Design simulation and analysis of manual block-making machine

Abstract

This paper reports the synopsis of design simulation and analysis of manual block-making machine; it is a small fraction of a bigger research-study. Analysis of the various components that make up the final design was done in order to establish the forces, stresses and dimensions. The studies included dynamic simulation, frame analysis and stress examination. Finite Element Analysis was conducted on the components that could have failed during the normal operation of the machine; as such two analyses were done, one to investigate the effect of member components weight due to gravity and the second to investigate the effect of the return load on the frame members. All drawings, calculations, design, assembly, simulations, and Finite Element Analysis (FEA) were done by the Autodesk Inventor, 2016 Engineering Design Software. The results are: Flat lever analysis: The maximum displacement achieved was 0.0000008642mm, while the safety factor was 15ul and so the design of the flat component was acceptable if subjected to loads as exposed. However, it seems that the part is overdesigned. Compactor frame analysis: The maximum displacement was 1.605mm and considering the fixed-end would not actually be fixed in the actual machine, this displacement was found to be acceptable. The minimum safety factor achieved was 4.35ul which is acceptable and the maximum 15 ul. Complete assembly analysis: Maximum contact pressure achieved was 36.72 MPa while some components received no contact pressure from the load. The safety factor for the whole machine was 15ul. The value may lead to an assumption that the machine has been “overdesigned”, but considering that some of the sections of the machine are actually unaffected by the load, or the loading conditions is short, and allowing for that it is an equipment that intends to operate on a daily-basis, and it is made of ductile-material, operated in repeated and impact mode of loading, environmental considerations and also to account for all the unpredictable-factors, then, this safety factor for the machine is acceptable. For single components however there would be a need to reduce the “overdesigning”. The study accomplished design simulation and analysis of manual block-making machine, resulting in 3D-view of the final assembly of the machine (made of mild steel) with all standard notations. Overall, the results of this concise study are rather positive, providing a good starting point for further and much- deeper exploration on the same. The major recommendation was made vis-à-vis design factor of safety, in order to eliminate/reduce “overdesigning” and to obtain sequential solutions that exhibit asymptotic convergence to values representing the exact solution, it is recommended to conduct h-refinement of the mesh in FEA.