01 Figure 1.2 Coconut water and coconut meat after pressing can be used for many different commercial purposes .... 03 Figure 1.6 Young Coconut Pressing Machine COM92H Cocoman .... 05 Fi
OVERVIEW OF THE TOPIC
Definition and application of coconut Pressing machine
- It is a coconut-splitting machine whose main use is to split coconuts in half to get water and coconut pulp to make ice cream or jam, replacing the manual pressing of coconuts.
Fig 1.1 Picture of chopping coconuts manually with a tool
Figure 1.2 Coconut water and coconut meat after chopping can be used for many different commercial purposes
1.2 The uses of a coconut after it is cut down.:
Coconuts provide food, fuel, cosmetics, folk medicine, and many other uses
+ The meat of a ripe coconut: Coconut milk can be squeezed out, can be used as food, and processed into coconut oil
+ Coconut shell: Used to make charcoal from the hard shell, and to produce coconut fiber
+ Coconut water: Due to its high nutritional content, it can be used in the beverage industry, canned food processing, and cosmetics
Figure 1.3 The products are made from coconut
Technology for coconut Pressing machines
2.1 Types of domestically produced coconut Pressing machines
To meet the demand for coconut-related products, the production and use of coconut-pressing machines are increasingly on the rise in Vietnam Currently, several companies are still producing coconut-pressing machines, including those for fresh coconuts:
▪ Tan Phat Manufacturing and Trading Company (TP)
▪ Hoang Tung New Technology Co., Ltd (HT)
▪ Viet Trung Machinery Technology Co., Ltd (VT)
▪ Some current models of coconut Pressing machines
Figure 1.4 Coconut splitting machine by Tan Phat Company
- Easy access: Coconut Pressing machines in Vietnam are easy to access and manufacture, readily available for purchase in the Vietnamese market, making it convenient for shopping and maintenance
- Affordable price: Since they can be produced domestically and are easy to manufacture, the price is suitable for local businesses
- Easy to use: Currently, most coconut Pressing machines in the country are mainly manual and not overly complex to manufacture, making them very easy to use and ready for immediate operation without requiring much time
- Low reliability: Domestically produced machines and tools may not meet certain high-quality standards etc
- Low durability and difficult maintenance: Most domestically produced coconut-pressing machines are made using manual production methods, so when they break down, they are almost unusable due to the difficulty of finding replacement materials or maintenance services
Lack of variety: Despite the large coconut market, industrial machines in Vietnam still lag in technology compared to international markets
2.2 Types of coconut Pressing machines from abroad.:
With foreign technology, the manufacturing technology of coconut- pressing machines from abroad is quite diverse and has several advantages over domestic machines
Some foreign factories producing coconut Pressing and processing machines:
• Zhengzhou Hento Machinery Co., Ltd (China)
• Guangzhou Shengtian Machinery Co., Ltd (China)
• Cocoman – Coconut Machines Manufacturer & Exporter (Malaysia)
Figure 1.6 Young Coconut Cutting Figure 1.7 High Efficiency Machine COM92H (Cocoman) Coconut Cutter (Hento)
- High reliability: Coconut pressing machines manufactured abroad are highly commercial, so they achieve high-quality standards
- High durability: Materials used to make the machine are made directly from abroad, so the machine casing and Pressing knife have high durability, besides, the mechanisms are assembled according to standards so they are smoother
- Diversity: The types of coconut processing and Pressing machines are more diverse than domestic machines
- Difficult to access: Because the product is from abroad, it sometimes causes difficulties in the purchasing and shipping process
- High price: Besides having to buy the machine at foreign prices, shipping costs and taxes are also quite high
- Difficult to use: Switch buttons as well as instructions for use are in a foreign language so it may be difficult for users to get the most out of the machine.
Research Objectives
- Propose and calculate technical parameters, Pressing tool force, coconut clamping force, and chain length
- Manufacturing coconut Pressing machine and coconut water filter.
Research Approach
- Currently, Pressing coconuts by machine in our country is still not too popular because most people use knives or manual tools to chop coconuts
- However, with manual Pressing of coconuts like this, we can only produce with very low productivity compared to market demand, leading to production steps such as coconut water, coconut meat, or coconut oil is reduced accordingly
- The current popular way to crack and extract coconut water manually today is: Using a cleaver to split the coconut
4.1 Manual methods of Pressing coconuts
Manual Pressing of coconuts is now very popular, most people cut coconuts using a machete to separate coconuts The cut is not straight and unsightly The coconut meat inside the coconut can be damaged or worse, cut into pieces This method is usually only used for manual workshops, is labor intensive and the output is not too high
Coconut Pressing cleavers are usually designed to be large, thick, and quite heavy That causes fatigue for workers, leading to low productivity This method is used for small and medium-sized factories
4.2 Principle of cutti coconut with a Pressing machine
Figure 1.8 Principle diagram of a coconut Pressing machine
The operating principle of the coconut-pressing machine is carried out through the following steps:
The user places the Coconut in the Coconut jigsaw (5) of the machine The user adjusts the system to ensure the coconut is held tightly and securely without being misaligned or moving too much
Start the machine, at this time the electric motor (2) is started and begins transmitting force from the transmission to the Pressing tool (3)
The Pressing tool (3) begins to move, moving in a top-down trajectory according to the machine's design The strong Pressing force from the tool will cut through the hard shell and core of the coconut
After separating the coconut shell The coconut water will flow down the drain to the coconut water tank mounted on the machine case
After completing the Pressing process, press the control button (6) to stop the machine The user will take the coconut shell out of the machine, leaving that part for other processes
From the way the machine operates, we can see that the above coconut-Pressing machine has the following characteristics:
- There are many manual operations such as holding the coconut with your right hand during the Pressing process
- The user must remove the coconut shell by hand after Pressing
4.3 Related to the graduation thesis
Currently, coconut Pressing machines have quite cheap market prices compared to the general market The following are the prices of coconut Pressing machines of some foreign brands
Guangzhou Kaineng Electric Equipment (ranging from 2250 USA) Henan Jinfuda Trading Co., Ltd ( ranging from 290 USA)
Shandong Boxing Bohong Machinery Equipment Co., Ltd (ranging from
With the above economic price range, we can see the possibility of creating a coconut-attaching machine with a coconut longitudinal diameter of 12 to 15 cm
Not only that, we have an advantage in improving the weaknesses of current coconut Pressing machines.
The urgency of the topic
For many industries, especially food processing, cosmetics, etc Coconut Pressing machines play a particularly important role, bringing benefits to the mentioned industries Below are some specific examples:
+ Food and beverage processing industry: Production of coconut water and coconut milk: Coconut Pressing machine helps peel and process coconut meat quickly Processing of coconut products such as desiccated coconut, coconut candy, cookies…
+ Cosmetics and personal care industry: The coconut Pressing machine helps peel and process the coconut meat quickly, helping to increase the efficiency of coconut oil extraction most productively, ensuring high-quality coconut oil
+ Agricultural industry: Coconut shells and pulp can be used as organic, environmentally friendly fertilizers Besides, coconut provides a large amount of nutrition and can be used as food for livestock
So with the above practical applications, we can see the importance of coconut Pressing machines, that necessity is shown through the following aspects:
+ Increase efficiency and save time: Coconut Pressing machines help increase productivity quickly, which is especially important for industries that need large output
+ Ensuring product quality and consistency: Using a coconut Pressing machine helps ensure that the coconut pieces are chopped evenly and uniformly, thereby ensuring the quality of the final product
+ Reduce labor costs: Helps reduce labor costs, can use money for other purposes, helping businesses increase profits
Therefore, designing and manufacturing domestic coconut-Pressing machines is very necessary This will help small businesses improve productivity, and product quality, save costs, and be more proactive with current flow-chasing technology
PRINCIPLE OF COCONUT PRESSING MACHINE
Pressing coconut principle
The basic principle of the coconut Pressing process is to use a blade to separate the surface of the coconut to extract water and remove residue in the coconut water
The main movement when Pressing coconut is translational in one direction When Pressing, the knife will be used by a cam structure attached to the knife through the moving shaft to separate the shell surface of the coconut
Figure 2.1 Simulation diagram of Pressing coconut principle
Structure of coconut Pressing machine
The 1-phase motor is the main engine to operate the coconut Pressing machine with capacity depending on the finished product output
+ Part 1: The stator is a stationary part of the motor, consisting of a core made of laminated steel plates with slots holding the stator coils (coils) These windings are arranged so that they form three separate circuits, each connected to one phase of the three-phase power supply
+ Part 2: The rotor is the rotating part of the engine There are two main types of rotors:
- Squirrel cage rotor: Made of conductive bars that are short-circuited by the end rings, forming a cage-like structure
- Wound rotor: Contains windings similar to the stator, connected to slip rings and external resistors for control, etc
Advantages of three-phase motors:
- High efficiency: Three-phase motors have higher efficiency than single- phase motors due to continuous power transmission
- Better starting torque: They have higher starting torque and smoother acceleration
- Balanced operation: The rotating magnetic field is balanced and uniform, reducing vibrations and mechanical stress
- Durability and Reliability: Simple and sturdy design makes them more reliable and easier to maintain
The primary moving component consists of interlinked chain links that form a continuous loop The chains are typically made of metal and designed to be durable and strong, and
Figure 2.3 Conveyor chain Advantages of Chain Conveyors
+ Durability: Chain conveyors are robust and can handle heavy loads and harsh operating conditions
+ Versatility: Suitable for a wide range of applications, including moving bulk materials, pallets, and other heavy items
+ Flexibility: Can be designed to move products horizontally, vertically, or on an incline
+ Reliability: Provide consistent and reliable operation with minimal maintenance
Depending on the shape, accuracy, and size of the machined part and the state of the workpiece, we use appropriate Knife forms
Figure 2.4 Pressing tool 2.4 Cam structure:
The cam mechanism is used to move the knife during Pressing by connecting directly to the knife shaft and the motor shaft
Figure 2.5 Slider crank arm mechanism
+ Precision: Can produce very precise and repeatable motion
+ Versatility: Can generate a wide variety of motion profiles with simple adjustments to the cam shape
+ Durability: When properly designed and maintained, cam mechanisms can be very durable and reliable, etc
An electric switch is a type of electrical device used to open and close an electrical circuit It is commonly used in industrial or residential electrical systems to control the flow of current through a circuit or portion of a circuit
Electric switches usually have two operating states: open and closed When in the closed state, the circuit breaker creates a continuous conductive path, allowing current to flow through the circuit When in the open state, the circuit breaker interrupts the circuit, cuts off the current, and prevents the flow of current
Electric switches are often designed to operate by rotating or moving a blade or some other part of the device, changing the position of the contacts to
Figure 2.6 Manual circuit breaker MCB LS BKN-b 20A 10kA 3P
16 circuit They can be controlled manually or through automatic or remote control systems
In electrical systems, electric switches are often used to cut off a circuit when maintenance or repairs need to be performed or to isolate a portion of a circuit when necessary This helps protect equipment and users from the risk of overload or other problems that may occur in the electrical circuit
- Some locations for installing circuit breakers:
+ On the main conductor of the electrical system
+ Connection position between parts of the circuit
+ In the control box or electrical cabinet
An emergency stop button is a device in a control system or industrial equipment, designed to immediately stop the operation of a machine or production process when a dangerous situation occurs or a sudden stop is required quickly The main function of the emergency stop button is to protect the safety of workers and equipment
When the emergency stop button is pressed, it will send an immediate signal to the control system of the machine or production process, the running machine will stop operating immediately This helps prevent dangerous situations and minimizes the risk of accidents
Emergency stop buttons are usually red for easy recognition and located in convenient locations for the operator to easily access in an emergency They
17 open or closed, can be installed on machines, production lines, or in work areas to ensure the safety of everyone involved
TECHNICAL DESIGN
Input data
The dried coconuts were taken by authors from a coconut factory in Ben Tre and were peeled by the workers there Coconuts are harvested immediately upon picking and peeling and are inspected to ensure no damage, to ensure uniformity in size
The diameter of dried coconut usually ranges from 15 - 25 cm
The length of dried coconut usually ranges from 20 - 30 cm
Dried coconuts weigh from 0.5 - 1kg
Figure 3.1 Image of dried coconut used in a Pressing machine
2 Operating principle of a coconut Pressing machine
The principle of Pressing coconut is to use a Pressing tool with a specially designed slanted blade to cut the coconut better, moving by a CAM mechanism moving from top to bottom
Figure 3.2 Operating principle of a coconut Pressing machine
The coconut is placed on the fixture (3), and when the machine starts, the motor (1) begins to rotate, through the chain transmission (2) the conveyor belt
(4) also begins to move, and at the same time the motor (1) also makes the Pressing tool (8) move up and down using the CAM system (7) Coconuts will be separated at the intersection between the conveyor belt (4) and the Pressing tool (8)
After Pressing, the coconut water will flow down the funnel (5) leading to the coconut water tank (6), while the coconut shell will be transported off the conveyor belt (4) and used for other products
+ The machine does not take up much space
+ High pressing efficiency and safer than manual pressing
+ Initial costs are quite high compared to small businesses or households
-Total mass of product and parts: Q ≈ 50kg so we choose the equivalent traction force ≥ 500N, F = 700N
- Productivity: 1000 ÷ 1200 pcs/h ≈ 0,27 ÷ 0,33 pcs/s, the maximum number of products put on 1 meter of the chain is 7 pcs, we need 3 seconds to chop 1 product, so v = 0.3 m/s
- Required capacity of the working shaft:
F: conveyor chain traction V: velocity of chain conveyor
- Transmission performance: n = nx 4 nođ not = 0.97 4 ×0.995×0.99= 0.872 [2] nx: efficiency chain drives
21 nođ: efficiency bearing not: efficiency plain bearing
Based on table 5.5 in document (1)
And n sb =nct x u sbh x u sbx = 49.7*30*1= 1491 rpm [2] u = 𝑛𝑑𝑐
Figure 3.3 Performance values of different types of transmitters and drives [2]
Figure 3.4 Transmission ratio should be used for the transmissions in the system [2]
We choose Motor with moder VX15-003 Liming :0,5Kw , revolutions
Figure 3.5 Motor VX15-003 Liming specifications
Figure 3.6 Mechanical properties of SS400 steel
Fast moving shaft, small and medium load, we use a shaft with ss400 material
4.2 Determine the Torque (T) from the Motor:
The torque output from the motor is typically provided in Newton meters (Nm)
4.3 Calculate the Radius (r) of the Sprocket:
The sprocket’s pitch circle diameter D can be found using the formula for the pitch circle diameter of a sprocket:
19 ) (mm) [2] where p is the pitch 19.05 and 𝑁 is the number of teeth 19
𝑝 = 19.05 mm Calculate the D pitch circle diameter of a sprocket:
Calculate the radius 𝑟 as half of the sprocket:
2 = 57,85 mm You can calculate the torque using the following formula:
• 𝑇 is the torque in Newton meters (Nm)
• P is the power in watts (W)
• 𝑁 is the rotational speed in revolutions per minute (rpm)
The force exerted by the sprocket is calculated using the relationship between torque and force:
4.5 Calculate the Radius (r) of the Sprocket:
The sprocket’s pitch circle diameter (PCD) can be found using the formula for the pitch circle diameter of a sprocket:
D = 𝑃 sin( 180 19 ) [2] where p is the pitch (25.4 mm) and N is the number of teeth (19)
Convert the pitch to meters:
𝑝 = 19.05 mm Calculate the D pitch circle diameter of a sprock:
Calculate the radius 𝑟 as half of the D:
4.6 Determine the Torque (T) from the shaft working:
4.7 Calculate the Radius (r) of the Sprocket:
The sprocket’s pitch circle diameter (D) can be found using the formula for the pitch circle diameter of a sprocket:
19 ) [2] where 𝑝 is the pitch of 25.4 mm and 𝑁 is the number of teeth 19
Calculate the radius 𝑟 as half of the D:
The force exerted by the sprocket is calculated using the relationship between torque and force: 𝐹1= T r = 40352.1
We have: Ra + Rb = 175+721+721+721 = 2338 N The torsional moment at support A
Ra + 1098.7 = 2338 N , Ra = 1239.3 N Bending moment My at support shaft A :
Figure 3.7 Diagram of internal forces of the shaft
4.9 Calculate the moment of inertia of the front shaft when there is a keyway:
To calculate the bending moment of a shaft with diameter D 20d = 20 mm và 4 keyway, we will follow these steps:
D (outer diameter of shaft) = 20 mm
Figure 3.8 Diagram of jig for placing a dry coconut on a coconut Pressing machine b (width of keyway) = 6 mm t (depth of keyway) = 3.4 mm
The moment of inertia of a solid cylindrical shaft (without keyway) is calculated by the formula:
32 = 785,4 Since there are 4 keyways, the total bending-resisting moment will be:
5 Calculate the technical parameters of coconut jigs
This is a diagram of the coconut jigging equipment used to transport it to the pressing table and transfer the coconut shell out of the machine Two rubber roll bars (1) on both sides help clamp the coconut from moving to either side during Pressing and transportation, it is positioned with 2 degrees of freedom The rubber roll bar is installed with a power bar (2), and to be able to clamp the coconut, a spring (3) is used to form a lever mechanism, helping to increase the clamping force on the coconut
The most important part, as well as the part that bears almost all the force of pressing the coconut, is the coconut support table (4) with the shape of a 4- degree-of-freedom positioning funnel The coconut support table not only supports the coconut in the right position but also creates a reaction force to help increase the tightening force to be able to split the coconut To create more reaction force to help chop the coconut better, the PIN (5) will do that task In addition, it can also help compensate for the height from the support table (2) to the contact surface of the coconut
To be able to chop coconuts, the authors used a slider mechanism attached directly to the Pressing knife that moves up and down That's why
Figure 3.9 Force diagram of coconut pressing mechanism and Diagram of coconut pressing structure
30 we need to calculate the pressing force right at the moment the knife touches the coconut
To be able to calculate the tightening force, let the lever arm AB tilt at an angle of 400 as shown in Figure 3.5 Using a motor with nct 49,7 rpm
Choosing B as the extreme point we have the following equation:
Based on the clockwise rotation axis and the vector force properties, we can draw a force vector diagram as follows:
Using the principle of sinusoids in triangles we can calculate the magnitude of the vectors: 𝑉 ⃗ 𝐶 , 𝑉 ⃗ 𝐵𝐶 , 𝑉 ⃗ 𝐵
Based on the coconut pressing mechanism, we have the following acceleration diagram:
Figure 3.11 Pressure force acceleration diagram
At the point B, we have:
7 The tightening force required to hold the part:
Figure 3.12 The clamping mechanism holds the coconut for transportation and tightness
Fms1, Fms2: Sliding friction between the rubber pad and the coconut shell when chopped down
P: Pressing force when Pressing coconut
P1: The reaction force from the coconut pressing table acts on the coconut
During the pressing process, a pressing force P will be generated When acting on the support table, a reaction force P1 will be created
To process the detail, the force when Pressing must be: kP ≤ Fms1 + Fms2 + P1
P = P1 Fms1 = W1 f1 ( Ignore the mass of the coconut)
Fms1 = W1 f1 (Ignore the mass of the coconut) k = k0 + k1 + k2 + k3 + k4 + k5 k0 : General safety factor (k0 = 1.5) k1: The coefficient takes into account the state of the machined surface ( k1 = 1.2 ) k2: Factor that takes into account the increase in force due to pressing tool wear k3: Coefficient that accounts for the increase in pressing force
35 when machining on discontinuous surfaces (k3 = 1.2 −
1) k4: The coefficient accounts for the change in clamping force depending on the transmission mechanism k5: The coefficient refers to the rotation ability of the part Rewrite: kP ≤ W1 f1 + W2 f2 + P
Therefore, the force W1, and W2 at position A only needs to be greater than 0 and must be smaller than the force that deforms the part Avoid preventing the coconut shell from breaking into small pieces and falling off the support table
7.3 Clamping force of the structure
The clamp head uses the elastic force of the spring to keep the coconut during the Pressing process from flying and can also self-unlock so that the coconut shell falls out by inertia It is for the above reason that we assume clamping force W ≥ 472,74 N
Figure 3.14 Clamping force diagram of a jig using a spring combined with a lever mechanism
Because the coconut jig uses 2 springs on each side and uses a lever mechanism to hold the coconut during the Pressing process, from there we can get the following system of equations:
Flx1 + Flx2 + Flx3 + Flx4 = W = 23,2 N Assuming that:
When we consider only one side of the jig, we have the following system of equations:
2 = 5,8 N Considering the horizontal force we have:
2 Because the springs used in the jig are all of the same type and it is assumed that:
Based on the Misumi lookup table [9], we can choose the spring we are looking for as the heavy load pull spring OD3 - 10
Parameters of heavy load traction spring OD3 – 10:
So we can use OD3 - 10 springs to make coconut clamps It creates enough elastic force as proven to be able to grip coconuts
8 Electrical circuit diagram and principle diagram
The diagram shows a three-phase power supply (L1, L2, L3) along with a neutral wire and a protective earth wire (PE)
There are two main switches, each connected to different parts of the circuit These are safety or disconnect switches
The contactor coil (K) is used to control the main power source to the motor (M) When the coil is energized, the contactor closes, allowing current to flow through the motor
The motor (M) is connected to the contactor When the contactor operates, the motor will run
Thermal overload relay (RN) protects the motor from overheating It will open the circuit if the motor pulls too much current
Push buttons (START, STOP, EMG):
START button: Used to start the motor by energizing the contactor coil
STOP button: Used to stop the motor by disconnecting the contactor coil
EMG (Emergency Stop): Used to immediately stop the motor in an emergency
These are additional contacts on the contactor (K) that provide feedback or control other parts of the circuit They are denoted the same as contactors (K) but have different numbers (for example: 13, 14)
Indicator lights (ON, OFF, ALARM):
These lights indicate the status of the system
The ON light indicates the system is running
The OFF light indicates the system is not running
The ALARM light indicates an error or alarm condition
When the START button is pressed, the contactor coil (K) is energized, closing the contactor contacts and allowing current to flow through the motor (M), starting the motor
When the STOP button is pressed, the contactor coil (K) is de-energized, opening the contactor contacts and stopping the motor
A thermal overload relay (RN) will open the circuit if there is an overload condition to protect the motor
Indicator lights display engine and system status
When the motor is turned on, the drive shaft rotates and the chain moves We place the coconut on the fixture, the coconut reaches the place where the tool is and then presses it down, the tool moves thanks to the cam mechanism connected to the drive shaft
Figure 3.17 3D coconut water filter mesh
Figure 3.19 Coconut water filter mesh
Choose electric motor
-Total mass of product and parts: Q ≈ 50kg so we choose the equivalent traction force ≥ 500N, F = 700N
- Productivity: 1000 ÷ 1200 pcs/h ≈ 0,27 ÷ 0,33 pcs/s, the maximum number of products put on 1 meter of the chain is 7 pcs, we need 3 seconds to chop 1 product, so v = 0.3 m/s
- Required capacity of the working shaft:
F: conveyor chain traction V: velocity of chain conveyor
- Transmission performance: n = nx 4 nođ not = 0.97 4 ×0.995×0.99= 0.872 [2] nx: efficiency chain drives
21 nođ: efficiency bearing not: efficiency plain bearing
Based on table 5.5 in document (1)
And n sb =nct x u sbh x u sbx = 49.7*30*1= 1491 rpm [2] u = 𝑛𝑑𝑐
Figure 3.3 Performance values of different types of transmitters and drives [2]
Figure 3.4 Transmission ratio should be used for the transmissions in the system [2]
We choose Motor with moder VX15-003 Liming :0,5Kw , revolutions
Figure 3.5 Motor VX15-003 Liming specifications
Roughly calculate shaft diameter
Figure 3.6 Mechanical properties of SS400 steel
Fast moving shaft, small and medium load, we use a shaft with ss400 material
4.2 Determine the Torque (T) from the Motor:
The torque output from the motor is typically provided in Newton meters (Nm)
4.3 Calculate the Radius (r) of the Sprocket:
The sprocket’s pitch circle diameter D can be found using the formula for the pitch circle diameter of a sprocket:
19 ) (mm) [2] where p is the pitch 19.05 and 𝑁 is the number of teeth 19
𝑝 = 19.05 mm Calculate the D pitch circle diameter of a sprocket:
Calculate the radius 𝑟 as half of the sprocket:
2 = 57,85 mm You can calculate the torque using the following formula:
• 𝑇 is the torque in Newton meters (Nm)
• P is the power in watts (W)
• 𝑁 is the rotational speed in revolutions per minute (rpm)
The force exerted by the sprocket is calculated using the relationship between torque and force:
4.5 Calculate the Radius (r) of the Sprocket:
The sprocket’s pitch circle diameter (PCD) can be found using the formula for the pitch circle diameter of a sprocket:
D = 𝑃 sin( 180 19 ) [2] where p is the pitch (25.4 mm) and N is the number of teeth (19)
Convert the pitch to meters:
𝑝 = 19.05 mm Calculate the D pitch circle diameter of a sprock:
Calculate the radius 𝑟 as half of the D:
4.6 Determine the Torque (T) from the shaft working:
4.7 Calculate the Radius (r) of the Sprocket:
The sprocket’s pitch circle diameter (D) can be found using the formula for the pitch circle diameter of a sprocket:
19 ) [2] where 𝑝 is the pitch of 25.4 mm and 𝑁 is the number of teeth 19
Calculate the radius 𝑟 as half of the D:
The force exerted by the sprocket is calculated using the relationship between torque and force: 𝐹1= T r = 40352.1
We have: Ra + Rb = 175+721+721+721 = 2338 N The torsional moment at support A
Ra + 1098.7 = 2338 N , Ra = 1239.3 N Bending moment My at support shaft A :
Figure 3.7 Diagram of internal forces of the shaft
4.9 Calculate the moment of inertia of the front shaft when there is a keyway:
To calculate the bending moment of a shaft with diameter D 20d = 20 mm và 4 keyway, we will follow these steps:
D (outer diameter of shaft) = 20 mm
Figure 3.8 Diagram of jig for placing a dry coconut on a coconut Pressing machine b (width of keyway) = 6 mm t (depth of keyway) = 3.4 mm
The moment of inertia of a solid cylindrical shaft (without keyway) is calculated by the formula:
32 = 785,4 Since there are 4 keyways, the total bending-resisting moment will be:
5 Calculate the technical parameters of coconut jigs
This is a diagram of the coconut jigging equipment used to transport it to the pressing table and transfer the coconut shell out of the machine Two rubber roll bars (1) on both sides help clamp the coconut from moving to either side during Pressing and transportation, it is positioned with 2 degrees of freedom The rubber roll bar is installed with a power bar (2), and to be able to clamp the coconut, a spring (3) is used to form a lever mechanism, helping to increase the clamping force on the coconut
The most important part, as well as the part that bears almost all the force of pressing the coconut, is the coconut support table (4) with the shape of a 4- degree-of-freedom positioning funnel The coconut support table not only supports the coconut in the right position but also creates a reaction force to help increase the tightening force to be able to split the coconut To create more reaction force to help chop the coconut better, the PIN (5) will do that task In addition, it can also help compensate for the height from the support table (2) to the contact surface of the coconut
To be able to chop coconuts, the authors used a slider mechanism attached directly to the Pressing knife that moves up and down That's why
Figure 3.9 Force diagram of coconut pressing mechanism and Diagram of coconut pressing structure
30 we need to calculate the pressing force right at the moment the knife touches the coconut
To be able to calculate the tightening force, let the lever arm AB tilt at an angle of 400 as shown in Figure 3.5 Using a motor with nct 49,7 rpm
Choosing B as the extreme point we have the following equation:
Based on the clockwise rotation axis and the vector force properties, we can draw a force vector diagram as follows:
Using the principle of sinusoids in triangles we can calculate the magnitude of the vectors: 𝑉 ⃗ 𝐶 , 𝑉 ⃗ 𝐵𝐶 , 𝑉 ⃗ 𝐵
Based on the coconut pressing mechanism, we have the following acceleration diagram:
Figure 3.11 Pressure force acceleration diagram
At the point B, we have:
7 The tightening force required to hold the part:
Figure 3.12 The clamping mechanism holds the coconut for transportation and tightness
Fms1, Fms2: Sliding friction between the rubber pad and the coconut shell when chopped down
P: Pressing force when Pressing coconut
P1: The reaction force from the coconut pressing table acts on the coconut
During the pressing process, a pressing force P will be generated When acting on the support table, a reaction force P1 will be created
To process the detail, the force when Pressing must be: kP ≤ Fms1 + Fms2 + P1
P = P1 Fms1 = W1 f1 ( Ignore the mass of the coconut)
Fms1 = W1 f1 (Ignore the mass of the coconut) k = k0 + k1 + k2 + k3 + k4 + k5 k0 : General safety factor (k0 = 1.5) k1: The coefficient takes into account the state of the machined surface ( k1 = 1.2 ) k2: Factor that takes into account the increase in force due to pressing tool wear k3: Coefficient that accounts for the increase in pressing force
35 when machining on discontinuous surfaces (k3 = 1.2 −
1) k4: The coefficient accounts for the change in clamping force depending on the transmission mechanism k5: The coefficient refers to the rotation ability of the part Rewrite: kP ≤ W1 f1 + W2 f2 + P
Therefore, the force W1, and W2 at position A only needs to be greater than 0 and must be smaller than the force that deforms the part Avoid preventing the coconut shell from breaking into small pieces and falling off the support table
7.3 Clamping force of the structure
The clamp head uses the elastic force of the spring to keep the coconut during the Pressing process from flying and can also self-unlock so that the coconut shell falls out by inertia It is for the above reason that we assume clamping force W ≥ 472,74 N
Figure 3.14 Clamping force diagram of a jig using a spring combined with a lever mechanism
Because the coconut jig uses 2 springs on each side and uses a lever mechanism to hold the coconut during the Pressing process, from there we can get the following system of equations:
Flx1 + Flx2 + Flx3 + Flx4 = W = 23,2 N Assuming that:
When we consider only one side of the jig, we have the following system of equations:
2 = 5,8 N Considering the horizontal force we have:
2 Because the springs used in the jig are all of the same type and it is assumed that:
Based on the Misumi lookup table [9], we can choose the spring we are looking for as the heavy load pull spring OD3 - 10
Parameters of heavy load traction spring OD3 – 10:
So we can use OD3 - 10 springs to make coconut clamps It creates enough elastic force as proven to be able to grip coconuts
8 Electrical circuit diagram and principle diagram
The diagram shows a three-phase power supply (L1, L2, L3) along with a neutral wire and a protective earth wire (PE)
There are two main switches, each connected to different parts of the circuit These are safety or disconnect switches
The contactor coil (K) is used to control the main power source to the motor (M) When the coil is energized, the contactor closes, allowing current to flow through the motor
The motor (M) is connected to the contactor When the contactor operates, the motor will run
Thermal overload relay (RN) protects the motor from overheating It will open the circuit if the motor pulls too much current
Push buttons (START, STOP, EMG):
START button: Used to start the motor by energizing the contactor coil
STOP button: Used to stop the motor by disconnecting the contactor coil
EMG (Emergency Stop): Used to immediately stop the motor in an emergency
These are additional contacts on the contactor (K) that provide feedback or control other parts of the circuit They are denoted the same as contactors (K) but have different numbers (for example: 13, 14)
Indicator lights (ON, OFF, ALARM):
These lights indicate the status of the system
The ON light indicates the system is running
The OFF light indicates the system is not running
The ALARM light indicates an error or alarm condition
When the START button is pressed, the contactor coil (K) is energized, closing the contactor contacts and allowing current to flow through the motor (M), starting the motor
When the STOP button is pressed, the contactor coil (K) is de-energized, opening the contactor contacts and stopping the motor
A thermal overload relay (RN) will open the circuit if there is an overload condition to protect the motor
Indicator lights display engine and system status
When the motor is turned on, the drive shaft rotates and the chain moves We place the coconut on the fixture, the coconut reaches the place where the tool is and then presses it down, the tool moves thanks to the cam mechanism connected to the drive shaft
Figure 3.17 3D coconut water filter mesh
Figure 3.19 Coconut water filter mesh
Calculate the pressing force
To be able to chop coconuts, the authors used a slider mechanism attached directly to the Pressing knife that moves up and down That's why
Figure 3.9 Force diagram of coconut pressing mechanism and Diagram of coconut pressing structure
30 we need to calculate the pressing force right at the moment the knife touches the coconut
To be able to calculate the tightening force, let the lever arm AB tilt at an angle of 400 as shown in Figure 3.5 Using a motor with nct 49,7 rpm
Choosing B as the extreme point we have the following equation:
Based on the clockwise rotation axis and the vector force properties, we can draw a force vector diagram as follows:
Using the principle of sinusoids in triangles we can calculate the magnitude of the vectors: 𝑉 ⃗ 𝐶 , 𝑉 ⃗ 𝐵𝐶 , 𝑉 ⃗ 𝐵
Based on the coconut pressing mechanism, we have the following acceleration diagram:
Figure 3.11 Pressure force acceleration diagram
At the point B, we have:
The tightening force required to hold the part
Figure 3.12 The clamping mechanism holds the coconut for transportation and tightness
Fms1, Fms2: Sliding friction between the rubber pad and the coconut shell when chopped down
P: Pressing force when Pressing coconut
P1: The reaction force from the coconut pressing table acts on the coconut
During the pressing process, a pressing force P will be generated When acting on the support table, a reaction force P1 will be created
To process the detail, the force when Pressing must be: kP ≤ Fms1 + Fms2 + P1
P = P1 Fms1 = W1 f1 ( Ignore the mass of the coconut)
Fms1 = W1 f1 (Ignore the mass of the coconut) k = k0 + k1 + k2 + k3 + k4 + k5 k0 : General safety factor (k0 = 1.5) k1: The coefficient takes into account the state of the machined surface ( k1 = 1.2 ) k2: Factor that takes into account the increase in force due to pressing tool wear k3: Coefficient that accounts for the increase in pressing force
35 when machining on discontinuous surfaces (k3 = 1.2 −
1) k4: The coefficient accounts for the change in clamping force depending on the transmission mechanism k5: The coefficient refers to the rotation ability of the part Rewrite: kP ≤ W1 f1 + W2 f2 + P
Therefore, the force W1, and W2 at position A only needs to be greater than 0 and must be smaller than the force that deforms the part Avoid preventing the coconut shell from breaking into small pieces and falling off the support table
7.3 Clamping force of the structure
The clamp head uses the elastic force of the spring to keep the coconut during the Pressing process from flying and can also self-unlock so that the coconut shell falls out by inertia It is for the above reason that we assume clamping force W ≥ 472,74 N
Figure 3.14 Clamping force diagram of a jig using a spring combined with a lever mechanism
Because the coconut jig uses 2 springs on each side and uses a lever mechanism to hold the coconut during the Pressing process, from there we can get the following system of equations:
Flx1 + Flx2 + Flx3 + Flx4 = W = 23,2 N Assuming that:
When we consider only one side of the jig, we have the following system of equations:
2 = 5,8 N Considering the horizontal force we have:
2 Because the springs used in the jig are all of the same type and it is assumed that:
Based on the Misumi lookup table [9], we can choose the spring we are looking for as the heavy load pull spring OD3 - 10
Parameters of heavy load traction spring OD3 – 10:
So we can use OD3 - 10 springs to make coconut clamps It creates enough elastic force as proven to be able to grip coconuts.
Electrical circuit diagram and principle diagram
The diagram shows a three-phase power supply (L1, L2, L3) along with a neutral wire and a protective earth wire (PE)
There are two main switches, each connected to different parts of the circuit These are safety or disconnect switches
The contactor coil (K) is used to control the main power source to the motor (M) When the coil is energized, the contactor closes, allowing current to flow through the motor
The motor (M) is connected to the contactor When the contactor operates, the motor will run
Thermal overload relay (RN) protects the motor from overheating It will open the circuit if the motor pulls too much current
Push buttons (START, STOP, EMG):
START button: Used to start the motor by energizing the contactor coil
STOP button: Used to stop the motor by disconnecting the contactor coil
EMG (Emergency Stop): Used to immediately stop the motor in an emergency
These are additional contacts on the contactor (K) that provide feedback or control other parts of the circuit They are denoted the same as contactors (K) but have different numbers (for example: 13, 14)
Indicator lights (ON, OFF, ALARM):
These lights indicate the status of the system
The ON light indicates the system is running
The OFF light indicates the system is not running
The ALARM light indicates an error or alarm condition
When the START button is pressed, the contactor coil (K) is energized, closing the contactor contacts and allowing current to flow through the motor (M), starting the motor
When the STOP button is pressed, the contactor coil (K) is de-energized, opening the contactor contacts and stopping the motor
A thermal overload relay (RN) will open the circuit if there is an overload condition to protect the motor
Indicator lights display engine and system status
When the motor is turned on, the drive shaft rotates and the chain moves We place the coconut on the fixture, the coconut reaches the place where the tool is and then presses it down, the tool moves thanks to the cam mechanism connected to the drive shaft
Figure 3.17 3D coconut water filter mesh
Figure 3.19 Coconut water filter mesh
DESIGN OF THE CHAIN CONVEYOR AND SHAFT
Calculating and choosing the number of teeth of the sprocket
We choose the number of teeth of the sprocket drive: z 1 = 29 - 2u ≥ 19
We choose the number of teeth of the sprocket driven: z 2 = u z1 =
Pitch of chains
Calculating and choosing the chain driven:
The capacity of a motor is 0.83 kW so we selected the pitch of chains as 19.05 and revolutions no1 = 50 Based on table 5.5 [2]
K= K0×Ka×Kdc×Kbt×Kđ×Klv
Ka: Center distance and chain length factor
Kdc: Adjust chain tension factor
Klv: Rating factor kz = z01/z1 %/27 = 0.93 kn = n01/n1P/49.7 = 1
Velocity ratio of the chain drives
The velocity ratio of a chain drive is given by
27 = 49.7 rpm where N1 = Speed of rotation of smaller sprocket in rpm,
N2 = Speed of rotation of larger sprocket in rpm.,
T1 = Number of teeth on the smaller sprocket, and
T2 = Number of teeth on the larger sprocket
The average velocity of the chain is given by v = 𝑇×𝑝×𝑁
60000 = 0,4 m/s [2] where T: teeth of the sprocket
N: The revolution speed of the sprocket p: Pitch of the chain
Center shaft distance and number of chain links
The minimum center distance between the smaller and larger sprockets should be 30 amin = (30÷50)p = (30÷50) x 19.05 = 571,5 ÷ 952,5 (mm)
To accommodate the initial sag in the chain, the value of the center distance is reduced by 2 to 5 mm by the formula:
We know that the number of chain links [2]
Center shaft distance and number of chain links
The minimum c distance between the smaller and larger sprockets should be 30 amin = (30÷50)p = (30÷50) x 19.05 = 571,5 ÷ 952,5 (mm) [2]
To accommodate the initial sag in the chain, the value of the center distance is reduced by 2 to 5 mm by the formula:
Figure 4.1 Allowable capacity [P] of roller chain [2]
We know that the number of chain links
Figure 4.2 Parameter of the roller chain [2]
6 Diameter of sprocket: d1 = p/sin(𝜋/𝑧 1 ) %.4/sin(𝜋/19)4.3 mm [2] z1 = z2 so: d1 = d2 = 154.3 mm da1 = p[0,5+cotg(𝜋/𝑧 1 )] 4,9 mm [2] da2 = 164.9 mm df1 = d1-2r = 167,97-2.6,03 = 155.9 mm, df25,9 mm
Figure 4.3 Table of roller chain step where: r= 0,5025d1 + 0,05=0,5025.15.88 + 0.05= 8.03, and d1.88 based on table 5.2 in [1]
SHAFT MACHINED Steel bill : D= ỉ22, Le4 mm , Materials: SS400
Work I: Turning face and flank:
Three-jaw chuck: Control 3 degrees of freedom
3 Clamping : Clamps tightly with a self-centering 3-jaw chuck
4 Chose machine: Board 9-38 handbook CNCTM 3 chose milling machine
Technical parameters of turning machine 1K62:
+ The largest diameter of the machined part: 400 +Distance between two centers: 710-1400
+ Wattage: 7.5kw + Number of spindle revolutions (rpm): 12,5-2000
5 Cutting tool: Combination center drill [5]
In there :Kv=Kmv.knv.Kuv=0.8 [6] knv=1
Spindle speed based on machine: n = 1500 (rpm)
L: Length of machined surface (mm)
L2: Tool exit length (0.5÷ 2)mm = 2 mm
S: Feed rate (mm/rev) n: revolutions
Step 1: Drilling center hole face
Spindle speed based on machine: n = 500 (rpm)
Work II: Turning flank and drill center hole
Trong đó :Kv=Kmv.knv.Kuv=0.8 knv=1
Spindle speed based on machine: n = 1500 (rpm)
L: Length of machined surface (mm)
L2: Tool exit length ( mm ) ( 1 ÷ 3)mm =2mm
S: Feed rate (mm/rev) n: revolutions
Step 1: Drilling center flank hole
Spindle speed based on machine: n = 500 (rpm)
Workpiece III: Turning ỉ22 down to ỉ20 :
Three-jaw chuck: Control 3 degrees of freedom
Tailstock center: Control 3 degrees of freedom
3 Clamping : Clamps tightly with a self-centering 3-jaw chuck
4 Chose machine: Same as work I
5 Cutting tool: Combination center drill [5]
• Cutting mode: Turning tool BK6 [5]
• Step 1: Rough turning ỉ22 down to ỉ21
Kv = Kmv.knv.Kuv=0.8 knv = 1
Spindle speed based on machine: n = 1800 (rpm)
L: Length of machined surface (mm)
L2: Tool exit length ( mm ) ( 0.5 ÷ 2)mm =2mm
S: Feed rate (mm/rev) n: revolutions
Kv = Kmv.knv.Kuv = 0.8 knv = 1
Spindle speed based on machine: n = 1500 (rpm)
L: Length of machined surface (mm)
L2: Tool exit length (mm) (0.5 ÷ 2)mm = 2 mm
Work I: Milling faces 1 and 2, length 45,5
2 Position: Limited to 5 of freedom
The static jaw of a vise: 2 of Freedom
3 Clamping : Clamp tightly with a vise’s moving jaws
5 Cutting tool: Face milling cutter with indexable inserts made of BK8 carbide
- Feed rate: SZ = 0,24 ( mm/tooth ) [6]
Feed per revoluton: S = S Z x Z = 0,24 x 12 = 2,8 ( mm / rev )
- Main adjustment factors k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness material k 5 = 1: adjustment factor dependent on the milling width
Computed speed: Vt = Vb.k1.k2.k3.k4.k5 = 158.1.0,8.0,8.1.1 = 101,1 (m/min)
- The calculated spindle speed is:
- We select the spindle speed according to the machine, n = 1000 (rpm )
Feed rate Sm = Sz x Z x n = 1080 (mm/ min) [6]
The following formula determines the basic time:
Where: L: length of the machined surface ( mm )
S: Feed per revolution ( mm/rev ) n: Revolutions or double strokes per minute
Length of the machined surface: L = 59 (mm) Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 5 (mm)
Feed per revolution: S = 2,88 (mm /rev)
The basic machining time is:
The operation time for this process is
Work II: Milling faces 1 and 2, to reach dimension 45mm
2 Position: Limited to 5 of freedom
Static jaw of a vise: 2 of Freedom
3 Clamping : Clamp tightly with a vise’s moving jaws
5 Cutting tool: Face milling cutter with indexable inserts made of BK8 carbide
- Feed rate: SZ = 0,24 ( mm/tooth ) [6]
Feed per revoluton: S = SZ x Z = 0,24 x 12 = 2,8 ( mm / rev ) [6]
Main adjustment factors k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness of the material k 5 = 1: adjustment factor dependent on the milling width
Computed speed: Vt = Vb.k1.k2.k3.k4.k5 = 158.1.0,8.0,8.1.1 = 101,1 (m/min) [6]
- The calculated spindle speed is:
We select the spindle speed according to the machine, n = 1000 ( rpm ) [6]
The following formula determines the basic time:
Where: L: length of the machined surface ( mm )
L2: Tool exit length ( mm ) S: Feed per revolution ( mm/rev ) n: Revolutions or double strokes per minute Have:
Length of the machined surface: L = 59 (mm)
Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 5 ( mm )
Feed per revolution: S = 2,88 (mm/rev)
The basic machining time is:
The operation time for this process is
Step 2: Reverse the workpiece and perform the same steps as in step 1
WORK III: Milling faces 5 and 6, to reach dimension 58.6 mm
2 Position: Limited to 5 of freedom
Static jaw of a vise: 2 of Freedom
3 Clamping : Clamp tightly with a vise’s moving jaws
5 Cutting tool: Face milling cutter with indexable inserts made of BK8 carbide
- Feed rate: SZ = 0,24 ( mm/tooth ) [6]
Feed per revoluton: S = SZ x Z = 0,24 x 12 = 2,8 (mm /rev)
Main adjustment factors k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness of the material k 5 = 1: adjustment factor dependent on the milling width
Computed speed: Vt = Vb.k1.k2.k3.k4.k5 = 158.1.0,8.0,8.1.1 = 101,1 (m/min) [6] The calculated spindle speed is:
We select the spindle speed according to the machine, n = 1200 (rpm)
The following formula determines the basic time:
𝑆 𝑛 Where: L: length of the machined surface (mm)
S: Feed per revolution (mm/rev) n: Revolutions or double strokes per minute
Length of the machined surface: L = 59 (mm)
Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 5 (mm)
Feed per revolution: S = 2,88 (mm/rev)
The basic machining time is:
2,88×1000 = 0.04 min [4] The operation time for this process is
Feed rate: SZ = 0,24 ( mm/tooth ) [6]
Feed per revoluton: S = SZ x Z = 0,24 x 12 = 2,8 (mm/rev)
12 Main adjustment factors: k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece
65 k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness of the material k 5 = 1: adjustment factor dependent on the milling width
Computed speed: Vt = Vb.k1.k2.k3.k4.k5 = 141.1.0,8.0,8.1.1 = 99,2 (m/min)
The calculated spindle speed is:
We select the spindle speed according to the machine, n = 1200 ( rpm )
The basic time is determined by the following formula:
Where: L: length of the machined surface ( mm )
S: Feed per revolution ( mm/rev ) n: Revolutions or double strokes per minute
Length of the machined surface: L = 41 (mm)
Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 5 (mm)
Feed per revolution: S = 2,88 (mm/rev)
The basic machining time is:
2,88×1200 = 0.03 min [4] The operation time for this process is
Step 2: Reverse the workpiece and perform the same steps as in step 1
Adjustment factor dependent on hardness of material: k1 = 1
Adjustment factor dependent on the surface condition of the workpiece: k2 = 0,8 Adjustment factor dependent on tool life: k3 = 1,0 (Table 8-1)
𝜋.8 = 1011 (rev/min) Spindle tool machine: n = 800 (rev/min)
Total time with the formula:
Length of machined surface: L = 41 (mm)
3 + 2 = 6,2 (mm) Length of existing tool: L2 = 3 (mm)
Adjustment factor dependent on hardness of material: k1 = 1
Adjustment factor dependent on the surface condition of the workpiece: k2 = 0,8 Adjustment factor dependent on tool life: k3 = 1,0
Total time with the formula:
Length of machined surface: L = 41 (mm)
3 + 2 = 9 (mm) Length of existing tool: L2 = 3 (mm)
Adjustment factor dependent on hardness of material: k1 = 1
Adjustment factor dependent on the surface condition of the workpiece: k2 = 0,8
Adjustment factor dependent on tool life: k3 = 1,0
Spindle tool machine: n = 200 (rev/min)
Total time with the formula:
Length of machined surface: L = 41 (mm)
3 + 2 = 12,3 (mm) Length of existing tool: L2 = 3 (mm)
Feed rate: SZ = 0,1 ( mm/tooth ) [6]
Feed per revoluton: S = SZ x Z = 0,1 x 24 = 2,4 ( mm / rev ) [6]
24 Main adjustment factors k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness of the material k 5 = 1: adjustment factor dependent on the milling width
Cutting speed: Vt = Vb.k1.k2.k3.k4.k5 = 120.1.0,8.0,8.1.1 = 84,5 (m/min)
The calculated spindle speed is:
We select the spindle speed according to the machine, n = 800 ( rpm )
Feed rate Sm = Sz x Z x n = 1200 (mm/ min)
The following formula determines the basic time:
Where: L: length of the machined surface ( mm )
S: Feed per revolution ( mm/rev ) n: Revolutions or double strokes per minute
Length of the machined surface: L = 59 (mm)
Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 41 ( mm )
Feed per revolution: S = 2,88 (mm/rev)
The basic machining time is:
The operation time for this process is
Diameter of sprocket
d1 = p/sin(𝜋/𝑧 1 ) %.4/sin(𝜋/19)4.3 mm [2] z1 = z2 so: d1 = d2 = 154.3 mm da1 = p[0,5+cotg(𝜋/𝑧 1 )] 4,9 mm [2] da2 = 164.9 mm df1 = d1-2r = 167,97-2.6,03 = 155.9 mm, df25,9 mm
Figure 4.3 Table of roller chain step where: r= 0,5025d1 + 0,05=0,5025.15.88 + 0.05= 8.03, and d1.88 based on table 5.2 in [1]
SHAFT MACHINED Steel bill : D= ỉ22, Le4 mm , Materials: SS400
Work I: Turning face and flank:
Three-jaw chuck: Control 3 degrees of freedom
3 Clamping : Clamps tightly with a self-centering 3-jaw chuck
4 Chose machine: Board 9-38 handbook CNCTM 3 chose milling machine
Technical parameters of turning machine 1K62:
+ The largest diameter of the machined part: 400 +Distance between two centers: 710-1400
+ Wattage: 7.5kw + Number of spindle revolutions (rpm): 12,5-2000
5 Cutting tool: Combination center drill [5]
In there :Kv=Kmv.knv.Kuv=0.8 [6] knv=1
Spindle speed based on machine: n = 1500 (rpm)
L: Length of machined surface (mm)
L2: Tool exit length (0.5÷ 2)mm = 2 mm
S: Feed rate (mm/rev) n: revolutions
Step 1: Drilling center hole face
Spindle speed based on machine: n = 500 (rpm)
Work II: Turning flank and drill center hole
Trong đó :Kv=Kmv.knv.Kuv=0.8 knv=1
Spindle speed based on machine: n = 1500 (rpm)
L: Length of machined surface (mm)
L2: Tool exit length ( mm ) ( 1 ÷ 3)mm =2mm
S: Feed rate (mm/rev) n: revolutions
Step 1: Drilling center flank hole
Spindle speed based on machine: n = 500 (rpm)
Workpiece III: Turning ỉ22 down to ỉ20 :
Three-jaw chuck: Control 3 degrees of freedom
Tailstock center: Control 3 degrees of freedom
3 Clamping : Clamps tightly with a self-centering 3-jaw chuck
4 Chose machine: Same as work I
5 Cutting tool: Combination center drill [5]
• Cutting mode: Turning tool BK6 [5]
• Step 1: Rough turning ỉ22 down to ỉ21
Kv = Kmv.knv.Kuv=0.8 knv = 1
Spindle speed based on machine: n = 1800 (rpm)
L: Length of machined surface (mm)
L2: Tool exit length ( mm ) ( 0.5 ÷ 2)mm =2mm
S: Feed rate (mm/rev) n: revolutions
Kv = Kmv.knv.Kuv = 0.8 knv = 1
Spindle speed based on machine: n = 1500 (rpm)
L: Length of machined surface (mm)
L2: Tool exit length (mm) (0.5 ÷ 2)mm = 2 mm
Work I: Milling faces 1 and 2, length 45,5
2 Position: Limited to 5 of freedom
The static jaw of a vise: 2 of Freedom
3 Clamping : Clamp tightly with a vise’s moving jaws
5 Cutting tool: Face milling cutter with indexable inserts made of BK8 carbide
- Feed rate: SZ = 0,24 ( mm/tooth ) [6]
Feed per revoluton: S = S Z x Z = 0,24 x 12 = 2,8 ( mm / rev )
- Main adjustment factors k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness material k 5 = 1: adjustment factor dependent on the milling width
Computed speed: Vt = Vb.k1.k2.k3.k4.k5 = 158.1.0,8.0,8.1.1 = 101,1 (m/min)
- The calculated spindle speed is:
- We select the spindle speed according to the machine, n = 1000 (rpm )
Feed rate Sm = Sz x Z x n = 1080 (mm/ min) [6]
The following formula determines the basic time:
Where: L: length of the machined surface ( mm )
S: Feed per revolution ( mm/rev ) n: Revolutions or double strokes per minute
Length of the machined surface: L = 59 (mm) Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 5 (mm)
Feed per revolution: S = 2,88 (mm /rev)
The basic machining time is:
The operation time for this process is
Work II: Milling faces 1 and 2, to reach dimension 45mm
2 Position: Limited to 5 of freedom
Static jaw of a vise: 2 of Freedom
3 Clamping : Clamp tightly with a vise’s moving jaws
5 Cutting tool: Face milling cutter with indexable inserts made of BK8 carbide
- Feed rate: SZ = 0,24 ( mm/tooth ) [6]
Feed per revoluton: S = SZ x Z = 0,24 x 12 = 2,8 ( mm / rev ) [6]
Main adjustment factors k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness of the material k 5 = 1: adjustment factor dependent on the milling width
Computed speed: Vt = Vb.k1.k2.k3.k4.k5 = 158.1.0,8.0,8.1.1 = 101,1 (m/min) [6]
- The calculated spindle speed is:
We select the spindle speed according to the machine, n = 1000 ( rpm ) [6]
The following formula determines the basic time:
Where: L: length of the machined surface ( mm )
L2: Tool exit length ( mm ) S: Feed per revolution ( mm/rev ) n: Revolutions or double strokes per minute Have:
Length of the machined surface: L = 59 (mm)
Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 5 ( mm )
Feed per revolution: S = 2,88 (mm/rev)
The basic machining time is:
The operation time for this process is
Step 2: Reverse the workpiece and perform the same steps as in step 1
WORK III: Milling faces 5 and 6, to reach dimension 58.6 mm
2 Position: Limited to 5 of freedom
Static jaw of a vise: 2 of Freedom
3 Clamping : Clamp tightly with a vise’s moving jaws
5 Cutting tool: Face milling cutter with indexable inserts made of BK8 carbide
- Feed rate: SZ = 0,24 ( mm/tooth ) [6]
Feed per revoluton: S = SZ x Z = 0,24 x 12 = 2,8 (mm /rev)
Main adjustment factors k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness of the material k 5 = 1: adjustment factor dependent on the milling width
Computed speed: Vt = Vb.k1.k2.k3.k4.k5 = 158.1.0,8.0,8.1.1 = 101,1 (m/min) [6] The calculated spindle speed is:
We select the spindle speed according to the machine, n = 1200 (rpm)
The following formula determines the basic time:
𝑆 𝑛 Where: L: length of the machined surface (mm)
S: Feed per revolution (mm/rev) n: Revolutions or double strokes per minute
Length of the machined surface: L = 59 (mm)
Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 5 (mm)
Feed per revolution: S = 2,88 (mm/rev)
The basic machining time is:
2,88×1000 = 0.04 min [4] The operation time for this process is
Feed rate: SZ = 0,24 ( mm/tooth ) [6]
Feed per revoluton: S = SZ x Z = 0,24 x 12 = 2,8 (mm/rev)
12 Main adjustment factors: k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece
65 k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness of the material k 5 = 1: adjustment factor dependent on the milling width
Computed speed: Vt = Vb.k1.k2.k3.k4.k5 = 141.1.0,8.0,8.1.1 = 99,2 (m/min)
The calculated spindle speed is:
We select the spindle speed according to the machine, n = 1200 ( rpm )
The basic time is determined by the following formula:
Where: L: length of the machined surface ( mm )
S: Feed per revolution ( mm/rev ) n: Revolutions or double strokes per minute
Length of the machined surface: L = 41 (mm)
Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 5 (mm)
Feed per revolution: S = 2,88 (mm/rev)
The basic machining time is:
2,88×1200 = 0.03 min [4] The operation time for this process is
Step 2: Reverse the workpiece and perform the same steps as in step 1
Adjustment factor dependent on hardness of material: k1 = 1
Adjustment factor dependent on the surface condition of the workpiece: k2 = 0,8 Adjustment factor dependent on tool life: k3 = 1,0 (Table 8-1)
𝜋.8 = 1011 (rev/min) Spindle tool machine: n = 800 (rev/min)
Total time with the formula:
Length of machined surface: L = 41 (mm)
3 + 2 = 6,2 (mm) Length of existing tool: L2 = 3 (mm)
Adjustment factor dependent on hardness of material: k1 = 1
Adjustment factor dependent on the surface condition of the workpiece: k2 = 0,8 Adjustment factor dependent on tool life: k3 = 1,0
Total time with the formula:
Length of machined surface: L = 41 (mm)
3 + 2 = 9 (mm) Length of existing tool: L2 = 3 (mm)
Adjustment factor dependent on hardness of material: k1 = 1
Adjustment factor dependent on the surface condition of the workpiece: k2 = 0,8
Adjustment factor dependent on tool life: k3 = 1,0
Spindle tool machine: n = 200 (rev/min)
Total time with the formula:
Length of machined surface: L = 41 (mm)
3 + 2 = 12,3 (mm) Length of existing tool: L2 = 3 (mm)
Feed rate: SZ = 0,1 ( mm/tooth ) [6]
Feed per revoluton: S = SZ x Z = 0,1 x 24 = 2,4 ( mm / rev ) [6]
24 Main adjustment factors k 1 = 1: adjustment factor dependent on tool life k 2 = 0,8: adjustment factor dependent on the surface condition of the workpiece k 3 = 0,8: adjustment factor dependent on the grade of the carbide tool k 4 = 1: adjustment factor dependent on the hardness of the material k 5 = 1: adjustment factor dependent on the milling width
Cutting speed: Vt = Vb.k1.k2.k3.k4.k5 = 120.1.0,8.0,8.1.1 = 84,5 (m/min)
The calculated spindle speed is:
We select the spindle speed according to the machine, n = 800 ( rpm )
Feed rate Sm = Sz x Z x n = 1200 (mm/ min)
The following formula determines the basic time:
Where: L: length of the machined surface ( mm )
S: Feed per revolution ( mm/rev ) n: Revolutions or double strokes per minute
Length of the machined surface: L = 59 (mm)
Since this is the first step of the face milling operation, the feed length is:
L1 = √0,5(60 − 0,5) + 2 (mm) = 7.5 mm Tool exit length: L2 = 41 ( mm )
Feed per revolution: S = 2,88 (mm/rev)
The basic machining time is:
The operation time for this process is
DESIGN OF THE PRESSING TOOL COMPONENT
Design of the pressing tool component
The factors for choosing the material, size, and shape of the pressing tool are :
- The largest diameter of the coconut is 12 – 15 cm
The feed speed is operated according to the slider crank mechanism so that when pressing, the rotation force from the motor is used to achieve the desired tightening force To achieve stability during the Pressing process, we need to choose a material with hardness and impact resistance that is good enough to overcome the hardness of the coconut shell
Also for the above reason, we chose the pressing tool material SKD11 Mechanical properties of SKD11 steel:
+ Has very good tensile strength
+ After heat treatment, it can reach a hardness of 58 - 60 HRC
Based on the size of the coconut jigsaw, especially the size of the coconut jigsaw table with a length of 413 mm and a width of 100 mm, with a load-bearing thickness of 3 mm, we have designed a Pressing knife with the same shape and size optimization in the Pressing process
We used Inventor software to design the pressing tool:
Fig 5.1 Preliminary geometry of coconut Pressing tool
The main external force acting on the Pressing knife is the reaction force from the coconut shell as well as the pulling force in the vertical direction through the motor To ensure that the tool can cut coconut shells, we designed the knife to be rectangular
The pressing tool edge tilt design of 100 0 will help the Pressing process go more smoothly because the contact area is reduced
Because the coconut pressing tool is designed and processed specifically for coconut Pressing machines to chop coconuts smoothly, for that reason, the pressing tool’s handle must also be specifically designed to meet the needs of the coconut Pressing machine to meet the conditions to cut tool movement
Fig 5.2 Design drawing of the pressing tool
If using the existing pressing tool’s handle handles, likely, they will likely not be able to withstand the load of the Pressing knife, leading to the Pressing process possibly getting stuck and not having enough force to split the coconut in half Or if the jig doesn't have enough holding power, the Pressing tool can create too much force, causing the coconut to fly out of the jig, or even break the coconut
Based on the intended use of the pressing force we create as well as the convenience of processing and installation The purpose is to help the pressing process go smoothly
The supported parts we have designed for pressing tool holders include the guide shaft, Fixing tool, and Holding pad pressing tool
Because the distance from the trough on both sides is 303mm and the height of the coconut cutter is 75mm Therefore, the guide shaft needs to have enough length to create a large enough stroke to help create a large tightening force when the working shaft rotates
To be able to connect the guide shaft with the tool pressing fix, we have designed a clamping part with 2 main components including 1 hole with a diameter of 32.2 mm to be able to connect with the guide shaft, the rest is a 5 mm open groove that can be connected to the pressing tool holder pad
Thanks to this detail, we can convert from rotation of the motor to translational vertical motion
After reviewing and using the software design, we begin to process and create mounting details
Name part Products of machine part
Calculating the frame machine design
The distance between the driving shaft and the driven shaft is 836,5 mm The size of the Pressing table is 413,5 x 100 x 3 mm
+ The largest diameter of a coconut is 12 - 15 cm
The height of the coconut Pressing knife is 750 mm with a stroke large enough to create enough force to split the coconut Besides, it needs to have enough height to be able to place the motor to drive the line through the crank system slider to create pressing force
From the distance of the two driving and driven axes, we can take that as a basis to determine the length of the frame
We use Inventor software to design the frame:
Fig 5.5 Preliminary geometry of the frame pressing
The main force acting on the frame wall is the pressing force of the knife When the tool press into the coconut, thanks to the coconut frame, a counter- force is created that acts on the coconut The frame is made up of 2 parts: the upper part is to hang the chain and coconut poles, and the lower leg is used to bear the load of the upper frame, helping to disperse the force to the four supporting legs
We choose SS400 as the material to make the frame for the coconut Pressing machine SS400 is considered one of the popular types of steel and is widely used in several industries and construction today
With advantages such as high flexibility and easy shaping, low price, good technology, especially convenient for welding
SS400 steel material chemical composition parameters:
Table 5.1 Table of the chemical composition of SS400 steel
Parameter of physical properties of SS400 steel:
Thickness (mm) Flow limit (Mpa) Tensile strength (MPa) d ≤ 16 ≥ 245
Table 5.2 Table of physical properties of SS400 steel
Fig 5.6 Technical design frame drawing
To test the durability of the chassis, we use Inventor software The material selected to make the frame is SS400 With a Pressing force of 23,2 N, we set the force directions as follows:
Fig 5.7 Placing force on the frame
The results of the simulation:
After simulating the displacement and pressure of the frame using Inventor software, we can see that the 1.221 Mpa, this result is less than the Tensile stress of 400 – 510 Mpa So the machine frame is completely suitable to withstand the load during the coconut Pressing process because that stress is very small and almost does not affect the machine frame at all
The largest displacement is 0,00868 mm, which does not affect the chassis too much After conducting force simulation in a 3D environment, we begin machining and installing the machine frame
After ensuring the suitable frame after simulation testing and actual installation, we can proceed to install the coconut pressing tool set on the machine to complete the machine
Figure 5.11 Image of coconut pressure machine after being completed
CONCLUSION AND DEVELOPMENT DIRECTION
Conclusions
After 5 months of researching as well as designing and implementing the project "Design and research of coconut Pressing machine", the group has also achieved the initial goals set despite many difficulties during the project process also tried to complete the schedule set by the school The processes are carried out sequentially from the initial design ideas of the machine to the machine's assembly, in which the design and testing part is the most time-consuming part
As a result, the machine's performance, although it has a few shortcomings, does not affect it too much
During the process of working and implementing the project, what the team members learned was:
+ Know how to calculate the appropriate chain length in machine making
+ Understand that to be able to cut materials, sometimes hard material is not enough, you need to try other methods like mine to make it harder
+ Reapply the knowledge you have learned
+ Design and manufacture a coconut Pressing machine
+ Learn how to adjust the chain and sprockets
+ Improved ability to calculate the bearing capacity of the slider crank mechanism
+ Know the force distribution of the conveyor
+How to calculate the shaft +Application of cam mechanism + Have the opportunity to interact more with processing machines to create products
Although the machine is designed and manufactured with advantages such as being able to run at high capacity as well as having a certain rigidity, the machine also has a few limitations:
+ Because this is an R&D product, the outer cover does not look professional
+ There is no integration of automatic programs, only basic operations such as running and stopping can be performed through buttons
+ Because I don't have much experience designing the casing of the chain transmission, it's a bit unimaginative
+ During long-term work, noise may be generated due to a lack of understanding about chain tension when moving
The topic " Design, manufacturing coconut Pressing machine” is a potential topic with very high applicability in life This is an opportunity to approach and improve learning to apply the knowledge learned." In addition, this is also an opportunity to work with high pressure and maximum concentration, not only in terms of working attitude but also in terms of professional working ability the time is limited and the experience of the group members is not too much, so shortcomings cannot be avoided, so we hope that the teachers can sympathize and give opinions to be able to contribute to the machine can become more perfect.
Development direction
To catch up or exceed current productivity, as possible, the team also has solutions in version 2.0 to be more secure, the team needs to change the technology and automation settings on the machine chop coconut:
+ Equipped with equipment that can supply coconuts automatically
+ Improved coconut water path into the tank
+ Increase the length of the conveyor belt to ensure a safe length when feeding coconuts into the machine
+ Install an additional safety sensor system when hands or body parts accidentally come into close contact with tight areas
+ Rework the electrical box to be more compact
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