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CHAPTER 1

INTRODUCTION

Consumption of oil in Ethiopia is increased as the result of increasing demand brought about by
the rapid population growth and improved living standards of the rural areas. As a result, there
has been a serious shortage of edible oil on the market and exaggerated rise in price where the
government was forced to intervene. The intervention of the government, however, hasn’t
brought about a sustainable solution and it has opted to ensure a different direction. Believing
that fixing the price alone can’t ameliorate the shortage sustainable; it is working hard to adopt
technologies that will play pronounced role in improving the availabilities of the most demanded
goods like oil by producing them locally.

To assess the existing situation of the oil industries in Ethiopia, a number of researches indicate
that the significance of the edible oil sub-sector in the Ethiopian economy has been declining.
For instance, the edible oil sub-sector accounted for 1.5 percent of the value added of the
Ethiopian manufacturing sector in 1995/96, while the level of contribution, at 0.7%, shrank by
half in 2003/04.

On the other hand, Ethiopia is one of the highest potential oil-rich seeds producers. Ethiopia is
the fifth world producer in linseed and sixth in sesame seed and a leading producer of noug.
Ethiopia is the third world exporter of sesame seed after India and Sudan and a leading exporter
of noug. Sesame seed has the highest value per ton of Ethiopian oilseeds, more than twice the
value of linseed. World sesame and olive oil imported prices are the highest: 3 to 4 times the
price of almost all other edible oils.

The major export is sesame oil seed and has a share of 90% of the total oil seeds export. The
main destination of sesame is Far East Asian countries for use as edible oil. Noug is the second
exportable oil crop and has shown substantial growth in production. Noug seed is the most
preferred raw material for local food oils and a high value bird food ingredient especially in the
United States of America. It is a small seed and particularly attractive to finches.

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The third exportable oil seed is linseed and used as industrial oil. Recently the demand for
linseed showed an increasing trend in the world market. Ethiopia, as one of the major producers
has shown the potential to benefit from this opportunity by exporting to the European Union.

Ethiopia's oil crop cultivation is rain fed under smallholder dominated production systems with
low yields. The low level of oil seed crop production and productivity has constrained the
supply of oil seeds to the food oil industry and results in a high dependency on imported oils.
The shortage of improved seeds is a deeply rooted persistent problem of the oil seed subsector.
The Ethiopian Seed Enterprise is the only government body involved in the multiplication of
major improved seeds, but cannot satisfy the demand of the food oil sub sector. Despite the vast
market opportunities for improved seed promotion in the country, the involvement of private
companies in the seed multiplication in general and in oilseeds subsector in particular is minimal.

1.1 PROBLEM STATEMENT

Consumption of oil is increased as the result of increasing demand brought about by the rapid
population growth and improved living standards of the rural areas. As a result, there has been a
serious shortage of edible oil on the market and exaggerated rise in price where the government
was forced to intervene. The intervention of the government, however, hasn’t brought about a
sustainable solution and it has opted to ensure a different direction.

Also oil extracted mostly in traditional way that’s why not sustained the customers’ needs also it
has a healthy problem because of lack of purity and it is not possible to produce sufficient
amount of oil from edible oil seeds in traditional way so in order to solve this problem we need
to design an efficient oil extraction machine that can be operated by any person.

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1.2 OBJECTIVES OF THE THESIS

The main objective of the project will be to design an electrically operated medium scale oil-
pressing machine and also this project mainly focuses on the following:
 To design and develop an efficient oil-pressing machine capable of extracting oil continuously at
large quantities of oleaginous material with minimal labor.
 To develop a light weight, easily operable, and contamination free oil-pressing machine.
 To introduce new technologies, this will serve as a platform for future developments of oil-
extracting machineries.
 To substitute some imported oils by extracting them locally thereby saving foreign currency.

1.3 METHODOLOGY

The medium scale oil extraction machine helps to extract oil and it has main so in order to design
we must consider the following:
 Selection of material which will not contaminate or poison the extracted oil.
 Selection of easy pressing mechanism.
 Development of the screw type of oil pressing machine.
 Design of oil drainage.
 Design of flange.
 Design of belts and pulleys.
 Determination of the torque required to extract oil from selected oil rich seeds.
 Preparation of manufacturing drawing.

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1.4 SCOPE

The general scope of this project is to design every component of a medium scale oil extraction
machine such as belts, shafts, pulley, screw, oil drainage and flange and prepare detail
manufacturing drawing for each part.

1.5 RESULT

After finishing this project, the medium scale oil extraction machine has many use since it is
operated by any person, it is capable of extracting oil continuously at large quantities and extract
pure oil. Also it is possible to use any where as we want. We can use the waste (cake) for animal
food.

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CHAPTER 2

LITERATURE SURVEY ON SEED OIL EXTRACTION

2.1 FUNDAMENTALS OF FLUID PROPERTY FOR THE COMPRESSED SEED

(SESAME)

Sesame (figure1.1) Oil is called "Nalla Ennai" and translated in English to "good oil". Sesame
seeds are protected by a capsule which only bursts when the seeds are completely ripe. The
ripening time tends to vary, so farmers cut plants by hand and place them together in an upright
position to continue ripening until all the capsules have opened.

Figure 1.1: a) Flower of sesame, b) Seed of sesame

Sesame seeds are primarily produced in developing countries, a factor that has played a role in
limiting the creation of large-scale, fully automated oil extraction and processing techniques.

Sesame oil can be extracted by a number of methods, depending on the materials and equipment
available.

In developing countries, sesame oil is often extracted with less-expensive and manually intensive
techniques such as hot water flotation, bridge presses, ram presses, or by using a small-scale
expeller. In developed countries sesame oil is often extracted using an expeller press, larger-scale
oil extraction machines, or by pressing followed by chemical solvent extraction.

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Sesame oil can also be extracted under low-temperature conditions using an expeller press in a
process called cold pressing. This extraction method is popular among raw food adherents
because it avoids exposing the oil to chemical solvents or high temperatures during extraction.

While some manufacturers will further refine sesame oil through solvent extraction,
neutralization and bleaching in order to improve its cosmetic aspects, sesame oil derived from
quality seeds already possesses a pleasant taste and does not require further purification before it
can be consumed. Many consumers prefer unrefined sesame oil due to their belief that the
refining process removes important nutrients.

Sesame oil is one of the more stable natural oils, but can still benefit from refrigeration and
limited exposure to light and high temperatures during extraction, processing and storage in
order to minimize nutrient loss through oxidation and rancidity. Storage in amber-colored bottles
can help to minimize light exposure.

2.2 SESAME OIL RECOVERY PROCESS

Sesame oil recovery process is a combination of several stages such as cleaning, pretreatment,
extraction, filtration and lastly packaging and storage as seen in Figure 1.2

The first step of the overall process is cleaning process of the seeds. The common cleaning
methods are air aspiration, indent cylinder cleaning, sieve cleaning, or a combination of these.
By cleaning process, foreign materials like broken stone, sand, or metallic powder are avoided
from mixing into seed barrel. This is an important process, because the particles which have high
hardness coefficient factors may damage the machine parts.

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Figure 1.2: sesame Oil Recovery Process

Secondly, pretreatment stage is required for increasing the amount of oil recovery by
preconditioning the seed using some methods like heat treatment, moisture adjustment, etc.
At the extraction stage, there are basically two methods which are called mechanical and solvent
extraction. They are used in different application areas depending on the desired production
property, capacity and economical aspects.

After the extraction process, sesame cake can be directly used as animal feeding. Sesame oil is
applied one more process which is the filtration. Filtration is the clarification of contaminants,
such as fine pulp, water, and resins from the oil. Leaving the oil undisturbed for a few days is
one of the cheapest and the easiest way of clarification.

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In case of a requirement for improved purity of the oil, then a fine filter cloth can be used.
Furthermore, the oil can be heated to remove the left water particles and kill any bacteria.

After filtration process, the oil can be used directly in food. Packaging and storage of the oil is
one of the most important step, because keeping the oil in dry containers made up of glass or
plastic avoids rancidity. Also, colored containers increase the shelf life of the oil since the oil is
prevented from sun rays. The shelf life of oil is usually 6 to 12 months, if it is packaged and kept
away from heat and sunlight properly.

The previous theoretical and experimental studies about the flow behavior of the compressed
seeds have provided considerable contributions into understanding of the fundamentals about
seed oil extraction process. A mathematical model of oil and cake flow during the compression
process requires certain assumptions depending on real application conditions. Thus, the
behavior of the flow cannot be explained by only specific theoretical considerations.

We need to focus on the optimization of the parameters such as pressure, temperature and
moisture content of the seeds in order to optimize the oil recovery rate. Also, resizing into
smaller volumes before the compression process has considerable effects on the oil recovery rate.
Resizing of the seeds reduces the required force that is used for compressing the seeds.

Preheating is one of the most effective one among all pretreatments. Since the viscosity of the
sesame oil is high at room temperature, separation and leakage of the oil particles is
comparatively lower than at higher temperatures. The viscosity specifies the flow velocity of the
fluid through porous medium. At higher temperatures, the viscosity of the oil decreases, and oil
recovery rate increases. However, there is an important consideration about the maximum
allowable temperature which is applied to the seeds because quality of the oil is directly related
with the applied temperature. As a consequence, the preheating is allowed in certain ranges of
temperature to acquire quality product.

The moisture rise in the seeds has some certain advantages. It decreases the maximum working
temperature which must be maintained under 90ºC to conserve the cake and oil quality. Another
benefit of the moisture rise is decreasing the specific energy consumption during the
compression process.

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The flow rate of oil is higher at higher temperatures which means higher oil recovery rate. It is
related with the kinematic viscosity of the oil which changes proportionally with the temperature
as represented in Figure 2.1. Kinematic viscosity of oil is inversely proportional with
temperature. As it can be seen in Figure 2.1, viscosity gradient is very large between -5°C and
30°C. After 30°C, since the slope of the curve is small, temperature increase slightly affects the
viscosity.

Figure 2.1: Temperature – viscosity performance of rape seed oil [6]

Temperatures above 90°C adversely affect the cake and oil quality. Temperature increase can
also occur during the compression process, between the compressed seeds and the machine
components. Also, with a temperature rise, not only the oil quality is affected, but also the
maximum yield stress of the materials, which are exposed to frictional heat, decrease.

The oil recovery rate depends on the permeability and consolidation property of the seed
assuming that other environmental conditions are constant. Permeability is a measure of how
easily a fluid can pass through a porous medium as seen in Figure 2.2.

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a) Easy to flow, high permeability b) Difficult to flow, low permeability

Figure 2.2: Schematic Illustration of Permeability [6]

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CHAPTER 3

CONCEPTUAL DESIGNS FOR OIL EXTRACTING MACHINES

3.1 COMPARISON BETWEEN OIL EXTRACTION METHODS

There are basically four types of oil extraction methods as represented in Figure 3.1. First one is
the chemical extraction method in which enzymes or solvents are used to extract oil. In the
solvent extraction type, a solvent is mixed with the ground seed. Grinding process is necessary,
because the contact area of the seed with the solvent should be maximized in order to increase
the oil yield. In general, hexane is used as solvent which is a petroleum distillate. Then by
heating the oil up to 100°C, solvent is separated from the oil. Theoretically, after this process, oil
gets free of solvent. However, microscopic portions of solvent remain both in the cake and the
finished oil.

Figure 3.1: Basic oil extraction methods [7]

The oil extraction process by using enzymes is implemented by big vegetable oil companies
because the process produces many high value products. The seeds are cooked and put into
water. Enzymes are then added which digest the solid material. The basic difference of this type
of extraction method from the solvent type is that the residual enzymes in the oil are separated by
the use of a liquid centrifuge. In the high pressure (super critical, at 31°C and 70 bar) carbon
dioxide extraction, seeds are mixed with high pressure carbon dioxide in liquid form.

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Most essential oils are extracted using steam distillation. Essential oils are the highly
concentrated essences of aromatic plants used in healing of the body and the mind. As the steam
break down the plant, it’s essential; oils are released in a vaporized form. When these pass
through cooling tanks, the volatile essential oils return to liquid form and are separated and are
easily isolated as pure essential plant oil.

Other oil extraction method is a mechanical process. Mechanical extraction method is the oldest
known method. It is based on mechanical compression of the seeds. Different mechanisms can
be used for compression. There are two well-known mechanisms which are called the hydraulic
press and screw press mechanisms.

Methods of high pressure CO2 extraction and distillation are not included to the comparison
stage. The reason is that these methods are used in extraction of essential oil used for
aromatherapy. Aromatherapy is the art of using these oils to promote healing of the body and the
mind which is beyond the scope of this study.

Table 3.1: Comparison between Solvent and Mechanical Types of Seed

Oil Extraction Methods [10]

SOLVENT MECHANICAL
Capacity of Production High Medium
Location Near High Traffic Points Agricultural Production
Capacities Large Scale Small Scale
Oil In Seed Cake 1% 15%
Oil quality Low High
Investment Cost High Low
Working Cost Low High
Energy Consumption High Low
Wastes Chemicals, Water No Wastes
Security Requirements High Low
Transportation Distance Long Short

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The advantages and disadvantages of the solvent and mechanical extraction methods are
presented in Table 3.1 in order to understand which method conforms with the scope of this
study most. Despite, solvent extraction method has some superiority on mechanical extraction
methods; depending on the conditions and expectations, the mechanical extraction method is
better especially for small scale production. For example, in mechanical extraction method,
residual oil in the cake is high; however it is an advantage in the villages since it is used as
nutritious animal feeding. Also, the production of oil in mechanical extraction methods is in
smaller scales; however it may be sufficient to compensate a village need.

Other advantages of mechanical extraction methods are that the investment cost is lower than the
solvent extraction set up. Further, the equipment can be easily constructed, maintained and
operated by semi-skilled labor. Also, it can be adapted quickly for different kinds of seeds.
Furthermore, the mechanical extraction process is more safe and simple compared to solvent
extraction method.

After deciding that mechanical extraction method is more suitable for the scope of this study,
then a further comparison step between different mechanical press systems is to be discussed.
For the mechanical extraction methods, two types of presses are generally used which are called
hydraulic press and screw press. The superiority of screw press system is based on the
continuous flow of seeds. Also, hydraulic presses are slow and not efficient in oil recovery rates
whereas the screw presses are more preferable since they are more efficient.

Result of the comparison between the two different mechanical extraction systems shows that
screw press system is more advantageous for this particular.

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3.2 COMPARISON BETWEEN SCREW SHAFT CONFIGURATIONS

There are various types of screw shaft configurations have been developed and considered. Some
basic configurations of screw shafts are presented in the subsections.

3.2.1 Straight Screw Shaft

The type of screw shaft configuration which is represented in Figure 3.2 is commonly used in
screw presses, because the manufacturing process is easy. The pitch and the root diameter are
constant through the screw shaft. The rate of pressure increase in this type of a screw press is
analogues to the rate of pressure increase in hydraulic presses. In both of them, pressure
increases linearly. However, seed flow in the screw press is continuous whereas the compressed
seeds must be replaced after each stroke in a hydraulic press.

Figure 3.2: Illustration of a straight screw shaft

3.2.2 Screw with Tapered Shaft

In this type of screw shaft (Figure 3.3), the pitch is constant, where the annular area is decreasing
through the length of the screw and takes its minimum value at the end of the screw. The volume
swept by the screw thread in each turn is the multiplication of the annular area and the pitch
distance. In this type of screw shaft, the rate of pressure increase is higher than straight screw
shaft. Besides, machining of this part requires a CNC machine.

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Figure 3.3: Illustration of a Screw with Tapered Inner Shaft

3.2.3 Screw with Variable Pitch

This is a screw type with decreasing pitch as represented in Figure 3.4. This type of a screw
thread can only be machined with a 5-axes CNC machine tool. So, in order to reduce the cost,
total shaft is separated into several sections. Each section has a constant pitch, but different from
the other’s pitch. The screw, through which the seeds are fed, has the maximum pitch in order to
increase the seed capacity.

Figure 3.4: Illustration of a Screw with Variable Pitch

Similar to the tapered shaft system, in this type of screw shaft system, volume is decreased by an
amount in each turn. The main difference between them is the rate of pressure increase through
each thread. In tapered screw, pressure increase linearly through the screw shaft whereas in
screw with variable pitches distance, pressure is constant through each thread and increase at the
transitions as shown in Figure 3.5.

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Figure 3.5: Pressure vs. Length graphs of the screw with variable pitch and the screw with
Tapered shaft [9]

3.2.4 Screw with Tapered Shaft and Variable Pitch

This is the combination of the screw types with variable pitch and tapered shaft as represented in
Figure 3.6. Rate of pressure increase in this type of screw is higher when compared with the
other type of screws. The same pressure can be determined in a shorter time because the pressure
attains its maximum value in fewer revolutions when compared with the same sized screw types.

Figure 3.6: Illustration of a Screw with Tapered Shaft and Variable Pitch

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3.3 COMPARISON OF THE CHOKE MECHANISM ALTERNATIVES FOR CAKE

DRAINAGE

The common property of cake drainage systems in screw presses is the adjustability of the cake
drainage opening. Narrower openings result in low residual oil content in the cake. Also, the
opening size depends on the type of the seed. There are various types of cake drainage systems
are considered. Working principles of these cake drainage systems are presented in the
subsections.

3.3.1 Nozzle Type Choke Mechanism

Generally, in small types of screw presses, nozzle type choke mechanism is used. In nozzle type
choke mechanisms (Figure 3.7), one end of the screw shaft is free and the other end has two
bearings. The screw shaft is short enough to compensate any deformation arising from buckling.

Seeds continue to accumulate at the end of the screw until the maximum pressure has been
reached. During compression, oil part of the seeds leaks from the filter and the left cake starts to
extrude out from the nozzle, at the end of the screw. Besides, the required maximum pressure
can be provided by adjusting the nozzle diameter.

Figure 3.7: Nozzle Type Choke Mechanism

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In this type of choking mechanism, the maximum pressure at the end of the screw pushes the
screw backward. The resultant force is the multiplication of the axial component of the
maximum pressure and the circular area of the screw.

Since the application area of the back force is comparatively larger than in conical type of choke
mechanisms, bearing which carries the axial back force should be larger in this type of systems.
Another disadvantage for this choking system is the probability of a blockage at the entrance of
the nozzle.

3.3.2 Conical Type of Choke Mechanism

This type of a system (Figure 3.8) is both practical and economical when compared with the
equivalent systems. The maximum pressure and the cake thickness can be changed by adjusting
axial displacement of the screw shaft forward and backward in order to achieve the required
pressure. The force pushing the screw backward is relatively less here when compared with the
nozzle type choke mechanism since the effective pressure area is less than the normal cross-
section.

Figure 3.8: Conical Types Choke Mechanisms

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3.4 COMPARISON OF OIL DRAINAGE SYSTEMS

There are three typical systems used in commercial screw presses for oil drainage which are
presented in this subsection.

3.4.1 Drilled Holes

The main advantage of this system is no extra parts for oil drainage system are required.
However the oil drainage openings in this system are not adjustable.

In this type of screw press, oil leaks out from the holes as represented in Figure 3.9. The holes
are drilled on the vessel. The oil drainage hole has a larger diameter outside the vessel and this
diameter continues up to few millimeter thickness of the vessel. This small thickness of the
vessel is drilled with a smaller diameter.

Most probably, the reason for the short length of the smaller hole is to prevent it from choking
with cake. Also, oil drainage zone is far from the cake drainage zone. At the cake drainage zone,
cake pressure is Maximum. So, if the oil drainage holes were drilled close to the cake drainage
zone, then the holes can be choked with cake easily.

Dry cake extrudes from the nozzle. At the cake drainage, there is a heating system. Heat provides
higher oil yield and lower residual oil in the cake. In this type of screw presses, different kinds of
seeds can be compressed by changing the nozzle and the rotational speed of the screw shaft.

3.4.2 Lining Bars with Spacers

In this type of oil drainage system, lining bars are fixed inside surface of the vessel cage. Spring
type metal spacers are placed between two bars. Different sizes of gaps can be obtained by using
spacers in different thicknesses. Also, in this system, lining bars canalize the compressed seeds
to forward. They prevent jamming by creating obstacles to the rotating compressed seeds, so
they are pushed forward more strongly.

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Figure 3.9: Detailed Picture of Screw Press

3.4.3 Fiber Filter Sleeves

This kind of liquid drainage system is generally used for the substances which do not require
high pressure. Since the fiber is a deformable material, high pressures would result in expansion
of the fiber.

3.4.4 Barrel Rings

The vessel is made up of barrel rings with triangular barrels. The barrel rings are separated by
circular spacers, that slide onto the tie bars to form the drained barrel of the press. This
arrangement offers greater flexibility to adjust the drainage gaps of the press and forms a very
simple assembly that can be easily maintained.

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CHAPTER 4

PRELIMINARY DESIGN OF THE OIL EXTRACTION MACHINE

4.1 PRELIMINARY DESIGN

In this section, design tree and block diagram of the selected system, separation of the system
into subsystems and specifications of these subsystems are given (Figure 4.1).

4.1.1 Design Tree

In the design tree of the screw press, the system is separated into its subsystems to analyze the
design from top to bottom. In Figure 4.2, components of the screw press are represented. The
screw press is composed of skeleton, hopper, main body, connection elements and drive system.

Skeleton carries the main body. Hopper is mounted onto the vessel. Drive system is connected to
the end of the screw shaft. And connection elements are used to connect the bearings to the
platform and flange to the vessel. Assigned numbers to the machine components are represented
in Figure 4.1.

Seeds are fed into the system from the hopper (3), and pass through the screw shaft (4) to the end
of the vessel (5) where the cake is drained out. Oil leaks out from the holes which are machined
on the vessel. Shaft is mounted between two bearings (1) at each end. Flange (6) is mounted to
the vessel with connection elements (7).

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Figure 4.1: The 3D Model of the Developed Screw Press

Figure 4.2: Design Tree of the Screw Press

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4.1.2 Frame

Frame (Figure 4.3) carries the main body of the screw press. The screw shaft is bedded with the
bearings. The bearing bushings are elevated to a height where the screw shaft can rotate
concentrically inside the vessel.

Figure 4.3: 3D Model of the Developed Frame

4.1.3 Hopper

Hopper is used to carry and canalize the seeds into the screw press. Feeding does not need any
energy; gravity is sufficient for feeding. It is a stationary part and mounted onto the vessel. The
passage hole of the hopper should be large enough in order to prevent choking of the seeds. In
some conventional screw presses, it has a vibration unit to overcome such situations. But, in this
design no vibration unit will be used to reduce the cost.

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Figure 4.4: 3D Model of the Developed Hopper

4.1.4 Main Body

The main body is composed of three parts which are the screw shaft, the vessel and the flange.
Their functionalities are described in the subsections.

4.1.4.1 Screw Shaft

As represented in Figure 4.5, a screw with tapered root diameter type is used in the design. As
mentioned in Section 3.2.2, when compared to straight screw shafts, rate of pressure increase is
higher in this type of screw shaft configurations depending on the taper angle of the shaft. The
seeds are compressed in two ways. First way of compression occurs by the continuous feeding of
the seeds into the system. Newly fed seeds compress the seeds which are already present in the
system. Other way of compression takes place between the inside surface of the vessel and inside
surface of the screw shaft. As the depth of the thread decreases continuously, the distance
between these two surfaces decrease. Then, forwardly pushed seeds are applied compression
between these two surfaces. For these reasons, this type of screw shaft configuration is evaluated
as the most appropriate one.

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Screw shaft rotates inside the vessel. There is a small clearance between the vessel and the screw
shaft. This small clearance is necessary for avoiding the seeds penetrating between the outside
diameter of the screw shaft and the inside surface of the vessel. In such a case, friction force
between the screw shaft and vessel increases, and required torque becomes higher.

Screw shaft is a tapered shaft. The outside diameter is constant whereas the root diameter is
inclined through the screw. Thread depth disappears at the end of the screw. In this type of
screws, pressure increase is much higher compared to straight screws as explained in Section.

The seeds are fed at where the thread depth is Maximum. As the seeds pass through the screw,
swept volume of each turn decreases. Under high pressure, oil is separated from the compressed
seeds and drains back to the previous turns at where the pressure is lower. Since cake has no
such a fluidity property like oil, it continues to the end of the screw shaft and drained out as
flakes. At the end where the cake is drained, the screw shaft and the vessel have conical features
which are concentric. Cake drains out radically between these two conical features. By adjusting
the screw shaft in the longitudinal direction, the gap size of the cake drainage can be reduced or
increased. As the gap size is smaller, the residual oil content of the cake becomes lower, because
the compressed seed is applied higher pressure.

Figure 4.5: 3D Model of the Developed Screw Shaft

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4.1.4.2 Vessel

Vessel shown in Figure 4.6 is the cage of the screw shaft. It has a big hole for seed feeding. This
feeding hole is machined at the beginning of the screw shaft at where the thread depth is
Maximum.

On the mid zone of the vessel, there are oil drainage holes as shown in Figure 4.6. The oil
drainage zone is slightly far from the cake drainage zone or in other words, the maximum
pressure zone. The reason is that, these small holes are filled and choked with compressed cake
at high pressure levels. However, on the mid zone of the vessel, pressure of the cake is not that
much high and oil can easily pass through these holes.

As represented in Figure 4.6, there are grooves through inside the vessel. These grooves are
necessary for preventing jamming. At high pressure levels, friction force between the
compressed seeds and the surface of the screw threads increases, and compressed seeds start to
rotate with the screw shaft without any movement forward. Then flow stops. However, grooves
act as obstacles to the rotating compressed seeds and canalize the compressed seeds forward.

Figure 4.6: 3D Model of the Developed Vessel

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4.1.4.3 Flange

Flange is connected to the vessel at the cake drainage end as shown in Figure 4.7. It is necessary
for elevating the vessel upper from the platform. Then, oil can easily flow under the vessel. Also
it separates the drained cake and recovered oil from each other.

Flange is mounted to the platform. As seen in Figure 4.1, in order to avoid buckling of the vessel,
the same elevation is provided to the other end of the vessel by using additional support. But, this
support has only contact relation with the vessel, not connected with fasteners.

Figure 4.7: 3D Model of the Assembly of the Vessel and Flange

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CHAPTER FIVE

DESIGN ANALYSIS

5.1 DESIGN OF V-BELT

V-belt is mostly used in factories and workshops where a great amount of power is to be
transmitted from one pulley to another when the two pulleys are near to each other. V-belts are
made of fabric and cords covered with rubber or with fabric and rubber. Their shape is
trapezoidal and is made endless. These are particularly suitable for short drivers. V-belts are
made according with manufacturing standards, mainly of five types namely: A, B, C, D, and E.

 Reason For Selecting V-Belt

1. Center to center distance is small

2. Very strong
3. Give the compactness due to the small distance of the pulley
4. The drive is positive b\c the slip b\n the belt and the pulley groove is negligible.
5. It provides longer life
6. Since the v-belt is made of endless and there is no joint trouble .therefore the drive is smooth.
7. The V-belt may be operated in either direction, with tight side of the belt at the top or bottom.
The center line may be horizontal, vertical or inclined.

 Characteristics of V-Belt Drive

 Initial cost-cheaper
 Shock absorption –better
 Maintenance-low
 Provide longer-life 3 to5 years
 Lubrication-none
 Noise-low
 Efficiency-87-97%

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 Limitation

 Can’t be used with large center distance

 They are subjected to contain amount of creep
 V-belts are not durable as flat ones
 Improper belt tensioning and mismatching of belt length can reduce service life.
 The centrifugal tension prevents the use of V-belts at speeds below 5m/s and above 50m/s
 The belt life greatly influenced with temperature changes, improper belt tension and mismatching
of belt lengths.
 The construction of pulleys for V-belt is more complicated than pulleys of flat belt.

5.1.1 FIRST BELT REDUCTION

Design Specification

Engine power =15KW

Engine speed =1400rpm

Figure 5.1: V-belt

Assume D1= Diameter of smaller pulley

D2 =Diameter of larger pulley
n1 = rpm of smaller pulley
n2 = rpm of larger pulley

Based on the given data let the let the engine rpm n1 = 1400rpm

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 Since we used a v-belt it can reduce maximum 4. So let’s take the V.R=4:1

V.R = = 4=

n2=350 rpm

 From data the drum velocity to be 600-700 rpm now from relation we have the following,

=
Assume d1 = 100mm

d2 = d1* = 100*

d2 = 400mm

 The peripheral speed the belt is given by

V1 = * d1 *

 Substitution the above values and we get

Vbelt = V1 = * 100 *

Vbelt = 7.33 m\s

Therefore this is same with that of the speed of smaller pulley speed of larger pulley is also given
by
V2 = * d2 *

V2 = * 400 *

V2 = 7.33m\s (the peripheral speed of larger pulley)

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Design power

Design power (pd ) of belt drivers is given by;

pd = power transmitted * safety factor
For uniform drive machinery, safety factor (ks) = 1-1.2 say 1.15
Now the pd = 15KW * 1.15
pd = 17.25 kw

Torque transmitted by the belt

Now the power transmitted by the belt is given by;

P = T * W1
p = T*2* *

T = 60 *

T = 119.66 NM say 120Nm

Using this torque (120Nm) the corresponding type of belt and pulley diameter are;

Table 5.1: Torque and Minimum Permissible Pulley Diameters [1]

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Center to center distance

 Center to center distance is calculated by;

C = (0.07-0.1) * Vbelt
Take 0.07 to be the multiplication factor
C = 0.07 * 7.33
C = 0.5131m

Angle of contact on pulleys

1, the angle of contact on smaller pulley is given by

= 180 – 2sin-1 [( ]

= 180 – 2sin-1 [( ]

= 146.01

2, the angle of contact on the larger pulley is given as

= 180 – 2sin-1 [( ]

= 214

Length of the V-belt

 Length of the belt is calculated as;

L = 2*c + + 1.57 * (d2+d1)

L = 2*0.5131+ + 1.57 * (0.4+0.1)

L =1.855m

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V-Belt Selection

Figure 5.2: Cross-Section of V-Belt and V-Grooved Pulleys [3]

 From table V belt selection c type;

= 22mm

t = 14mm
 Assume the belt is made of rubber with density;

= (t1- t2) * V, Where t1 = Tension on the height side, N

t2 = Tension on the slack side, N
V = velocity of belt in, m/s

Again T1 can be calculated by

m= area*length*density
Now m= 1000*1.855*A

Where A= b*t at b= 22mm and t1 =14mm

A= 0.022 * 0.014
A= 3.08*10-4 m2

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So m = 1000 * 1.855 * 3.08 * 10-4

m = 0.571kg/m

Now, TC = mv2
= 0.571*7.332
=30.67N

 We know that the relation b\n t1and t2 is given by;

= 2.3 log ( )

= cosec

Table 5.2: Rubber Coefficient Of Friction [1]

Dry Wet Greasy

0.3 0.16 0

Take of rubber = 0.3

At =179.99 =3.14 radian and 2 = 40

Now 2.3 log ( ) =0.3*3.14*cosec

Log ( ) = 1.197

= 3.31 -------------------------------- (1)

 The maximum tension in the belt is given by;

T= *b *t
Where =allowable bending stress
B = width of the belt
t = thickness of the belt

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 For rubber C belt type;

Table 5.3: Rubber Belt Type [3]

 =2.1mpa
 b = 22mm
 t = 14mm
T = 2.1*22*14
= 646.8 N

 Therefore tension in the tight side of the belt can be obtained from;

T1= T-Tc
T1= 646.8- 30.67
T1 = 616.13 N
Now from (1) we get

=3.31

T2 =186.14 N

 Now, the power transmitted by the belt tension is given by;

Pt = (t1 - t2)*v
= (616.13- 186.14) * 7.33
= 3151.83w

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 Torques on the driving and driven pulley is;

T1 = (t1 - t2)*r1
T1 = (616.13 – 186.14)*50
T1 = 21.499NM

Substituting the corresponding values and we get since d1 =100mm

And T2 = (t1 - t2) * r2
T2 = (616.18-186.14) *

T2= 85.998 N-m

 Initial tension of the belt (ti); t1 + t2 =2*ti

= *( + )

= *( + )

= 9.616
Ti = 92.47N

Table 5.4: Standard V-Belt Type [2]

 The maximum power transmitted by the belt is given by;

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Pmaxb =Tmax * V
= 616.13 *7.33
= 4516.233W

 And the belt correction factor k2 is selected as;

Table 5.5: Standard Nominal Belt Length [2]

The correction factor k1 =0.99 (from the graph) interpolating the above value and we get, the
rated horse power as indicated from table, page 9676) of Joseph Edward Shingly.

Hr = 2.80hp and the corrected horse power (H) is given by

H= 4.516 * 0.99 *0.95
H= 4.247

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5.1.2 SECOND BELT REDUCTION

Assume d3= diameter of drum smaller pulley

d4= diameter of drum larger pulley
n3 = rpm of drum smaller pulley
n4= rpm of drum larger pulley

 Based on the given data from first reduction

Since the drum pulley rpm = drum smaller pulley

n2= n3=350

Now from relation we have the following

=
Assume d3 =100mm

 Since the V- belt reduce maximum 4 and lets the V.R = 4 from data the drum larger
pulley to be;

V.R = = 4=

n4=87.5rpm

d4 = d3 * = 100 * = 400mm

 The peripheral speed the belt is given by;

V3 = * d4 *

Substituting the above values and we get

Vbelt = V3 = * 100 *

Vbelt = V3 = 1.833 m\s

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 The speed of larger pulley is also given by;

V4 = * d4 *

V4 = * 400 *

V4 = 1.833m\s (peripheral speed of larger drum pulley)

Design Power

 Design power (pd) of belt drives is given is given by;

pd = power transmitted * safety factor

 For uniform drive machinery, safety factor (ks) =1-1.2 say Ks=1.15

The power on the shaft is not directly transferred to the output shaft. Because there is a power
loss due to;
 In belt engagement
 Friction in Bering
 Temperature change of belt

 The efficiency of a belt redaction is given by;

= 1* 2 * 3

Where 1= loss duo to friction in belt engagement

2 = loss duo to friction in Bering
3= loss duo to temperature change of belt

1 = 1- * which is approximately 0.96 to 0.98

Let 1= 0.97
2= between 0.96 to 0.99
2= 0.98
3= 0.98
Therefore = 1* 2 * 3

= 0.932

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Table 5.6: Powers on the Shaft

Shaft Efficiency Power (Kw)
1 - 15
2 0.932 13.98
3 0.932 13.02

 The design power (pd) will be;

pd = 13.98 * 1.15
pd =16.037 KW

Torque Transmitted By the Belt

 Now the power transmitted by the belt is given by;

P= T *w1

P= T * 2* *

T= 60 *

T= 119.66 NM

Table 5.7: Recommended Torques and Minimum Permissible Pulley Diameter [1]

 Since the torque transmitted by the belt is 119.66 NM using this torque (Nm) type C is
selected.

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Center To Center Distance

 Center to center distance is calculated by;

C = (0.07-0.1) * Vbelt
Take 0.07 to be the multiplication factors
C= 0.07 * 1.833 m\s
C= 0.33
Length of the V-belt

 Length of the belt is calculated as;

L= 2* C+ + 1.57 *0.3 =0.1

L== 2* 0.33+ + 1.57 *(0.4+0.1)

L= 1.513m

Angle of Contact on Pulley

1. The angle of contact on drum smaller pulley

3 =180 -2sin-1 [( )]

3 =180 -2sin-1 [( )]

3= 125.9

2. The angle of contact on drum larger pulley

3 =180 +2sin-1 [( )]

3 =180 +2sin-1 [( )]

3= 234.1
From Table for type C, At =230*10-6mm2

Assume, the belt is made of rubber with density =1000kg\m3

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Table 5.8: V-Belt Dimension [1]

 Now, the power transmitted by the belt is given by;

P = (t3-t4)*V
Again T1 = T-Tc
Where Tc is the centrifugal tension of the belt and is calculated by;

Tc = mv2= 0.347*1.833m\s
= 0.64N
m = area * length * density
m = 230*10-6* 1.513 *1000
m = 0.347kg/m

We now that the relation b\n the t1 and t2 is given by;

= 2.3log ( )

= cosec
From table 5.2 Take of rubber = 0.3
At =179.99 =3.14 radian and 2 =40

Now 2.3log ( ) =0.3*3.14*cosec

Log ( ) =1.197

( ) = 3.31 ---------------------------------- (1)

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 The maximum tension in the belt is given by;

T= *b*t where = allowable bending stress

b = width of the belt
t = thickness of the belt
For rubber C V-Belt type;
 = 2.1mpa
 B=22mm
 t =14mm
 T=2.1*22*14
= 646.8N

 Therefore tension in the height side of the belt can be obtained;

T3 = T-Tc = 646.8-0.64
T3 = 645.414N
Now from (1) we get

= 3.31

T4 = =194.989N

 Now, the power transmitted by the belt tension is given by;

Pt = (t3-t4)*V
pt =(645.415- 194.989)* 1.8332
pt =1516W Torques’s on the driving and driven pulleys are

T3 = (t3 – t4) *r3 = (646.16-194.989)* 50

= 22.521Nm

And T4 = (t3 – t4) *r4 = (646.26-294.989) *200

= 90.254Nm

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5.2 BELT-LIFE

Durability (life) correlations are complicated by the fact that the bending induces flexural
stresses in the belt. The corresponding belt tension induces the same maximum tensile stress. If
fb1 at the driving sheave and fb2 at the driven pulley. These equivalent tensions are added to f1 as:

T1= f1+ (fb1) = f1 + kb/d1

T2= f2 + (fb2) = f1 + kb/d2
 Where kb is given as;

Table 5.9: V-Belt Parameters [2]

 Since the belt type is C, kb=1600 and kc=1.716

The tension passes trade-off question as used by the gates Rubber Company is:

Tb np= kb
From the minor rules used to sum damage incurred by the two tension peaks.

1/np = (k/T1)-b + (k/T2)-b or

np = [(k/T1)-b + (k/T2)-b]-1 passes

The life in hours is given by, T=

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NOTE:- if np>109 report that np>109 and t> without placing confidence in numerical value

beyond the validity interval.

 Where the value of b for belt C is from the table 5.9 is equal to 11.173.

Table 5.10: Durability Parameters for Some V-Belt Section [2]

Figure 5.3: V-Belt Tensions [2]

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Now, at F1=635.1N
F2=191.87N
F=F1-F2=443.23N

 Now, the equivalent tensions are:-

T1= F1+

= 635.1+

= 651.1 N

Similarly, T2= F2+

=191.87+

=197.2 N

Now, np= [( )-11.173+ ( )-11.173]-1

=3.44*105

 The life time t will be

T= , where Lb= length of the belt=1.387m

Vb= 1.745 m/s

Substituting and we get t in hours

T= = 67110 hrs

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5.3 PULLEY ANALYSIS

Pulleys are used to transmit power from one shaft to another by means of flat belt or ropes. The
pulley may be made up of cast iron, steel, wood and paper. Selection of pulley for our purpose is
based on the following;

Table 5.11: Design Matrix

No. Cast iron Steel pulley Aluminum Wooden
property
pulley pulley pulley
1 Machine ability 3 4 5 5
2 Cost 3 2 5 5
3 Strength and durability 5 4 3 2
4 Friction 5 3 4 5
5 Availability 3 3 5 5
6 Liable to break 4 5 3 2
7 Life time 5 5 3 2
Total 28 26 28 26

Steel pulleys are not provided in our purpose, because they are used when the center to center
distance of shafts is small. Therefore it is better to use cast iron pulley or aluminum pulley.

In our case for the pulleys on the shafts should be cast iron pulleys, in order to prevent wear of
belt and pulley due to the maximum speed. Otherwise for the rest pulleys it is better to use
aluminum pulley.

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5.3.1 LARGE PULLEY ANALYSIS

 The type of material selected for this specific design is;

 Cast iron

 Functional requirement;
 Economical
 Longer lived
 Excellent friction characteristics
 Stable

Figure 5.4: Solid Cast Iron Pulley [3]

 Now, the centrifugal stress induced in the run of pulleys;

Fc = *v2
Where , = density of the rim material = 7200kg/m3 cast iron
V= velocity of rim and is given by = *0.1*

 Now, v1 = speed of smaller pulley;

V1= *d1* = *0.1*

V1 = 7.33m/s

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 V1 = similarly V2 can be calculated and has a value of;

V2 = *d2* = *0.4*

V2 = 7.33m/s

 The centrifugal tensions of the belts respectively is given as;

Fc1 = 7200*(7.33)2
Fc1 = 386.84*103 kg/ms2
Fc1 = 0.3868mpa

Similarly for Fc2 =7200 *7.332

Fc2 = 0.386mpa

Arm Considerations
 Tangential load per arm,

wt = T/ (r*n12) = Where t = torque transmitted

r = radius of pulley
n = number of arms

We know that the torque transmitted is given by

T=

 Substituting the corresponding value and we get;

T=

T = 0.471N 471Nm

wt =

= , since N

= 3140N

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 Cross section of arms is given by;

= fb where M=maximum bending moment on the arm at the hub end

Z= section modulus of arm
fb= bending stress for arm material

 Z is given by; Z= , and M= = Where d= diameter of arms

M= = = 471 N-mm

 The allowable bending stress for cost iron is given as fb = 15mpa, then from the relation;

= fb , we get

Z= =

Z = 31400mm3

 Again Z is given by; Z = , from this equation;

d3 = putting the above value

d3 =

d = 68.387mm

Determination of Hub Diameter

d1 = 2*d where d = diameter of shaft

d1 = diameter of hub
d1 =2*68.387 = 137mm

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 To find the diameter of hub let’s find first diameter of shaft, we know that the torque
transmitted by the shaft is given by;

T=

= 471Nm

 Bending moment on the shaft due to tension of the belt is given by allowable shear stress
of the shaft; = ; = 320mpa and F.S =2;

Shaft = 80mpa

 The minimum length of the hub is given as;

L= or = * B, where B = width of pulley and it can be obtained as

Table 5.12: Standard Width of Pulley [3]

B= b+13
B=2*17*13= 47mm say 50mm

Now L= *17 = 31mm say L=35mm

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5.3.2 SMALL PULLEY ANALYSIS

 Material: Cast Iron

The centrifugal stress induced in the rim of pulleys,

fc = *v2 where = density of the rim material = 7200kg\m2, for cast iron.
V= velocity of rim and is given by
So the velocity of rim can be calculated V = *d1*

V = 7.33m\s
Now substituting these values we get,
fc =7200*7.332m\s
fc = 0.386mpa
Arm consideration

 Tangential load per arm:

wt = where T =torque transmitted by smaller pulley

T= = =117.66N.m

Wt = =

Wt = 2353. 2N
 Cross section of arms

= fb

Where Z = and M = = = 117.66Nm

fb =15 Mpa

Now, Z = = 10981.6mm3

d3 = = = 111,857.66

d = 48.18mm say d=50mm

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Determination of hub diameter;

 From the measured data of motor diameter d=30mm

Since diameter d=30mm

Now hub diameter d1=2*d = 60mm

Table 5.13: Groove Dimensions for V-Belt Sheaves [1]

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5.4 SHAFT DESIGN

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 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 moment. The various members are mounted on the shaft by means of keys.

The material used for shaft should have the following properties;

1. It should have high strength.

2. It should have good mach inability.
3. It should have low notch sensitivity factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties.

Table 5.14: Mechanical Properties of Steels Used For Shaft [3]

 From these materials, Material 40C8, carbon steel is selected with;

u =560 670mpa
u =320mpa
F.s =2.5

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5.4.1 DESIGN OF SMALLER PULLEY SHAFT

Let T1 = tension in the tight side of the belt on pulley C.

T2 = tension in the slack side of the belt on pulley C.
T3 = tension in the tight side of the belt on pulley D.
T4 = tension in the slack side of the belt on pulley D.

 From design of V-belt

T1 = 616.13 N T3 = 645.145 N
T2 = 186.14N T4 = 194.98N

 From angle contact of the pulley (from first redaction)

= 2- 1

= (214-146.01) = 67.99
Therefore Since 3 = 4 = 67.99

 T3H = 646.415 * =241.88N

T3V = 646.415 * = 598.376N

 T4H = 194.989 * =73.1 N

T4V =194.989 * =181 N

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 From the angle of contact of the pulley (from the second redaction)

= 4- 3= 243.1-125.9
= 108.2
 T1H = 616.13* = -192.44 N

T1V =616.13 * = 585.31 N

 T2H = 186.14 * =-58.138 N

T2V =186.14 * =176.83 N

 Therefore vertical load acting on the shaft at C;

WC = T1V + T2V = 585.31+ 176.83

WC = 762.14 N

And vertical load acting on the shaft at D;

WD = T3V + T4V = 598.376 + 181
WD = 779.376 N

 We know that torque acting on the pulley C;

T = (T1V - T2V) *RC = (585.31- 176.83)*

T= 20.424Nm

And Torque acting on the pulley D;

T = (T3V - T4V) *RD = (598.376- 73.1)*

T= 105.055Nm

 And also Horizontal load acting on the shaft at C

WCH = T1H + T2H = -192.44-58.138

WCH = -250.578N

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 And Horizontal load acting on the shaft at D

WDH = T3H + T4H = 241.88 + 73.1 = 314.98 N

Now let’s find the maximum bending moment for the vertical and horizontal loading. First let’s
consider the vertical loading at C. Let RAV and RBV be the reaction at the bearings A and B.

Figure 5.5 Maximum Bending For the Vertical Loading

RAV + RBV =WCR + WDR

RAV + RBV = 762.14+779.376
RAV + RBV = 1541.516N

 Taking the moment about A,

RBV *250 =762.14 * 77 + 779.376 * 173

RBV = 774.1N
And RAV + RBV = 762.14 + 779.376
RAV + 774.1 = 762.14 +779.376
RAV = 767.416 N

 We know that B.M at A and B,

MAV = MBV = 0
B.M at C, MCV = RAV * 77 =767.416 *77
MCV = 59.1NM

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B.M at D, MDV = RBV * 77

= 774.1 * 77
= 59.61 N-mm

Now considering horizontal loading at D. let RAH and RBH be the reactions at the A and B
respectively.
RAH + RBH =WCH + WDH
RAH + RBH = - 250.578+314.98
RAV + RBV = 64.402N

 Taking the moment about B,

RBH *250 =762.14 * 173 + 779.376 * 77

RBH = 767.4486N

And RAH + RBH = 64.402

RBH = 64.402-767.4486
RBH = -703.046 N

 We know that B.M at A and B,

MAH = MBH = 0
B.M at C, MCH = RAH * 77 =767.046 *77
=59093.54N-mm
MCH = 59.093Nm

B.M at D, MDH = RBH * 77

= -703.046 * 77
= -54179.51 N-mm or 54.179 N-m

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 Resultant B.M at C;

MC =

=
= 83.578 N-mm

 And resultant B.M at D;

MD =

=
= 80.552 N-mm

 Bending moment is Maximum at D. Therefore maximum bending moment;

M=MD =83.578 N-mm

Let d= diameter 0f the shaft

 The equivalent twisting moment;

Te = =
Te = 134.24Nm
Te = 134.24 * N-mm

 And equivalent twisting moment (Te),

s shear stress for shaft material = =128mpa

134.24 * = * *

d = 17.48mm

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 Again the equivalent bending moment;

Me = (M + )= (M +Te)

= (83.578 +134.24)

= 108.91 * N-mm

 The equivalent bending moment is equal to;

108.91 * = * b*

all = = 240mpa

108.91 * = *240*

= 4622.28
d = 16.65mm

Taking larger of two values, we have d = 17.48mm say = 40mm

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Figure 5.6: Bending Moment Diagram

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5.4.2 DESIGN OF LARGER PULLEY SHAFT

Figure 5.7: Larger Pulley Shaft

Let T5 = tension in the tight side of the belt on pulley E.

T6 = tension in the slack side of the belt on pulley E.
T7 = tension in the tight side of the belt on pulley F.
T8 = tension in the slack side of the belt on pulley F.

 From design of V-belt

T5 = 645.145 N T7 = 645.145 N
T6 = 194.989N T8 = 194.98N

 From the 1st design, the angle of belt on pulley C is equal to the angle of the belt on pulley E.

= 4- 3

= (243.1-125.9)
= 108.2
Therefore Since 5 = 6 = 108.2
T3H = 645.145 * =-201.5N
T3V = 645.145 * = 612.86N
T3H = 194.989 * =-60.9 N
T4V =194.989 * =185.23 N

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 For the pulley F; T7H = 645.145N

T8H = 194.98N

 Therefore load acting on the shaft at E;

WEv = T5V + T6V = 612.86N + 185.23N = 798.09 N

And vertical load on the shaft at F;
WFV= 0

 The torque acting on the pulley E;

T = (612.86-185.23)*

= 85.526Nm

 And also horizontal load acting on the shaft at E;

WEH = T5H + T6H = 201.5 + 60.9 = -262.4 N

And horizontal load acting on the shaft at F

WFH = T7H + T8H = 645.145 + 194.989 = 840.134 N

Now let’s find the maximum bending moment for the vertical and horizontal loading. First let’s
consider the vertical loading at E. let RAV and RBV be the reaction at the bearing A and B
respectively.

Figure 5.8: Maximum Bending For the Vertical Loading

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 Taking moment about A;

RBV *250 =798.09 *173

RBV =552.28N

And RAV +RBV = 798.09N

RAV =798.09-552.28
RAV=245.81N

 We know that B.M at A and B equal to zero;

MAV=MBV=0
B.M at E, MEV = RAV *173mm
MEV = 245.81 * 173mm
MEV =42525.13N-mm

Now, considering horizontal loading at E. let RAH and RAH be the reactions at reaction at the
bearing A and B respectively.

Figure 5.9: Maximum Bending For the Horizontal Loading

 Taking moment at point A

RBH*250 = 840.134*77= (-262.4*173)

RBH*250 = 19295.11
RBH = 77.18N-mm

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RAH + RBH = 840.134 - 262.4

RAH + RBH = 577.73

RAH = 577.73 - 77.18

RAH = 500.55N-mm

We know that B.M at A and B equals to zero. So,

MAH = MBH = 0

 Taking B.M at E;

MEH = RAH * 173 – (840.134 *96) -RBH *77

MEH = 500.55 * 173 – (840.134 *96) -77.18 *77
MEH = - 0.574N-mm

 Resultant B.M at E;

ME =

=
= 42525.13 N-mm

Taking B.M at F, MFH = RAH *77-262.4*96-RBH*173

MFH = 500.55 *77-262.4*96-77.18*173
MFH = -0.19N-mm

 Resultant B.M at F;

MF =

=
= 0.19N-mm

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 Bending moment is maximum is maximum at E. Therefore maximum bending moment;

M = ME = 42525.13N-mm

 The equivalent twisting moment;

Te = =
Te = 95.51N-m

 And equivalent twisting moment (Te);

s Shear stress for shaft material = =128mpa

95.51 * = * *

d = 15.6mm

 Again the equivalent bending moment,

Me = (M + )= (M +Te)

= (42.52513+95.51)

= 69.02N-m

 The equivalent bending moment is equal to;

69.02 * = * b*

Where all = = 240mpa

69.02 * = *240*

= 2929.3

d = 14.3mmTaking larger of two values, we have d=15.6mm say 40mm

Therefore d=40mm

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5.5 DESIGN OF KEY

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the shaft.

Keys are used as temporary fastening and are subjected to considerable crushing and shearing
stresses. A keyway is a slot or recess in a shaft and hub of pulley to accommodate a key.

Figure 5.10: Keys

5.5.1 DESIGN OF KEY FOR SMALLER PULLER

 Assume

Type of key: rectangular key

Material selected: mild steel
= 560-670Mpa
=320 Mpa
F.S= 3, with =106.67Mpa
= 200Mpa

 Form the Table--- for shaft diameter d=30mm, the corresponding value of the key width
and thickness are:

W = 10 mm
t = 8 mm

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Table 5.15: Proportion of Standard Parallel, Tapered and gib Head Key [3]

 Now the length of the key is obtained by considering the key in shearing and crushing.
Considering shearing of the key (torque transmitted) of the key;

T=l*w*

= l*10*128 *

=19200V * l

Where T=60*

=117.66 N

Equating T=19200*l
117.66=19200*l
L=6.12mm
 Remark: the length of the key should be at least equal to hub length. Since the hub length
is taken as L= 60 mm. Now the length of the key should be Lk= 60mm.

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Checking the key for shearing and crushing

Figure 5.11: Key Dimension

Let’s now check the induced shear and crushing stresses in the key:

 Shearing:

= ; where F = force applied ds=30mm And T=117.66 Nm

As= shear area

F= = =7.844*103 N

As = L*w= 60*10=600*10-6 m2

= =

= 13.07Mpa
Since this is less than (13.07Mpa<106.67Mpa). Therefore it is safe.

 Crushing:-

Where Ac = = = 240*10-6 m2

= 32.68Mpa

=32.68Mpa
Since this is less than (32.68Mpa<200Mpa). Therefore design of the key for crushing is safe.

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5.5.2 DESIGN OF KEY FOR INTERMEDIATE AND LARGER PULLEY

 Assumption

Type of key: Rectangular key

Material selected: Mild steel
= 560-670Mpa
=320 Mpa
F.S= 3, with =106.67Mpa
= 200Mpa

 Form shaft diameter d=40mm, the corresponding value of the key width and thickness
are:

W=14mm
t= 9mm

 Now the length of the key is obtained by considering the key in shearing and crushing.
Considering shearing of the key (torque transmitted) of the key;

T=l*w* = l*14*128*

= 35840*l

Where T= 60* = 60*

= 438.64 Nm

Equating T=35840*l
438.64 = 35840*l
L=12.24mm say 20mm

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Checking the key for shearing and crushing

Let’s now check the induced shear and crushing stresses in the key:
 Shearing:

= Where F= force applied; ds=40mm And T=438.64N

As=shear area

So, F= = =21.932*103 N

As = L*w = 20*14=280*10-6 m2

= =

= 104.42Mpa

Since this is less than (104.42Mpa<106.67Mpa). Therefore it is safe.

 Crushing:-

Where Ac = l* = = 140*10-6 m2

=210Mpa
Since this is less than (210Mpa<240Mpa). Therefore design of the key for crushing is safe.

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5.6 DESIGN OF BEARING

Bearing permit smooth, low-friction movement between two surfaces. The movement can be
either rotary (a shaft rotating with in a mount) or linear (one surface moving along another).

Bearing can employ either a sliding or a rolling action. Bearing based on rolling action are called
rolling-element bearings. Those based on sliding action are called plain bearings. Plain bearings
are bearings that work by sliding action with or without lubricant.

Some of the guidelines for selecting bearing which are valid more often than not are as follows:

 Ball bearings are less expensive choice in the smaller sizes and under lighter loads;
whereas roller bearing are less expensive for large size and heavier loads.
 Roller bearings are more satisfactory under shock or impact loading that ball bearing.
 Ball-thrust bearing are for pure thrust loading only. At high speeds a deep groove or
angular contact ball bearing usually will be a better choice, even for pure thrust loads.
 Self aligning ball bearing and cylindrical roller bearing have very low friction
coefficients.

Figure 5.12: Standard Designations Ball Bearing [3]

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Can be one directional grooved-race bearing having grooved races very similar to those in radial
bearings or two directional, grooved-race bearings consist of two stationary race, one rotating
race, and two ball components.

Known value
 Diameter of shaft=40mm

Wt= where T- is the torque at pulley D= 105.005Nm

dp- is the diameter 0f the pulley D=400mm

= = 525.275N

Cos =

= =

= 21.88

 Wr = Wt*tan = 525.275N*tan21.88o

Wr = 210.946N
 Wa=Wt*tan =525.275*tan25

Wa =244.939N

 The reaction force at the bearing FA=767.416N

FB = 774.1N

 From The Table 5.12 for machine for continuous 24-hr service, the recommended
life is (50-60) Kh.
 50Khr is selected

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Table 5.16: Life of Bearings for Various Types of Machines [2]

 Assuming trial value of;

KA=KB=0.75

 The equivalent radial load on bearing A is given by;

FeA=0.4FrA+KA [ + TB]

= 0.4*767.416+0.75[ + 244.930]

FeA=854.49N

Since FeA>FAR, FeA is used as effective load.

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5.6.1 BEARING LIFE DETERMINATION

 Using reliability of 90%;

F*L1/a=constant--------------------------- (1) Where a=3, for ball bearings.

From equ (1) F1*L11/a = F2*L21/a

 And associate load F1 with C10, life measure L1 and L10;

C10L101/a = FD*(LD* nd *60)1/a Further it can be written as;

C10* (LR* nR *60)1/a=FD*(LD* nd *60)1/a

 C10= load rating FD = desired radial load in kN

 LR= rating life in hrs LD = desired life, hrs
 nR= rating speed, nd = desired speed,


Solving for C10 gives;

C10=FD * ( )1/a

Now at LD=15,000 hrs

nd = 87.5 rev/min

 FD1=767.416N and FD2= 774.1N are reaction forces on bearing respectively.

The expression LR* nR *60=106

 The design basic dynamic radial load C10 will be;

C10=767.416 * ( ) 1/3

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 Design basic dynamic radial load C10=3.289 KN*AF

Where AF= Application factor (load factor) = 1-1.5

C10=3.289 KN*1.2
C10=3.9468 KN

The basic life of bearing is (the number of revolution or hours at constant speed). That 90% of a
group of bearings will achieve or exceed before the failure criterion develops and given by,

L10=

Where Fe is the equivalent radial load and is given

Fe=Fr =767.416 N

Now, bearing life L10=

L10= 258.95*102 hr

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5.7 BEARING SUPPORTS

Figure 5.13: Bearing Support [3]

Bushed bearing is an improved solid bearing which a bush or brass or gun metal provided. The
outside of the bush is driving fit in the hole of the casing where as the inside is a running fit for
the shaft. When bush work out it can be easily replaced in small bearing. The frictional force
itself holds the bush in position, but for the shaft transmitted high power grub screw are used for
the prevention of rotation and sliding of the bush.

Design of bearing caps and bolt

Bearing cap is tightened on the top. Load is usually carried by the bearing not on the cap, but in
some cases a considerable load comes on the cap of the bearing. Therefore the cap and the
holding down bolt must be designed for the full load.

Cap is generally regarded as a simple support beam, supported by holding down and loaded at
the center.

A=distance between center of holding down bolts

W=load supported at center
l=length of the bearing
t=thickness of the cap

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 The weight applied on the bearing will be the sum of the

Weight of the Pulley Wp,

Weight of the shaft Ws,

3
 Material for the shaft: steel, steel=7800kg/m

Where Ws=m*g
m= *v
V=A*l where A= cross sectional area of the shaft
l = length of the shaft

v= *l

 From the design of shaft l=250mm, d=40mm

v= *250

v=314.16* m3
Ws = *v*g=7800*314.16* *10
Ws =24.5N

Pulley weight analysis

Pulleys made with cast iron (CI) hub and arms and grooved part save as much as 60% of weight.
Vp= Vr +Va-Vs
Where Vr=volume of rim
Va=volume of arm
Vs=volume of sheave groove
Vh=volume of hub

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Varm= 4*Aa = =

Varm= 4.248* m3

 For the sheave from the pulley design; W=22mm, n=2

Vs = =

Vs=5.474* m3

Vrim = =

= 4.802* m3

Therefore Vt =Va +Vr+ Vh -Vs

Vt =4.24* *4.802* +9.95* -5.474*
Vt=9.702* m3

3
Take density of the cast iron pulleys to be, ci=7200kg/m

Mt= Vt * =9.702* *7200=6.98kg

 Weight of pulley, Wp = m*g

Wp= 6.98*10 = 69.8N

So, W= Wp + Ws=69.8N + 24.5N= 94.3N

 Now the load applied on each bearing is = 47.15N

 Material selected for the cup Cast-iron with: ut = 100-200mpa;

u = 120mpa
E= 100-200Gpa, take 150Gpa
F.s=4

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 Maximum bending moment at the center;

M = W* at a=84mm

all= =50mpa

b = Z=169.8mm3

Section modules of the cap Z=

Z=169.8mm3 I=d=62mm

169.8 =

= 16.43mm2
t= 4.05mm say 10mm

When an oil hole is provided in the cap, diameter of the hole should be subtraction from the
length of the bearing. Cap of the bearing should also be investigated for the stiffness. For simply
supported beams at the center the deflection is;

= where I=

I=5166.7mm4, t=10mm, =150*103mpa

= 48*150*103*5166.7=0.0015mm

In order to design the holding down bolts the loads on each of the bolts is taken 33% higher than
the normal load on each bolt load on each bolt = 4* *n.

 Where n is number of bolts in this bearing support;

= 4*

=125.7N
 Since the load design for a bolt should be 33% higher than the normal load.

Now W = 125.7N + 0.33 * 125.7N

W= 167.18N

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From this = Where = core diameter of the bolt

= tensile stress for the material of the bolt

 For bolt material = = 25Mpa

So, =
Say 14mm.

Table 5.17: Design Dimensions of Screw Threads, Bolts and Nuts [3]

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 From standard the corresponding dimension will be;

M18 coarse series

Pitch 2.5mm

 Major diameter of nut and bolt d=D=18mm

Nut = 15.294 mm
Bolt = 14.933 mm
Depth of thread (bolt) = 1.534 mm
Stress area = 1925 mm2

 Total required number Bolt = 4

Bearing caps = 2

Stresses are screwed fastening due to static loadings. Initial stress due to screwing forces;

1. Tensile stress due to stretching of the bolt. The maximum safe axial load which may be
applied is:

 Psafe = permissible stress * area A, at the bottom of the thread or stress area.
The stress area is given by;

A= where dp , dc are pitch and minor diameter of the thread.

A=

A =78.01 mm2

Psafe = *A = 25Mpa*78.01 mm2

Psafe = 1950.25Mpa

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2. Torsion shear stress causes by the frictional resistance of thread during tightening.

 From v-belt design, the torque transmitted;

T=60*

T=117.66 Nm

= 0.18 Mpa

3. Shear stress across the threads

 For screw (bolt);

Where, b is width of the thread section at the root. b= = = 1.25

n is number of the nut, n=7

d is major diameter of the nut, d=18mm

= 3.94Mpa

 For the nut;

at d=15.294mm

= 4.64Mpa

4. Compression or crushing stress on threads;

= 3.512 Mpa

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5. Bending stress is negligible since the surface under the head or nut is perfectly parallel to the
bolt axis.

 Stress due to external forces

1. Tensile stress

External load applied, p =

= = 11.13 Mpa

2. Shear stress

 Shearing load carried by the bolts;

= = 1.09 Mpa

 Maximum shear stress;

<[

Mpa < 30 Mpa it is safe

<[

= = 11.235 Mpa < 25 Mpa it is safe

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5.8 REQUIRED OIL RECOVERY RATE

First design specification is the required seed capacity rate which is selected as 120 kg/h. The
design calculations will mostly based on this specification.

Table 5.18: Screw Press Capacity

Capacity (kg seed/ h) Motor (kw)

30 – 40 4
70 – 100 7.5
120 – 200 15
220 – 300 22
400 – 500 30
700 – 900 45
1500 – 1800 110

Source: - equipment for decentralized cold pressing

of oil seeds, ERIK FERCHAU, November 2000

There are some pretreatment that directly affect the oil recovery rate such as the moisture content
and temperature of the seeds. The seed capacity is given in terms of mass flow rate, however it
should be converted into the unit of volumetric flow rate, since one of the important inputs to the
design calculations is the volumetric flow rate of the seed.

Weight of the 100ml uncompressed sesame seed is measured as 72 grams. According to this
data, 120kg/h seed is equal to

120000g/h* = 166666.66ml/h

= 167 l/h
Theoretically, the volume swept by the feeding turns of the screw shaft is assumed to be equal to
this seed capacity. However, the feeding screws would never be able to push forward the
complete volume of seeds that they swept, this assumption is not realistic.

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So an efficiency rate is assumed between the swept volume by the feeding turns and the volume
of the seeds which are transferred forward. VolumeT is the theoretical volume which is the swept
volume by the feeding turns. VolumeR is the real volume that is transferred forward by the
feeding screws. Feeding efficiency, ç is taken as 90%.

= VolumeR

VolumeR = = 185.6 l/h

Under sufficient pressure and no drainage condition, the total volume of certain of seeds drops
half of it as given in fig. t is total applied pressure, i is seed cake pressure and U is fluid
pressure.

According to Figure 5.14, the volumetric flow rate at the inlet section of the oil expeller will
drop to half of it at the outlet section. After compression without a drainage, the total volumetric
flow rate, Qcompressed _ seed, which is composed of the flow rate of the compressed cake,
Qcake , and the oil content, Qoil , becomes 92.8 L/h.

Figure 5.14: Pressure Change in Volume of Cake and Oil expressed vs. Time graph [8]

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Qcompressed _ seed = Qoil + Qcake (1)

 Then volumetric flow rate of the cake can be determined by;

Qcake = Qcompressed _ seed – Qoil

 To determine Qcake, first Qoil should be determined.

Table 5.20: Seeds Moisture and Oil/Fat Content [6]

seed Moisture content Oil/fat content Uses

(%) (%)
sesame 5 50 Salad oil, cooking oil
sunflower 5 35 Salad oil, cooking oil
rape 9 40 Salad oil, cooking oil
poppy 9 50 Salad oil, cooking oil

Since oil content of sesame is 50% of the total weight of seed, and residual oil content in the
cake is assumed as 15% of the total oil. Oil recovery efficiency of the system,  , is given,
=

Seed capacity, SC, is 120 kg/h, however it is assumed that more than 50 kg seed is fed into the
system in order to allow a margin for errors. Errors may depend on slippage of the seeds inside
the system. The seeds may not be effectively pushed forward. So, seed capacity is divided by a
correction factor, named feeding efficiency, , which is assumed as 90% in the previous
calculations.

Then the corrected seed capacity becomes 125 kg/h. Oil content, is 50% and efficiency,  , is
65% . Then, oil recovery rate, Moil, is calculated as [8];
Moil = SC 
= 125kg/h*0.5*0.65
= 40.625kg/h

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Volumetric oil recovery rate, Qoil (m3 / h), is determined by dividing the mass flow rate to the
density of sesame oil, (kg /m3), as given in Equation 5. Density of sesame oil is 640kg / cm3 at
20°C.
Qoil =

Qoil = 0.063 m3/h = 63L/h

Then, volumetric flow rate of the cake, containing residual oil, can be determined by
Qcake = QCompressed _ seed - Qoil
Qcake = 92.8 L/h - 63L/h
Qcake = 29.8 L/h

Table 5.21: Volumetric Flow Rates of oil and cake for 120kg/h Seed Capacity for 65%
Efficiency
Volumetric flow rate (L/h)
Quncompressed _ seed 167
185.6

Qcompressed _ seed 92.8

Qoil 63
Qcake 29.8

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5.9 DESIGN OF SCREW

 Functional requirement;
 High strength
 High corrosion resistant
 High heat resistant
 Hard and wear resistant and retain its hardness at high operating temperature, and it
resist cracking and distortion during heat treatment.

 Material selection

Table 5.22: Material Screw Shaft [2]

 The material selected is stainless steel (514600) with the following properties;

= 600Mpa
= 758Mpa
= 300Mpa
 Assumption

 Coefficient of friction between the screw and the seeds f=0.3

 Safety factor (F.s=4)

Given power (P) = 15Kw

P=w

P=w

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15000watt = w*

15000watt = 0.3485W
W = 43,044.24N

 Core diameter of the screw Ac = , now to find the core diameter of the screw under
pure compression.

W= * Ac where = = = 300Mpa

From this to find the value of dc;

Ac =

W= * Ac

dc = = 13.52mm

From standard table

dc = 40mm(minor diameter)
do =100mm(nominal diameter)
Pitch, p = 60mm

 Mean diameter of screw;

dm = = = 70mm

 Torque required rotating (move) the screw in the vessel ;

T = P* d= dm

=w * =w *

Where = f = 2.5 = 43044 *

= 524,507.7N-mm

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 We know that torque transmitted by the screw;

T= * * from this the shear stress is

= = = 41.74N/mm2

 Direct compressive stress on the screw due to axial load;

= = = 34.25Mpa

 According to maximum shear stress theory, we have;

max =

max =

= 45.12Mpa
Therefore, since 45.12Mpa < 75Mpa then the design is safe.

Now considering the screw as a column, buckling has to be checked. So according to J.B
Johansson’s formula,

Wcr = * [1- Where Wcr = critical load

= yield stress
L = length of screw under buckling
C = end fixity coefficient
K = least radius of gyration

 Considering the screw as column, assume both ends fixed C;

K= =

= = 10

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 Let L = unsupported length of screw = 500mm

Ac = = = 1256.64mm2

= 600Mpa
E = 207*103
K= 10
C=4

Substituting the above formula values in the formula,

Wcr = 719,385.02N
Therefore Wcr > W, then it is safe.

The determined volumetric flow rates are used to calculate the unknown parameters as the thread
depth, pitch and the radius of the screw shaft.

Initially, torque on the screw shaft is determined. The screw shaft is a single square-threaded
power screw having an increasing root diameter. In Figure 5.15, l is the pitch, f is the coefficient
of friction between the seeds and the screw shaft and taken as 0.3, N is the normal force, Fxs is
the axial force that pushes the seeds forward and Fts is the tangential force. If pressure is assumed
to apply on the surface of the threads as perpendicular, then Fxs and Fts are the two components
of the overall pressure on the screw shaft.

Figure 5.15: Illustration of Force Directions on the Unwrapped Thread While

Pushing the Seeds Forward

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 The relation between Fxs and Fts is given in Equation 1. Is the lead angle which is equal

to .

Lead angle = = = 3.18 [10]

Fts = (1)

 The torque can be written as:

Ts = (2)

Although pitch diameter increases through the length of the screw shaft, ds is taken as the outside
diameter of the screw shaft which is constant in order to be on the safe side. The reason is that
is a very small angle as 2.5° so the difference between the initial and final radius is negligible.

Fxs can be determined by integrating the pressure distribution along the thread length as given in
Equation 3 [9].

Fxs = (3)

As shown in Figure 4.9, Lt is the thread length of the screw for one turn which can be
determined by using Equation 4 [9].

= *2 (4)

= *2

= 478.11mm
To calculate the total thread length, Lt should be multiplied with the number of the turns of the
screw. The number of the turns of the screw can be calculated by dividing the pitch distance to
the axial length of the screw as given in Equation 5.

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#turns = (5)

#turns = 11.79

. #turns is the total thread length which can be calculated by using Equation 4 and Equation 5.
P(ξ) is the function of the pressure distribution along the thread length as represented in Figure
5.16.

H(ξ) is the function of the thread depth which is linearly decreasing along the thread length and
becomes zero at the cake drainage as represented in Figure 5.17.

Figure 5.16: Graph of Assumed Pressure Distribution on the Screw Shaft From
The Inlet to Outlet

In order to calculate P(ξ) , pressure is assumed to increase along the helix length of the screw in
the third order as represented in Figure 5.16. The general equation of the pressure distribution is
given in Equation 6 [9].
P (ξ) =aξ3 (6)

P2, which is the highest pressure occurring at the cake drainage zone, is taken as 60 Mpa (Figure
5.14) and P1 which is the atmospheric pressure (1 atm) is assumed as 0MPa since it is negligible.

For ξ = *#turns, P (ξ) = P2 = a*( * #turns) 3

ξ= *#turns
= 487.77 * 11.79
= 5644.6

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 Then, a is equal to * ξ3 that Equation 6 can be written as:

P (ξ) = * ξ3

P (ξ) = * 5644.63

P (ξ) = 86.67mpa

 The linear change in the thread depth along thread length is shown in Figure 5.17.

Figure 5.17: Graph of Height Distribution through the Screw Shaft

Linear equation of the height of the thread through the thread length is given in Equation 7. H2 is
equal to zero since the thread depth becomes zero at the last point of the screw as shown in
Figure 5.17.

H(x) = *x+H1 (7)

 Ls can be written in terms of and H1 as represented in Equation 8.

Ls = = = 687.11mm (8)

 The extended for of the Equation 4.10 is given in Equation 2.

Ts = * *( ) (10)

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Second equation is the volumetric flow rate of the uncompressed seed with a correction factor as
given in Equation 11. It is equal to the swept volume by the first turn of the screw in 3 second.
Tooth thickness, t, is taken as 20 mm according to maximum shear strength calculations. And l is
the pitch of the screw. If the thickness of the tooth is subtracted from the pitch, then the gap
distance between the first and the second turn of the screw can be determined. The area of this
gap is equal to H1 (l - t). Decrease in height of the tooth between first and second turns can be
neglected since the tapered angle is small. So, it is assumed that the height is constant along the
first pitch.

The gap area should be multiplied by the helix length for one turn in order to determine the
volume swept by the first turn of the screw in one revolution. One revolution is completed in 2
seconds since the rotational speed of the screw shaft is taken as 87.5rpm. So, in order to calculate
the volumetric flow rate of the seeds, the swept volume should be divided into 6 seconds.

= (11)

Then there are three unknowns in Equation 11 which are H1, ds, l. However there are two
Equation 10 and Equation 11 In order to determine the unknowns, a reasonable value should be
assigned to one of the unknowns such as “ds”. One of the criteria while assigning the value of ds
is concerning the capacity of the manufacturing machine which will be used in production of this
part and the expected size of the overall machine. After assigning a value to ds, the other
unknowns can be calculated. The required power should be below 15 kW. Accordingly, the
required torque should be below 524,507.7N-mm if the rotational speed is 87.5 rpm.

Table 5.23: The Results of the Three Unknown Parameters

Ds L H1
100mm 57.5mm 30mm

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5.10 OIL DRAINAGE ZONE

For oil drainage, holes are machined onto the vessel. These holes should be far enough from the
cake drainage zone at where the pressure is Maximum; otherwise the holes can be choked with
high pressurized cake. Therefore, oil drainage holes should be placed where the seeds are not
compressed yet as shown in Figure 5.18. Oil flows from the high pressure zone to the low
pressure zone until it finds an opening to rush out.

Whole seeds are present at the low pressure zone. Here oil can easily leak out from the openings,
because whole seeds cannot choke these openings. In order to prevent any choking, the diameter
of the hole, Dh, is assumed as 2 mm, because minimum diameter of sesame seed is measured as
2.5 mm among the100 unit of samples. It is seen that the holes are not choked with cake which
are 70 mm or more far from the cake drainage.

However, depending on the maximum stress which occurs inside the vessel, maximum number
of holes at a cross-section can be determined. The inside pressure at the oil drainage zone should
be determined in order to calculate the maximum stress inside the vessel.

 The pressure can be taken as;

= P (ξ) (Lt (# turns – )) [10]

 These value calculated ready calculated in the shaft design;

=86.67 (478.77 (11.79 - – ))

= 43.871Mpa

High pressure develops in tangential directions as shown in Figure 5.18. The tangential stresses
can be determined by using Equation 12. Is negligible compared to .
Longitudinal stress exists when the end reactions to the internal pressure are taken by the
pressure vessel itself. In this design, the end reactions are not taken by the pressure vessel itself.

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They are carried by the bolts which are used in fastening the frame and the vessel.
Then, = 0Mpa.

Figure 5.18: Illustration of Inside and Outside Pressure for the Vessel

= [9] (12)

In Equation 12, is the root diameter of the vessel and is the outside diameter of the vessel.
r is taken as the root diameter of the vessel, since the maximum stress will develop inside the
vessel. The tangential stress can be converted into nominal stress by using Equation 13.
However, this value should be multiplied with the stress concentration factor which is shown in
Equation 14. Lh is the distance between two holes 5mm.

nom = [9] (13)

max = * nom (14)

Stress concentration factor can be calculated by using Equation 15 for 0 1.

=3-3.095( )+0.309( )2+0.786( )3 (15)

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If Equation 13 is substituted into Equation 14, then the relation between and max is
given in Equation 16.

max = (16)

In Figure 5.19, is constant, 3, after Lh >4mm. To be on the safe side, Lh is assumed as

5mm.

Figure 5.19: Vs graph [5]

For the ease of manufacturing, the vessel material is selected as Al 7075 for the prototype. Also
Al 7075 is selected since cost and yield strength of this material is suitable for this stage of the
design. The maximum tensile stress of this material is 450 Mpa. With a factor of safety of 1.5,
the maximum available stress inside the vessel can be 300 Mpa. Then if max is 300MPa, from
Equation 16, tangential is calculated as 120 Mpa.

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120*106 =

120*106 - 120*106* = + 59.8*106

60.2*106 =180*106

=
= 1.73

 So the thickness of the vessel is calculated as 37.5 mm where the outside pressure, Po, is
taken as 101.325 Kpa.

Circumference of the inside vessel is equal to 2. .rvi .where 101 mm is the Diameter of the inside
vessel. The maximum number of holes at one cross section can be determined by using Equation
17.

Nhi = (17)

Nhi = 120holes

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5.11 DESIGN OF SUPPORT FRAME

Material selected
 Steel with = 540mpa and = 540mpa

Consider the support as column with one end free and the other end fixed.

 The critical load (crippling) load is given by;

Wcr = =

Where = crushing or yield stress in compression

a = rank in constant; a =

L = equivalent length of the column and

K = least radius of gyration; K =

Table 5.24: Relation between Equivalent Length (L) and Actual Length (L) [3]

 L from table Assume one end free and the other end fixed;

L=2*l

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 Cases for buckling to occur;

1, if Wcr < Wapp or

2, > all

The weight applied on the support frame; assume it is the weight of the pulley, shaft, bearing,
screw, flange, oil drainage, crash head casing and crash head to be;

 From pulley weight analysis;

Wp = 69.8N since we have six pulleys = 69.8N*6 = 418.8N

Ws = 24.5N since we have three shafts = 24.5N * 3 = 73.5N
Wb = 10N since we have six bearing = 10N * 6 = 60N
Ws = 50N since we have two screw = 50N * 2 = 100n
Wf = 25N since we have two flange = 25N * 2 = 50N
Wo = 15N since we have two oil drainage = 15N * 2 = 30N
Wc = 20N since we have two casing = 20N * 2 = 40N
Wn = 10N since we have two crash head = 10N * 2 = 20N

 The total we have WT = 418.8N+73.5N+60N+100N+50N+30N+40N+20N

WT = 792.3N
 Since we are considering the frame as a column; the force applied on one of the supports
is given by;

= =198.075N

 Factor of safety for steady load is given as; F.S = (5-6) therefore, the critical load;

Wcr = Fs *198.075N
Assume the support is angle iron type steel with dimensions of b=t. Assume the length of the
frame to be L= 1350mm.

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 From Euler’s formula of crippling load the polar moment of inertia I is given by;

I = Wcr *

Assume Esteel = 200 – 220 Gpa

I = 990.375 *

I = 8.71 * 10-9m4

 Where I for square cross section is given by I = , subsisting the above values and we
get;

8.71 * 10-9m4 =

a = 17.98mm say 50mm

 Let’s check the value of the normal stress with the allowable one;

= = = 0.216 mpa

Since = = = 54mpa

Since is smaller than the allowable stress, for buckling the design is safe. Therefore the
dimensions for the selected cross section will be 50mm * 50mm.

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CHAPTER 6
DISCUSSION, CONCLUSION AND RECOMMENDATION

The aim of the thesis is to develop an oil extraction machine for the sesame seed. The main
criteria of this thesis are the required seed capacity which is 120 kg/h and the maximum available
power which is 15 kW. During the thesis, various alternatives were generated depending on the
previous studies. Different screw configurations, oil and cake drainage systems were developed
for this design.

6.1 DISCUSSION ON MANUFACTURING AND ASSEMBLY

STAGE OF THE PROTOTYPES

At the manufacturing and assembly stage, several problems were expected. The most important
problem during the manufacturing will be the eccentricity between the screw shaft and the
vessel. Depending on the tolerances of the manufacturing machines and manufacturing
methodology, eccentricity problems may occur. In this thesis, concentricity was very important
for the screw shaft and the vessel. Since there was small clearance between the screw shaft and
the vessel, any small eccentricity resulted in locking of the system arising from the contact of the
metal parts.

In the manufacturing and assembly stage in order to overcome the eccentricity problem on the
screw shaft, all the machining process of the screw shaft were performed between two centers of
the CNC turning machine. Since the vessel was mated to the flange with bolts, slope at the
mating surface of the vessel and the flange or at the bottom surface of the flange might cause
eccentricity. The problem was overcome by supporting the free end of the vessel with a block in
order to make the axes of the vessel parallel to the platform surface. This step was really difficult
to implement since the minimum clearance between the screw shaft and the vessel was 1 mm. So
any small difference in the heights of the bearings would cause locking of the mechanism.

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The other thing is the groove profile; the groove profile was manufactured by using CNC
WEDM. However, this production method was both expensive and time consuming. It took 15
hours to machine the groove profile in the CNC WEDM. So an alternative geometry for the ease
manufacturing of the groove profile was developed.

Cutting tool was machined in the shape of a perpendicular triangle. Then it was driven in the
longitudinal direction of the inside vessel with a small penetration (0.7 mm) to form the grooves.

Manufacturing of the oil drainage holes was a difficult and time consuming process. Duration of
the drilling for one hole took 5 minutes which means for 200 holes it takes 1000 minutes (16.7
hours) and there were 120 holes drilled on the vessel since it was determined as sufficient.

Assembly and disassembly of the machine components was another important problem during
the study. The screw press was left to be cooled down before the disassembly process of the
machine components for cleaning. However, cooled screw press was very hard to disassemble.

At high temperatures, compressed seed could easily penetrate through the clearance between the
vessel and the screw shaft by the expansion of the material at high temperatures. After cooling
down, the dry seeds caused high friction force between the vessel and the screw shaft. In order to
overcome this problem, after each operation of the screw press, the cake drainage cone can be
moved forward before cooling down. As a second alternative solution to prevent locking of the
mechanism, the vessel can be composed of two parts which are separated in the axial direction
after each operation. Furthermore, by this configuration, the disassembly can be performed by
only separating the vessel easily.

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6.2 DISCUSSION ON THE TESTING OF THE PROTOTYPES

There are four main features affected the compression efficiency. These were the groove profile
inside the vessel, the taper angle of the screw, the operating temperature and the rotational speed.

Grooves were very effective in canalizing the compressed seeds and prevented jamming of the
system. In order to obtain an effective canalizing of the compressed seeds, the direction of short
edge of the groove should be in the radial direction. So, the maximum available tangential force
can be applied to stop the rotating compressed seeds. As an experience, the length of the grooves
should not be machined from one end to the other. Since the grooves serves as oil channels, oil
may go back to the feeding section and may choke the feeding tube. The curvature shaped
groove profile of the vessel was very successful in the compressed seeds at high pressures.

There are screws with alternating pitch configuration. However, tapered screw shaft was more
effective in compressing the seeds. The reason depends on the compression of the seeds in two
directions in the tapered screw shaft. First one occurs between the adjacent two turns of the
screw by the compression of the newly added seeds. Other way of compression takes place
between the inner surface of the vessel and the inner surface of the screw shaft.

Temperature is essential for increasing the oil recovery rate. During the study, temperature
increased the fluidity of the oil. So oil could be able to move faster and easily penetrated into the
gaps of the cake easily.. A heating mechanism also can be used to increase the temperature at the
cake drainage. But it may result in higher oil recovery rates and very thin cake flakes. So there
was no need for a heating mechanism since the temperature of the whole system increased
naturally because of the friction between the compressed seeds and the machine components.

Rotational speed is another important factor which affects the flow of the seeds. If the rotational
speed is higher than the required, then the system can be jammed. Or if the rotational speed is
lower than the required, and then seeds cannot be pushed forward effectively and 87.5 rpm was
convenient for the developed screw press according to our design. So Jamming problem was
overcome by increasing the rotational speed to an upper value.

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6.3 CONCLUSION

Table 6.1: Technical Data for the Developed Screw Press

Seed capacity of the screw press 72kg/h

Cake thickness 0.8mm
Extraction efficiency of the screw press 65%

( )

Motor Power 15kw

Rotational Speed 1400rpm

Seed capacity rate was assumed as 120 kg/h at the beginning of the design calculations. However
the present system has a seed capacity of 36 kg/h. Since we have two screw presses it will be
72kg/h theoretically, assumed seed capacity is three times greater than the real seed capacity of
the developed screw press. This means, the feeding efficiency which was assumed as 0.9 in, is
not correct for the developed screw press. It should have been taken as 0.3 to obtain 120 kg/h
seed capacity. However, if the feeding efficiency is taken as 0.3, then the machine size enlarges
too much.

Another alternative to increase the seed capacity of the present screw press is increasing the
capability of the grooves inside the vessel. This can be achieved by adjusting the groove profile,
depth and length.

The efficiency of the system was assumed as 85%; however the efficiency of the developed
machine is 62.5%. Since lower oil recovery rate was obtained, the maximum pressure inside the
vessel has never reached to 60 Mpa, which was an assumed value for an oil recovery rate of
85%. Accordingly, lower pressure resulted in lower torque and, lower torque lead to lower
required motor power.

Another assumption, which would have lead to a higher theoretical motor power, was the kinetic
friction coefficient between the seeds and the machine components. Although the friction

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coefficient was taken as constant through the shaft, it was different for compressed and
uncompressed seed.

During stress analysis of the screw shaft, factor of safety was calculated slightly higher than 3 at
the most critical cross-section of the shaft according to Maximum Shear Stress Theory.
However, real torque obtained during the tests was determined as 260N-m which is equal to 1/5
of the calculated torque. Then, factor of safety becomes 4 which mean the design is safer.

The maximum temperature obtained was 88°C at the cake drainage zone of the screw shaft. The
temperature of the recovered oil should be preserved under 90°C for the quality of the oil. The
obtained maximum temperature (88°C) is under the limit. However, it should be lower than 88°C
since it is very close to 90°C.

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6.4 RECOMMENDATION

After the machine is being manufacture, it can solve a very wide problem but it still has some
problem. So the following thing should be considered.

1. As a design criterion it was aimed to produce a screw press that can easily be assembled
for cleaning purposes. However, it was hard to reassemble due to the need to readjust the
concentricity of the shaft and vessel after every disassembly. It also necessitates some
expertise and time to put everything back in place, which can also be considered to be a
drawback for a possible future marketable machine.

2. After the oil is extracted from the oil seed, there is a waste or cake. So at the first time
there is a possibility to get less amount of oil than what we are required due to
temperature fluctuation or other means. Therefore, we should recover the waste or cake
product again so we can get some amount of oil.

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ASSEMBLING PROCEDURE

1. Prepare the main support frame and attach the motor together with the pulley into the
main frame.
2. Insert the bearing into the bearing support and attach them on the main frame.
3. Placed the shafts on the upper of supporting frame through the bearing.
4. Fix the shafts on the upper of supporting frame using bearing bolts.
5. Attach pulleys on the upper shafts.
6. Connect the lower and upper pulleys using belt strands.
7. Provide pulleys cover and belt cover for the attached pulley and shafts.
8. Attach the sheet metal and fix it using bolt with the support frame.
9. Attach the flanges concentricity with the upper two shafts and connect the flanges with
bolts.
10. Insert the screw shafts through the flange and couple with the shafts by using the key.
11. Connect the oil drainage to the flange since both have a thread part but at this time check
the concentricity between the oil drainage and the flange.
12. Connect first the crash head casing with the crash head and then connect both to the oil
drainage. In this assembly also both the crash head casing and crash head must be
concentricity.
13. Insert the nozzle to the crash head remember there are plates with different inside
diameter that are inserted in the nozzle first.
14. Attach the upper and lower support in the position of the flange and connect upper and
lower support with bolts.
15. Finally attach the hoppers into the flange.

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REFERENCES

1. Jose M. Dominguez Estupinan and Mokonen G/silasie, teaching material on machine design,
Mekelle, Tigray, Ethiopia. November 2003.
2. Joseph Edward Shigley, C.R Mischeke, mechanical engineering design, 6th edition. New York,
2001.
3. R.S.Khurmi J.K.Gupta, a text book of machine design, 4th edition, New Delhi, 2004.
4. Robert C.Juvinal / Kurt M. Marshek, fundamentals of machine design, 1st edition component
design, 3rd edition, New York, 1967.
5. Singh, J. and Bargale, P.c., 2000, Development of a small capacity double stage compression
screw press for oil expression: Journal of food engineering, v.43, P.75-82.
6. Hui, Y.H. Bailey’s industrial oil and fat products volume 2: “Edible oil and fat products: oil and
oil seeds.’’ Hui, Y.H.1996.John Wiley and sons.
7. Ward, J.A., 1976, processing high oil content seeds: Journal of the American oil chemist’s
society, P.261-264.
8. Mrema, G. C., McNulty P. B., “Mathematical Model of Mechanical Oil Expression from
Oilseeds”, Journal of Agricultural Engineering Research, 31(5), (1985), 361-370
9. Oyinlola, A., Ojo, A., Adekoya, L.O., “Development of a laboratory model screw press for
peanut oil expression”, Journal of Food Engineering 64 (2004), 221-227
10. J, Uziak, I.A. Loukanov and J.D.G. Foster, “A Simplified Model of an Offset Ram Press for
Sunflower Oil Expression”, African Journal of Science and Technology (AJST), Science and
Engineering Series 3, 61-68
11. http://www.scribd .com/doc/45491885/edible-oil-summery, June 2012.
12. Ram Press – Kick Start Technologies (NGO in Kenya)
http://kickstart.org/tech/technologies/oilprocessing.html June 2012.
13. Oilseed processing equipment mostly from India
http://trade.indiamart.com/offer/plant-machinery/oil-extraction-machinery/sell1.html June 2012
14. Oil press machinery – China
http://lightinfo.en.ec21.com/product_detail.jsp?group_id=GC01966495&product_id=CA0198573
4&product_nm=200A-3_Oil_Press
15. Oilseed processing for small-scale producers http://attra.ncat.org/attra-pub/PDF/oilseed.pdf
June 2012.

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