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DESIGN OF PEDAL POWER WATER LIFTING MACHINE
ABSTRACT
This project is important for people that living in dry areas such as pastorals and
farmers of dry areas. Man power can be good alternative to fulfill the energy
requirements for performing many activities like ground water lifting. Pedaling is the
most efficient way of utilizing power from human muscles. Keeping these things in
mind a pedal powered water lifting can is developed. The machine system comprised of
three subsystems namely:
1. Energy Unit: Comprising of suitable peddling mechanism and Flywheel
conceptualized as Human Powered Flywheel (HPF)
2. Suitable torsion and power transmission shaft
3. Water contain unit (bucket). Though human capacity is 0.1hp continuous duty, the
processes needing the minimum power even up to 20w can be energized by this
machine concept to safe human power operating this machine. This is a water lift which
is run by rotating the pedal of a cycle and rotating the rope on the flywheel that is
connected with full of water bucket. This mechanism lift the water about 10 gallons per
one complete cycle from 10m deeps of hole by extending the rope.
FINAL PROJECT I
DICLARATION
This project is entirely our own work. It is clear that any work has owner. We would
like to make clear that this project is done by us. All theories and analysis except that
we have taken from the reference materials and from internet are our own suggestions
and descriptions. We have spent full of our effort and time to work this project. We
believe that we are human beings in general we are neither absolutely right nor
absolutely wrong. There may be error or any other possible problems in this project.
We hope all readers will play their own role in correcting those problems.
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ACKNOWLEDGEMENT
First of all, we would like to thank the almighty God for blessing us with strength,
aptitude and patience for successfully completing our project. Our special appreciation
goes to our INS: W/GEBRIEL.G for giving us the opportunity to work with him and
directing us to design this project. His inseparable follow up of our progress of day to
day is really very interesting and we come up with this accomplish through his effort at
all.
We have been able to compile and complete this project report on comprehensive
manner due to guidance, support and counseling that he has provided to us. Next, we
would also have thanks for mechanical engineering department that given us such
fascinating course to solve society’s problem through designing. Finally yet
importantly, our sincere thanks go to each and every one who has helped and supported
us in writing, searching, and analysis data significantly indifferent stages to accomplish
this project.
FINAL PROJECT III

Table of Contents
Contents
ABSTRA CT ...............................................................................................................................................................I
DICLA RATION ...................................................................................................................................................... II
ACKNOW LEDGEM ENT .................................................................................................................................... III
List of figure ........................................................................................................................................................... VII

List of table.............................................................................................................................................................. VII
CHAPTER O NE ............................................................................................................................................................1
INTRODUCTION .........................................................................................................................................................1
1.1 PEDAL POWERED W ATER LIFTING ..............................................................................................................1
1.2 COMPONENTIS OF PEDAL POWERED WATER LIFTING MACHINE .........................................................1

1.2.1 SHAFT .......................................................................................................................................................1
1.2.2 FLY WHEEL...............................................................................................................................................2

1.2.3 Gearbox ...................................................................................................................................................2
1.2.4 CLUTCH ....................................................................................................................................................2
1.2.5 LEVER (HANDLE AT THE SIDE OF CLUTCH) ........................................................................................3

1.2.6 HANDLE (SUPPORTIG BEAM) ...............................................................................................................3
1.2.7 FRAME......................................................................................................................................................3
1.2.8 TANKER ....................................................................................................................................................3

1.2.9 BUCKET ....................................................................................................................................................3
1.2.10 WIRE ROPE ............................................................................................................................................4

1.3 WORKING PRINCIPLE.....................................................................................................................................4
1.4 OBJECTIVE OF THE PROJECT.........................................................................................................................4
1.4.2 SPECIFIC OBJECTIVE...............................................................................................................................5

1.5 SCOPE ...............................................................................................................................................................5
CHAPTER TWO ...........................................................................................................................................................6

LITERATURE RIVEW ...................................................................................................................................................6
2.1 TYPES OF W ATER LIFTING DEVICES ............................................................................................................6
2.1.1THE SHADUF.............................................................................................................................................6
2.1.2BUCKET AND WINDLASS ........................................................................................................................6
2.1.3BUCKET PUMP .........................................................................................................................................7
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2.1.4 PEDAL POWERED W ATER LIFTING MACHINE ...................................................................................7

CHPTER 3 ....................................................................................................................................................................9
METHODOLOGY AND PROPLEM STATMENT .......................................................................................................9

3.1 METHODOLOGY .............................................................................................................................................9
3.2 PROBLEM STATEMENT..................................................................................................................................9
3.3 LIMITATION .....................................................................................................................................................9

CHAPTER 4 ............................................................................................................................................................... 10
DESIGN ANALYSIS................................................................................................................................................... 10
4.1 GEOMETRICAL ANALAYSIS ....................................................................................................................... 10

4.2 MATERIAL SELECTION FOR COMPON ENT DESIGN .............................................................................. 10
4.2.1 MATERIAL SELECTION FO R SHAFT ................................................................................................... 10

4.2.2 MATERIAL SELECTION FO R FLYWHEEL............................................................................................ 11
4.2.3 MATERIA SELECTION FOR CLUTCH .................................................................................................. 11
4.2.4 MATERIAL SELECTION FO R PEDAL ................................................................................................... 11

4.2.5 MATERIAL SELECTION FO R WIRE ROPE .......................................................................................... 11
4.2.6 MATERIAL SELECTION FO R LEVER .................................................................................................... 12

4.2.7 MATERIAL SELECTION FO R PIPE ....................................................................................................... 12
4.2.8 MATERIAL SELECTION FO R KEY ........................................................................................................ 13
4.2.9 MATERIAL SELECTION FO R BUCKET................................................................................................. 13

4.2.10 MATERIAL SELECTION FOR GEAR BOX .......................................................................................... 14
4.2.11 MATERIAL SELECTION FOR TANKER .............................................................................................. 14
4.3 PART DESIGN ............................................................................................................................................... 15

4.3.1 DESIGN OF GEAR BOX ..................................................................................................................... 15
4.3.2 SHAFT AREA ....................................................................................................................................... 32
4.3.3 PRESSURE REQUIREM ENT FOR THE SYSTEM ................................................................. 32

4.3.2 SHAFT DESIGN ................................................................................................................................ 34
4.3.3 FLYWHEEL DESIGN ...................................................................................................................... 38
4.3.4 CLUTCH DESIGN ............................................................................................................................ 39

4.3.5 LEVER DESIGN ................................................................................................................................ 41
4.3.6 HANDLE DESIGN ............................................................................................................................ 42

4.3.7 LEVER A RM DESIGN..................................................................................................................... 43
4.3.8 SHAFT JOURNAL DESIGN ........................................................................................................... 44
4.3.9 PEDA L DESIGN ................................................................................................................................ 45
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4.3.10 KEY DESIGN ................................................................................................................................... 46

4.3.11 PULLY DESIGN.............................................................................................................................. 49
4.3.12 BUCKET DESIGN .......................................................................................................................... 51

4.3.13 DISCHURGING PIPE DESIGN ................................................................................................... 54
4.3.14 ROPE DESIGN................................................................................................................................. 56
4.3.15 FRAM E DESIGN FOR MACHINE COMPONENT ................................................................ 57

4.3.16 WELDING DESIGN ....................................................................................................................... 58
4.3.17 BEARING SELECTION ................................................................................................................ 60
4.3.18 DESIGN FOR FASTENERS ......................................................................................................... 61

4.4 OUTPUT ENERGY ................................................................................................................................... 61
CHAPTER FIVE ................................................................................................................................................... 63

5.1 MANUFA CTURING PROCESS ............................................................................................................ 63
5.2 COST A NALIYSIS.................................................................................................................................... 64
5.3 GENERA L ASSEM BLY .......................................................................................................................... 64

CHAPTER SIX ...................................................................................................................................................... 66
CONCLUSION A ND RECOMMONDATION ............................................................................................... 66

6.1 CONCLUSION ........................................................................................................................................... 66
6.2 RECOMMONDATION ............................................................................................................................ 67
6.3 FUTUR WORK .......................................................................................................................................... 67

REFERA NCE......................................................................................................................................................... 68
APPENDIX............................................................................................................................................................. 69
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List of figure
Figure 1 pedal powered water lifting machine............................................................... 8

Figure 2 geometrical analysis of PPWLM ................................................................... 10
Figure 3 Interference of meshing gears........................................................................ 25
Figure 4 sample image of teeth .................................................................................... 31
Figure 5 shaft ............................................................................................................... 35
Figure 6 flywheel ...................................................................................................... 38
Figure 7 clutch ............................................................................................................. 39
Figure 8 lever ............................................................................................................... 42
Figure 9 pedal............................................................................................................... 45
Figure 10 pulley ........................................................................................................ 50
Figure 11 bucket........................................................................................................... 52
Figure 12 sectioning part.............................................................................................. 53
Figure 13 welding designAssumption ......................................................................... 58
Figure 14 bearing ......................................................................................................... 61
Figure 15 fasteners ....................................................................................................... 61
Figure 16 manufacturing method ................................................................................. 63
Figure 17 assembly drawing ………..……………………………………………….60
List of table
Table 1 Material features, application and precision rating ........................................................................... 20

Table 2 Gear and pinion material tensile strength and Brinell hardness number ....................................... 20
Table 3 the comb ined of gear and pinion .......................................................................................................... 21
Table 4 depth angle and number of teeth........................................................................................................... 23
Table 5 standard proportions in module ............................................................................................................ 24
Table 6 force required to apply on the pedal..................................................................................................... 32
Table 7 area of the shaft on which the force is applied ................................................................................... 32
Table 8 pressure distribution when the force is applied on the area of the mech anism. ........................... 33
Table 9 energy input for the system to operate the mach ine. ......................................................................... 34
Table 10 cost analysis ........................................................................................................................................... 64
FINAL PROJECT VII

CHAPTER ONE
INTRODUCTION
1.1 PEDAL POWERED WATER LIFTING

Pedal powered water lifting is machine used for the farmers to lift atones of
water from any depth and apply for irrigation crops. This machine lifts the water
from any depth by extending the rope. When it is rains the water level is high the
farmers can be stored at well and can be lift with less effort. So the water can be
stored in a container for future use especially during drought period of time. The
stored water in a tanker can be piped in farm land for irrigation by pipe. A single
machine can be used for many farmers. Farmers will buy the machine for less than
$500(when mass produced) or rent it on an hourly basis. The pedal powered water
lifting machine that we are going to design is lift up to 38 liters per minute when
pedaled by singled by single person. Two or more people may pedaling at the same
time to proportionally increase its lifting capacity. PPWLM is require almost no
maintenance, no requiring more cost, is more reliable locally serviceable in case of
manufacturing, low noise, no pollution and high weight. The PPWLM need not only
lift the entire water needed for irrigation but also it needs for lift the water for
drinking.
1.2 COMPONENTIS OF PEDAL POWERED WATER LIFTING MACHINE
1.2.1 SHAFT
A shaft is a rotating machine element which is used to transmit power from one
place to another. The power is delivered to the shaft by some tangential force and
the resultant torque (or twisting moment) set up within the shaft permits the power
to be transferred to various machines linked up to the shaft. In order to transfer the
power from one shaft to another, the various members such as pulleys, gears etc.,
are mounted on it. These members along with the forces exerted upon them causes
the shaft to bending. In other words, we may say that a shaft is used for the
transmission of torque and bending moment. The various members are mounted on
the shaft by means of keys or Splines.
1
1.2.2 FLY WHEEL
Flywheel used in machines serves as a reservoir which stores energy during the
period when the supply of Energy is more than the requirement and releases it
during the period when the requirement of energy is more than supply. Flywheel is a
rotating body acts as reservoir of the energy.
1.2.3 Gearbox
The most common use is in motor vehicles, where the transmission adapts the
output of the internal combustion engine to the drive wheels. Such engines need to
operate at a relatively high rotational speed, which is inappropriate for starting,
stopping, and slower travel. The transmission reduces the higher engine speed to the
slower wheel speed, increasing torque in the process. Generally, gearboxes are used
to increase torque while reducing the speed of a prime mover output shaft (e.g. a
motor crank shaft). This means that the output shaft or a gearbox rotates at a slower
rate than the input shaft, and this reduction in speed produces a mechanical
advantage, increasing torque. A gearbox can be set up to do the opposite and
provide an increase in shaft speed with a reduction of torque. For example lathe
machine.
Functions of a Gearbox
 A gearbox is precisely bored to control gear and shaft alignment.

It is used as a housing/container for gear oil.
It is a metal casing for protecting gears and lubricant from water, dust and
other contaminants.
Use of Gearbox
A variety of gearboxes find applications in a number of industries depending on the

end use. Some of the industries using gearboxes include Agricultural, Industrial, and
Construction, Mining, Petrochemicals and Food processing
1.2.4 CLUTCH
A clutch is a machine member used to connect a driving shaft to a driven shaft so

that the driven shaft maybe started or stopped at will, without stopping the driving
shaft. The use of a clutch is mostly found in automobiles. A little consi deration will
show that in order to change gears or to stop the vehicle, it is required that the
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driven shaft should stop, but the engine should continue to run. It is, therefore,
necessary that the driven shaft should be disengaged from the driving shaft. The
engagement and disengagement of the shafts is obtained by means of a clutch which
is operated by a lever.
1.2.5 LEVER (HANDLE AT THE SIDE OF CLUTCH)
A lever is a rigid rod or bar capable of turning about a fixed point called fulcrum. It is
used as a machine to lift a load by the application of a small effort. The ratio of load
lifted to the effort applied is called mechanical advantage. Sometimes, a lever is
merely used to facilitate the application of force in a desired direction. A lever may
be straight or curved and the forces applied on the lever (or by the lever) may be
parallel or inclined to one another. We use this clutch to break the power, lock the
driving shaft and to change the direction of rotation. The principle on which the lever
works is same as that of moments.
1.2.6 HANDLE (SUPPORTIG BEAM)
A handle is component of PPWLM which is used to support the operator during

pedaling for lifting water by the machine.
1.2.7 FRAME
Frame is the bathe of the machine which is used to support the components.
1.2.8 TANKER
A water tank is a container used to store the water. The need for water tank is as old
as civilization, providing storage of water for drinking water, irrigational agriculture
and other application.
1.2.9 BUCKET
The bucket is the material used contain the water for lifting from the ground and
discharge to the tanker.
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1.2.10 WIRE ROPE
The wire ropes are extensively used in hosting Hal slag and material handling
equipment. They are also used in stationary application; such as guy wire and stays.
When a large amount of power is to be transmitted over long distances from one
pulley to another (i.e. when the pulleys are up to 150 meters apart), then wire ropes
are used. The wire ropes are widely used in elevators, mine hoists, cranes, conveyors,
hauling devices and suspension bridges. The wire ropes run on grooved pulleys but
they rest on the bottom of the grooves and are not wedged between the sides of the
grooves. The wire ropes are made from cold drawn wires in order to have increase in
strength and durability. It may be noted that the strength of the wire rope increases
as its size decreases. The various materials used for wire ropes in order to increasing
strength of wrought iron, cast steel, extra strong cast steel, plough steel and alloy
steel. For certain purposes, the wire ropes may also be made of copper, bronze,
aluminum alloys and stainless steel
1.3 WORKING PRINCIPLE

The principle of operation of the machine is very simple and requires only one man
to operate. To operate the machine first tied the rope on the bucket, then after
rotate the lever to return the bucket to the ground water. To fetch the water the
bucket will sick on the water by itself due to its spherical shape and we design the
bucket sectioning on the tope surface to sink in the water easily. After it fetches the
water the operator will drive the pedal to lift the water from the well. When it
reaches at the suitable level rotate the lever to the opposite direction in order to
stop the movement of the bucket. After the mechanism will stop, direct the pipe of
the bucket to the tanker and by opining the check valve that found on the bucket
and makes the flow of the water to the tanker.After the tanker will be full of water,
by opining check valve at the bottom of the tanker and watering the crop by
applying pipe.
1.4 OBJECTIVE OF THE PROJECT

This project has two objectives.The general objective which include about the
general objective of the project and the specific objective which express about the
entire parts of the project.
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1.4.1 GENERAL OBJECTIVE
 To design pedal powered water lifting machine.
1.4.2 SPECIFIC OBJECTIVE
 To design shaft
 To design flywheel
 To design gear box
 To design a clutch
 To design pedal
 To design frame for the mechanism
 To design lever
 To design pipe
 To design rope
 To design bucket
 To design pulley
1.5 SCOPE
This pedal powered water lifting machine design paper is aimed to design a pedal
powered water lifting machine which is used to lift the water from the well. This
project is focused on the purpose of irrigation to minimize the shortage of water
during dry season. This paper also uses for mechanical engineering students as a
reference to beused for academic purpose and to be stored as a document for
mechanical engineering.
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CHAPTER TWO
LITERATURE RIVEW
2.1 TYPES OF WATER LIFTING DEVICES

Many people throughout the world rely an underground water supply for clean
drinking water. Also in hot regions where rain fall is low or unreliable, water is often
lifted from rivers, channeled and also from the dams and wells in to field to water or
irrigate the crops. Different device have been invited over the ages to raise water.
Most of them are still in use. Such as;
 The shaduf
 Bucket and windlass
 Bucket pump
 The Persian wheel
 The rope pump
 The pedal powered flywheel motor
 Pedal powered water pump
2.1.1THE SHADUF
The Shaduf is a simple water lifting device that has been used for the past 4500
years and also used in the Middle East. It is made of an upright past on whish is
balanced along thin pole. A rope and bucket are fixed at one end, and heavy counter
balanced weight is attached to the other end to balance the bucket. Then it is only
necessary to pull on rope lower bucket to the water. The weight can then lift up the
full bucket.
2.1.2BUCKET AND WINDLASS
In many parts of Africa and Middle East, the bucket and windlass device is widely
used as means of raising water from well. This is a type of wheel and axels on the
right are diagrams of two buckets and windlass machine.
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2.1.3BUCKET PUMP
There are three parts to the pump
 The pump stands including footings and windlass.

 The bucket and chain.
 The PVC (plastic) casing which sits in the well.
The bucket pump has a cylindrical still bucket with simple none return valve at its
base so that the water can flow in but not out. The bucket is connected to the
windlass through the length of chain. The bucket is raised or lowered through a PVC
casing which is either mounted in a hand drilled tube well or wide diameter well.
2.1.4 PEDAL POWERED WATER LIFTING MACHINE
PPWLM is the machine which is used to lift the water from above 10 gallons per
minute from wells and bored above 10 meter of depth or from any depth by
extending the rope to provide irrigation and drinking water where the electricity is
not available. From the other water lifting mechanism we have to select and to
design the pedal powered water lifting machine for the following reason. Pedal
powered water lifting machine:
 Can lift the water from any depth. Just extending the rope.
 Cheap to product
 More reliable, no electrical parts
 Works 24 hours a day
 Less risk of theft. Machine have less weight, can be dissembled within a short
period of time and taken a home after completion the purpose.
 No more maintenance for components
 We may goat some materials for production in a simple way.
 It is simple mechanism comparing to the others.
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Figure 1 pedal powered water lifting machine
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CHPTER 3
METHODOLOGY AND PROPLEM STATMENT
3.1 METHODOLOGY
To achieve the goal of our project we used the primary and secondary data analysis.
Primary data collection:
We collected data for project analysis we observe some method from the existing
water lifting systems.
Secondary data collection:
It is expected to do this project by using different resources; such as Internet access,

different books and our concept. The reference books that we used are:
 Text book of machine design

 Machine element of second edition
 Use Internet
 Interview and observation
3.2 PROBLEM STATEMENT

It is known that there is a shortage of water on the land surface of most desert rural
areas; especially in the low land area of our country. No loose of water in the
developed country easily like in our country. They can use either the rain fall or
ground water properly by applying technology. That is why the government of our
country forces farmers and pastorals to construct wells and dams around their
location. But they did not care to use the water properly. It is mean that; the
population gets risk while they are fetching water and they will be tiered when they
fetch water. That is why we forced to design this project which is known as pedal
power water lifting machine that is used for water lifting from underground.
3.3 LIMITATION
This project entirely concerned with the pedal powered water lifting machine that is
used lift the water from the ground in order to minimize the problem due to the
shortage of the water at the dry area. But this project has the following limitations:
 The mechanism has no on and off system.

 Operating by man power mechanically, not automatically.
 If the operator tiered during operating the bucket of water turns to the well.
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 Because it has no automatic connected system.
CHAPTER 4
DESIGN ANALYSIS
4.1 GEOMETRICAL ANALAYSIS
Figure 2 geometrical analysis of PPWLM
4.2 MATERIAL SELECTION FOR COMPONENT DESIGN
4.2.1 MATERIAL SELECTION FOR SHAFT
Since the shaft is a rotating machine element used to transmit power from one part
to the other. So to safe operation from risk and shaft from damage we have to select
carbon steel of grade 50C12. Because it has the following property:
 It has high strength

 It has good mach inability
 It has low notch sensitivity factor
 It has high wear resistance property
 It has good heat treatment
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4.2.2 MATERIAL SELECTION FOR FLYWHEEL
Flywheel is a heavy rotating body that acts as reservoir of energy. The energy is
stored in the flywheel in the form of kinetic energy. We select the cast iron for this
component by considering the following property:
 It is cheap
 It can be any complex shape without involving machine operation
 It has an excellent ability to damp vibration
4.2.3 MATERIA SELECTION FOR CLUTCH
A clutch is a machine member used to connect a driving shaft to a driven shaft’s that
the driven shaft may be started or stopped at the will of operator, without stopping
the driving shaft. We select alloy steel material for this component. Because of the
following property:
 It has high heat conductivity

 It has high wear resistance
 It has the ability to stand high temperature that caused by slippage
 It is not affected by moisture and oil
4.2.4 MATERIAL SELECTION FOR PEDAL
Pedal system is any foot operated lever or other device which is used to rotate the
shaft. We select aluminum alloy material for this component. Because of the
following property:
 It is light in weight or mass

 It has high resistance to corrosion
 High reflection to both heat and light
4.2.5 MATERIAL SELECTION FOR WIRE ROPE
Since, the wire rope is made of cold drawing wires in order to have a greater
strength and durability. We select the wrought iron. Because of the following
property:
 It is tough, malleable and ductile material

 It has higher durability from the fiber rope
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ADVANTAGES OF WIRE ROPE OVER FIBER ROPE
The wire ropes have the following advantages as compared to fiber ropes.
 These are lighter in weight,

 These offer silent operation,
 These can withstand shock loads,
 These are more reliable,
 These are more durable,
 They do not fail suddenly,
 The efficiency is high, and
 The cost is low. Has high strength to weight ratio
 Has greater reliability
 Silent operation even at high velocity
 Has high strength to weight ratio
4.2.6 MATERIAL SELECTION FOR LEVER
Lever is a component used to engage and disengage the clutch for process of
opening and closing the operation. We select cast iron for this component. Because
of the following property:
 Cheapest or low cost

 High wear resistance
 Good machinability
4.2.7 MATERIAL SELECTION FOR PIPE
The pipes are used for transporting various fluids like water, steam, different types
of gases, oil and other chemicals with or without pressure from one place to other
place. We select polyethylene plastic material for this component. Because of the
following property:
 Relatively low cost per unit weight

 Good corrosion resistance
 Principally low weight
 Generally has excellent plastic property
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4.2.8 MATERIAL SELECTION FOR KEY
We use key to prevent relative motion or rotation between shaft and flywheel. There
are different types of key. From them we select sunk. Also the sunk key can be
classified as many type depend on the shape of keys. So by considering the shearing
and crushing of the key we select rectangular sunk steel material that has the same
property with shaft material which is carbon steel of grade 50C12.Because it may be
minimize the crushing and shearing of the key as the key material has the following
the same property with the shaft materials.

 It has good machinability
 It has low notch sensitivity factor
 It has high wear resistance property
 It has good heat treatment
4.2.9 MATERIAL SELECTION FOR BUCKET
Bucket is a material which has a circular cone shape that used to contain the water
when we are fetch the water from the ground or from the well. This material can
always contact with moisture in case it is used to contain the water. As we know if
the most materials can contact with water or moisture rusting or corrosion of the
component will be form. Due to this reason to prevent or minimize the corrosion of
this component we select the aluminum alloy with aluminum number 2017 that has
the following properties;
 Yield strength( )=70Mpa

 Tensile strength( )=179Mpa
 Fatigue( )=90Mpa
 Elongation in 2in%=22
 Hardiness=45 HB
 Specific gravity=2.7
We select this material for the following reason
 High corrosion resistance
 Ease of fabrication
 High specific gravity than water
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4.2.10 MATERIAL SELECTION FOR GEAR BOX
The materials of most of the gears used for transmitting reasonable torque and
speed mainly need to be mechanically strong in shear and bending, sufficiently tough
and resistant to wear, fatigue and chemical degradation. Many factors influence the
selection of materials for gears, and the relative importance of each can vary. These
factors include:
 Mechanical Properties
 Grade and Heat Treatment
 Cleanliness
 Dimensional Stability
 Availability and Cost
 Harden-ability and Size Effects
 Mach-inability and Other Manufacturing Characteristics.
Generally, the gears may be manufactured from metallic or non-metallic materials.
The metallic gears with cut teeth are commercially obtainable in cast iron, steel and
bronze. The non-metallic materials like wood, rawhide, compressed paper and
synthetic resins like nylon are used for gears, especially for reducing noise. The cast
iron is widely used for the manufacture of gears due to its good wearing properties,
excellent mach-inability and ease of producing complicated shapes by casting
method. The cast iron gears with cut teeth may be employed, where smooth action
is not important.
The steel is used for high strength gears and steel may be plain carbon steel or alloy
steel. The steel gears are usually heat treated in order to combine properly the
toughness and tooth hardness.
4.2.11 MATERIAL SELECTION FOR TANKER
A water tank is a container used to store the water. The need for water tank is as old
as civilization, providing storage of water for drinking water, irrigation for agriculture
and other application. Various materials are used for making water tank such as
plastic, steel, stone and fiber glass. From these materials we select the fiber glass.
Because of the following property
 Light in weight
 Can weather resistance
 Both stiff and strong in tension and comparison
 Cheapest in cost
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4.3 PART DESIGN
4.3.1Design of gear box
In engineering and technology the term gear is defined as a machine element used to
transmit motor and power between rotating shafts by means of progressive
engagement of projections called teeth. For mechanical power transmission, gears are
generally categorized into three distinct types
1) Those transmitting power and motion between parallel shafts, namely, spur and
ordinary helical gear.
2) Those for shafts with intersecting axes, the angle between the shaft being
generally 900 , bevel gear.
3) Those where the shafts are neither parallel nor intersecting the axes generally
making 900 (or some other angle) to each other but in different planes, worm and
worm gear, crossed-helical gear, hypoid gears.
Gear drives are mainly used as reducer which may be made in single, double or
triple stages. Single, two and three stage reducer may appear with its shafts in parallel,
also two stages with power bifurcation or with coaxial input and output shafts. With
axes inclined at right angles for bevel gear or combination of bevel and spur gears.
Worm and gear drive with the worm placed horizontally below or above the worm
gear or with the worm placed in vertical position. Combinations of double worm and
wheel reducer or spur gear and worm wheel drive are also common.
The main objective of gear drive is to transmit high power with comparatively
small overall dimensions of the driving system which can be constructed with
minimum possible manufacturing cost, runs reasonably free from noise and vibration
and which requires little maintenance.
The following are the advantages and disadvantage of the gear drive
Advantages
It transmits exact velocity ratio

It may be used to transmit large power
It may be used for small center distances of shaft
It has high efficiency
It has reliable service
It has compact lay out
FINAL PROJECT 15
Disadvantage
Since the manufacture of gears requires special tools and equipment,
therefore it is costlier than other drives the error in cutting teeth may cause
vibration and noise during operation it requires suitable lubricant and
reliable method of applying it, for the proper operation of gear drives
Design consideration for a gear drive the following requirements must be
met in the design of a gear drive.
The gear teeth should have sufficient strength so that they will not fail under
static loading or dynamic loading during normal running conditions
The gear teeth should wear characteristics so that their life is satisfactory
The use of space and material should be economical.
The alignment of the gears and deflections of the shafts must be considered
because they effect on the performance of the gears.The lubrication of the
gears must be satisfactory.
Given parameters
A. specification
i. power [kw]:- 1kw
ii. input speed [rpm]: 1200
iii. total gear ratio:- 3:1
iv. arrangement:- perpendicular drive
v. driving machine: pedal power
vi. driven machine:-simple power mechanism machine
vii. housing design:- casting
B. Main task of the project
1. Select the best alternative for gears carrying out preliminary calculation.
2. Calculate precisely the geometry of the selected alternative so that the
relative slippages at the boarder points of the length of engagement are
equalized.
3. Check the strength of the pair of gears.
4. Check the strength of the shafts and key joints.
5. check critical speeds of the shafts
6. select an appropriate lubrication
7. Prepare a design report of the gearbox containing the assumptions,
considerations, calculations and remarks concerning the project.
Velocity ratio or gear ratio: is defined as the ratio of the rotational speed of
the input gear to the output gear for a single pair of gear.
i=⍵input /⍵output =Routput/Rinput=Doutput/Dinput=N output/Ninput=ninput/noutput ----- R [1]
Where ⍵-angular velocity
R-radius of the gear
D-diameter of the gear
FINAL PROJECT 16
N-number of teeth of the gear

N-Rotational speed of the gear (rpm)
There for the gear ratio is given i=3
And * = =3
Where = input gear ratio and = Output gear ratio
The number of stage reduction in the gear is
1) From the input to the output
There are two gears and two shafts
GA- input pinion gear
GB – out put gear
And
S1 – input shaft
S2 – out put shaft
Let’s take = (1.25)*( )(0.5)

(0.5)
And (1.25)*( ) *= itotal=3
(1.5)
(1.25)*( ) =3
( )(1.5) = 2.4
= 1.79
Let’s take = 1.8
And * = itotal=3
= / = 3/1.8
= 1.67
There for * = =3=1.8*1.67
Show the calculation of output torques and output angular speed
Output angular speed
Given data =120rpm
=1KW, = 1.8 and t = 1.67
= 1.67= / =120rpm/
=120rpm/1.67
=71.85rpm
FINAL PROJECT 17
Output performance
The output power is (98–99) % times input power.
Efficiency = power output / power input = P out put /
Useful range of gear efficiency
Gear Efficiency
Spur (98–99)%
Let’s take efficiency 99%
0.99* = and P=2* *n*T/60
Where P-power, T-torque and n-Rotational speed of the gear (rpm)
P=2* *n*T/60
0.99*2* *Tinput * /60 =2* *Toutput * /60
0.99* * = *
Where =60*Pinput / (2* *ninput )
0.99*(60* / (2* *ninput ))* =Toutput *
=0.99*(60* /2* *ninput )* /
=0.99*60* / (2* *noutput )
Given data = 1KW
= =71.85rpm
=0.99*60*(1KW)/ (2* *71.85rpm) = 131.57Nm
Before we determine the geometry of the gear and the pinion on each stage let’s select
the gear and pinion type and material for the gear and pinion.
Select of Gear and Pinion type
Spur gears have teethes that are straight and arranges parallel to the axis of the shaft
that carries the gear. The curved shape of the faces of the spur gear teethes have a
special geometry called an involutes’ curve. This shape makes it possible for two
FINAL PROJECT 18
gears to operate together with smooth, positive transmission of power. Straight spur
gear drives have the advantage of no axial loading
Spur gears are the cheapest of all types for parallel shaft applications. Their straight
teeth allow running engagement or disengagement using sliding shaft and clutch
mechanisms. Typical applications of spur gears include manual gearboxes. And the
input speed is given is 120rpm.
At the beginning of the design, in order to select the type of gear teeth, we may use
the formula of the empirical velocity given by:
V= 0.11 √
Where =Input power=1KW
=input velocity.
=output velocity.
V= 0.11 √ where Pin = 1kw
= = =12.56m/s
= = 7.52m/s
= 0.11( √ ) = 1.92m/s thus the gear type
of this design is super gear
Conclusion:
There for the gear selected for the gear and the pinion is Spur Gear and Spur Pinio n
because of the above reasons and given value of input speed.
Material selection for the Gear and Pinion
The material used for the manufacture of gears depends upon the strength and service
conditions like wear, noise etc. The gears may be manufactured from metallic or
non-metallic materials. The metallic gears with cut teeth are commercially obtainable
in cast iron, steel and bronze. The non-metallic materials like wood, rawhide,
FINAL PROJECT 19
compressed paper and synthetic resins like nylon are used for gears, especially for
reducing noise. The cast iron is widely used for the manufacture of gears due to its
good wearing properties, excellent machinability and ease of producing complicated
shapes by casting method. The cast iron gears with cut teeth may be employed, where
smooth action is not important. The steel is used for high strength gears and steel may
be plain carbon steel or alloy steel. The steel gears are usually heat treated in order to
combine properly the toughness and tooth hardness. To select the material for the gear
and pinion based on those properties
Table 1 Material features, application and precision rating
Material Applications Outstanding Features Obtainable

Applications Precision Rating
Cast Irons Low cost, good Large-size, moderate Commercial quality

machining, high power rating,
Internal damping commercial gears
Cast Steels Low cast, high Power gears, medium Commercial quality
strength
Ratings
Plain-Carbon Steels Good machining, Power gears, medium Commercial to

heat-treatable medium precision
Ratings
Alloy (steel) Heat treatable, highest Severest power Precision and high
requirements precision
strength durability
Some of the outstanding features, application and obtainable precision rating of the
gear martial.
Table 2 Gear and pinion material tensile strength and Brinell hardness number
Material Tensile Strength (N/mm2 ) Brinell hardness number
Cast Irons (Tempered and 350 365

Heat treated)
Cast Steels 550 145
Carbon Steels (40 Cr 1 Mo 900 350
FINAL PROJECT 20
60,Hardened and tempered)
Alloy (steel) 600 90
Tensile strength and Brinell hardness number of the Gear and Pinion materials.
The combined of gear and pinion

The majority of power gears are manufactured from hardened and case hardened steel.
Other materials used such as
Table 3 the combined of gear and pinion
Gear Material Pinion Material
Cast iron Cast iron
Cast iron Carbon steel
Carbon steel Alloy steel
Alloy steel Alloy steel
Alloy steel Case hardened steel
Table typical material matches for gears and pinions.
By using the above two tables to select the materials for both gears and pinions. And
by making Pinion harder than Gear to equalize wear. Beneficial results from a wear
standpoint are obtained by making the pinion harder than the gear. The pinion, having
a lesser number of teeth than the gear, naturally does more work per tooth, and the
differential in hardness between the pinion and the gear (the amount being dependent
on the ratio) serves to equalize the rate of wear. The harder pinion teeth correct the
errors in the gear teeth to some extent by the initial wear and then seem to burnish the
teeth of the gear and increase its ability to withstand wear by the greater hardness due
to the cold-working of the surface. In applications where the gear ratio is high and
there are no severe shock loads, a casehardened pinion running with an oil-treated
gear, treated to a Brinell hardness at which the teeth may be cut after treating, is an
excellent combination. The pinion, being relatively small, is distorted but little, and
distortion in the gear is circumvented by cutting the teeth after treatment.
The material selected for the Gear and Pinion are cast iron (grade 35, Heat treated)
and Carbon Steels (40 Cr 1 Mo 60, Hardened and tempered.
For the Gear

FINAL PROJECT 21
There for material for the gear are Cast Irons (Tempered and Heat treated)
BHN=Brinell hardness number = 350
Minimum tensile strength = 350 N/mm2
Note: The allowable static stress ( ) for gears is approximately one-third of the
minimum tensile strength ( ) i.e. = /3.
= /3=350 N/mm2 /3=116.7 N/mm2
For the Pinion
There for material for the pinion is Carbon Steels (40 Cr 1 Mo 60, Hardened and
tempered)-R [4]
BHN=Brunel hardness number = 355
Minimum tensile strength = 900 N/mm2
Note: The allowable static stress ( ) for pinion is approximately one-third of the
minimum tensile strength ( )
i.e. = /3
= /3=900 N/mm2 /3=300N/mm2
Normal Pressure angle α
An important variable affecting the geometry of the gear teeth is the normal
pressure angle. This is generally standardized at 20o . Other pressure angles should be
used only for special reasons and using considered judgment. The following changes
result from increasing the pressure angle
 Reduction in the danger of undercutting and interference

 Reduction of slipping speeds
 Increased loading capacity in contact, seizure and wear
 Increased rigidity of the tooting
 Increased noise and radial force
FINAL PROJECT 22
Table 4 depth angle and number of teeth
System of gear teeth, υ Minimum number of teeth on the

pinion
14.50 composite 12
14.50 full depth in 32

volute
200 full depth in volute 18
200 sub in volute 14
The minimum number of teeth on the pinion is shown blow
And because of the above reason let’s use pinion of 200 full depth in volute.
There for GA - input pinion gear

GB – out put gear from pinion gear
=1.8and = 1.67
ZA + ZB = constant
There for = 1.67 = ZB / ZA , ZB = 1.67* ZA
ZA + ZB = constant
2.67*ZA = constant
The number of teeth on the pinion (ZP ) in order to avoid interference may be obtained
from the following relation
ZA
√ ( )
Where AW = Fraction by which the standard addendum for the wheel should be
multiplied, usually =1
G = Gear ratio or velocity ratio = ZG / ZP = DG / DP ,
υ = Pressure angle or angle of obliquity.
FINAL PROJECT 23
For pinion A
Known data: G = 3, Φ=20o
ZA
√ ( )
ZPA=8.03 let ZA=8
ZB=1.67*ZA =1.67*8 => ZB=14
ZA +ZB = constant
8+14=22
By using the above formula and the table value i conclude that there is no interference
and the table blow show the number of teeth in the pinion and gear.
Table 5 standard proportions in module
Gear’s N-number of teeth n-rotational speed of the gear (rpm)
GA - input pinion gear ZA=8 120
GB – out put gear from pinion gear 1 ZB=14 71.85
Interference
The contact of portions of tooth profiles that are not conjugate is called interference. The initial and final
points of contact are designated A and B, respectively, and are located on the pressure line. Now notice
that the points of tangency of the pressure line with the base circles C and D are located inside of points
A and B. Interference is present. Contact begins when the tip of the driven tooth contacts the flank of the
driving tooth. In this case the flank of the driving tooth first makes contact with the driven tooth at point
A, and this occurs before the involutes portion of the driving tooth comes within range. In other words,
contact is occurring below the base circle of gear 2 on the non-in volute portion of the flank. The actual
effect is that the in volute tip or face of the driven gear tends to dig out the non-in volute flank of the
driver. In this example the same effect occurs again as the teeth leave contact. Contact should end at
point D or before. Since it does not end until point B, the effect is for the tip of the driving tooth to dig
out, or interfere with, the flank of the driven tooth.When gear teeth are produced by a generation process
interference is automatically eliminated because the cutting tool removes the interfering portion of
FINAL PROJECT 24
the flank. This effect is called undercutting; if undercutting is at all pronounced, the undercut tooth
is considerably weakened. Thus the effect of eliminating interference by a generation process is
merely to substitute another problem for the original one. The smallest number of teeth on a spur
pinion and gear,1 one-to-one gear ratio, which can exist without interference is NP . This number
of teeth for spur gears is
Figure 3 Interference of meshing gears
Interference can be eliminated by using more teeth on the pinion. However, if the pinion is to
transmit a given amount of power, more teeth can be used only by increasing the pitch diameter.
Interference can also be reduced by using a larger pressure angle. This results in a smaller base
circle, so that more of the tooth profile becomes involutes. The demand for smaller pinions with
fewer teeth thus favors the use of a 20◦ pressure angle even though the frictional forces and bearing
loads are increased and the contact ratio decreased.
Module CALCULATION
It is the ratio of the pitch circle diameter in millimeter to the number of teeth. It is usually
denoted by m.
Mathematically, Module, m = D / Z
FINAL PROJECT 25
Where D-Pitch circle diameter: It is the diameter of the pitch circle. The size of the gear is usually
specified by the pitch circle diameter. It is also called as pitch diameter.
Z- Number of teeth
Calculation of module for first stage
We know that power transmitted by the gear,
P=2* *n*T/60
We know that the torque transmitted by the pinion gear in first stage
T = 60* / 2* *
Given data P= 1KW and = 120rpm
T = 60*1KW / 2* * 120rpm = 79.57Nm
The design tangential tooth load is obtained from the power transmitted and the pitch line velocity
by using the following relation:
WT =P* CS / V
P = Power transmitted = 1KW
CS-service factor (let’s take C S=1)
WT =1000W/1.068*m = 936.3 / m (N)
The pitch line velocity, V= *D* / 60 = *m* ZA* / 60
Where D - Pitch circle diameter
m – Module (mm)
ZA- Number of teeth = 8
-Speed in (r.p.m)=120rpm
V= *m*8*120rpm / 60 (mm/sec) = 50.26*m (mm/s)=0.05026m (m/s)
We know that tangential tooth load, apply the Lewis equation as follows
WT = *b.π m.y = ( × ) *b*π *m*y*(L-b)/L
Notes: where (L-b)/L is bevel factor.

FINAL PROJECT 26
(i) The Lewis equation is applied only to the weaker of the two wheels (i.e. pinion or gear).
(ii) When both the pinion and the gear are made of the same material, then pinion is the weaker.
(iii) When the pinion and the gear are made of different materials, then the product
of ( × y) or ( × y) is the deciding factor.
The Lewis equation is used to that wheel for which (σw × y) or (σo × y) is less.
There for the gear and the pinion made from different material the weaker is taken
Gear is cast iron (Tempered and Heat treated)with = 116.7 N/mm2 (ZB=14)
Carbone Steels (40 Cr 1 Mo 60, Hardened and Tempered) = 300N/mm2 (ZA=8)
Tooth form factor for 20° full depth in volute system is = y
pinion y=0.154-(0.912/Z) = 0.154-(0.912/8)=0.04
gear y=0.154-(0.912/Z) = 0.154-(0.912/14)=0.088

2
* ,pinion =0.04*300 N/mm =12 N/mm2
* ,gear =0.88*116.7 N/mm2 =10.27N/mm2
There for the weakest is selected ,gear =116.7 N/mm2 and y=0.133
= × -permissible working stress, -Allowable static stress
Let us take velocity factor, for accurate cut gears
=6 / (6+V) = 6 /(6+0.05026m)
√( ) ( ) √( ) ( ) √( ) ( )
L=m/2[(142 +82 )1/2 ] m
b= L/3=8.06/58m/3 m
L-length b/n center gear and pinion
b - Width of gear face.
WT = ( × Cv) b*π* m*y*(L-b)/L
116.7 π* m
FINAL PROJECT 27
( )
=129.6m2
129.6m3 =5617.8+47.06m
129.6m3 - 47.06m - 5617.8 = 0
Solving this equation by hit and trial method, we find that
m = 3.56mm
Note: The recommended series of modules in Indian Standard are 1, 1.25, 1.5, 2, 2.5, 3, 3.5, 3.75, 4,
5, 6, 8, 10, 12, 16, 20, 25, 32, 40 and 50.
There for module became m=3.5mm
Fig.3
The following table shows the standard proportions in module (m) for the two gear systems as
discussed in the previous article.
FINAL PROJECT 28
Particulars 200 full depth in volute system
Module M
Number of teeth Z
Addendum 1*m
Dedendum 1.25*m
Working depth 2*m
Minimum total depth 2.25*m
Tooth thickness 1.5708*m
Minimum clearance 0.25*m
Fillet radius at root 0.4*m
Pitch circle diameter Z*m
Face width 2.68*m
Dedendum circle (Root circle diameter) Z*m*cos υ
Adden um circle Z*m*cos υ+2.25*m
When two gears mesh, it is essential for smooth operation that a second tooth begins to make
contact before a given tooth disengages. The term contact ratio is used to indicate the average
number of teeth in contact during the transmission of power. The contact ratio is defined as the
ratio of the length of the line-of-action to the base pitch for the gear. The line-of-action is the
straight- line path of a tooth from where it encounters the outside diameter of the mating gear to
the point where it leaves engagement.
Forces and stress analysis on Pinion and Gear
Consider each tooth as a cantilever beam loaded by a axial load (WN) or (Wa) as shown in Fig
below. It is resolved into two components i.e. tangential component (WT ) and radial component
FINAL PROJECT 29
WR) acting perpendicular and parallel to the centerline of the tooth respectively. The
tangential component (WT ) induces a bending stress which tends to break the tooth. Hence, the
bending
Fig 4 action of loads on teeth
stress is used as the basis for design calculations.
FOR PINION A (ZA = 8 and m=3.5mm)
WT =P* CS / V
CS-service factor (let’s take C S=1)
N=120rpm
V= *D* / 60 = *m*ZA * / 60
= *3.5mm*8*120rpm/60=175.93mm/s = 0.1759m/sec
WT =P* CS / V =(1KW*1)/0.1759m/sec
=5685N
=WT tan =5685N*tan 200
=2069N
=WT /cos =5685N/cos200
=6049.8N
FOR GEAR B (ZB = 14 and m=3.5mm)
WT=P* CS / V
FINAL PROJECT 30

CS-serves factor (let’s take CS=1)
V= *D*n
GB,input / 60 = *m*ZB*nGB,input / 60
= 3.5mm*14*71.85rpm/60=58.67mm/s = 0.05867m/sec
WT=P* CS / V =1KW*1/.05867m/sec
=58.67N
=WT tan =N*tan 20
=21.35N
=WT / cos =1880.87N/cos20
=62.44N
Figure 4 sample image of teeth
FORCE ANALYSIS
FORCE RIQUIRED FOR THE SYSTEM
From the gravitational force analysis:
F=mg because our force applied due to gravity. So;
= g=50kg*9.81=490.5N 55kg*9.81 ⁄
FINAL PROJECT 31
Gravity(in
No of masses Mass ( in kg) No of forces Force(in N)
2
m/s )
9.81
m1 50 9.81 F1 490.5
m2 55 9.81 F2 539.55
m3 60 9.81 F3 588.6
m4 65 9.81 F4 637.65
m5 70 9.81 F5 686.7
m6 75 9.81 F6 735.75
m7 80 F7 784.8
Table 6 force required to apply on the pedal
4.3.2 SHAFT AREA
Since the shaft circular in shape
A =π
( )
π =126.67
No of diameters Diameter( in mm) No of areas Area(in mm2 )

d1 12.7mm A1 126.67
d2 25.4mm A2 506.71
d3 38.1mm A3 1140.09
d4 50.8 A4 2026.82
Table 7 area of the shaft on which the force is applied
4.3.3 PRESSURE REQUIREMENT FOR THE SYSTEM
p= from the pressure analysis formula
P= = =3.869* pa
FINAL PROJECT 32
Pressure(in Pressure(inN
(in N) Area(in mm2) (in N) Area(in mm2)
N/mm2) /mm2)
126.67 3.869 126.67 4.647
506.71 0.986 506.71 1.126
490.5 588.6
1140.09 0.430 1140.09 0.516
2026.82 0.242 2026.82 0.315
Pressure(in Pressure(in
(in N) Area(in mm2) (in N) Area(in mm2)
N/mm2) N/mm2)
126.67 4.259 126.67 5.034
506.71 1.065 506.71 1.258
539.55 637.65
1140.09 0.473 1140.09 0.559
2026.82 0.266 2026.82 0.315
Area Pressure(i Pressure(i Area

(in Area (in (in Pressure(i
(in (in n n (in
N) mm2) N) n N/mm2)
N) mm2) N/mm2) N/mm2) mm2)
126.67 126.67
5.691 126.67 5.808 6.189
506.71 506.71
1.355 506.71 1.452 1.549
686.7 1140.0 735.75 784.8 1140.0
0.602 1140.09 0.645 0.688
9 9
0.339 2026.8 0.363 0.387
2026.8 2026.8
Table 8 pressure distribution when the force is applied on the area of the
mechanism.
ENERGY INPUT FOR SYSTEM

The energy input for the mechanism is the potential energy because the force applied
is the force due to gravity. So estimate the input energy we have to consider the height
of the operator to perform the mechanism. As we have taken the height in design
specification; H= (140-170). So;
PE=mgh
PE1 =F1h1=490.5N*1.4m=686.7j
FINAL PROJECT 33
(in N) Height (in m) Energy (in J) (in N) Height (in m) Energy (in J)
1.4 686.7 1.4 824.04
1.45 711.225 1.45 853.47
1.5 735.75 1.5 882.9
490.5 1.55 760.275 588.6 1.55 912.33
1.6 784.8 1.6 941.75
1.65 809.325 1.65 971.19
1.7 833.85 1.7 1000.12
(in N) Height (in m) Energy (in J) ( in N) Height (in m) Energy (in J)
1.4 755.37 1.4 892.71
1.45 782.4375 1.45 924.5925
1.5 809.325 1.5 956.475
539.55 1.55 836.28 637.65 1.55 988.3575
1.6 863.28 1.6 1020.24
1.65 890.2575 1.65 1052.1225
1.7 917.235 1.7 1084.005
(in Height Energy (in Height Energy (in (in Height Energy
N) (in m) (in J) N) (in m) J) N) (in m) (in J)
1.4 961.38 1.4 1030.05 1.4 1098.7
1.45 995.72 1.45 1066.83 1.45 1137.9
1.5 1030.1 1.5 1103.62 1.5 1177.2
686.7 1.55 1064.4 735.75 1.55 1140.41 784.8 1.55 1216.4
1.6 1098.7 1.6 1177.2 1.6 1255.6
1.65 1133.1 1.65 1213.98 1.65 1294.9
1.7 1167.4 1.7 1250.77 1.7 1334.1
Table 9 energy input for the system to operate the machine.
4.3.2 SHAFT DESIGN
The shaft should be designed on the basis or on the consideration of strength and
rigidity. We select carbon steel
Grade 50C12
Ultimate tensile strength ( ) =700Mpa
Yield strength ( ) =390Mpa
F=637.7=638N
D=31.8mm=0.0318m
L=1.4m
FINAL PROJECT 34
Figure 5 shaft
Shaft subjected to the combination of both twisting moment and bending moment.
When shaft is to combined twisting moment and bending moment, then the shaft must
be designed on the basis of the two moment simultaneously. The following two
theories are important from the subject point of view.
Maximum shear stress theory
Maximum normal stress theory
But we use the formula of maximum shear stress theory since the material we selected
for this
shaft material is ductile material.
=√
we have the following equation when shaft is subjected to twisting moment

= …………………………….………..………….eq (1)
Where T =twisting moment acting up on the shaft
J =polar moment of inertia of the shaft about the axis of rotation
τ =torsional shear stress and
r =distance from the neutral axis to the outer most fiber or r=
We know that for round solid shaft polar momentum of inertia (J)
J= *
So the eq (1) may be written as the following
T= *τ* …………………………………..…….…………………eq (2)

So, the torque of the shaft when the force 637.6N is applied on the shaft of 31.8mm in
diameter having 7.94 is calculated as the following.
T= *τ*
FINAL PROJECT 35
We know that τ= but A= =794.2

=
= 0.8
=0.8Mpa
T= *0.803293756 *( )
=5072N.mm
We the following equation when the shaft is subjected to bending
= ……………………………………………….eq (1)
Where M=bending momentum
I=momentum of inertia of cross-sectional area of the shaft about
the axis of the shaft.
=bending stress
Y=distance from neutral axis to the outer most fiber
It is known that for a round solid shaft momentum of inertia (I),
I= ………………………………….eq (2)
Fig 3.3 bending momentum diagram

Take ΣMA=0
RB*1400mm-638N*700mm=0
RB= =319N
Again taking Σ =0
+ -F=0
=F-
=638N-319N
=319N
Σ = *1.4 + F*0.7
=319*1.4 + 638*0.7
=893.2N.m
FINAL PROJECT 36
= 0+893.2=893.2N.m
=
I= = =51471.85
y=
From the above
= , = =277.65Pa
=√ =√ =2.132kpa
Factor of safety
F.S=
But = = =195Mpa and
=0.18 =0.18*700Mpa=126Mpa
S0 safety factor of the shaft will be:

F.S= = =1.5
Mass of shaft
M=ƍ*v
Where mass density of steel is 7850 ⁄ and volume shaft is area of shaft
multiplied by lengthof shaft (the shaft is solid)

V=794.2 *1400mm
=1111880 =0.001111880
So, mass of shaft will be:
M=7850 ⁄ *0.001111880 =8.73kg
Weight of shaft
W=mg=8.73kg*9.8=85.6N
Angular velocity of shaft
V= = =100 ⁄
FINAL PROJECT 37
4.3.3 FLYWHEEL DESIGN
Specification
Selected material is cast iron having
Tensile strength=100Mpa
Compressive strength=400Mpa
Shear strength=120MPa
Mass of flywheel=20kg (our assumption)
Density of cast iron=7200 ⁄
The flywheel should be designed based on the consideration ofCross-sectional area

dimension of the flywheel rimDiameter and length of hub
Figure 6 flywheel
CROSS-SECTIONAL AREA OF THE RIM

A=b*t
=2
Where t=thickness of the flywheel rim
b=width of the flywheel rim and b=2t
Assume mass of the flywheel rim is 20kg diameter of the flywheel is 150mm
Mass (m) =density*volume
=A* D*ρ
Where A=area of the rim=2
D=diameter of the flywheel
ρ=density of the cast iron=7200 ⁄
Because the material that we selected for this purpose is cast iron
FINAL PROJECT 38
So 20kg=2 *π*0.15m*7200 ⁄
10kg= *π*0.15m*7200 ⁄
=0.002947
t=√ =0.054289m=54.289mm=54mm
Area of the rim
A=2 =5832m
Volume of the flywheel
V= A*πD
=3.14*5832m *120mm
=2197497.6
Width of the flywheel rim (b)
b=2t =2*54mm=108mm
DIAMETER AND LENGTH OF THE HUB
Let, d=diameter of the hub= 2
=diameter of the shaft
l=length of the hub
We know the shaft diameter before d1 (31.8mm)
The diameter of hub (d) is twice of the shaft diameter (d1)
d=2 =2*31.8mm=63.8mm=64mm and
Length of the hub (l) is twice of the width of the rim (b)
L=2*b =2*108mm=216mm
Weight of the flywheel=m*g=20kg*9.81 ⁄ =196.2N
Angular velocity
V= = =376.8mm⁄s
4.3.4 CLUTCH DESIGN
Selected material is alloy steel 35Ni1cr60

Mass of clutch=15kg (assumption)
We design the clutch by considering the two friction surfaces maintained in contact
by an axial thrust (W) as shown in the figure below.
Figure 7 clutch
Where: p=intensity of axial pressure with which the contact surface are haled
together
FINAL PROJECT 39
r1and r2 =mean radius of the friction face

μ=coefficient friction
W=an axial thrust.
Consider an elementary ring of radius (r) and the thickness diameter (dr) in the fig.
3.5
We know that area of the contact surface or friction surface
A=2 r*dr
Therefore: normal or axial force on the ring
W=pressure*area
=p*2 r*dr and
The frictional force on the ring acting tangentially at radius (r):
Fr=μ* W=μ*p*2 r*dr
Therefore: frictional torque (TR) acting on the ring will be
TR=Fr*r=μ*p*2 r*dr*r
TR=2 *μ*p*dr
The pressure is uniformly distributed over the entire area of the friction face as shown
in the fig. (a), then the intensity of pressure will be:
P=
Where:W=axial thrust with which the friction surfaces are haled together.
We have discussed above that the frictional torque on the elementary ring of radius (r)
and thickness (dr) is:
TR = 2π *μ*p*dr
Integrating this equation within the limits from and for total frictional torque.
Therefore: total frictional force acting on the friction surface or on the clutch is:
T=∫ π ∗ μ ∗ p ∗ dr=2πμp [ ⁄ ] =2πμp[ ]
=2πμ* * ]= ⁄ ]π w
=N*W*R
Where: R= ⁄ ]
R=mean radius of the friction surface.

The plate clutch having a single driving plate with contact surface on each side is
required to 20 w at 60 rpm. The outer diameter of the contact surface is to be 35mm.
the coefficient of friction is 0.4 and the uniform pressure is 2.06 ⁄ and the outer
diameter of the contact surface (d1) is 35mm.
Then we have to determine the inner diameter (d2) of the contact surface.
We know that the torque transmitted by the clutch.
T= = =3.1Nm=3100Nmm
Axial thrust with which the contact surfaces are held together is:
W= Pressure*Area =p*π* =2.06*[(17.5mm) -( )]
W=1982[1- ]……………….……………eq (1)
FINAL PROJECT 40
And mean radius of the contact surfaces for the uniform pressure condition is:
R= ⁄ ]
R= ⁄ ]…………………….....eq (2)
We know the torque transmitted by the clutch
T=ɳ*μ*w*R…………………………………………..eq (3)
By substituting eq (1) and eq (2) in eq (3) we will gate
T= ɳ*μ*6.5*[(17.5mm) -( )* ⁄
=2*0.4*6.5*[(17.5mm) -( )* ⁄
= ⁄ *2*0.4*6.5*[(17.5mm) -( )]
=3.5*[(17.5mm) -( )]
But the torque transmitted by the clutch is 3.1Nm or 3100Nmm from the privies
calculation.
T=ɳ*μ*w*R
3100N.mm=3.5*[(17.5mm) -( )]
= [(17.5mm) -( )]
885.7=5359.4-
=4473.7
=√
=16.477mm, =33mm
Weight of clutch
W=m*g =15kg*9.81 ⁄ =147N
4.3.5 LEVER DESIGN
We design the lever for operating the clutch to connect and disconnect the operation.
The lever can be operated either by a single person or by two persons. The maximum
force in order to operate the lever may be taken as 400 N and the length of handle as
300 mm. In case the lever is operated by two persons, the maximum force of
operation will be doubled and length of handle may be taken as 500 mm. The handle
is covered in a pipe to prevent hand scoring. The end of the shaft is usually squared so
that the lever may be easily fixed and removed. The length (L) is usually from400 to
450 mm and the height of the shaft Centre line from the ground is usually one meter.
In order to design such levers, we have to put the following in to consideration.
The diameter of the handle (d)
The cross-section of the lever arm is usually rectangular having uniform
thicknessthroughout.
The induced shear stress in the section of the lever arm near
theboss, caused by the twisting moment
FINAL PROJECT 41
checking the maximum principal or shear stress

The diameter journal of the shaft.
SPECIFICATION
We select cast iron having

Tension and compression =80Mpa
Shear stress =50Mpa
Length of the handle=300mm
Length of the arm=400mm
Overhang of the journal=100mm
Mass of lever=2kg (assumption)
Figure 8 lever
NB: - It is assumed that the effort (p) applied on the handle acts at ⁄ of the
length. Thepermissible bending stress for the lever material may be taken as 50Mpa
and shear stress for shaftmaterial as 40Mpa. The lever is acted by single a person.
4.3.6 HANDLE DESIGN
Since the force applied acts at a distance of ⁄ length of the handle from its free
end, thereforethe maximum bending momentum is:
M= (1 - ⁄ )p∗ l= ⁄ p*l
= ⁄ *400∗300=80*103 N-mm
Section modulus (Z)
Z= ⁄ *
FINAL PROJECT 42
Z=0.0982* …………………………….…………eq (1)

Resisting bending momentum
M= *Z=50*0.0982* M=4.91 N-mm……………………………..……eq (2)
From equation 1 and 2 we will gate the diameter of the handle

So the diameter is
= =16.3*
=√
=25mm
Area of the handle
A=
=490.6
Volume of the handle
V=A*L=490.6 *300mm
=147187.5
4.3.7 LEVER ARM DESIGN
Assume the lever arm is designed for 25% more bending momentum, so the
maximum bending
Momentum of the lever is:
M=1.25p*l =1.25*400*400
=200* N-mm
The section modulus (Z), since the lever is rectangular section:
Z= ⁄ *t*
Where: t=thickness of the lever arm in mm and
B=width of the lever arm near the boss, in mm
Assume B=2t
Z= ⁄ *t* = ⁄ *t*( )
=0.667
From the bending stress ( )
= = , 50=
=
=6* =√ =18.2=20mm
B=2t=2*20=40mm
Area of lever arm
A=2
=800
Volume of lever arm
V=A*h=800 *400mm
FINAL PROJECT 43
=320000
T0tal volume
Vt=320000 +147187.5
=467187.5
Including bending and shear stress we have to check the lever arm
Bending momentum on the lever arm near the boss
(Assuming that the length of the arm existed up to center of the shaft) is given by:
M=p*l=400*400
=160* N-mm
Section modulus (Z)
Z= ⁄ *t* = ⁄ *20* =5333
= = =30Mpa
Therefore: Included bending stress is within safe limits.

The twisting momentum:
T= ⁄ p*l = ⁄ ∗ 400 ∗ 300
=80* N-mm
From twisting momentum
T= ⁄ B* *τ80* N-mm= ⁄ *40* *τ
So, τ= =22.5Mpa
Check the cross-section of the lever arm for maximum principal or shear stress
maximum principal stress
( )= ⁄ [ (+ √( +4 )]
= ⁄ [30+√( + )] =42Mpa
Maximum shear stress

τ (max) = ⁄ +√( +4 )
τ (max) = ⁄ +√( + ) =27Mpa
Therefore the maximum principal and shear stresses are also within safe limit.
4.3.8 SHAFT JOURNAL DESIGN
Since the journal of the shaft is subjected to twisting momentum and bending
momentum, there for: its diameter is obtained from equivalent twisting momentum, so
Equivalent bending momentum is:
Te= √ ( )
FINAL PROJECT 44
=400√ ( )
From the equivalent twisting momentum (Te)
200* = ⁄ ∗ τ∗
200* = ⁄ ∗ 40∗
=
D= √ =30mm
Weight of lever
W=mg=2kg*9.81 ⁄ =19.6N
4.3.9 PEDAL DESIGN
The pedal is used to rotate the shaft when the force is applied on it. When we design
the pedal for this mechanism we essentially consider the following.
Figure 9 pedal
Let l=length of rod of pedal

y=height of foot
D=diameter of the pedal
h=total length of the pedal
x=length of foot
l+y=43mm+24mm=67mm
x=26mm
t=20
FINAL PROJECT 45
From the measurement of pedal of bicycle we assume the total length (h) of the pedal
is equals to 100mm.
h=D+l+y
D=h-(l+y)
D=100mm-(43mm+24mm)=33mm
Total area
AT=A1+A2+A3
= ⁄ = ⁄ *(33 )
=855
=t*l
=20mm*43mm=860
=x*y
=26mm*24mm =624
AT= A1+A2+A3=855 +860 +624 =2339
Volume of the pedal
V=AT*h=2339 *100mm
=233900 =0.0002339
Mass of the pedal
M=ƍ*v
Where ƍ=density of the pedal
V=volume of the pedal
But the volume the pedal is 2700 ⁄ because the material that we selected is
aluminum
So, M= ƍ*v=2700 ⁄ *0.002339m3
=0.63153kg
Weight of the pedal
W=m*g=6.21kg*9.81 ⁄
=6.1953093N=6.2N
For four pedal w=6.2*4=24.8N
Stress of the pedal

δ= = =0.0267 ⁄
4.3.10 KEY DESIGN
Key is the component used to prevent the relative motion or rotation between the shaft
and the flywheel when we connect them to transmit the torque due to the applied
force. When a key is used in transmitting torque from the shaft to a rotor or hub, there
are two types of forces acts on the key.
Force (F1) due to fit of the key in in its key way, as in a tight fitting straight key
or in tapered key driven in place. These forces produce compressive stresses in the
key which are difficult to determine in magnitude.
FINAL PROJECT 46
Force (F) due to the torque transmitted by the shaft. These forces produce
shearing and compressive (or crushing).The distribution of the force along the length
of the key is not uniform because the forces are concentrated near the torque- input
end. The non-uniformity of distribution is caused by the twisting of the shaft within
the hub. In designing a key, forces due to fit of the key are neglected and it is assumed
that the distribution of forces along the length of key is uniform.
Fig 3.8 key

Let T=torque transmitted by the shaft
F=tangential force acting at the circumference of the shaft
d=diameter of the shaft
L=length of key
h=thickness of key
b=width of key and
τ & =shear and crushing stress for the material of key
τ1=shear stress for shaft material.
The rectangular sunk key parameters have the following proportion:
b= ⁄
h=2 ⁄ = ⁄
Consider that due to the power transmitted by the shaft, the key may fail due to
shearing orcrushing.Considering shearing of the key, the tangential shearing force
acting at the circumference of theshaft:
F=area of resisting shearing*shear stress
=L*b*τ
Therefore torque transmitted by the shaft will be:
T=F∗ ⁄
=L*b*τ* ⁄ ………………………..eq (1)
Considering crushing of the key, the tangential crushing force acting at the
circumference of the
Shaft:
FINAL PROJECT 47
F=area of resisting crushing*crushing stress

=L* ⁄ *
Therefore torque transmitted by the shaft will be:
T= F∗ ⁄
= L* ⁄ * ⁄ * …………….…eq (2)
Consider that the strength of key will be equal both in shearing and crushing.
So L*b*τ* ⁄ = L* ⁄ * ⁄ *
= …………………….....eq (3)
In order to find the length of the key to transmit full power of the shaft, the shearing
of the key isequal to the torsional shear strength of the shaft.
We know that shearing strength of the key
T= L*b*τ* ⁄ ……………………………...eq (4)
Torsional shear strength of the key
T= ⁄ *τ1* ………….………….…………eq (5)
From eq (4) & eq (5) we will gate
L*b*τ* ⁄ = ⁄ *τ1*
L=1.571d since, we select the same material for shaft and key
τ=τ1
L=1.571d…………………………...…………………eq (6)
Length of key
L=1.571d we have shaft diameter (d=32mm)
=1.571*32mm
=50.272mm
Width of key
b= ⁄ = =8mm
Thickness of key
h= ⁄ = ⁄ = =5.3mm
Volume of key
V=h*b*L=50.272mm*8mm*5.3mm
=2131.5
Shear stress (τ)
Since we select the materials for shaft and key they have equal shear stress.
τ=τ1 we have shear stress of shaft (τ1=803293.756 ⁄ )
=803293.756 ⁄
Crushing stress (δc)
We know that = from eq (3) so,
=3τ
=3*803293.756 ⁄ =2409881.268 ⁄
FINAL PROJECT 48
4.3.11 PULLY DESIGN
We have design the pulley by adapting the following procedure.

Dimension of the pulley
Dimension of the arms
Dimension of the hub
DIMENSIONS OF THE PULLEY
The dimension of the pulley may be obtained either from velocity ratio consideration
or centrifugal stress consideration. We know that the centrifugal stress induced in the
rim of the pulley (δt):
=ƍ*v2
Where: ƍ=density of rim material
=7200 ⁄ since the selected material is cast iron
V=velocity of the rim=
=
=628 ⁄
D=diameter of the pulley and
N=speed of the pulley
DIMENSIOM OF THE ARMS
We have taken four arms for the pulley diameter ( =200mm)

The cross-section of the arm is usually elliptical with major axis is equal to twice of
the minor axis. The cross-section is obtained by considering the arm as cantilever that
mean fixed at the hub andcarrying can center led loaded at the rim end. The length of
cantilever is taken equal to the radiusof the pulley. It is further assumed that any given
time the power is transmitted from the hub to the rim or vice verse through only halve
the total number of the arms.
Assume: T=torque transmitted
R=radius of pulley
ɳ=number of arms
Therefore: Tangential load per arm is (WT)
WT= =
⁄
Maximum bending momentum on the arm at the hub end:
M= *R=
DIMENSION OF HUB
The diameter of the hub (d1) may be fixed by the following relation:
d1=1.5d + 25mm
Where: d1=hub diameter
d=shaft diameter (take d=50mm)
L=hub length so,
FINAL PROJECT 49
d1=1.5d + 25mm
=1.5*50mm+25mm
=100mm
The diameter of the hub should not be greater than 2d.
The length of the hub (l)
L= ⁄ *d
= ⁄ ∗ 50mm
=78.54mm=79mm
Figure 10 pulley
The selected material is cast iron. Pulley transmits 20w at 60rpm, we take the
diameter of the pulley ( =100mm) and the pulley has four straight arms of elliptical
cross-section in which themajor axis is twice the minor axis. The allowable bending
stress is 1Mpa. Then we have to findthe dimension of the arm and mention the plan in
which the major axis of the arm should be lie.
We know that the torque transmitted by the pulley:
T=
=
=3.1Nm
Therefore: the maximum bending per arm at the hub end is:
M=
=
=1.5Nm and
Section modulus (Z)
Z= ⁄
FINAL PROJECT 50
Where: b1=minor axis and

a1=major axis=2b1 so
Z= ⁄
Z= ⁄
Z=
We know that the bending stress ( )
=
But Z=
=
⁄
=
⁄
=1500
So from the above result we have to calculate the minor and major axis.
The minor axis:
Z=
1500 =
so
=
=3821.7
=√
b1=15.6mm =16mm and
The major axis (a1) is equal to twice of minor axis (b1)
a1=2b =2*16mm =32mm
4.3.12 BUCKET DESIGN
To design the bucket we have to consider:

The bucket area
The bucket volume
The mass of the bucket
The weight of the bucket
the circular sectioning part of the bucket
Volume of water per bucket
Mass of water
The weight of the water
FINAL PROJECT 51
We select the aluminum alloy number 2012 for this material that has the yield
strength( =70Mpa), tensile strength ( =179Mpa), fatigue ( =90Mpa), elongation
in 2%in=22 andhardness=45HB. The specific gravity of the aluminum is 2.7.
Figure 11 bucket
Where: R=the major radius (take, R=25mm)

r =the minor radius (take, r=15mm)
h=the height between the minor and the major radius (take, h=40mm)
s=the length of the surface
BUCKET AREA
A=π(R+r) s or
= π (R+r)√) ( )
= (0.25m+0.15)√ ( )
=0.6407m2=640.7*
BUCKET VOLUME
V= ⁄ (R2+r2+r*R)
= ⁄ *0.04m (0.02 + 0.01 + 0.025*0.015)
=0.000513
=0.0005
MASS OF BUCKET
To determine the mass of the bucket, it is known that the specific gravity of the
aluminum that is
2.7.
S.G=
Where: S.G=specific gravity of aluminum
=density of aluminum
= density of water
FINAL PROJECT 52
So, the density of bucket is:

= =S.G*
=2.7*1000 ⁄
=2700 ⁄
Then mass of the bucket will be:

=
Mb= *
=2700 ⁄ *0.0051 =1.4kg
WEIGHT OF THE BUCKET

= *g
=1.4kg*9.8 ⁄
=14N
CIRCULAR SECTIONING PARTS OF THE BUCKET
Take D=20mm
Figure 12 sectioning part
Let A=area of sectioned part

G=location of centroid
Ix=∫ dA= moment of area about x axis
=∫ dA= moment of area about y axis
=∫ xydA= max.moment of area about x and y axis
JG=∫ dA=∫( + ) dA=Ix + = polar moment area about axis th.r G
x= =squared radius of gyration about x axis
( )
So, A= = =314.159
( )
Ix= = = =7853.98
=0
( )
JG= = =15707.96
VOLUME OF WATER TO OBTAIN FOR 10 GALLON

We decide that the amount of water to take up per one complete cycle is 10 gallons.
So, 1gallon=0.003785 =0.0038
FINAL PROJECT 53
10 gallons=x
By cross multiplication we gate x=0.038
So, the volume of water to obtain per one cycle is 0.038 .
MASS OF WATER FOR 10 GALLON

We know the density of fluid is:
ρ=
Where: =density of water=1000 ⁄
=volume of water
Mw=mass of the water
Mw= ρ*v=1000 ⁄ *0.03=38kg
WEIGHT OF WATER
The weight of water for 10 gallon will be:
W=Mw*g
=38kg*9.81 ⁄ =372.78N
4.3.13 DISCHURGING PIPE DESIGN
The design of the pipe involves the determination of inside diameter of the pipe and
its wall thickness.
INSIDE DIAMETER OF THE PIPE

The inside diameter of the pipe depends on up on the quantity of fluids to be deliver
Where: D=inside diameter of the pipe
V=velocity of fluid flowing per minute
Q=quantity of fluid carried per minute
t=thickness of the pipe
It is known that the quantity of fluid flowing per minute is:
Q=Area*velocity
Assume that the flow rate is 3 and the velocity of the fluid is 30 then,
Q=A*V
A= = 0.1
So the internal diameter of the pipe will be
A=
=
d=√
FINAL PROJECT 54
=√ =0.36m
WALL THICKNESS OF THE PIPE

The thickness of the wall (t) in order to withstand the internal pressure (p) may be
obtained by using a thin cylinder formula. Because the fluid transported is water.
According to the thin cylinder formula the wall thickness of the pipe will be:
t=
Where: =tensile strength of the pipe
P=pressure flow of the fluid
d=internal diameter of the pipe
The tensile strength of polyethylene material is 38Mpa from the property of selected
thermoplastic of material science of fourth edition. And pressure is 2.06 ⁄ from
the force analysis. So the thickness of the pipe will be:
⁄
t=
⁄
t=0.0098m=9.8mm
For the thin cylinder the internal diameter divided by the wall thickness must give
greater than twenty (i.e. >20).
Therefore: = =36.7=37
37>20 it is safe
VOLUME OF THE PIPE

V=A*t
Where: A=area of the pipe
t=thickness of the pipe
So, the volume of the pipe will be:
V=0.1 *0.0098m=0.00098
MASS OF THE PIPE
Mp= *VP
Where: =density of the pipe
VP=volume of the pipe
We select the polyethylene material having the density 960 ⁄ from the scienceand
engineering of the material selection fourth edition.

Therefore: Mp=960 ⁄ *0.00098
=0.941kg
WEIGHT OF THE PIPE
= *g
FINAL PROJECT 55
Where: =is mass of the pipe

g=gravity of the pipe
So, the weight of the pipe will be:
=0.941kg*9.81 ⁄
=9.23N
4.3.14 ROPE DESIGN
Specification
Height of the frame to support the component from the ground=1m
Height of the pulley to flywheel=3m
Height of the pulley to the top of the well=4m
Depth of the well=10m
To design the rope we have to consider the depth of the well, the distance from the top
of the well up to the flywheel (the height of the pulley from the flywheel and from the
top of the well), the weight of the discharging pipe, the weight of the bucket.
LENGTH OF THE ROPE
Length of the rope ( ) is the sum of (the height of the pulley flywheel +the height
of the pulley from the top of the well + the depth of the well).
=1m+3m+4m+10m
=18m
STRENGTH OF THE ROPE
We have to consider the rope have to be lift the load or lift the weight of the (bucket
+pipe+water). So the strength of the rope will be calculated as the following.
= + +
Where: =strength of the rope
=weight of the bucket
=weight of the water
Therefore: =15N + 9.23N +372.8N=396.03N
DIAMETER OF THE ROPE
We wire rope of the rope type from the rope property of machine design second
edition and its tensile strength 1800Mpa is 595 .
Where (d) is the diameter of the wire rope. Equating this tensile strength to design
load.
= 595
396.03N=595
=
⁄
=0.665
FINAL PROJECT 56
d=√
d=0.816mm
AREA OF THE WIRE ROPE
=0.38
Where: d is the diameter of the wire rope. But the coefficient of diameter (d) is
0.38 that have taken from the machine design second edition.
Therefore: the wire rope area is:

=0.38(0.816mm)
=0.31m
WEIGHT OF THE ROPE
To find the weight of the rope we have taken the weight coefficient
(0.0363 ⁄ ) from the type rope of machine design of second edition. So,
=0.0363 *length of the rope.

=0.0363(0.816mm) *18M
=0.0363 ⁄ *0.6659 * 18M
=0.4351N
Weight of operator must be greater than the sum lift up of the weight of (rope
+discharge pipe + bucket + water).
Therefore:
> + +
Where: =weight of the operator
=weight of the pipe
=weight of bucket
=weight of water
So, 637.7>0.4351N+14N+372N+9.23N
637.7>395.7N It indicate that the operator will operate easily.
4.3.15 FRAME DESIGN FOR MACHINE COMPONENT
For frame metals we select gray cast iron 4.5%C ASIM A-48
Tensile strength =130Mpa
Yield strength=200Mpa
FINAL PROJECT 57
4.3.16 WELDING DESIGN
We use the welding in the process to join the frame metals, pulley supporting metal
bars and operator handle.
Specification
Considering the load capacity we select Single transverse fillet weld due to its high
concentration and has high tensile strength.
Load capacity =weight of component applied on the frame
P=weight of (operator + shaft + flywheel + clutch + lever +pedal + other)
= (85.6+196.2+147+19.6+24.8+638) N =1111.2N=1.5KN
Length of welding (L=100mm)
Figure 13 welding design
Assumption
Since the weld is weaker than the plate due to slag and blow holes therefore the
weld is given a reinforcement which may be taken as 10% of the plate thickness.
In order to determine the strength of the fillet joint, it is assumed that the section
of the
fillet is a righted angle triangle with hypotenuse making equal angles with other two
sides.
Where, t=throat thickness
S=leg or size of weld
L=length of weld
t =S * sin
A=t*L
F=A*
Yield stress
From table of fillet weld joint (table 10.5 stresses for welded joint), the stress for all
type (Tension,
Compression, and Shear) is given by 80Mpa.
=80Mpa
FINAL PROJECT 58
The stress concentration factor for transverse fillet weld is given by 1.5. But for static
loading and any type of joint, stress concentration factor is 1.
Length of welding
L=100mm
Adding 12.5 for starting and ending
L=100mm+12.5mm
Throat thickness
In transverse fillet weld joint, the size of the weld S is equal to the thickness of the
plate ( )
S=
The throat thickness becomes
t = S * sin 450
Throat area
The minimum area of the weld or throat area is given by
A = Throat thickness * Length of weld
=t*l
= S * sin *32.5mm
= S*22.98mm
A = (22.98*S) mm
Since the weld is weaker than the plate due to slag and blow holes, therefore the weld
is given a reinforcement which may be taken as 10% of the plate thickness.
A=S * sin *32.5mm+ S * sin *32.5mm
A=45.96*S
The size of the weld
Case – 1 Static loading
The tensile strength of the joint for single fillet weld,
P=Throat area * Allowable tensile strength
P=45.96*S * 80Mpa
S= P / (45.96 * 80)
=1.5kN/ 3676.8
=0.40796mm
L=112.5mm
Case – 2 Fatigue loading
The tensile strength of the joint for single fillet weld
F = Throat area * Allowable tensile stress
Tensile stress for fatigue = Tensile stress of static loading / Stress concentration factor
= 80Mpa / 1.5
For fatigue = 53.3Mpa
P= (45.96*S * 53.3Mpa
S= (P/ (45.96*S * 53.3)
S= 1.5kN/ 2449.668
=0.612mm
We know that the size of the weld is less than or equal to the thickness of the plate.
In the above two cases, the size of the weld are less than the thickness of the plate.
Therefore, the dimension is safe.
Take the maximum of the two case (in fatigue loading) the weld size is
FINAL PROJECT 59
S=3
The stress developed
In order to have a safe welding portion, the permissible stress is must be greater than
the allowable stress.
Permissible stress
Permissible stress =
=
=100Mpa
Allowable stress
Allowable stress= P / A but
The throat area = (45.96*S)
= (45.96*3)
=137.88
P = 1.5kN /137.88
=10.87Mpa
The allowable stress is less than the permissible stress, so the design of the frame is
S=3
4.3.17 BEARING SELECTION
A bearing is a machine element which supports another moving machine element

(known as journal). It permits a relative motion between the contact surfaces of the
members, while carrying the load. A little consideration will show that due to the
relative motion between the contact surfaces, a certain amount of power is wasted in
overcoming frictional resistance and if the rubbing surfaces are in direct contact, there
will be rapid wear. If bearing is necessary for the mechanism we select from the
following ball bearing. principal dimensions ball bearing.
Bearing no. 206
Bore diameter= 30mm
Outside diameter =62mm
Width of bearing= 16 mm
FINAL PROJECT 60
Figure 14 bearing
4.3.18 DESIGN FOR FASTENERS
Bolts, screws and nuts used to hold the container holder on the frame have to
carry the summation load acts on it this maximum load. This load may shear the rivets
when it is not the rivets do not resist this load.
Washers are used to protect the outer surface of the connected material from
damage as the bearing or gear was torqued or turned with respect to the shaft.
Figure 15 fasteners
4.4 OUTPUT ENERGY

Output energy is the energy out or exposed during due to the work is done. So, for our
mechanism is potential energy the result from the process of pedaling motion at 60
rpm and transmitting power by shaft, flywheel, pulley and rope to achieve the out
put.so,
=( + + + )*
Where =output energy
=bucket weight
=water weight
=pipe weight
=rope weight
=height from the water level to discharge
FINAL PROJECT 61
= (14N+372.78N+9.23N+0.4351N)*14m
=396.4455N*14m
=5550kJ
Efficiency =1 –
=1 – but we minimum input energy (988.9KJ)
=1 −
=0.82*100
=82%
So the operation is safe.
FINAL PROJECT 62
CHAPTER FIVE
5.1 MANUFACTURING PROCESS
Manufacturing is the use of machines, tools and labor to produce goods for use or
sale. The term may refer to a range of human activity, from handicraft to high tech,
but is most commonly applied to industrial production, in which raw materials are
transformed into finished goods on a large scale. Such finished goods may be used for
manufacturing other, more complex products, such as aircraft, household appliance or
automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell
them to end users the "consumers". Manufacturing is a collection of interrelated
activities that includes product design and documentation, material selection,
planning, production, quality assurance, management and marketing of goods. The
fundamental goal of manufacturing is to use these activities to convert raw materials
in to finished goods on a profitable base. The ability to produce this conversion
efficiently determines the success of the enterprise. The five inputs required are raw
materials, equipment, tooling and fixtures, energy and labor.
Figure 16 manufacturing method
The manufacturing process for our machine is the following process:

We prepare the flywheel, lever handle, lever arm, pulley and beam for supporting by
cast molding process. We produce the shaft, clutch, pedal and bucket by molding
process. We produce the rope wire drawing process. We use lath machine turning,
FINAL PROJECT 63
tapering, treading, and surface finishing of components; like shaft, flywheel, clutch,
pulley, pedal, key and lever. We use the drilling machine for boring and drilling the
hole of the components: like the hole on the pedal ring, on the shaft, on the lever
parts, on the clutch, on cover of the shaft and on beam metals for frame We use the
electrical cutting ax sow for cutting the components; like shaft, lever parts, beam or
bar metals for frame and pedals. We use welding machine for joining the component;
like beam for frame.
5.2 COST ANALIYSIS
Cost analysis include the total cost expend on the machine to design the machine
components, manufacturing (to buy) the machine components, to assemble the
machine components and the payment for operator.
Table 10 cost analysis
Design cost in birr= 40,000

Machining cost in birr=2000
Assembling cost including welding in birr=1000
Salary cost per employment per month if the machine is used for community=3000
But if the machine used by individual the user by obtain the operator or may operate
by himself.
Total cost = component cost + design cost + machining cost + assembling cost +
salary cost.
=11200+40,000+6000
=57,200 birr
5.3 GENERAL ASSEMBLY
Assembling is the process of arranging the components at their appropriate location

for function able operation. After the selection of material for components, analysis
and design the components and manufacturing the components we have to be
assemble each component to get the available operation of the mechanism. So, we
FINAL PROJECT 64
assemble our design components of pedal powered water lifting machine as the
following stapes.
1. First adjust the metal bars of frame to support and hold the body of the machine
component, pulley supporting metal and handling metal to support the operator.
2. Inter the shaft in the pedals ring. Then fixing the pedal ring with shaft by bolt;
3. Locating the shaft on the frame at its supporting point.Putting the internal rotary
ball bearing if it is necessary to reduce the friction between the shaft and the
supporting metal. Join the above cover of the shaft to frame by bolt.
4. Adjust the clutch at one end-side the main shaft and meshing its fixed side with
shaft. Then fix the external part of clutch on the frame by bolt.
5. Adjust the lever and mesh it with driven shaft, fix the above holding shaft to the
frame by bolt. The handle of the lever can be supported with lever arm by bolt and the
lever arm mesh with lever boss by treed or fixed by wilding. Then the shaft and the
lever boss can be joined by spline the rectangular shape (journal) at the end of the
shaft and the rectangular shape inside of the boss.
6. Adjust the flywheel on the other end-side of the main shaft and join the flywheel
with shaft by bolt.
7. Fix one end-side of rope with flywheel
8. Adjust the pulley on the pulley supporting metal.
9. Extend the rope on pulley
10. Fix the other end of rope with bucket arm.
11. Lastly site the tanker at appropriate position of bucket side.
Assembly drawing
FINAL PROJECT 65
CHAPTER SIX
CONCLUSION AND RECOMMONDATION
6.1 CONCLUSION
The primary focus of this project is to create the equipment with the capability to lift
up the water from the ground or well by the means of energy generated by
human-muscle. The main purpose is to build the pedal powered water lifting machine
with a mechanism to convert mechanical energy created during the machine will
operated. The human body has the potential to create an enormous amount of energy
if we are able to channel it in the right way. Will considering the human energy our
project study how to generate power through the use of human energy and to promote
awareness of the belief that the human energy is an untapped resource can aid in
solving society’s escalating energy.
The benefits relating with the access to use the ground water provide a strong
agreement to increase resource allocations to interventions aimed at further improving
the current shortage of water situation, as a key entry point for achieving much wider
livelihood benefits.
Generally, most of farmers and pastorals this pedal powered water lifting machine is
one of the most advantageous type of water lifting machine used to help them during
the dry season and gate better revenues from agriculture and indirectly it is better to
came up for sustainable development for our country.
FINAL PROJECT 66
6.2 RECOMMONDATION
Our project included almost all design procedures and has full performance to operate
the mechanism with functional. We design all the main machine components properly
and due to time limitation we cannot conclude some related components but we put
into consideration to design in the future. But for design procedure due to the
limitation we decide as the following to some components such as bucket, frame for
the machine and stand bar for the pulley.
It decided to buy the tanker from the market with considering its property to
meet the performance.
It decided to buy the metal bars for frame.
It decided to buy the metal bars for used to support pulley
The frame metals, pulley supporting bars and the handle of operator by appropriate
welding process at appropriate position, length and height have to be joining to give
full function.
6.3 FUTUR WORK
Agriculture including cultivation, pastoral and farming is the back bone of our
country incomes. So to support such sectors we use agricultural machinery like pedal
powered water lifting machine. In this paper pedal powered water lifting machine
designed as the energy for operating is the human muscle as much as possible. But in
the future if other research will be done on this paper or will be modified by our group
member or by any one, they have consider following alternative additional.
Weight of the machine
Design the alternative mechanism with bucket to fellow water directly from
ground well to tanker.
Design additional self operating mechanism to open the check valve of the
bucket and direct the fellow of water to tanker during the bucket reaches at discharge
point.
Increase the adaptability of the machine at every place where the shortage of
water is available.
Instead of human muscle use alternative energy sours like sun, wind and other
FINAL PROJECT 67
REFERANCE
1. Shigley’s Mechanical Engineering Design, Eighth Edition

2. R.S Khurmi and J.K Gubta, a text book of machine design, 2oo5, First Edition.
3. S.L. Dixon, Fluid mechanics and Thermodynamics of Turbo machinery, Fifth
Edition
4. www.sharedasolutions.com
5. www.water in cyclopeda.com/Po-Ro/
6. Pump traditional.html
FINAL PROJECT 68
APPENDIX
Table of results and discussion
Angular velocity of shaft=100 ⁄ Applied force=638N

Angular velocity flywheel=471 ⁄
Angular velocity pulley=628 ⁄
The 3D, 2D and section views of pedal powered water lifting machine and its
components.
FINAL PROJECT 69
Drawn by Checked Approved by Date

group by
member W/GEBRIEL.G 14/5/2010EC
Container
Bucket Scale 1:2
FINAL PROJECT 70
Drawn by Checked Approved by date

group by
Direction controller
Clutch Scale 1:2
FINAL PROJECT 71

group by
Lever parts
Lever Scale 1:2
FINAL PROJECT 72

group by
Rotor
Flywheel 1:2
FINAL PROJECT 73

group by
Transmitter
Shaft Scale 1:2
FINAL PROJECT 74

group by
Transmission shaft
Shaft Scale 1:2
FINAL PROJECT 75
FINAL PROJECT 76

group by
2D Assemble drawing Assemble parts

Scale 1:2
FINAL PROJECT 77

group by
3D Assemble drawing Assembly parts

Scale 1:2
FINAL PROJECT 78
FINAL PROJECT 79
FINAL PROJECT 80
FINAL PROJECT 81

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DESIGN OF PEDAL POWER WATER LIFTING MACHINE

FINAL PROJECT III

List of figure ........................................................................................................................................................... VII

1.2 COMPONENTIS OF PEDAL POWERED WATER LIFTING MACHINE .........................................................1

1.2.2 FLY WHEEL...............................................................................................................................................2

1.2.5 LEVER (HANDLE AT THE SIDE OF CLUTCH) ........................................................................................3

1.2.8 TANKER ....................................................................................................................................................3

1.2.10 WIRE ROPE ............................................................................................................................................4

1.4.2 SPECIFIC OBJECTIVE...............................................................................................................................5

CHAPTER TWO ...........................................................................................................................................................6

2.1.4 PEDAL POWERED W ATER LIFTING MACHINE ...................................................................................7

METHODOLOGY AND PROPLEM STATMENT .......................................................................................................9

3.3 LIMITATION .....................................................................................................................................................9

4.1 GEOMETRICAL ANALAYSIS ....................................................................................................................... 10

4.2.1 MATERIAL SELECTION FO R SHAFT ................................................................................................... 10

4.2.4 MATERIAL SELECTION FO R PEDAL ................................................................................................... 11

4.2.6 MATERIAL SELECTION FO R LEVER .................................................................................................... 12

4.2.9 MATERIAL SELECTION FO R BUCKET................................................................................................. 13

4.3 PART DESIGN ............................................................................................................................................... 15

4.3.2 SHAFT AREA ....................................................................................................................................... 32

4.3.3 PRESSURE REQUIREM ENT FOR THE SYSTEM ................................................................. 32

4.3.4 CLUTCH DESIGN ............................................................................................................................ 39

4.3.6 HANDLE DESIGN ............................................................................................................................ 42

4.3.9 PEDA L DESIGN ................................................................................................................................ 45

4.3.10 KEY DESIGN ................................................................................................................................... 46

4.3.12 BUCKET DESIGN .......................................................................................................................... 51

4.3.15 FRAM E DESIGN FOR MACHINE COMPONENT ................................................................ 57

4.3.18 DESIGN FOR FASTENERS ......................................................................................................... 61

CHAPTER FIVE ................................................................................................................................................... 63

5.3 GENERA L ASSEM BLY .......................................................................................................................... 64

CONCLUSION A ND RECOMMONDATION ............................................................................................... 66

6.3 FUTUR WORK .......................................................................................................................................... 67

Figure 1 pedal powered water lifting machine............................................................... 8

Table 1 Material features, application and precision rating ........................................................................... 20

FINAL PROJECT VII

1.1 PEDAL POWERED WATER LIFTING

1.2 COMPONENTIS OF PEDAL POWERED WATER LIFTING MACHINE

1.2.2 FLY WHEEL

 A gearbox is precisely bored to control gear and shaft alignment.

A variety of gearboxes find applications in a number of industries depending on the

A clutch is a machine member used to connect a driving shaft to a driven shaft so

1.2.5 LEVER (HANDLE AT THE SIDE OF CLUTCH)

1.2.6 HANDLE (SUPPORTIG BEAM)

A handle is component of PPWLM which is used to support the operator during

1.2.10 WIRE ROPE

1.3 WORKING PRINCIPLE

1.4 OBJECTIVE OF THE PROJECT

1.4.1 GENERAL OBJECTIVE

 To design pedal powered water lifting machine.

1.4.2 SPECIFIC OBJECTIVE

2.1 TYPES OF WATER LIFTING DEVICES

2.1.2BUCKET AND WINDLASS

There are three parts to the pump

 The pump stands including footings and windlass.

2.1.4 PEDAL POWERED WATER LIFTING MACHINE

Figure 1 pedal powered water lifting machine

METHODOLOGY AND PROPLEM STATMENT

Primary data collection:

Secondary data collection:

It is expected to do this project by using different resources; such as Internet access,

 Text book of machine design

3.2 PROBLEM STATEMENT

 The mechanism has no on and off system.

0.99* = and P=2* nT/60

0.992 Tinput /60 =2* Toutput /60

Where =60Pinput / (2 *ninput )

0.99(60 / (2* ninput )) =Toutput *

=0.99(60 /2* ninput ) /

=0.9960 / (2* *noutput )

=0.9960(1KW)/ (2* *71.85rpm) = 131.57Nm