STIRLING ENGINE KITCHEN SMOKE REMOVER MACHINE COMPONENT DESIGN BMCD3523

STIRLING ENGINE KITCHEN SMOKE REMOVER

FAKHRURAZI BIN AZIZ B040910051 HALIMATON BASMATU BINTI ALI B040910081 MOHD AZARUL SYAZARI BIN CHE AZIZ B040910167 MOHD IDHAM KHALID BIN ABU HASAN B040910094 NURUL NADIA BINTI ABDULLAH B040910227 SYED ZULKARNAIN BIN SYED SAIDIN B040910037

DUE DATE 1 JUNE 2012

LECTURE SHAFIZAL BIN MAT

Bachelor of Mechanical Engineering (Thermal-Fluid), Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka, Durian Tunggal, Melaka.

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STIRLING ENGINE KITCHEN SMOKE REMOVER List of Contents

List of Tables.....3 List of Figures............4 Abstract......5 Acknowledgement.6 Introduction.......7 Chapter 1 : Objective and Problem Statement 7-8 1.1. Objective.......7 1.2. Problem Statement...........8 Chapter 2 : Theory..8-12 Chapter 3 : Methodology..12-14 Chapter 4 : Conceptual design.15-19 4.1. Design 1...............................15 4.2. Design 2...............................16 4.3. Design 3..........................16-17 4.4. Weight Decision Matrix.......17-18 4.5. Pugh method.......................19 Chapter 5 : Detail design..19-26 Chapter 6 : Discussions and Design Analysis .....27-47 6.1. Analysis due to welding27-30 6.2. Analysis of shaft31-32 6.3. Bolt Analysis..32-35 6.4. Bearing analysis ...36-37 6.5. Bevel gear analysis38-40 6.6. Non-Permanent Joints. 40-45 6.7. Discussion..46-47 Chapter 7 : Conclusion...........................................47 References48

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STIRLING ENGINE KITCHEN SMOKE REMOVER List of Figures

Figure 1 Screw.........................................................................................................................10 Figure 2 strength of bolt.........................................................................................................11 Figure 3 Gear...........................................................................................................................12 Figure 4: Stirling Engine........................................................................................................12 Figure 5: Stirling Engine Parts..............................................................................................13 Figure 6: Parts involved in power generation......................................................................14 Figure 7: Electricity powered................................................................................................15 Figure 8 : Solar powered........................................................................................................16 Figure 9 : Stirling Engine powered.......................................................................................17 Figure 10 : Blade....................................................................................................................19 Figure 11 : Suction Tunnel.....................................................................................................20 Figure 12 : Gears and Shaft..................................................................................................20 Figure 13 : Bearing................................................................................................................21 Figure 14 : Stirling Engine.....................................................................................................21 Figure 15 : Stove including the stove cabinet.......................................................................22 Figure 16 : Final Rendering..................................................................................................22 Figure 17 : Engine Assembly.................................................................................................23 Figure 18 : Bill of Material....................................................................................................24 Figure 19 : 2D Drawing..........................................................................................................25 Figure 20 : 2D Drawing of Stove Assembly.........................................................................26 Figure 21 : welding part 1.....................................................................................................27 Figure 22 : Welding part 2....................................................................................................29 Figure 23 : shaft part..............................................................................................................31 Figure 24 : bolt part................................................................................................................32

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STIRLING ENGINE KITCHEN SMOKE REMOVER List of Tables

Table 1 : Table 11-2................................................................................................................36 Table 2 : Table 8-15................................................................................................................40 Table 3 : Table 8-11................................................................................................................41 Table 4 : table 8-1..................................................................................................................41 Table 5 : Table A-30...............................................................................................................42 Table 6 : Table 8-8..................................................................................................................44

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STIRLING ENGINE KITCHEN SMOKE REMOVER Abstract

In this project, stirling engine concept is being used for green technology aspect to run the blade. Why the Stirling Engine being choose? It is because the sustainable type of energy that has a lot more benefits than the conventional energy that uses electricity as the source. But the main objective in this project is to analysis each parts of mechanical component that being installed in this engine. The mechanism will be working by allowing compression and expansion of air or other gas at different temperature levels such that there is a net conversion of heat energy to mechanical work. Then the process will be transferred into mechanical part. All of the parameter will be calculated according to the aspects that have been given. Whether the dimension of the component is suitable for the system or not, is the factor safety is not below then one or not? And many more aspect have been consider to build this sisten

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STIRLING ENGINE KITCHEN SMOKE REMOVER Acknowledgement

We owe a great many thanks to a great many people who helped and supported us during the build this project, many thank to Sir. Shafizal Bin Mat who has given us a chance to prove that we can do things on our own. He gave a positive perspective in life and sharing his valuable time with giving us an information to finish this project. Although, the project is quit challenging, but we can finish it on time. We would have not finished this project without the support of our team mate whose has encouragement each other to keep going and struggle to ensure this project was success. And special gratitude to our classmate whose helped us in researching on different fields concerning this project and giving a fresh idea that help us a lot to complete this project.

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STIRLING ENGINE KITCHEN SMOKE REMOVER Introduction

Nowadays, green technology is something that no longer alien to our daily life. We can see how the scientist manipulated each type of energy to become new useful machinery that can save our environment. From the light energy that can convert into electrical energy by using solar panel, from the mechanical energy or also known as vibration energy also can convert into electrical energy by using Piezoelectric, also from the wind, see waves, and many more. But here we will focused on stirling engine that can convert onto mechanical energy. Stirling Engine is one of the reversible thermodynamic cycle application, they work based on compression and expansion cycling of air or other gas. They are also traditionally know as an external combustion engine. They are widely can found in industry application because of the high thermal efficiency, form a quiet and safe operation, ease of operation and able to working with any form of thermal energy. The most efficient type of sterling engine is the type that can handle the low temperature difference. Such as temperature between the hand palm and the ambient temperature. Advantage of applying this technology are, can operate with any type of heat source, it is last longer than reciprocating engine type and also having the simple engine mechanisms. it is also using the single-phase of working fluid that will reduce the explosion rate. lastly, they also a flexible technology. For the disadvantage, it need huge size of engine to supply large amount of power, and it will cost of a lot of money. Type of gas being used also need to be considered, the gas should have a low heat capacity to produced high pressure.

Chapter 1 : Objective and Problem statement

1.1. Objective

1.1.1. To design a kitchen smoke remover that uses sustainable energy as source of energy 1.1.2. To analysis each part of mechanical component 1.1.3. To apply the principles of mechanical component design in this project

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STIRLING ENGINE KITCHEN SMOKE REMOVER 1.2. Problem statement

Based on the conventional kitchen smoke remover that being use nowadays, it is using electricity as the source of energy to run the suction blade. It is not very environmental friendly because electricity is not one of the sustainable energy. Furthermore, consumers will be burdened with excessive electricity bills every month. Now, from what we can see the earth will not allowing us to stick to one source of energy, the available sources like coal, oil and other will diminish. And now we need to design a new technology that will use sustainable energy that easy to get in our daily life. It is our objective to change this type of energy to a more sustainable energy as the alternative to a more environmental friendly energy.

Chapter 2: Theory

An Exhaust Smoke system was used to remove smoke that produces by kitchen. This system was work based on stirling engine that placed on the kitchen. There are several part on the system had been analyze. A small machine components are joined together to form a larger machine part. The design of joint are important because it was critical part that ensure that the system were able act with the force react on the system. A week of joint may spoil a utility of the machine part. Bolt was one of nonpermanent joint where it was temporary of joining the materials. To ensure the joint that causing by bolt was safety, there was several analysis was done to know the factor safety, preload recommendation for the type of bolt, preload stress and stress the can be supported by the bolt. All the value of preload was used to calculate the load factor, yielding factor that can cause by the bolt, and also the load factor guarding against join separation. The analysis was depending on the type of material of bolt and also the type of bolt. A different type and material of bolt that used were giving a different value of safety factor. A mass of part that was used the nonpermanent joint was mostly effected the safety factor of the bolt were it was concern as force load that act on the joint. The total force that acts on the plate was divided by the amount of the bolt that used on the plate. The calculations of all the part of analysis on bolt are based on these equations.

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STIRLING ENGINE KITCHEN SMOKE REMOVER Torque necessary to achieve preload; T = K Fi d (1)

Load factor; nL = ( SP At Fi)/ C(Ptotal /N) (2)

Yielding factor safety; nP = ( SP At)/ [C(Ptotal /N) + Fi] (3)

Load factor guarding against join separation; no = Fi /[ (Ptotal /N)(1-C)] (4)

Welding was type of permanent joint where it cannot be dissemble without damaging the components. The part that was weld is used molecular force to joint the component. The permanent joints are preferred on the part that face with a high load and its was durability. Advantage of this type of joint are high load bearing capacity, better distribution of stresses through the material and also has higher yield strength of the combined structure. The two plate of metal was melt at the bottom by using high temperature where the aid of filler material a weld pool was created. The joint made permanent by reducing the work piece temperature to the room temperature. There were several type of weld such as Gas welding and also several type of joint such as butt joint, corner joint, edge joint, lap joint and also tee joint. To ensure the type of weld and joint are safe for the structure, there were analysis that used to calculate the factor safety of the weld. The depths of weld were the critical part in the welding design. The type of force that acts on the welding are based on bending or torsional force. Different types of weld were giving a different analysis. An equation that used on analyze the welding to find the factor safety are:

Primary shear = V/A (5)

Secondary shear bending = Mc/I (6)

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STIRLING ENGINE KITCHEN SMOKE REMOVER Total shear, = (2 + 2)1/2 (7)

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Factor safety Fs = Ssy/max (8)

Shaft is rotating member where it used to transmit power or motion. There was several type of material that used for shaft. The shaft rotates due to the transmitting power from the stirling engine that produce by the kitchen. The forces that involve are bending and torsional. The shaft was rotate due to torsional and bending. To find the maximum shearing stress that act on the shaft, equations below are used;

max =

(9)

Screw was also one of the types of non permanent joint. The helical-thread screw was undoubtably an extremely important mechanical invention. It was the basis of power screw, which change angular motion to linear motion to transmit power or develop large forces and threaded fastener. All the threads are made according to right-hand rule unless noted. The thread geometry of metric M and MJ profiles is shown in figure below;

Figure 4 Screw These assemblies may structural as a load bearing of component that subjected both shear and tensile stresses.

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Figure 5 strength of bolt Torque for raising the load; TR = ( ) (10)

Torque required lowering the load; TR = ( ) (11)

One of machine element is bearing that constrain the relative motion between two or more parts to only desired type of motion. It was manufactured to take pure radical loads, pure thrust load, or a combination of the kinds of loads. It used to allow and also promote a free linear movement or free rotation around a fixed axis. In selecting a bearing for a given application, it is necessary to relate the desired load and life requirements to the published catalog load rating corresponding to the catalog rating life. Where; FR(LR nR 60)1/a = FD(LD nD 60)1/a Where; FR = catalog rating LR = rating life nR = rating speed FD = desired radial load LD = desired life nD = desired life

(12)

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Gear is a rotating machine where it has cut teeth which mesh with another toothed part in order to transmit torque. The gear that had working in tandem is known as transmission and it can provide a mechanical advantage through the gear ratio.

Figure 6 Gear Chapter 3 : Methodology

Energy Concept

A Stirling engine is a type of external combustion engine that uses the expansion and compression of air in order to create a mechanical energy.

Figure 4: Stirling Engine 1/6/2012

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Typical of heat engines, the general cycle consists of compressing cool gas, heating the gas, expanding the hot gas, and finally cooling the gas before repeating the cycle. The efficiency of the process has an upper limit set by the efficiency of the equivalent Carnot cycle operating between the same hot and cold temperatures. Advantages -The Stirling engine is noted for its high efficiency compared to steam engines, quiet operation, and the ease with which it can use almost any heat source. This compatibility with alternative and renewable energy sources has become increasingly significant as the price of conventional fuels rises, and also in light of concerns such as peak oil and climate change. -This engine is currently exciting interest as the core component of micro combined heat and power (CHP) units, in which it is more efficient and safer than a comparable steam engine.
Cooling Compartment

Cool Piston

Heating Compartment

Hot Piston

Figure 5: Stirling Engine Parts

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STIRLING ENGINE KITCHEN SMOKE REMOVER Mechanism of Power Generation

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Heat Conductor

Blade Coil

Gear

Shaft

Figure 6: Parts involved in power generation

1) When the stove is ignited, heat will be transmitted by the heat conduction coil to the Stirling engine in order to generate heat. 2) When enough heat had been accumulated, the Stirling engine will start to operate and starts to transmit rotational motion to the shaft. 3) The shaft will transmit the power towards the gear compartment. 4) Bearing that is being placed at the shaft will smooth the rotary motion. 4) In gear compartment, the gear will increase the rotational power of the shaft; hence we will get more power. 5) From gear compartment, a small shaft will transmit the power towards the blade, and the blade will spins. 6) When the blade spins, smoke from the stove will be sucked to the blade and out of the kitchen.

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STIRLING ENGINE KITCHEN SMOKE REMOVER Chapter 4 : Conceptual design

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A concept design could be regarded as the initial proposed design for a particular product. Usually several design drawings will be made in order to make the best choice from the options that is given. It will make it easier for a design team to make assessment of the potential design and make the right choice out of it. For our design, we had come out with several concept designs that is designed based on its type of energy used. Out of the three designs, we had chosen the best design that met our design requirements.

4.1 Design 1

For this design, we used electricity as the source of energy. Electricity could also be regarded as renewable energy as long as it is based on hydroelectric power. Hence it is suitable with our energy requirement that requires us to use renewable energy. However, electricity is not quite suitable due to the fact that it requires monthly bill cost and also some of it is generated by coal power plant that is not a renewable energy. So, we decided to scrap this idea.

Figure 7: Electricity powered 1/6/2012

STIRLING ENGINE KITCHEN SMOKE REMOVER 4.2 Design 2

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The second design uses solar energy as the primary source of energy in our system. This type of energy is very suitable based on our requirement because it is readily available, reliable and also maintenance free. However, there had been some issues on the installation cost of solar panels because it is very expensive. Consumers will refuse to invest huge amount of energy for such system, hence this desgin had also been scrapped.

Figure 8 : Solar powered

4.3 Design 3

This final design uses an energy source that is very rare in our country nowadays. Although it had been around for quite some time, Stirling engine is yet to be commercialized in open market. Stirling engine is the most efficient engine in the world and the cost for a Stirling engine is also not that much compared to solar panels. Hence, we had chosen this design as our project design.

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Figure 9 : Stirling Engine powered

4.4. Weight Decision Matrix Objective Tree For The Design Of A Kitchen Smoke Remover

KITCHEN SMOKE REMOVER

COST

QUALITY IN SERVICE

ROI

Mfg. Cost

Reparability

Durability

Reliability maintenance

Safety

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STIRLING ENGINE KITCHEN SMOKE REMOVER O1 = 1.0

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O11 = 0.5

O12 = 0.5

O111 = 0.3

O112 = 0.4

O113 = 0.3

O121 = 0.4

O122 = 0.3 O123 = 0.3

O124 = 0.3

Weighted Decision Matrix Decision Criterion Weight Factor Unit s

Electric Score Rating 1.20

Stirling engine Score 6 Rating 0.90 Score 4

Solar Rating 0.60

maintenance

0.15

RM

Manufacturing cost Reparability Durability Reliability ROI Safety

0.20

RM

1.40

1.40

1.00

0.15 0.20 0.15 0.15 0.20

EXP EXP EXP HR EXP

5 6 5 5 8

0.75 1.20 0.75 0.75 1.60 7.65

9 8 9 7 5

1.35 1.60 1.35 1.05 1.00 8.65

8 8 8 4 7

1.20 1.60 1.20 0.6 1.40 7.60

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STIRLING ENGINE KITCHEN SMOKE REMOVER 4.5. Pugh method Number criteria solar datum

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Stirling engine

1 2 3 4 5 6 7

maintenance Manufacturing cost Reparability Durability Reliability ROI Safety plus minus

+ + 2 5

+ + + 3 4

Chapter 5 : Detail design

Figure 10 : Blade

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Figure 11 : Suction Tunnel

Figure 12 : Gears and Shaft

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Figure 13 : Bearing

Figure 14 : Stirling Engine

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Figure 15 : Stove including the stove cabinet

Final Rendering

Figure 16 : Final Rendering

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Figure 17 : Engine Assembly

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Figure 18 : Bill of Material

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Figure 19 : 2D Drawing

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Figure 20 : 2D Drawing of Stove Assembly

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STIRLING ENGINE KITCHEN SMOKE REMOVER Chapter 6: Design analysis and Discussions

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ANALYSIS OF EACH PART

6.1. Analysis due to welding

part 1

Figure 21 : welding part 1 Due to bending force;

By assuming Sy = 300MPa, Force =250kN h=8 Primary shear, = V/A, where V = shear force Secondary shear bending, = Mc/I, where I = 0,707hIu Total shear, = (2 + 2)1/2 From table 9-2 (pg 488; shigleys) N0 6; throat area, A = 1.414h (b + d)

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STIRLING ENGINE KITCHEN SMOKE REMOVER Location of G, = d/2 X = b/2 Unit second moment of area, Iu =

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Calculation; A = 1.414h (b + d) = 1.414 (8) (780 + 379.814) = 13119.82 mm2 X = b/2 = 780/2 = 390mm = d/2 = 379.814/2 = 189.91mm Iu = = = V/A= (250x 103)/ 13119.82 = 19.06N/mm2 I = 0.707hIu= 0.707(8) (65392793.8) = 369.8616x106 mm4 = Mc/I = 250 x103(550)(189.91)/ 369.8616 x106 = 70.60N/mm2 max = (2 + 2)1/2 = (70.602 + 19.062)1/2 = 73.13N/mm2 Ssy = 0.577Sy = 0.577(300) = 173.1 MPa Factor safety = Ssy/max = 173.1 / 73.13 = 2.37
3

Explanation;

Based on the calculation that had done based on the dimension from the solid work drawing, the value of factor safety are 2.37.Its was due to the dimension of the welding process where the depth of welding between the plate to the and the exhaust smoke casing are 8mm. Amount of area that are weld are 13119.82mm2 . The forces that attract on the welding are bending force. By assuming the value of distortion-energy criterion, the stresses are 300MPa where the stresses allowable are 173.1 MPa. Due to the calculation that had done the value of maximum stress are 73.13MPa. The factor safety is based on the allowable stress over maximum stress where it was 2.37. The depths of weld in this system are safe. The value of factor safety shown that the weld between plate and the exhaust smoke casing are safe.

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STIRLING ENGINE KITCHEN SMOKE REMOVER Part 2

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Figure 22 : Welding part 2 Due to bending force;

By assuming Sy = 300MPa, Force =250kN h = 12 Primary shear, = V/A, where V = shear force Secondary shear bending, = Mc/I, where I = 0,707hIu Total shear, = (2 + 2)1/2 From table 9-2 (pg 488; shigleys) N0 6; throat area, A = 1.414h (b + d) Location of G, = d/2 X = b/2 Unit second moment of area, Iu = Calculation; A = 1.414h (b + d) = 1.414 (12) (780 + 50) = 14083.44 mm2

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STIRLING ENGINE KITCHEN SMOKE REMOVER X = b/2 = 780/2 = 390mm = d/2 = 50/2 = 25mm Iu = =
3

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= V/A= (250x 103)/ 14083.44= 17.75N/mm2 I = 0.707hIu= 0.707(12) (2987500) = 25.34595x106 mm4 = Mc/I = 250 x103(252.447)(25)/ 25.34595x106 = 62.25N/mm2 max = (2 + 2)1/2 = (17.752 + 62.252)1/2 = 64.73N/mm2 Ssy = 0.577Sy = 0.577(300) = 173.1 MPa Factor safety = Ssy/max = 173.1 / 64.73 = 2.67

Explanation;

Based on the calculation that had done based on the dimension from the solid work drawing, the value of factor safety is 2.67. The depth weld between the plate of the exhaust smoke casing and plate of shaft are 12mm. The depth welding of the part are greater compare the depth welding between the plate and the exhaust smoke casing because it was critical part compare with that. Its because, when the system was running based on the stirling engine process, the shaft was rotating and that may causing a vibration on the part. The vibrations were giving a more force on the weld. So, the weld should be greater to circumvent the system from broken. The amounts of area that are weld are about 14083.44mm 2. The forces that attract on the welding were due to bending force. By assuming the value of distortionenergy criterion, the stresses are 300MPa where the stresses allowable are 173.1 MPa. The values of maximum stress that are act at the weld are 64.73MPa. The factor safety is based on the allowable stress over maximum stress where it was 2.67. The depths of weld in this system are safe. Its also greater than the value of safety factor of plate and the exhaust smoke casing are safe.

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STIRLING ENGINE KITCHEN SMOKE REMOVER 6.2. Analysis of shaft

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Figure 23 : shaft part Assuming N=500rpm Power, P = 20kW Sy= 300MPa Mass gear = 0.5 kg

Given( from drawing) L = 1210mm d = 30mm

Calculation; Ssy = 0.577sy = 0.577(300) = 173.1MPa Bending moment, M = P x L Wgear = 0.5(9.81) = 4.905 N P= Wgear= 4.905 N M = P x L = 4.905(1210) = 5935.05 Nmm From power, P = T T = P/ , where = 2N/60 = 2(500)/ 60 = 52.36 rad/s so, T = 20x103 / 52.36 = 381.97097Nm = 381970.97Nmm max = max = = 72.06 MPa

thus; factor safety = Ssy/ max = 173.1/ 72.06 = 2.40 1/6/2012

STIRLING ENGINE KITCHEN SMOKE REMOVER Explanation;

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Shaft is rotating member where it used to transmit power or motion. The material of shaft that used is steel. The rotating of the shaft are about 500rpm that transmit power about 20 kW. The mass of the gear that was placed at the shaft are 0.5kg and the value of distortion-energy criterion, the stresses are 300MPa where the stresses allowable are 173.1 MPa. The length of the shaft are 1210mm. the length of shaft was greater because it was placed from the stirling engine at the kitchen and transmit the power to the gear and the rotation of the gear were move the fan blade on the exhaust smoke. From the analysis that had done, the force that act on the shaft are bending moment and torque. The diameters of shaft are about 30mm. from the amount of power that transmit by the shaft, the value of a torque were find that are about 381970.97 Nmm. The bending moment those acts on the shaft are about 5935.05 Nmm. The maximum shear stress that had calculated based on the equation is 72.06 MPa. Due to the factor safety calculation, the amount of safety factor of this system is 2.40. This was shown the type and diameter of shaft was suitable to used in these system that are not exceed to 1.

6.3. Bolt Analysis

Figure 24 : bolt part Type of material : steel Type of bolt : Hex Head (upset) Mass : 20kg Area : 10 x 40 = 400mm2 Angle = 900C = 1.57 rad Times, t = 1sec K = 0.18 (lubricated) N = 3( total bolt) 1/6/2012

STIRLING ENGINE KITCHEN SMOKE REMOVER From table 8.8 (pg 130:shigleys) Poisson Ratio : 0.291 Elastic Modulus : 207 Gpa A : 0.78715 B : 0.62873 From table 8.9 (pg 433) *Psi = lbf/in2 *Sp ( minimum Proof Strength) SAE Grade No: 5 (material: Medium carbon, Q & T) Minimum Proof Strength : 85 kpsi = 586.05 MPa Minimun Tensile Strength : 120 kpsi = 827.37 MPa Minimum Yield Strength : 92 kpsi = 634.32 MPa By assumming Length of screw, L : 30mm d : 9.53mm From table 8.7( pg 426) Based on drawing l : 10mm LT = 2d + 6mm, L 125mm, d 48mm Length of unthreaded portion in grip : ld = L -LT Length of threaded portion in grip: lt = l - ld Area of unthreaded portion : Ad = d/ 4 Area of thereaded portion : At from table 8.1 Fastener stiffness : kb= From table 8.1(pg 412) Nominal Major Diameter, D : 14mm Pitch, p : 2mm Tensile-stress Area, At : 125 mm2 Minor-Diameter Area, Ar : 116mm2

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Equations that was used: (8.23) (pg 429) C= Fp = At Sp 1/6/2012 (pg 436)

STIRLING ENGINE KITCHEN SMOKE REMOVER Fi = 0.90 Fp (permenent connection) i = Fi / At b = Fb/ At = (CP+ Fi) / At T = K Fi d nL = ( SP At Fi)/ C(Ptotal /N) nP = ( SP At)/ [C(Ptotal /N) + Fi] no = Fi /[ (Ptotal /N)(1-C)]

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Calculations : LT = 2(9.53) + 6mm = 25.06 mm ld = 30 25 = 5mm lt = 10 5 = 5mm Ad = Bolt stiffness; kb = Members stiffness; km / (207x 106)(9.53) = (0.78715) exp [(0.62873)(9.53)/10 )] km = 1.7092 x 109 Mpa Stiffness constant; C = (1.8802 x 1012) / (1.8802 x 1012 + 1.7092 x 109 ) = 0.9991 = 1.8802 x 1012 Mpa = 71.33 mm2

Proof load; Fp = 125 (856.05 Nmm2) =107.01 kN Preload recommandation; Fi = 0.90 (107.01 kN) = 96.31 kN Preload stress; i = Fi / At = 96.31 x103 / 125 = 770.45 N/mm2 Stress under the service ; b = Fb/ At = (CP+ Fi) / At Fp = ma, a = x/t2 X= r = 4.77 (1.57) = 7.4889mm a = 7.4889 / 12 = 7.4889 mm/s 1/6/2012

STIRLING ENGINE KITCHEN SMOKE REMOVER Fp = 20 (7.4889) = 149.778 N P = Fp/A = 149.778 / 400 = 0.37 Pa b = [(0.9991)(0.37) + 96.31)/ 125] = 0.7734N/mm2 Torque necessary to achieve preload; T = K Fi d = 0.18 (96.31x 103) (9.53) = 162.21 kNmm Load factor; nL = ( SP At Fi)/ C(Ptotal /N) nL = ( 856.05(125) 96.31x103) / 0.9991(0.37/3) = 86.804x103 Yielding factor safety; nP = ( SP At)/ [C(Ptotal /N) + Fi] nP = ( 856.05(125))/ [0.9991(0.37/3) + 96.31x103] = 1.11 Load factor guarding against join separation; no = Fi /[ (Ptotal /N)(1-C)] no = 96.31x103 / [(0.37/3)(1-0.9991)] = 867.66x106

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Explanation;

Bolt are the types of nonpermanent joints. On this system the material that used are steel and the bolt are Hex Head (upset) type. The mass of this system is about 20 kg. The plate that used is not much heavy where it was suitable for the system. The areas that are involved with bolt are 400mm2. The major of the bolt are 14mm and the fastener diameter of the bolt is 9.53mm. From all the specification on the system, there are several tables had been refer to find the accurate value of torque, load factor, yielding factor safety and also the load factor guarding against join separation. Due to the bolt that had used on the system, the value of preload and service load stresses are respectively ten percent less than the proof strength. Therefore the types of bolt are suitable applied at this system where the torque that was applied at the bolt is only about 162.21 kNmm. Based on the theoretical calculation, the yielding factor of safety that guarding against the static stress exceeding the proof strength that is about 1.11. Based on the factor safety that is not exceeding 1, the bolt was suitable for this system. The fillets of the bolt are the point of stress concentration. This type of bolt can stand with the vibration that produces by the shafts that are including the different frequency. The bolt was also durable for this system.

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STIRLING ENGINE KITCHEN SMOKE REMOVER 6.4. Bearing analysis

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Given: 02-series deep groove ball bearing :Desired load Desired life LD Desired speed nD Ball bearing; a Application factor, af The rating life is revolutions.( based on the SKF manufactured )

= 1.2kN = 30 000h = 400 rpm =3 = 1.2

( = 10755.371 N = 10.75 kN

So from the Table 11-2, we obtain;

Table 7 : Table 11-2 The new C10 Bore OD 1/6/2012 =12.7 kN = 20 mm = 47 mm

STIRLING ENGINE KITCHEN SMOKE REMOVER Based on the SKF manufactured :X0 = 0.02 = 4.459 b = 1.483 so from the data above ( - X0 ) = 4.439 XD= = = 720

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From the new C10, Based on the equation Reliability, R ( )

( (

* )

R < 0.90

For the ball bearing decision making we choose 02-series, deep groove ball bearing on our product. First we assume the desired load for the ball bearing is about 1.2kN as a load that will be apply to the ball bearing. Then we assume the desired life for that material is 30 000h. For this ball bearing we put it as a shaft for the fan and we assume it as 400rpm . it is how fast if the fan rotate as 400rpm and give the bearing force to rotate. Every bearing that we created is based from 2 manufactured that is Timken manufactured and SKF manufactured. For the ball bearing we use is we decide from the SKF manufactured. For SKF manufactured we need to refer its own rating life for the every purchase of manufactured. For the ball bearing the value for a is 3. 1/6/2012

STIRLING ENGINE KITCHEN SMOKE REMOVER 6.5. Bevel gear analysis

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All the units calculation are in mm units. Given: Bevel Gear N = 400 rpm Transmit power, H = 40 kW

Solution The pitch angles are ( ) = 35o ( ) =32o The pitch-line velocity corresponding to the average pitch radius is

V = 1.6755

Therefore the transmitted load is

Which act in the positive z-direction

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Where Wr is in x-direction and Wa is in y-direction In preparing to take sum of the moments about bearing D, define the position vector from D to G.

We shall also required a vector from D to C;

Then, summing moments about D gives;\

-------------------1

When we replace the details in equation 1 become equation 2. ( )

After the two cross products are taken, the equation become -----2 From which T = 5037.30 N.m --3 -------------

Now sum the forces to zero. Thus

FD + FC + W = 0 when the details are inserted, Equation 4 becomes ( --------4 1/6/2012 )

STIRLING ENGINE KITCHEN SMOKE REMOVER

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Find we see that

= 460459 N, and so

+ Then, from Equation

FD = ( 668i - 9605.57k ) N In determining shaft and bearing loads for bevel-gear applications, the usual to use the tangential or transmitted load that would occur if all the forces were concentrated at the midpoint of the tooth. Here we prepared the picture the bevel gears dimension and the force distribution for every part of critical point of the bevel gears. The force transmitted to the bevel gears and it calculated by vector methods. In the bevel gears we have tangential force Wt, radial force W r, and axial force W a. All the three forces Wt ,Wr, and Wa are at right angles to each other and can be used to determine the bearing loads by using the methods of statics.

6.6. Non-Permanent Joints.

1. Tightening torque, T = KFid

Table 8 : Table 8-15

Torque factor,K= 0.20

Preload, Fi = 0.75 Fp 1/6/2012

STIRLING ENGINE KITCHEN SMOKE REMOVER Proof load, Fp = At Sp From Table 8-11;

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Table 9 : Table 8-11

For M12, Sp = 310 MPa From table 8-1;

Table 10 : table 8-1

For M12 and Course-Pitch series, At = 84.3 mm2

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STIRLING ENGINE KITCHEN SMOKE REMOVER Proof load, Fp = At Sp Fp = (84.3)(310) Fp = 26133 MPa.mm2 Preload, Fi = 0.75 Fp Fi = 0.75(26133) Fi = 19600 MPa.mm2 Therefore; Tightening torque, T = KFid T = (0.2)(19600)(8) T = 31360 N.m

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2. Factor safety guarding against yielding. Bolt length, L = l + H given; l = 20mm

From table A-30

Table 11 : Table A-30

Height, H = 7.76 mm Therefore;

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STIRLING ENGINE KITCHEN SMOKE REMOVER Bolt length, L = 20 + 7.76 = 27.76 mm 28 mm ( From table A-17)

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Treaded length, LT = 2d + 6 LT = 2(8) + 6 LT = 22 mm Length of unthreaded portion in grip, ld = L - LT ld = 28 - 22 ld = 6 mm Length of threaded portion in grip, lt = l - ld lt = 20 - 6 lt = 14 mm

Area unthreaded portion, Ad = Ad = Ad = 16 mm2

Fastener stiffness: kb = kb =

E = 207 GPa ( Table 8-8 for steel)

kb = 7.252x1011 Member stiffness, km = AEd exp (Bd / l )

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STIRLING ENGINE KITCHEN SMOKE REMOVER From table 8-8;

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Table 12 : Table 8-8

A= 0.78715 B= 0.62873 E= 207 GPa Member stiffness, km = AEd exp (Bd / l ) km = (0.78715)( 207 G)( 0.62873)( 0.62873x8/ 20) km = 1.6763x1012

Stiffness constant of the joint, C = C= C = 0.3020

Resultant bolt load, FB = Pb + Fi = CP + Fi , P = 50KPa / 5 = 10KPa = (0.3020)(10x103) + 19600 MPa = 22620 N Resultant load on connected member, Fm = Pm + Fi = (1-C)P - Fi = (1-0.3020)(10x103) - 19600 = -12620 N

Factor Safety for tension in members,

n=

, Ssy = 340 MPa

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= = 149.70 MPa Therefore, n = = 2.27 Factor Safety for bolt, n =

= = 200 MPa n= n = 1.7

In order to find the value of resultant bolt load, FB and resultant load on the connected members, Fm, first step is identify several parameters required. The purpose of finding the resultant load is to determine the factor safety. First is need to find the tightening torque,T where the value that were obtained from the calculation is 31360 N.m. Before the value factor safety can be determine, the value of member stiffness, Km and Kb must be calculate. The value of Km obtained is 1.6763x1012 and the value of Kb is 7.252x1011. By substituting into the equation, the value of stiffness constant of the joint, C can be determine and only then the value of the resultant bolt and the resultant load on the connected members can be determine. The value that were obtained for FB is 22620 N and the value for Fm is -12620 N. After that we can determine the stress concentration and then the factor safety. The value for the factor safety for tension in members is 2.27 which is guaranteed safe because it is in range. Meanwhile, the factor safety for bolt is 1.7. Even though it is out of safety range a little bit, but some observation has been made by surfing the internet where it is found that there are several companies that considered this kind of values is still in safety zone. Therefore, it can be conclude that this fastener is suitable for this application.

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STIRLING ENGINE KITCHEN SMOKE REMOVER 6.7. Discussion

46

After one semester of teaching and learning of Mechanical Component Design, this report is mainly about designing a product for Machine component Design subject. For this project, the application of stirling engine is used in order to complete the project. In this project, there are several factors that need to be considered. Factors that need to be considered are based on the parts of the design. Most parts must be calculated in order to ensure that the product meet the safety requirements. Each part of the design must be calculated to ensure that the product was safe to use. By considering the load of force that act on the system, the shear stress and factor safety can be calculated. The factor safety of the part must be greater than one. It was been calculate by referring the dimension of drawing for each component n solid work. If the factor safety that get was less than one, there are several part will be considered. That is change the dimension, change the material and also change the position. Due to welding part, there was bending and torsional force that act on the bending. The basic of torsional and bending force are based on type of welding. The areas of welding also give some effect on the force that act on the plate. In this project, there were two plates that were involved with welding. Meanwhile, bolt analysis was based on the type of material that was used and the type of head that used on the machine screw. The stiffnesss and the bolt strength had been calculated based on the material and type of bolt that used in this system. Shaft was the rotating cylinder that used to rotate the gear and provide the torque to rotate the blade to remove the hot air from the building to the environment. Shaft was the most important part where it was the main part of transmitted the power from the stirling engine through the gear to moving the blade. The other part that used in this system is gear. The type of gear that used in this system is bevel gear. The force analysis was used to determining shaft and bearing loads for the bevel gear application that was to used tangential and also transmitted load. The pitch of bevel gears is measured at the large end of tooth, and both the circular pitch and the pitch diameter are calculated. Screw was non-permanent joint that used in this system. The total amount that used was 10 pieces. Screw is among the important component as it holds bigger components together. Screw is used because it is cheap. Besides that, the calculation of the resultance force that acting on the fastener or bolt and the resulting force that acting on the members also 1/6/2012

STIRLING ENGINE KITCHEN SMOKE REMOVER

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been calculated. From the force that were obtained, the factor safety of the part can be calculated and the result that were obtained shown that the design is in safety range. On the other hand, bearing is used to smoothen any rotations in the system. The type of bearing used is ball bearing. Only one bearing is used in the design. However, there were also some problems that need to overcome in order to ensure that this design is successfully done. One of the problems are the design is of the stirling engine itself. A precise consideration needs to be done in order to make sure the stirling engine is applicable to the application. First is how to make it functioning. To be functioning the blade must be connected to the stirling engine and to overcome it, shaft was introduced to the system where it connect blade to the engine. Since there is a different in angle between the position of the engine and the blade, therefore, the bevel gear was applied to the shaft of the blade and the stirling engine.

Chapter 7 : Conclusion

Throughout this project, there is a lot of input were gained, especially for a better understanding in what have been learn in previous class. The knowledge and theory that Mr.Shafizal taught in class is obviously were strengthen much more after completing this project. And for this project, it can be conclude that, based on the calculation that been made the product which is the Smoke Kitchen Remover functioning according to plan and most importantly it is safe to be use in daily life. To be precise, the best design has been selected by using the method of Weighting Matrix and Pugh Method. Besides that, instead of using an electric current to run the stirling engine, the usage of heat from the stove to run the engine. So that, the daily electricity consume can be reduced and of course it is an important element that must be considered nowadays. Asides that, this project required a presentation by video montage, which is a good added value, since it is the first time student of 3 BMCT been exposed to that approach of presentation. On top of that, this project is extremely good for better understanding in Mechanical Engineering Design subject and of course, credit should be given to the lecturer, Mr.Shafizal Bin Mat for giving out this assignment at the first place.

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