connecting with a
practical world of engineering related knowledge that the student learnt in theoretical
approach in his past semesters. In short, internship is a mechanism by which a theoretical
knowledge is being applied on practical world.

3.1.2 Specific Objective

 It consolidates a practical skill.
 It increases theoretical knowledge.
 It develops a team work sprit.
 It enables to know company management system.
 To improve interpersonal skill.
 To know a work discipline and ethics of the company.

21
3.2 Methods and Procedures While Working
3.2.1 Methods used for Working in Tana beles sugar factory
In our internship the active participation in every day activity of the company we must to be
able to develop our knowledge and practical experience on our field .As a result we are trying
to be part of the factory by actively take parting on the work and discharging our
responsibility properly. As we have tried to explain before we spending our work time on
visiting and observing of the activity and adopting to the environment of the factory, after we
have familiarized within environment and we have been performing our task by discussing
with company workers, technician, labor worker who being very experienced and
professional people by asking the question and answer the question regarding practical skills
our approach for worker and involvements in any work make us very useful.

3.2.2 Procedures That We Followed While Performing a Task

When we come to Tana beles sugar factory for internship we have been performing our work
task in different ways. In Tana beles sugar Factory there are 4 sections for controlling the
factory. Such as:-
 Extraction section
 Boiler section
 Proces section
 Mechanical maintenance section(Work shop)
To complete the tasks that we were given we have used many procedures according to each task.
These procedures are:
 As safety comes first, we put on safety shoes and working suit
 Asking the senior technicians what we are going to do
 Read the job card and identify the problem
 Prepare the required equipment
 Work with the technicians to fix the problem which is written on the job card

3.3 Technical tasks/products

When I am first started working in the tana beles sugar factory, I hadn’t any skill in machine
maintenance. Even didn’t know how to use hand tools. And also, hardly know how to use
different machines such as lath machine, grinding machine, welding machine drilling
machine shaper machine, press machine and other machines. From these responsibilities we
have taken during the internship period include: -

22
  To work with work shop mechanics at every process,
 To work on bearing & pumps
 To identify any kind of problem and propose solution with mechanics,
 Identify any work-related problem with workers,
 Keep organization materials and secret properly, the organization gives such
responsibilities based on their willingness.

3.4 KNOWLEDGE AND ACQUAINTANCES ACQUIRED

Internship training delivers have various important outcomes. In addition to improve our
abilities of converting various theoretical knowledge into their real application in practical
world, it also delivers a number of additional benefits like Improving practical skills,
improving theoretical knowledge, improving team playing skills, improving interpersonal
communication skills, improving leadership skills and Understanding work ethics.

3.4.1 Improving Practical Skills

It is the main benefit of internship. Many knowledge we know in theory are there in TBSF
practically. Therefore, we improve our practical skills by performing different operations as
operations of different machines. We have got a lot of practical experience while we were
trying to troubleshoot and in maintaining during systems come across problem. Also, we
have got an opportunity to work on equipment’s which we have only know theoretically on
material handling as different hoists, hand chains and several transporting equipment’s. We
improved our performances by followings: -
 Understanding the instrument & their functions
 Full confidence understanding of the job
 Decision maker Increased problem-solving
 Good human relation

3.4.2. Improving theoretical knowledge

Even though, we have learnt a lot of things in the class theoretically, we got many knowledge
full activities while we saw things practically. Therefore, internship program was not only
used to improve our practical skill, but also used to impose my theoretical knowledge by
correlating the practical skill with theoretical knowledge. The main points that we have got
theoretically:
 About chain and elevator systems in detail
 We knew the details of mechanical machine parts one by one; machine tower, standby

23
 generator, boiler, compressor, condenser, grain cooler, fans, pump.
 To correlate the theoretical knowledge with the real work.
 We gain the knowledge of method of machine maintenance.
 We knew the process of plant one by one.
 We gain the knowledge of automatic stand by generator for emergency purpose.

3.4.3. Improving interpersonal communication

Team working was priceless while performing tasks that make the factory profitable. To do
activities and works alone in the factory is a difficult task. Therefore, by good communication
among the different sections in the factory we grasped wide knowledge. Good
communication has the following advantage;

 Analyze and perfect performance of targeted maintenance and inspection.

 Improving efficiency of the factory from some defect due to inter personal
communication.
 To handle information, the more we communicate with the different section in
the factory, the better we handle the information.
 To improve relationship with others if our day to day communication increases
my relationship among the different sections also improved.

3.4.4. Improving team skills

The most important point in team playing skill is just reach an agreement from different
points on the work to be done. For instance, in the case of applying kaizen working principle
all the factories worker was participating to insure the targeted goal in addition, the technique
division head, senior planners, Forman’s and mechanics discusses on issues that led them to
the team working. Thus achieving good team playing skill is essential for:
 Communication skill is developing.
 Increasing understanding of the task
 Effective completion of tasks.
 Saving times and increasing productivity

3.4.5. Improving leadership skill

Leadership was one of the functions of management which including Planning, organizing,
stetting, leading and controlling. This internship program guides me to be an ethical leader
that means ethical leadership provides the momentum, guidance and motivation among
members, significant traits for effective leadership in my working area. In addition to this the

24
internship program allow me what a good leader satisfied or fulfill like a change agent
innovative skill and entrepreneur for himself. Therefore, this is a good collaboration between
the leader and his staffs the company or the agency also successful or fruit full. Generally,
what we understood for the past four months Internship program is that anyone who is
willing to make the effort can become a good leader.

3.4.6. Understanding about work ethics and related issues

As worker made to specialize in different fields special codes of conduct were expected from
each worker while we were in the company most of the workers and company’s leader told us
what allowing a good ethics in working areas are: -
 Punctuality: - arriving at working place in time.
 Honesty: - spending working hours and resource totally on working rather than
spending too much time talking with friends over tea and coffees
 Willingness to learn: - Understanding the way things are done at work place and
trying to do it better any person however experienced will learn new things as time
passed.
 Initiative: - being prepared to see what needs to be done and to do work without
always

3.4.7 Entrepreneurship skill

Entrepreneur is a person who sees a good opportunity for a new business and works hard to
make it grow. Entrepreneurs are very important for the growth of economy. While we was in
the factories, we have got wide knowledge in the entrepreneurship skill that we should have
to find ourselves as an engineer and creative person by analyzing work opportunities and
employee. The major characteristics of entrepreneurship that we have seen in the factory
include the following;
Self-confident and multi- skilled: to be an entrepreneur engineer for the future we should
have to be confident to take positive or negative consequence. Therefore, the past four moth
internship programs lead me to a multi skilled engineer this skill creates confident in face of
difficulties and discouraging circumstances.
Innovative skills: a good skilled engineer can create a new mechanism in case of a difficult
challenge is occurring in the factory. Therefore, the past four moth internship program gave
me wide hint how we innovate if we were subjected to a difficult challenge.
Results oriented: to be successful it requires the drive that only comes from setting goals
and targets and getting pleasure from achieving them.

25
A risk taker: the successful entrepreneur exhibits as incremental approach to risk talking at
each stage exposing myself to only a limited measured amount of personal risk and moving
from one stage to another as each decision is proved.
Total commitment: hard work and energy are essential elements in the entrepreneur profile.
Finally, with this changing nature of work students must be enterprising and flexible and may
need to become entrepreneurial.

3.5 PROBLEMS ENCOUNTERED DURING THE INTERNSHIP PERIOD

In our internship we have faced different technical, personal, organizational problems.
Those are :-
 Lack of practical skill,
 Lack of sufficient knowledge,
 Lack of computer
 The Absence of peace in our region
 No books and also manuals that used to develop our knowledge,
 Lack of technical skill,
 Lack of internet access
We solve this problem by:
 Gathering, Importing, accepting information’s from shop technicians
Even though the machine is manufactured and produce in a broad country such as Germany
and our country worker have a little knowledge about the machine, it needs knowledge of
machine ethics and way of increase productivity. When the machine injured the company
needs a better maintenance worker who have a good knowledge about each machine to back
it productivity and to increase profit by increase the machine productivity, but this is not
happen, in addition there were some persons that were not responsible to solve this problem.
But, we tried to communicate to the quality head and the operational manager of the company
to advise us to solve these problems by communicating with those is not responsible persons.
Then we approached smoothly to the other volunteer workers to search the required
information’s by:
 Explaining internship programs.
 Observing in detail the machine spare parts.
 Working with and getting ideas from technicians and machine operators.

26
 Generally, by collecting soft copies, referring machine manuals from excellent
quality head department, engineers, and office persons to refer the required things for
doing our tasks.

27
 CHAPTER FOUR
DESIGN OF TRIPLE MECHANICAL MACHINE

4.1 INTRODUCTION
Triple mechanical machine is a machine which performs more than one operation. Triple
Mechanical Machine as we call it is a machine that is made especially for the small scale
industries where labors working are have very little technical knowledge. It performs
multiple operations simultaneously giving the workers more opportunity to perform their
work quickly and efficiently without the hassle of using different machines for performing
different operations on work piece. This project deal with design development and modeling
of triple mechanical machine. It is designed for the purpose of multi-operations i.e. drilling
cutting and grinding. It performs triple operation at same time with required speed and this
machine is automatic which is controlled or operated by one motor which is run with the help
of current. This model of multi operational machine is used in small scale industries and
domestic operation which can perform mechanical operations like drilling, cutting and
grinding of thin metallic as well as wooden model or body in work shop.

4.2 PROBLEM STATEMENT

Existing machine in the shop has only one function that means performs only one operation.
The sizes of the machines are not compact and needs individual space for cutter, grinder and
driller machine. Those planted machines i.e. grinding, cutting and drilling are operating
separately and needs more than one motor that means there is high power consumption .The
operation of the existing machines is requires time , so it consumes time ,the existing
machines require large space to plant them, so this machine is solve the above problems.

4.3 OBJECTIVE OF THE PROJECT

4.3.1 Main objective

The main objective of this project is to design of the triple (cutting, drilling ,grinding)
mechanical machine which perform cutting, drilling, and grinding operations at a time.
4.3.2 Specific objective
The specific objective of this project is to:
 To design pulley
 To design section of belt
 Design of bevel gear
 Design of shaft

28
  Design of key
 Design of grinder and blade

4.4 METHODES &MATERIAL

4.4.1 Methodology
Methodology is the method how to perform our project; we can follow the following step to
achieve our project
 Problem identification
 Specify the objective
 Analytically determine component of the machine
 Then select the available material for each component according to different
mechanical properties.
4.4.2 Materials
Table 1 Materials of each components
Components Material
Pulley Cast iron
Shaft 50C4 Carbon Steel
Belt Rubber
Column Cast iron
Hack saw bled Carbon steel

4.5 DETAIL DESIGN AND ANALYSIS

4.5.1Design of pulley
The pulleys are used to transmit power from one shaft to another by means of flat belts, V
belts or ropes. it is made The pulleys may be made of cast iron, cast steel or pressed steel,
wood and paper. The pulleys made of pressed steel are lighter than cast pulleys, but in many
cases they have lower friction and may produce excessive wear. The cast materials should
have good friction and wear characteristics and they are low in cost. Do to this reason we
select cast iron for design of pulley.
 Specifications Power of motor, p=1.5kw
 ρ =7200kg/m3
 Speed of motor, N=1400rpm
 σu=170Mpa, 𝜏𝑢 =240Mpa
 Assumption to be taken

29
  Diameter of motor pulley, 100mm
 Output speed to be, N=400rpm Factor of safety, F.s=4
𝜎

Table 2 dimension of standard v- grooved pulley according to IS2494-1974

Types f W D A C F E Groove
belt angle 2B
in
degrees
A 11 12 3.3 8.7 10 15 32,34,38
B 14 15 4.2 10.8 12.5 19 32,34,38
C 19 20 5.7 14.3 17 25.5 32,36,38
D 27 28 8.1 19.9 24 37 32,36,38
E 32 33 9.6 23.4 29 44.5
Note:-face width 𝐵 = (𝑛 − 1) + 2𝑓
Then we can calculate the diameter of shaft pulley in order to get the required speed by
considering velocity ratio.

Thickness of pulley rim is given between

Then we take the thickness of small pulley rim is taken as t=4mm.

Face width of pulley 𝐵 = (𝑛 − 1) + 2𝑓 we select A type belt with e=15,f=10, n=2
B= (2-1) x15+2x10=35mm
Number of arms may take as 4 for pulley diameter 200mm-600mm, so our pulley arms are 4.
Torque of the pulley is calculated as:

For small pulley

30
 𝑛

𝑛 𝑛

The arms are tapered from hub to rim then tapper is usually 1/48 to1/32.When the width of
the pulley exceeds the diameter of the pulley, then two rows of arms are provided.
4.5.2 Selection of belt
The belts are used to transmit power from one shaft to another by means of pulleys which
rotate at the same speed or at different speeds.
Following are the various important factors upon which the selection of a belt drive depends:
 Speed of the driving and driven shafts
 Speed reduction ratio
 Power to be transmitted
 Centre distance between the shafts
 Service conditions.
The V-belt is mostly used in the factories and workshops, where a great amount of power is
to be transmitted, from one pulley to another, when the two pulleys are very near to each
other.
Material Rubber
 Density of the material = 1140kg/m3
 Ultimate stress 𝜎𝑢=15M pa

31
Table 3 Dimension of standard v-belts according to IS2494-1974

Types f belt Power rages Top width Thickness(t) in Standard pitch length of v-belt in
in kw in (b) mm mm mm
A 0.7-3.5 13 8 645,690,1001,1026,1636,1661
B 2-15 17 11 1128,1204,1255,1331,1433,1458
C 7.5-75 22 14 1687,1763,1814,1941,2017.2068
D 20-150 32 19 270,2880,3084,3287,3693
E 30-350 38 23 5426,6137,6899,7661,8423,9185

From above standard table we can select the type of belt depending of motor in which type it
we that radius of pulley on the motor shaft.
𝑎𝑛 raduis of main shaft pulley From A type belt we select the

standard length of the belt, L=1661mm and also the length of the belt is given by the formula

Here we can calculate the center of distance between the pulleys

1661 = (175 + 50) + 2 + (175 + 50) 2/
2
− 516 + 1250 = 0 2 = 2/2 = 350/2 = 175 = −𝑏±√𝑏2−4𝑎𝑐 2𝑎 =
−(−516)±√5162−4x1x1250 2x1 =514mm or 2.45mm here we take the larger for or safe
design, X=514mm
From an open belt as shown in the figure

Figure 15 open belt

𝑠𝑛

and angle of lap the smaller pulley is 𝜃 = 180° − 2 = 151°

From A type belt the weight of the belt per meter length is given in the table w=1.06N the we
can calculate the mass of the belt per meter length

32
 = 𝑔 = 1.06 , 𝑔 𝑎𝑣 𝑦 (𝑔) = 9.82 /𝑠2 ,
= 1.06 𝑘𝑔 /𝑠 /9.81 /𝑠2 = 0.108 𝑘𝑔/
Centrifugal tension, 𝑇𝐶 = 𝑣2
𝑉 = 𝜋 1 1/ 60 𝜋100 × 1400/60 = 7326 /𝑠 = 7.32 /𝑠
𝑇𝐶 = 0.108 𝑘𝑔/ (7.32 ⁄ )2= 5.79
2
Area of belt is , = 𝜌𝑙 = 0.0000947
Maximum tension on belt T=𝜎 × 𝐴 = 15 𝑎 × 0.0000947 2 = 1421.05
Now tension on tight side of belt ,1 = 𝑇 − 𝑇𝐶 = 1421.05 − 5.79 = 1416.36
Let’s,2 = Tension in the slack side of the belt.
We knows that,2.31 log 𝑇 𝑇 = μ. θ. Cosecβ = 0.3 × 2.781. cosec34° = 1.492 then
𝑔𝑇 𝑇 𝑇 𝑇
𝑇 𝑇
Also we can calculate face width of belt, 𝐵 𝑏𝑏 𝐵

4.5.3 Design of bevel gear

The bevel gears are used for transmitting power at a constant velocity ratio between two
shafts whose axes intersect at a certain angle.
 Specification
 Material ,ordinary cast iron with allowable static stress 𝜎 = 105 𝑝𝑎
 Tooth profile ,20 full depth involutes systems,
In order to get appropriate output speed, we must take velocity ration V. R=1 The bevel gears
are used for transmitting power at a constant velocity ratio between two shafts whose axes
intersect at a certain angle.
𝑉 𝑇 𝑇
where , NP = pinion speed equal to shaft speed ,NP = 400rpm
NG = gear speed, TP = pinion teeth. TG = gear teeth
DG=gear diameter
𝑉 𝑝
 Determination of pitch angle
The angle between the shaft axes is 90°, then
𝜃𝑠 𝜃𝑝 𝜃𝑝
𝜃𝑝 𝑎𝑛 𝑉 𝑎𝑛 𝑎𝑛 𝑇 𝑇 𝑎𝑛
𝑎𝑛 𝜃𝑝 𝜃𝑝

33
For satisfactory operation of the bevel gears, the face width should be from 6.3 m to 9.5m,
where m is the module. Also the ratio L / b should not exceed 3. For this, the number of teeth
in the pinion must not less than 48/√(1+𝑉. 2) , where VR is the required velocity ratio.
𝑇 𝑉
𝑇 𝑇 𝑉
We know that formative number of teeth for pinion and gear is
𝑇𝑒𝑝 𝑇 𝑠𝑒𝑐 𝜃 𝑠𝑒𝑐
𝑇𝑒 𝑇 𝑠𝑒𝑐 𝜃 𝑠𝑒𝑐
Tooth form factor for the pinion and gear is
𝑝 𝑇𝑒𝑝

Since the allowable static stress (𝜎𝑎) for both the pinion and gear is same (i.e. 105 M Pa or
N/mm2) and , 𝑝 is the same𝑦′ , therefore the pinion is select. Thus the design based upon
the pinion. We know that the torque on the pinion,
𝑇 𝜋 𝑝 𝜋 mm
𝑇𝑎𝑛𝑔𝑒𝑛 𝑎𝑙 𝑙 𝑎 𝑛 𝑒𝑝𝑛 𝑛 𝑇 𝑇
𝑒 𝑘𝑛 𝑎 𝑝 𝑐 𝑙 𝑛𝑒 𝑣𝑒𝑙 𝑐 𝑦 𝑣 𝜋 𝜋 𝑇
𝜋 34 400/1000 =42.7m m/min=0.711mm/s.
We know that length of the pitch cone element or slant height of the pitch cone,
L 𝑠𝑛𝜃 𝑇𝑝 𝜃 𝑠𝑛
Since the face width (b) is 1/3rd of the slant height of the pitch cone, therefore
𝑏
We know that tangential load on the pinion,
WT= (𝜎 ×cv)b𝜋. y'P[ −𝑏/ ]but Tooth form factor
𝑐𝑣 𝑣
for accurate cut and ground metallic gear operating at velocity up to 20m/s.
𝑐𝑣 𝑒𝑛
𝑇 𝜋

Solving this expression by hit and trial method, we find that WT= 𝑇/
𝑏𝑢 𝑏 𝑠 𝑛 𝜃𝑝 𝑠𝑛
𝑏 𝑏

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 𝑝 𝑇𝑝 𝑎𝑛
𝑇
𝑇
 Forces Acting on a Bevel Gear
The tangential force (WT) acting at the mean radius ( ) of the pinion. We know that Now,
WT= 35828Nmm/36mm = 997.8N
Axial and radial force acting on the pinion shaft are given as follow respectively,
𝑎𝑛 𝑠𝑛
𝑉 𝑎𝑛 𝑐 𝑠
 Check for dynamic load
We know that pitch line velocity, V= 0.71 m = 0.71 × 2.5= 1.775 m / s and tangential tooth
load on the gear,
WT= 35828/ = 35828/2.5 = 14331N From Table 28.7,
we find that tooth error action for carefully cut gears having module 2.5 mm is
e = 0.025 mm,
Taking K = 0.111, for 20° full depth in volute system𝐸 =84 × 103 N/mm2; and EG = 84 ×
103 N/mm2, we have Deformation or dynamic factor,
𝐶 𝑘𝑒 𝐸𝑝 𝐸

 Dynamic load on the gear

WD = WT + 21(𝑏.𝑐+ 𝑇)/21𝑣+√𝑏.𝑐+ 𝑇=1727.98N From
Table 28.8[2], we find that flexural endurance limit ( ) for the gear material which is grey cast
iron having
B.H.N. =160, is 𝜎𝑒= 84 M Pa = 84 N/mm2
We know that the static tooth load or endurance strength of the tooth,
= 𝜎𝑒 .b.π. m. , 𝑝
=84 × 20.4 × π × 2.5 × 0.154 = 13451.76N
Since WS is greater than WD, therefore the design is satisfactory from the standpoint of
dynamic Load. WS≥1.25WD 13451N≥2159.97N
 Check for wear load
From Table 28.9[2], we find that for a gear of grey cast iron having
B.H.N. = 160,
the surface endurance limit is, 𝜎𝑒𝑠 = 630 MPa = 630 N/mm2

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Load-stress factor,
K=(𝜎𝑒𝑠)2/1.4 𝑠 𝑛 ∅ [ 1/ 𝐸𝑝 + 1/ E ]
𝐾 = (630)2/1.4 𝑠 𝑛 200 [ 1 /(84 103) +
Ratio factor 𝑇𝐸 𝑇𝐸 𝑇𝐸
Maximum or limiting load for wear,
= 𝑏 𝐾 𝑐 𝑠𝜃𝑝
𝑐 𝑠
 Since Ws and are less than , therefore, the is safe
4.5.4 Selection of grinder wheel
Grinding is a material removal process accomplished by wheel rotating at very high surface
speeds. The grinding wheel is usually disk-shaped which is made from silicon carbide with
density 3.186 𝑔 𝑐 3 and is precisely balanced for high rotational speeds. The preferable
parameters of the grinder taken from the standard to accomplish the surface finished are:
 = ×𝐵×𝑇× = 200 × 35 × 15 × 400 𝑝 .
 Volume =𝜋 2 = 𝜋 × 1002× 15 = 471000 3

 Mass=𝜌 × 𝑉 = 3.186 × 10-6𝐾𝑔/ 3 × 471000 m3 = 1.50𝐾𝑔

 Weight=mg= 10 × 1.50 = 15Kg

4.6.5 Selection of hacksaw blade

Blades are available in standardized lengths, and with anywhere from three to thirty-two teeth
per inch. The blade used is based on the thickness of the material being cut with a minimum
of three teeth in the material. Hacksaw blades are normally quite brittle, so care needs to be
taken to prevent brittle fracture of the blade. Bi-metal blades are meant to minimize this risk.
Hacksaw blades (both hand & power hacksaw) are generally made up of carbon steel or high
speed steel strip rolls.
 The common sizes of hacksaw blades are:
 Carbon steel hand hacksaw blade: 250x12.5x0.6
 Carbon steel [power hacksaw blade: 350x25x1.2
 High speed steel power hacksaw blade: 350x25x1.2
 Here, we select carbon steel power hacksaw blade: 350x25x1.2 for our design
depending on its requirement.

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4.6.6 Design of shaft
A shaft is a rotating machine element which is used to transmit power from one place to
another. In order to transfer the power from one to another, the various members such as
pulleys, gears, grinder, and disc plate are mounted on it.
Table 4shaft material

Indian standard designation Ultimate tensile strength , Yield strength, M pa

Mpa

40C8 560-670 320

45C8 610-700 350
50C4 640-760 370
50C12 700 490

For design of shaft we select the material 50C4 having Ultimate tensile strength 640-760 M
pa and Yield strength 370 M pa.
The calculated values of weights and applied loads on the shaft are as shown below.
Calculate centrifugal force on the grinding considered power and number of revolutions
= 𝐶×𝜔×
𝜔 = 2𝜋 /60 = 41.866 𝑎 /𝑠
𝐶= 𝜔× = 1500 ⁄𝑠 41.8 × 0.1 ⁄𝑠 = 358.38
Calculate centrifugal force on the wheel used to mounting hacksaw pin considered power
and number of revolutions
𝐶 𝜔
𝜔 𝜋 𝑎 𝑠
𝐶 𝜔 𝑠 𝑠
First find the reaction load at bearing B
Consider resultant loading 𝐶𝐴 + 𝐵 + 𝑇𝐶 + 𝑇 + 𝐶𝐸 = 0
𝐵 = 716 + 1416.4 + 1734.6 + 358 = 4222.3
applied loads on the shaft are as shown below
𝑇1 = 1416.36 ,2 = 318.28
𝑉 = 256.8 , = 256.8 ,
𝑇 = 1416.36

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 𝐵 = 4222.3N

To find diameter of shaft use the theory of:

1. Maximum shear stress theory
Assume factors (F.S) =2
3 2
𝜋/16 𝜏 =√( + 𝑇2)= √(799600 + 1921922)
𝜋/16 185 3 = 79830.93mm3
= 28mm

4.5.7 Design of key

A Key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to
connect these together in order to prevent relative motion between them.
 The standard dimensions of the sunk key
 Width of key, w= d / 4
 Thickness of key, t = d / 6
 Since, shaft material and key material are the same, (i.e. L= 1.571 d)
 where d = Diameter of the shaft
 w=28/4=7mm
 t=28/6≈5mm
 L=1.571x28=42mm

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4.5.8 Design of vertical column
We had three primary concerns:
 the strength of the structure, i.e., its ability to support a specified load without
experiencing excessive stress:
 the ability of the structure to support a specified load without undergoing
unacceptable deformations.
 From ergonometric structure. Our concern will be the stability of the structure, i.e.,
with its ability to support a given load without experiencing a sudden change in its
configuration.
Our discussion will relate chiefly to columns, i.e., to the analysis and design of vertical
prismatic members supporting axial loads. We assume that P is a centric axial load If the
cross-sectional area A of the column is selected so that the value 𝜎 = /𝐴 of the stress on a
Transverse section is less than the allowable stress for all the material Used, and if the
deformation 𝛿= /𝐴𝐸 falls within the given specifications; we might conclude that the
column has been properly designed. However, it may happen that, as the load is applied, the
column will buckle: instead of remaining straight, it will suddenly become sharply
curved .The properties of cast iron which make it a valuable material for engineering
purposes are its low cost, good casting characteristics, high compressive strength, wear
resistance and excellent machinability. The compressive strength of cast iron is much greater
than the tensile strength. Following are the values of ultimate strength of cast iron:

 Tensile strength = 100 to 200MPa  Compressive strength = 400 to 1000MPa

 Shear strength = 120MPa
 Modules elasticity =69GPa
 Reaction force == 4222.3
 𝜎𝐶 = 550 𝐴
 Analysis of deformation of column
Assumption
 t=40mm
 L=1200mm, W=150
 Dead weight of shaft, pulley and grinding =30kg
 Total load on columns (P)=422.23 + 30 = 453𝑘𝑔 ≈ 500𝑘𝑔

Now calculate

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A=t×w=40×150=6000mm2
𝛿= /𝐴𝐸
(5000×1680 )/(6000 2×69×109) = 2.02 × 10-8mm
There isn’t buckling of frame. And also check allowable stress with loading stress
𝜎 = /𝐴 = 5000/6000 = 0.833 𝑎 it is acting stress . Buckling load on the piston rod,
bucling Buckling load on the column 𝑐 = × .
𝑐 = 5000 × 1.5 = 7500
Since the column is fixed at its both ends, therefore equivalent length, 𝑙 = /2 = 600
Rankin’s formula gives a fairly correct result for all cases of columns, ranging from short to
long columns. So, for these project work use Rankine’s formula
𝑐 = 𝜎𝐶 × 𝐴 /(1 + 𝜎𝐶/𝜋2E × (𝑙/𝑘)2
𝜎𝐶/𝜋2𝐸 = 𝑎, 𝑎 𝑠 𝑎𝑛𝑘 𝑛𝑒 𝑐 𝑛𝑠 𝑎𝑛 , 1/1600
𝜎𝐶 = Crushing Stress or yield stress in compression
A=Cross-sectional area of the column
We know that the area of column 𝐴 = 𝑇 × = 120 × 120 − 40 × 40 = 17600 2
Its distance of center of gravity from bottom to top,
𝑦 = /2 = 600
The moment of inertia of the section about X-X,
3
𝐼 = × /12 = 150 × 12003 /12 = 2.16 × 10 10 4

The moment of inertia of the section about Y-Y,

3
𝐼𝑌𝑌 = × /12 = 1200 × 1503/12 = 0.405 × 1010 4

Since 𝐼𝑌𝑌is less than𝐼 ,therefore the column will tend to 𝐼𝑌𝑌 direction .thus we shall take
the value of I as 𝐼𝑌𝑌 = 0.405 × 1010 4

Assume column is long column for these case slandness ratio we take 80 then
𝑐 = 550 × 12800 /(1 + 1/1600 × (80)2 ) = 5028.5𝑘 𝑒 𝑒𝑓 𝑒
𝑐 > , 5028.5𝑘 > 5000 So, the column is safe

4.6 WORKING PRINCIPLE

The working principle of triple mechanical machine is based on the three major principles on
which our proposed machine. I.e. The scotches yoke mechanism and the power transmission
through bevel gear and belts. First of all, the power from the motor is transmitted to the shaft
by using belts. This belt transmits power from the source to this shaft by means of pulley
which rotates at different speed. Know this pulley is used to transmit the power from shaft to
the bevel gear by shaft attached to it. As shaft is rotated the power is transmitted to bevel

40
gear, scotch yoke mechanism and grinding system also mounted on it. The power
transmission through bevel gear is in which the axis of two shafts intersect at certain angle,
mostly perpendicularly to each other at constant velocity ratio between two shafts. This bevel
gear mounted on the shaft change the axis of rotational motion to the motion that used to drill
the material that we used. In addition to this grinder is mounted on the rotating shaft in order
to sharpening of tools and surface finishing of products. Finally, the power is transmitted to
cutter by scotch yoke mechanism that converts rotational motion to linear motion. This
conversion of motion is used to back and forth movement of the hacksaw to cut the material
what we want. Generally, the power from motor is transmitted to:
 Cutting mechanism by means of scotch yoke mechanism
 Drilling action by means of bevel gear mechanism
 Grinding mechanism by rotating shaft that contain rotating grinder at tip of it.

CHAPTER FIVE
CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION
Internship program is a good program of transmitting knowledge, improving practical skills,
up grading theoretical knowledge, improving practical skills, interpersonal communication
skills, team playing skills, entrepreneur ship skills and leadership skills, understanding about
work ethics related; therefore, this program should continue always where ever and
whenever. Especially the company that joined us was very practical with respect to reverse
engineering concept. Since we are understanding the concept engineering work shop
operation & the application area of mechanical machine element in tana beles sugar
factory. So, from the vision point of the company we would like to solve the problems what
we have seen by our proposed project. This project had wide range of scope in small scale
industries. This type of machine can be used by any one due to its simplicity of working
principles and multi range of operations.

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5.2 RECOMMENDATION
First we would like to recommend the industrial linkage group of the institute when they
contact with the company for the placement of the students, it is better that they complete all
related tasks even announcing the departments of the students to be join in to them. But this
problem may not be in all companies, since initially they identify what they accept.
Otherwise students may lose their beginning time by forming a suitable atmosphere in the
company. In the manufacturing section their material handling is not well organized. The
working materials are exposed to distraction like corrosion since it is accumulated in the
ground without any specimens and covering. This has its own impact in the quality of the
production, so it requires a quick action of remedy to save the life of metals. Some
manufacturing equipment’s are salvage which needs to be replaced otherwise beyond their
production quality problem they are danger for the worker’s life. In the maintenance section
there is overloading on the workers, the time given for a task and it takes are not proportional.
While this occurs has its own impact on the quality of the action to be performed and also has
problem on the employ (mechanics) humanity. Since we try to do design machinery which
used to the society, we like to recommend any manufacturers as well to manufacture and
distribute it to anyone who want to use especially for governmental institutions in rural area.

REFFERENCE
[1]. Dr. Toshimichi Moriwaki Professor Department of Mechanical Engineering Kobe
University, “Trends in Recent Machine Tool Technologies”
[2]. R. Sokhumi, J.K. Gupta s. Chand (2005) Text book of machine design
[3]. Groover.Mikell P. Fundamentals of modern manufacturing material process and systems,
4thed.
[4]. Dr. Pulak M. Pandey. “Selecting and Planning the Process of Manufacture:
[5]. Wikipedia.
[6]. Fadooengineers.com.

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 APPENDEX

PART DRAWING

Figure 16 Pulley

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 Figure 17 Belt

Figure 18 Bevel gear

Figure 19 Grinding wheel

44
 Figure 20 Hack saw

Figure 21 Shaft

Figure 22 Rectangular sunk key

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ASSEMBLY DRAWING

Figure 23 Triple mechanical machine

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