3.

6 EXPERIMENTAL SETUP

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3.6.1. Vibrating table: To carry out vibration a vibration device is used as shown in Figure 3.1. A low cost vibrating device fabricated is shown in Figure 3.2. Line diagram of this table is shown in Figure 3.3. This table is supported on four mild steel leaf springs 5 x 30 mm cross section with length 600mm. A DC motor is fitted below the platform of the table. In order to get fine control over the speed, DC motor has been chosen. An adjustable eccentric mass system as shown in Figure 3.4 is attached to the motor shaft. While rotation, this eccentric mass will cause unbalanced disturbing force that will tend to vibrate the table. By varying the speed of the motor, the frequency of excitation of the table could be varied. The amplitude of vibration can be varied by varying the eccentricity of the mass. Vibrations have been carried out only for fixed amplitude of vibration as vibration has no significant effect on the property change of the alloy [71].

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Figure 3.1 Vibrating Table

During fabrication Fig.3.2 Fabricated vibration table

After fabrication

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Figure 3.3 Line diagram of fabricated vibration table

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3.7 Design of fabricated vibration table

Total mass of vibration table consists of mass of vibrating platform, mass of leaf springs, mass of mould box and mass of DC motor as shown in figure 3.2 and 3.3. Vibrating platform and leaf springs are made up of Mild steel whose density is 7861 kg/m3. By measuring the dimensions of platform( 90.5 x 60 x 1 cm) and leaf springs (60 x 3 x 0.5 cm), mass is calculated using the relation Mass (m) = Density () x Volume (v) Hence mass of vibrating table = mass of vibrating platform + mass of 4 leaf springs + mass of mould box + mass of DC motor 32

Total mass, m = 42.5 + 2.8 + 32 + 45 = 123 Kg

Assuming each leaf spring as a cantilever, as shown above Deflection y = Where P = load l = length of leaf spring = 0.6 m E = Youngs modulus of spring material (Mild steel) = 200 x 109 N/m2 I = Moment of Inertia of spring = bd3/12 = (0.03 X (0.005)3) / 12 =3.125 x 10 Stiffness (K) = load / deflection =
12 EI l3 12 EI = 13888.88 N/m l3
K /m
-10

P 3 l 12 E I

Total stiffness of the table (K) = 4 x

Natural frequency of vibration table n1 =

= 10.6 rad/sec

n1 =

2 N1/60

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Hence N1 = 101.4 rpm

For the clamped-clamped system, second natural frequency occurs at about 2.75 times the fundamental natural frequency. Hence N2 = 278.82 rpm 3.7.1 Factor of safety Stiffness of each spring k = K/4 = 13888.88/4 = 3472 N/m We know k = P/ (load/ deflection) For 5 mm deflection, P = k x = 3472 x 5 x 10-3 = 17.36 N Bending moment M = P x l/2 = 17.36 x 0.6 /2 = 5.2 N-m Bending stress f = (M/I) y, where y = distance from neutral axis =
5 .2 5 x10 3 x = 41.6 N / mm2 2 3.125 x10 10

Factor of safety = Endurance limit stress/ working stress Endurance limit stress for hot rolled Mild steel = 0.35 x ultimate tensile strength = 0.35 x 1070 N/ mm2 = 374.5 N/mm2 Hence Factor of safety = 374.5/41.6 = 9 Hence this vibration table will work at a factor of safety of 9 for a deflection of 5 mm without fatigue failure.

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