FIRII

WOLLEGA UNIVERSITY
COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

DESIGN AND MODIFICATION OF HYDRAULIC MINI BRICK MACHINE
A THESIS SUBMITTED TO WOLLEGA UNIVERSITY IN PARTIAL FULFILLMENT

OF THE REQUIREMENTS FOR BACHELOR OF SCIENCE IN MECHANICAL
ENGINEERING
BY GROUP MEMBERS
NAME OF STUDENTS ID .NO

1. DAWIT TEKELE ................................................................................. 0309/15
2. CHALA SHEBERA .............................................................................. 0267/15
3. NAOL ALEMU ..................................................................................... 0871/15
4. BALACHEW ABDETA ....................................................................... 0189/15
5. GELANE BEDESA .............................................................................. 0494/15
ADVISORS NAME: Mr. JABESA A. (MSc). Mr. SHIMALIS M. (MSc)
SUBMITTED DATE: FEBRUARY 03, 2021
NEKEMTE, ETHIOPIA
DECLARATION
This thesis is our original work and has not been presented for a degree in any other university.
All sources of materials used for the research have been duty acknowledged.
S. No Name Signature Date
1. Dawit Tekele ________ ________
2. Chala Shebera ________ ________
3. Naol Alemu ________ ________
4. Belachew Abdeta ________ ________
5. Gelane Bedesa ________ ________
Page | I
APPROVAL PAGE
The thesis entitled “design and modification of hydraulic mini brick machine” submitted by
Dawit Tekele, Chala Shebera, Naol Alemu, Belachew Abdeta, Gelane Bedasa are approved and
accepted as a Partial Fulfillment of the Requirements for the Bachelor of Science degree in
Mechanical Engineering at Wollega University.
Advisor Name Signature Date
Jabesa A. ________ ________
Coadvisor Name Signature Date
Shimelis M. ________ ________
Examiner Name Signature Date
1. ________ ________
2. ________ ________
3. ________ ________
4. ________ ________
Page | II
ACKNOWLEDGEMENT
Primarily, we would like to thank almighty God for his blessing, protections, support in our entire
life and helping us in all aspects from the start to the end. Secondly, extended our sincere gratitude
to our Instructor and main advisor Mr. Jebesa A. (MSc), for his best guidance, encouragements,
unlimited advice, thought us scientific research method which helps us to prepare this research and
we also forwarded our thanks to our Instructor and co-advisor Mr. Shimelis M. (MSc.) for his
constructive and timely comments at all my work and professional guidance to prepare this thesis
work. Thirdly, our gratitude Department of Mechanical Engineering and particularly for staff
members for their considerable support in providing us required information, data and other
relevant reference materials. fourthly, we would like to express our thanks and sincere gratitude to
the Wollega University for granting us this opportunity to study for a Bachelor of Science degree.
The last but not the least we would like to thank our families, our friends for helping us ideally
and for their material support.
Page | III
Abstract
The hydraulic mini brick machine design is a machine that will improve the existing way of brick
production. Hydraulic mini brick machine is to make blocks under high pressure by the hydraulic
power. Hydraulic brick making machines depends on hydraulic system for power transmission
from the source of power production to the compressing piston. Design and modification of
hydraulic mini brick making machine with new features and simplified operation. Previous ways
of production have some problem like, Speed of production is low, Human power wasted versus
quantity of product is not proportion. Those problems can be overcome by designing of hydraulic
mini brick machine and Increase production number. Reduction of human power waste by using
actuator that convert hydraulic energy into mechanical energy. Force produced by actuators used
to moves external loads. The machine has two parts: fluid power components and mechanical
components. The production rate can be enhanced to 960 bricks per day (8 working hours). It
produces the bricks based on the raw material fed to the machine. The raw materials provided to
the machine are natural clay minerals produces a clay brick. There are so many methods for
molding of bricks, but we will use only hydraulic compression method.
Key words: bricks, raw material
Page | IV
Acronomy
ρ...........................................................................................Density
μ ..........................................................................................Viscosity
F ......................................................................................... Force
V.......................................................................................... Speed
P .........................................................................................Power
W ........................................................................................ Weight
A ......................................................................................... Area
h........................................................................................... Height
w ......................................................................................... Width
l .......................................................................................... Length
g ..........................................................................................Gravity
d .......................................................................................... Diameter
Q ......................................................................................... Flow rate
Vp ......................................................................................Pump displacement
Np .......................................................................................Pump shaft speed
ƞvp .......................................................................................Pump volumetric efficiency
ƞ .........................................................................................Efficiency
t ........................................................................................... Thickness
v...........................................................................................Volume
σm ....................................................................................... Maximum allowable stress
Page | V
Table of Contents pages
DECLARATION ................................................................................................................................................ I
APPROVAL PAGE ........................................................................................................................................... II
ACKNOWLEDGEMENT .................................................................................................................................. III
Abstract ........................................................................................................................................................ IV
Acronomy ...................................................................................................................................................... V
CHAPTER ONE ............................................................................................................................................... 1
1 INTRODUCTION ..................................................................................................................................... 1
1.1 Back ground .................................................................................................................................. 2
1.2 Statement of Problem ................................................................................................................... 3
1.3 Objective ....................................................................................................................................... 4
1.3.1 General Objective ................................................................................................................. 4
1.3.2 Specific objectives ................................................................................................................. 4
1.4 Significance of study ..................................................................................................................... 4
1.5 Scope of study ............................................................................................................................... 4
1.6 Expected result ............................................................................................................................. 4
CHAPTER 2 .................................................................................................................................................... 5
2 LITERATURE REVIEW ............................................................................................................................. 5
CHAPTER 3 .................................................................................................................................................... 7
3 MATERIAL AND METHODOLOGY .......................................................................................................... 7
3.1 components .................................................................................................................................. 7
3.2 Conceptual design ......................................................................................................................... 8
3.3 Selecting fluids for hydraulic pumps ............................................................................................. 9
3.3.1 Light Mineral oil .................................................................................................................. 11
3.4 Design Calculations ..................................................................................................................... 11
3.4.1 Design Parameter................................................................................................................ 11
3.5 Hydraulic component.................................................................................................................. 13
3.5.1 Hydraulic Cylinders design .................................................................................................. 13
3.5.2 Pump Design design ............................................................................................................ 16
3.5.3 Determination of Pump Displacement ............................................................................... 17
3.5.4 Shaft Torque........................................................................................................................ 18
Page | VI
3.5.5 Determination of Drive Power ............................................................................................ 18
3.5.6 Losses and Efficiency ........................................................................................................... 19
3.5.7 Control Valves ..................................................................................................................... 20
3.5.8 Design of Reservoir ............................................................................................................. 21
3.6 Mechanical component .............................................................................................................. 24
3.6.1 Design of Die and Punch ..................................................................................................... 24
3.6.2 Moulding chamber design .................................................................................................. 27
3.6.3 Mould Dimensions .............................................................................................................. 27
3.6.4 Feeder design ...................................................................................................................... 29
3.6.5 Design of Hopper ................................................................................................................ 30
3.6.6 U - Channel (Main Frame) ................................................................................................... 32
3.6.7 Design of bricks ................................................................................................................... 33
3.6.8 Design of Bolt ...................................................................................................................... 35
3.6.9 Design of nut ....................................................................................................................... 38
3.7 Working principle of hydraulic mini brick machine .................................................................... 39
3.8 Various Testing of the Brick ........................................................................................................ 40
3.8.1 Determination of the Mechanical and Physical Properties of the Bricks ........................... 41
3.9 Limitation of the project ............................................................................................................. 42
3.10 Overall efficiency of machine...................................................................................................... 42
Chapter four ................................................................................................................................................ 43
4 Result and discussion .......................................................................................................................... 43
4.1 Result .......................................................................................................................................... 43
Shaft Torque........................................................................................................................................ 43
4.2 Discussion.................................................................................................................................... 44
Chapter 5..................................................................................................................................................... 45
Conclusion and recommendation ............................................................................................................... 45
5.1 Conclusion ............................................................................................................................................. 45
4.2 Recommendation........................................................................................................................ 46
Reference .................................................................................................................................................... 47
Appendixes.................................................................................................................................................. 48
Page | VII
Lists of Figures Pages
Figure 1:1 Classification of bricks .................................................................................................. 2

Figure 3:1 The optimum operating of a hydraulic system depends viscosity................................. 9
Figure 3:2 General steps in machine design ................................................................................. 13
Figure 3:3 hydraulic cylinder ........................................................................................................ 14
Figure 3:4 The construction of a Gear Pump ................................................................................ 17
Figure 3:5 directional control valve .............................................................................................. 21
Figure 3:6The functions of the reservoir ...................................................................................... 21
Figure 3:7 Reservoir ..................................................................................................................... 22
Figure 3:8 Punch Plate .................................................................................................................. 25
Figure 3:9 Moulding Chamber...................................................................................................... 29
Figure 3:10 3D View of Feeder. ................................................................................................... 30
Figure 3:11 3D View of Hooper ................................................................................................... 31
Figure 3:12 The main frame of the machine. ................................................................................ 32
Figure 3:13 Sectional view of the main frame. ............................................................................. 33
Figure 3:14 brick ........................................................................................................................... 33
Figure 3:15 bolt ............................................................................................................................. 35
Figure 3:16 Nut view ................................................................................................................... 38
Figure 3:17 Working step ............................................................................................................. 39
Figure 3:18 assembly drawing ...................................................................................................... 40
Page | VIII
Lists of Tables Pages
Table 3:1 components ..................................................................................................................... 7

Table 3:2 major functions of a hydraulic fluid and the properties ................................................ 10
Table 3:3 different types of bricks with their physical characteristics ......................................... 14
Table 3:4 Specifications of external gear pumps. ......................................................................... 16
Table 4:1 results ............................................................................................................................ 43
Page | IX
DESIGN AND MODIFICATION OF HYDRAULIC MINI BRICK MACHINE 2021 G. C
CHAPTER ONE
1 INTRODUCTION
The basic needs of man are food, shelter and clothing. These needs are pertinent to man’s survival.
Also, shelter is one of the requirements for addressing our physiological needs (along with the
need for food, water, air, sleep). Representing human physiological needs as the base of a triangle
to show that meeting these needs are the most important in our lives. Thus, the drive to acquire
affordable, cleaner, more eco-friendly housing has been the basic human response to provide for
one of his pertinent needs. Brick making is an age-old process which developed out of the need
for man to provide shelter for his own.
A brick is a composite material used in construction which inbuilt consists of several other
ingredients. Hydraulic mini brick machine is a machine that makes blocks under high pressure by
hydraulic power. In this type of machine, there is transmission of high-pressure hydraulic fluid
throughout the machine to hydraulic cylinders which makes production faster than other brick
making machines. Hydraulic mini brick machine is to make blocks under high pressure. There has
been an increase in demand for brick making machines due to expansion in the construction
industry. The expansion is largely due to increase in demand for housing and improved economy.
The brick making machine are needed to ensure that there is constant supply of high quality and
cheap bricks to be used in the ever-expanding construction industry. This increase in demand for
bricks can no longer be satisfied by the traditional brick making processes. Although the demand
for brick making machines has mainly been pushed by high demand for bricks, quality bricks and
cheaper bricks; there are also other factors that have pushed the demand for brick making machine
upward. These factors include: reduced labor cost, ability to make bricks of varying designs and
reduced physical labor demand.
WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 1

1.1 Back ground

Bricks find mention in the Bible; the tower of Babel was built with burnt bricks. Brick is a building
material used to make walls, pavements and other elements in masonry construction. Bricks dated
7500BC were found in Jericho, the ancient Egyptian fortress of Buhen and the Indus Valley cities
(Matthews, 2006). Bricks were predominantly used in the Indus valley civilization. In fact, the
civilization was first discovered when ancient bricks being used to build railway ballast came to
the notice of a passing archaeologist (Overdorf, 2012). Srikanta (2012) established that during the
“cave era”, man lived within strong rock walls and roofs which were natural and safe. Slowly he
moved on to homes built with mud walls that were more flexible and convenient. Later came
sundried bricks and stones. Every new change has been geared towards shapes that were better
defined and handier for construction.
Down the ages, there have been various interesting historic and cultural references to bricks. Over
time, bricks have appeared, gained prominence, lost importance and then come to the forefront
again with various styles of architecture. Burnt bricks were used in ancient Indian.
classification of
bricks
based on based on
based on quality based on usage composition manufacturing
process
1. first class bricks 1. facing bricks 1. sun dried

1. common
2. second class bricks 2. high burnt clay bricks
temperature bricks 2. fired bricks
3. third classbricks resisting bricks
2. fire clay
4. fourth class bricks 3. acid resisting bricks
bricks
3. concrete
4. light weight bricks
clay bricks
4. fly ash bricks
5. engeering
bricks 5. sand lime
bricks
Figure 1:1 Classification of bricks

Composition of bricks
Mainly consists of clay and sand (Alumina and Silica), in such properties so as to render plastic
state when mixed with water.
i. Alumina: chief constituents of every clay readily absorb water, imparts plasticity to the
clay. Good brick contains 20 to 30% of Alumina. Excess Alumina makes bricks shrinkage.
ii. Silica: prevent brick from shrinkage, cracking, warping and undue hardness. Exists in free
or combined state. Free sand mechanically mixed with clay and in combined from exists
in chemical composition with Alumina as silicate of alumina. Good brick contains 50 to
60% of silica. Excess silica destroys the cohesion and makes the brick brittle and useless.
iii. Lime: presence of small quantity of lime in good earth is desirable and prevents from
shrinkage, enables the sand to fuse (or melt) during burning, bins particles together. Excess
lime causes the brick to melt and lose its shape.
iv. Oxide of iron: small quantities used to fuse sand and binds particles of brick together
giving hardness and strength. It imparts red color to brick and excess make it dark color.
v. Magnesia: small quantity in brick earth gives rise to yellow tint to bricks and decreases
shrinkage. Excess results in decay of bricks.
1.2 Statement of Problem

Most production of brick in Ethiopia is by manually operated using their hands to get a rectangular
shape brick. After the mixture they use their hands to give some strength and rectangular shape for
the brick. These ways of production have some problem like,
➢ Speed of production is low
➢ Human power wasted versus quantity of product is not proportion.
➢ Quality of production and product is poor.
➢ Strength of product is not sufficient.
So, those problem stated above can be overcome by designing hydraulic mini brick machine for
the production of brick.

1.3 Objective
1.3.1 General Objective
❖ Design and modification of hydraulic mini brick making machine with new features and
simplified operation.
1.3.2 Specific objectives
❖ Mathematical modelling of machine system and components.
❖ Increase production number by modifying.
❖ 2D drawing and 3D drawing by using Catia software.
❖ To evaluate the performance and efficiency of the machine.
❖ To model the complete mini brick machine system.
1.4 Significance of study
The first important of the machine is decrease the down time of the production and keep the safety
of the workers. The other is understands how to design the machine and help to change the past
syllabus of theoretical knowledge through project design process and parallelly Solving the social
problem.
1.5 Scope of study

❖ Focus on rectangular brick making machine with two holes.
❖ Reviewing literature and observe gap.
❖ Production of four bricks per one stroke.
1.6 Expected result
During the coverage of the design so many results will be obtained. Those will be
❖ Reduction of number of operators

❖ The improvement of production rate
❖ Simplification of the operation and control system
❖ Increase safety guarantee
❖ Satisfying customer needs and so on.
❖ To solve the deficiency of brick for different purpose focus on the high strength and
quality.
❖ To save the human power used in local ways of production.
❖ Increase machine efficiency

CHAPTER 2
2 LITERATURE REVIEW
A brick can be defined as a rectangular block of clay backed by the sun or in a kiln (an enclosed
chamber in which heat is produced to fire, burn or dry materials), which is used as a building
material or a paving material. Adobe bricks are a natural building material made from sand, clay,
water, and some kind of fibrous material (sticks, straw, dung), which is shaped into bricks using
frames and dried in the sun. Adobe structures are extremely durable and account for the oldest
existing buildings on the planet. In dry climates, compared to wooden buildings adobe buildings
offer significant advantages due to their greater thermal mass [1].
One of the most widely used was an open clamp, in which bricks were placed on a fire beneath a
layer of dirt and the fire died down over the course of several weeks. Such methods gradually
became obsolete after 1865, when the Hoffmann kiln was invented in Germany (Way back
Machine, 2008). Hydraulic machines are machines and tools which use fluid power to do work. In
this type of machine, high pressure hydraulic fluid is transmitted throughout the machine to various
hydraulic motors and hydraulic cylinders. The fluid is controlled directly or automatically by
control valves and distributed through hoses and tubes. The popularity of hydraulic machinery is
due to the very large amount of power that can be transferred through small tubes and flexible
hoses, and the high-power density and wide array of actuators that can make use of this power [4].
Hydraulic brick making machines depends on hydraulic system for power transmission from the
source of power production to the compressing piston. The power source is used to drive a pump
which creates pressures in the hydraulic fluid. Since pressure in fluid is equal at all points, the
pressure at the piston end in contact with the hydraulic fluid will experience the same pressure as
generated by the pump. Depending on the area of the piston with the fluid a force will be generated
for compressing the soil into brick. In our project, a high-quality machine in which optimize from
the current machine design is going to propose according to the feedback and the need from the
rectangular brick maker, so hydraulic load of pressing of the brick in simple rectangular brick
making machine about 1.5-2.5 ton. [5].

Hydraulic brick making machines depends on hydraulic system for power transmission from the
source of power production to the compressing piston. The power source is used to drive a pump
which creates pressures in the hydraulic fluid. Since pressure in fluid is equal at all points, the
pressure at the piston end in contact with the hydraulic fluid will experience the same pressure as
generated by the pump. Depending on the area of the piston with the fluid a force will be generated
for compressing the soil into brick. In our project, a high-quality machine in which optimize from
the current machine design is going to propose according to the feedback and the need from the
rectangular brick maker, so hydraulic load of pressing of the brick in simple rectangular brick
making machine about 1.5-2.5 ton. [6].
The high pressures also considerably reduce the size of the soil sample and this reduction must be
factored in so that the right amount of sample is used for a given brick size and shape. For various
brick shapes, the shape of mould of the machine is usually changed by changing its parts.
Mechanical brick making machines depends on levers for force multiplication. The distance from
the fulcrum to the effort arm is usually several times longer than from fulcrum to the load point.
The great difference between effort arm and load arm multiplies the force to levels high enough to
achieve a pressure of 20MPa that is required to compress soil during the brick making process. [3]
A Hoffmann kiln consists of a main fire passage surrounded on each side by several small rooms.
Each room contains a pallet of bricks. In the main fire passage, there is a fire wagon that holds a
fire that burns continuously. Then the gases pass into the adjacent room that is scheduled to be
fired next. There the gases preheat the brick. As the gases pass through the kiln circuit, they
gradually cool as they transfer heat to the brick. This is essentially a counter-current heat
exchanger, which makes for a very efficient use of heat and fuel. This efficiency is a principal
advantage of the Hoffmann kiln, and is one of the reasons for its original development and
continued use throughout history [2].
Although the process of brick making is simple, depending on the systems employed, many
techniques involved in the brickmaking process are subject to error, possibly reducing the quality
of the bricks produced [8].

CHAPTER 3
3 MATERIAL AND METHODOLOGY
This chapter consists of material and methods for completing the product (brick making machine).
For this project, the brick making machine was designed as a hydraulic type. This implies that the
compression of brick is done by the action of a hydraulic cylinder with an operator manning the
controls. The applied methods, primary and secondary sources which are well-structured; provide
a step-by-step approach to complete the task of this project. The primary source is direct
observation and secondary sources are mechanical and civil construction books, and different
journals. Background and literature review, problem statement, objectives are clearly defined and
finally to bring conceptual design.
3.1 components
Table 3:1 components
No. Part Name Material Properties
1. Motor Induction motor Flexible to use and matches the load and almost
everything.
2. Hydraulic cylinder 304 Stainless steel ability to resist corrosion, it doesn’t wear easily.
Durable in acidic environment and easily available.
3. Ball bearing Selected To reduce rotational friction and support radial and axial
loads.
4. Shaft Mild steel It has high strength, machinability.
5. Hopper Steel High strength
8. control valve Selected Allow mineral oil flow into different path from sources.
11. Steel beam Alloy steel Strength and
13. Wood - Available material
14. Filter Selected
15. Oil tank Steel tank High strength, Inexpensive and available
16. Mold cavity Grade steel S7 and P20 Internal shape molding.
17. Bolt Steel Machinability and Strength
18. Pump Selected (external gear Easy maintenance, less costly
pump)

3.2 Conceptual design

The machine creates the motion of piston in the cylinder due to the pressurized fluid. This
movement of the piston upward and down ward is used to compact the mixture (clay, sand and
water) in the mold cavity. This machine is used to create rectangular brick between upper die and
lower die due to the movement of piston down ward on the upper die.
The brick is made up of sand, clay, and water with different amount of quantity. To create this
machine, we use different shape of metal like sheet metal, solid metal, and duct metal. The machine
has four mold cavities so, this makes the machine can do at once four bricks. The transfer of energy
is an important consideration in the operation of fluid power systems. Energy from a prime mover
is transferred to a pump via a rotating motor shaft and couplings. The pump converts this
mechanical energy into hydraulic energy by increasing the fluid pressure. The pressurized fluid
does work on hydraulic actuators. An actuator converts the hydraulic energy into mechanical
energy and moves the external load.
Procedure of identifying and decide the size and shape of each part to be designed.
1. Identifying and decide the size and shape of the brick produced.
2. Preparing the mold cavity that fit the size and shape brick defined.
3. Preparing upper and lower die that is used to shape the brick.
4. Preparing the hydraulic circuit that can perform the task needed.
5. Preparing the overall frame used to hold and support the machine part.
6. Assembly all parts of the machine together to make the size and shape of brick
decided

3.3 Selecting fluids for hydraulic pumps

Hydraulic fluid is one of the most important components of a hydraulic system. It performs
multiple functions, such as power transmission, lubrication, heat transfer, and conveyance of
sludge, wear debris, and contamination with the important roles played by fluids, proper fluid
selection is critical in maximizing performance and life of hydraulic pumps, motors, and other
components. To make the right choice, a variety of fluid properties must be considered, along with
other factors such as operating parameters, system requirements, environmental conditions, and
regulations.
Figure 3:1 The optimum operating of a hydraulic system depends viscosity.

If the hydraulic fluid viscosity is too low, the oil film will be too thin causing direct metal to metal
contact which leads to excessive wear on components. Low viscosity fluids also increase the risk
of internal leakages generating a lower volumetric efficiency of pumps and motors. If the fluid
viscosity is too high, the system will suffer from a sluggish movement and a reduced mechanical
efficiency. This generates energy losses and unnecessary heat generation. Other negative effects
of a high fluid viscosity are cavitation’s, poor air release and inadequate lubrication.
The HF viscosity is influenced by ambient and operating temperature and system design. High
temperatures result in lower viscosity and vice versa. Choosing a hydraulic fluid with the right
viscosity is primordial for the overall efficiency of the hydraulic system. The fluid viscosity
determines both the mechanical efficiency and the volumetric efficiency and sets the limits of the
optimum operating range of a hydraulic system.

Table 3:2 major functions of a hydraulic fluid and the properties
Function property
Medium for power transfer and • Non compressible (high bulk modulus)
control • Fast air release
• Low foaming tendency
• Low volatility
Medium for heat transfer • Good thermal capacity and conductivity
Sealing medium • Adequate viscosity and viscosity index
• Shear stability
Lubricant • Viscosity for firm maintenance
• Low temperature fluidity
• Thermal and oxidative stability
• Hydrolytic stability/ water tolerance
• Cleanliness and filterability
• Demulsibility
• Antiwear characteristics
• Corrosion control
Pump efficiency • Proper viscosity to minimize internal leakage

• High viscosity index
Special function • Fire resistance
• Friction modifications
• Radiation resistance
Environmental impact • Low toxicity when new or decomposed
• biodegradability
Functioning life • Material compatibility

3.3.1 Light Mineral oil

Mineral oil is a liquid by product or hydrocarbon fluid derived from the distillation of petroleum
crude oil. The advantage oil is that is can generally handle extreme temperatures. However, these
fluids can also suffer from having
➢ Low flash point, 150o to 250o .
➢ Density (ρ) = 0.835 g/cm 3 = 835 kg/m3
➢ Viscosity: < 34.5 cSt at 40o
➢ Low reactivity with materials
3.4 Design Calculations

3.4.1 Design Parameter
For proper design of hydraulic cylinder, it is necessary to follow some standard and specifications
of cylinder.
Governing equation
F = 0.7 × t × L × UTS
Where:
F = Punch force
t = thickness of the brick
L = length of the brick
UTS = ultimate tensile strength of the clay material
UTS = 0.28 Mpa = 0.28 × 106 N⁄m2
F = 0.7 × t × L × UTS
F = 0.7 × 0.073 m × 0.222 m × 0.28 × 106 N⁄m2
𝐅 = 𝟏𝟔. 𝟒𝟖 𝐊𝐍

i. What is the specification of the job?
Force requirement = 16.48kN
Stroke length = 350mm
Speed of piston rod?
ii. What size of cylinder is needed?
Bore diameter
iii. Cylinder selection reasoning?
Small diameter cylinder because - high pressure
Smaller pump speed
iv. What capacity pump is needed?
Pump pressure
Flow rate
Pump selection
v. What size of electric motor is needed?
Power required to run pump
Efficient of the pump (assumption)
Electric motor (selected)

vi. Size of reservoir should be used?
(2.5 − 3.0) × pump capacity (L/min) − from standard
vii. Size of pump inlet?
Inlet flow velocity = (60 − 150) cm/sec − from standard
viii. Size of discharge tubing?
Outlet flow velocity = (200 – 450) cm/ sec − from standard

General steps in machine design
NEED
MECHANISM
ANALYSIS OF FORCE
MATERIAL SELECTION
DESIGN MACHINE ELEMENT
MODIFICATIONS IN DESIGN
DETAILED DRAWING
PRODUCTION OR MANUFACTURING
Figure 3:2 General steps in machine design
We divide the detail design in to two parts
Part-1
3.5 Hydraulic component

This section describes the most common component found in typical fluid power systems. They
are the building blocks for understanding how to select components.
3.5.1 Hydraulic Cylinders design

Cylinders are used to convert fluid power into mechanical motion. Cylinder consist of a cylindrical
body, closures at each and, movable piston, and a rod attached to the piston. when fluid pressure
acts on the piston, the pressure is transmitted to the piston rod, resulting in linear motion. The
piston is easily determined by the multiplying the line pressure by the piston area.
Force = pressure × Area

When calculating the pull force of a cylinder, the area covered by the piston must be subtracted
from the total area of the piston, the pressure does not act on area covered by the piston rod.
𝐹𝑝𝑢𝑙𝑙 = pressure [Area Piston-Area piston rod]
There is different design of cylinder like single acting cylinder, double acting cylinder, positional
or duplex cylinder, spring return cylinder, double rod end cylinder, Tendency cylinder, from above
type of cylinder we select /use double acting cylinder for hydraulic mini brick machine for the
purpose of pressing the mixture in the cavity to make a rectangular brick.
Figure 3:3 hydraulic cylinder

The hydraulic cylinder and the power pump were designed after the following calculations Active
stroke length, the speed of piston, and an internal diameter of the cylinder, Pump discharge, speed,
power, pressure, and torque of the pump. In designing and fabricating a particular machine, there
would be certain assumptions that are to be taken into account. The internal pressure or stress of
the mould is evenly distributed. The type of brick, the composition of raw materials, compression
pressure, weight, and standard dimensions as per the Indian standards were tabulated in Table.
Table 3:3 different types of bricks with their physical characteristics
Type of brick Composition Compression Weight in Kg Standard

Clay brick Clay = 60% 20Mpa 2.5Kg 222x90x73
Silica = 30%
Other = 10%
Concrete Cement = 16.66% 7 − 25Mpa 5 − 8Kg 250x210x140
brick Sand = 33.33%
Gravel = 50%
Fly Ash brick Fly Ash = 60% 10 − 30Mpa 2.5 − 2.7 230x110x70
Slaked lime = 30%
Gypsum = 10%

Force (push) = Pressure × Piston Area
Force
𝑃𝑖𝑠𝑡𝑜𝑛 𝑎𝑟𝑒𝑎 =
Pressure
𝐹 16.48 𝐾𝑁 = 16.48
𝐴= = × 10− 3 𝑚2
𝑃 20𝑀𝑝𝑎 20
𝐴 = 0.82 × 103 𝑚𝑚2 = 820 𝑚𝑚2
𝜋𝑑 2
𝐴=
4
4𝐴 4 × 820
𝑑2 = =
𝜋 𝜋
4 × 820
𝑑=√ = 32 𝑚𝑚
𝜋
𝒅 = 𝟑𝟐 𝒎𝒎
Force requirement = 16.48kN

Stroke length = 350mm
The time taken for piston rod is almost take 30 s.
Stroke length 350
speed(v) = = = 11.67 mm⁄s
Time taken 30s
Outer diameter = 40 mm
Density (ρ) = 0.835 g/cm 3 = 835 kg/m3
The time taken for piston rod is almost take 30 s.
Stroke length 350mm
Speed(v) = = = 11.67 mm⁄s
Time taken 30 s
Mass flow rate = ρ × A × V
Mass flow rate = 835 Kg⁄m3 × 0.00082m2 × 0.011167 m⁄s
Mass flow rate = 0.008 Kg⁄s

3.5.2 Pump Design design

Table contains specifications of external gear pumps of three different classes, which can be used
for the hydraulic section of the brick moulding machine.
Advantages of External gear pumps
➢ Ease of maintenance
➢ Steady flow
➢ Less expensive to buy and repair.
The viscosity range is limited to 300cSt
Table 3:4 Specifications of external gear pumps.
Class Speed(rpm) Pressure(Mpa) Discharge (liter/min)
A 1800 14 − 21 3.028
B 3600 14 − 21 6.057
C 1200 14 − 21 2.650
A gear pump develops flow by carrying fluid between the teeth of two meshed gears. One gear is
driven by the drive shaft and turns the other, which is free. The pumping chambers formed between
the gear teeth are enclosed by the pump housing and the side plates. A low-pressure region is
created at the inlet as the gear teeth separate. As a result, fluid flows in and is carried around by
the gears. As the teeth mesh again at the outlet, high pressure is created and the fluid is forced out.

Figure 3:4 The construction of a Gear Pump

3.5.3 Determination of Pump Displacement
The pump displacement is given by the following equation:
V p = (Qm x 1,000) ,
(np x ƞvol.p )
where:
V p = pump displacement [cm³/rev];
Q m = flow rate required by pump [liters/minute];
n p = pump shaft speed [rpm];
η vol.p = pump volumetric efficiency 0.9
(Q m x 1,000)
Vp =
(np x ƞvol.p )
3.028 × 1000 3028

Vp = = cm3 ⁄rev = 1.9 cm3 ⁄rev
0.9 × 1800 1600
𝐕𝐩 = 𝟏. 𝟗 𝐜𝐦𝟑 ⁄𝐫𝐞𝐯

3.5.4 Shaft Torque

Vp× p 1.9 cm3 ⁄rev × 150029 bar
T = = = 4536 Nm
20 π 20π
20Mpa = 150029 bar

Where:
T = torque (Nm)
p = pressure (bar)
Determination of Pump Power
The power rating of the pump depends on the pump displacement:

Px (Vp xnp )
Pout =
600,000
Where:
Pout = Power [kW];
P = Pressure [bar];
Vp = pump displacement [cm³/rev];
np = pump shaft speed [rpm].
20 Mpa = 150000 bar
P x (Vp x np ) 150,000 ( 1.9 × 1800)

Pout = = = 860 W
600,000 600,000
𝑷𝒐𝒖𝒕 = 𝟖𝟔𝟎 𝑾
3.5.5 Determination of Drive Power

The power rating of the prime mover is obtained accordingly:
P x (Vp x np )
Pin =
(600,000 x ηt.p )
Where:
Pin = power [kW];
P = pressure [bar];

Vp = pump displacement [cm³/rev];

np = pump shaft speed [rpm];
ηt.p = pump overall efficiency (0.8 − 0.9).
Here, the pump efficiently by assumption around 80%
P x (Vp x np ) 150,000 × ( 1.9 × 1,800)

Pin = =
(600,000 x ηt.p ) 600,000 × 0.8
510,000,000
Pin = = 1,100 KW
480,000
𝐏𝐢𝐧 = 𝟏𝟏𝟎𝟎 𝐖 = 𝟏. 𝟏𝐤𝐰
3.5.6 Losses and Efficiency
Input = output + losses
pin = pout + ploss
1100 W = 860 W + ploss
ploss = 240 W
output 860
Efficiency = ƞ = × 100% = × 100% = 80 %
input 1100
𝐄𝐟𝐟𝐢𝐜𝐢𝐞𝐧𝐜𝐲 = 𝟖𝟎 %

Selection of motor from standard

The present catalog deals with TEFC, three-phase, squirrel cage induction motors (Series BF) with
shaft heights from 71 up to 400 mm, in the following ranges:
0.37 up to 500 kW - 3000 rpm
0.185 up to 500 kW - 1500 rpm
0.12 up to 400 kW - 1000 rpm
0.09 up to 315 kW - 750 rpm
Depend on needed power for used for pump we select 0.09 up to 315 kW - 750 rpm.
For outputs lower than 3 kw. terminals = 220-240V/250-280V 50/60Hz & Y terminals = 380-
415V/440-480V 50/60Hz.
Determination of Velocity
The velocity is determined by the standard analytic expression:
Q = AV
π × V × D2
Q =
4
π × 0.7002 × D2
0.003028 =
4
D = 20mm
Where:
v = velocity in meters per second [m/sec];
Q = flow rate in liters per minute [liter/min];
D = inside diameter of pipe or hose in [mm].
3.5.7 Control Valves

Control valves are essential and appear in all fluid power systems. Valves are categorized by
function, which includes directional valves for directing fluid flow to one or the other side of a
cylinder or motor, pressure control valves for controlling the fluid pressure at a point and flow
control valves for limiting the fluid flow rate in a line, which in turn limits the extension or
retraction velocities of piston.

Valves are also characterized by the number of ports on the valve for connecting input and output
lines and by the number of operating pistons that the valve can assume. For example, a (3-way, 2
position), (2-way, 2 position), (4-way, 2 position), (four-way, spring – centered, 3-position
manually actuated valve), (four way, and solenoid actuated, 3-postion) and etc.
For the designed hydraulic mini brick machine, we use four-way, spring –centered, 3-postion
manually actuated valve because of simply to operate by every person.
Figure 3:5 directional control valve

3.5.8 Design of Reservoir
It holds the hydraulic fluid to be circulated and allows air entrapped in the fluid to escape. This is
an important feature as the bulk modulus of the oil, which determines the stiffness of hydraulic
system, deteriorates considerably in the presence of entrapped air bubbles. It also helps in
dissipating heat.
Figure 3:6The functions of the reservoir

Sizing: Recommended reservoir fluid volume is 3 to 5 times the pump(s) output flow per minute
with a 10% air cushion, expressed by the following formula:
V = 3 x Q x 1.1
Where:
V = reservoir volume [liters];
Q = flow rate of pump [liters/ minute].
V = 3 x Q x 1.1=3×3.028×1.1 liters
V = 10 liters
By choosing:
➢ Length of tank to be 20 cm;
➢ Width of tank to be 20 cm; and
➢ Volume of 10 liters (10,000 cm3);
The corresponding height can be calculated from:
𝑉 10,000 𝑐𝑚3
𝐻 = = = 25 𝑐𝑚
(𝐿 𝑥 𝑊) 20𝑐𝑚 × 20𝑐𝑚
𝑯 = 𝟐𝟓 𝒄𝒎
𝑇ℎ𝑒 𝑟𝑒𝑠𝑢𝑙𝑡 𝑖𝑠
L = 20 cm = 200 mm
W = 20 cm = 200 mm
H = 25 cm = 250 mm
Figure 3:7 Reservoir

Mechanical Power: The mechanical output of the motor (P) measured in Watts.
Speed: The number of revolutions per minute of the motor. Usually denoted “N” and measures
in rpm (revs per minute). In some formulae speed is measured in revs per second and denoted “
n”. In academic works a different unit called radians per second is often used and denoted “7”
The reason this unit Is used is because it simplifies some of the formulae.
Conversion Factors:
𝑛 = 𝑁/60
7 = 𝑁/60
Torque: The force with which a motor turns is called Torque measured in Newton metres (Nm).
A motor with high Torque accelerates quickly and can drive a heavy load.
The relationship between Power, Speed and Torque The higher the speed the more power, the
higher the torque the more power. In fact, the power depends on Torque multiplied by Speed.
Important Formula
2×𝜋×𝑇×𝑁
𝑃 =
60
P = power of motor
T = torque of shaft
N = speed
2 × 𝜋 × 4536 × 𝑁
1100 =
60
N = 417rpm

Part-2
3.6 Mechanical component

For this design the following design factors were taken into consideration. They are;
❖ cost
❖ production efficiency
❖ size of the bricks produced
❖ rigidity of the system
❖ strength of materials
❖ ease of handling
❖ safety
3.6.1 Design of Die and Punch

Punch and die design are the large division of tool engineering is a complex fascinating subject. It
is the most exciting of all areas of the general field of tool Engineering. The word dies in itself
means the complete press tool in its entirety with all the punches, die buttons ejectors stripers, pads
and blocks, simply with its component assembled together. This is a very essential design part for
the analysis of the project.
Design of Die
Purpose: used to compact the mixture in the mold cavity
During design of upper die, we consider: -

➢ Dimension of brick (222𝑚𝑚 × 90𝑚𝑚 × 73𝑚𝑚)
➢ Clearance needed (1𝑚𝑚)
➢ Compaction factor (30%)
➢ Number of bricks made at on cycle.
𝑆𝑜, 𝑑𝑢𝑟𝑖𝑛𝑔 𝑑𝑒𝑠𝑖𝑔𝑛 𝑜𝑓 𝑑𝑖𝑒𝑡ℎ𝑒 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑖𝑠 𝑛𝑒𝑒𝑑𝑒𝑑 𝑎𝑠 𝑖𝑡 𝑒𝑛𝑡𝑒𝑟 𝑡ℎ𝑒 𝑚𝑜𝑙𝑑 𝑐𝑎𝑣𝑖𝑡𝑦 𝑎𝑛𝑑 𝑚𝑎𝑘𝑒
𝑎 𝑛𝑒𝑒𝑑𝑒d Compaction because of this reason we leave 1mm from normal size brick at front and
side of the brick. There is four die connected to upper punch at the gap of 5mm from one
another, this indicates the machine make four- brick at one stroke / cycle.

To calculate the area of upper die, let take one of the die out of six die. Therefore,
A1 = Top of upper die

A2 = Side of upper die
A3 = front of upper die
A1 = (221 × 89) mm2 = 19669mm2
A2 = 89mm × 31mm = 2759mm2
A3 = 221mm × 31mm = 6851mm2
𝐓𝐡𝐞𝐫𝐞𝐟𝐨𝐫𝐞; the top die area = the bottom area = 19669mm2
The left side area = the right side area = 2759mm2
The front area = the rear area = 6851mm2
Design of Punch Plate
The punch plate is subjected to carry the force applied by the weight of mixture to be compacted.
Figure 3:8 Punch Plate

Assumptions:
The average weight of one brick = 2.5 kg
For four brick the average weight = 10 kg
The weight of the mold cavity = 8 kg

The load of the brick on the lower punch plate = (10 × 9.81) N = 98.1N
The load of mold cavity on the lower punch plate = 8kg × 9.81 m⁄s2 = 78.5N
𝐹𝑡 = load due to hydraulic cylinder + load due to brick weight + load due to the weight of mold
cavity.
F𝑡 = 16.48KN − 0.0981KN − 0.0785KN
𝐅𝒕 = 𝟏𝟔. 𝟑 𝐊𝐍
This part is also made from steel with ultimate stress 220MPa and the safety factor is = 3.
The formula used to calculate the thickness of the plate is from the following;
0.5F𝑡
σall = L l5
t 2 ( l + 0.623 L5 )
Where, F𝑡 = 16.3 KN(Thetotalloadonlowerpunchplate)

L = (Longsideoftheplate) = 450mm
l = (Shortsideoftheplate) = 185mm
σult 220Mpa
σall = (allowablestress) = = = 73.33Mpa
sf 3
0.5Ft
t2 = L l5
σall ( l + 0.623 L5 )
0.5 ∗ 16.81kN
t2 = 450mm (185mm)5
73.33Mpa(185mm + 0.623 (450mm)5
8405
t2 = mm2
73.33(2.43 + 0.623(0.0117)
8405
t2 = mm2
73.33(2.43 + 0.0073)
8405
t2 = mm2
73.33(2.437)
8405
t2 = mm2
178.72
√t 2 = √47
𝐭 = 𝟔. 𝟖 𝐦𝐦

3.6.2 Moulding chamber design

The moulding chamber (MC) was designed in such a way as to accommodate the changing of the
mould plates which give the bricks different shapes, that is, the MC can produce bricks with
grooves and bricks without grooves depending on the manufacture choice.
Determining Yield Stress (MPa)

Knowing that:
Yield Stress Point(MPa)
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑆𝑡𝑟𝑒𝑠𝑠= Factor of safety
Maximum Allowable Stress acting on mould walls = 20𝑀𝑃𝑎

Taking the factor safety = 5
Yield Stress Point = Maximum Allowable Stress x Factor of safety
Yield Stress Point = 20 Mpa × 5 = 100MPa
Knowing that the yield strength for Structural steel = 250MPa
Determining Mould Deflections and allowable thickness
To determine the mould deflections, the following design parameters were considered;
Distributed load intensity (ω) (N/mm)
Length of applied loading (L) (mm)
Moment of Inertia (I)(𝑘𝑔/𝑚2)
Young Modulus of Elasticity
Maximum deflection ( δ𝑚𝑎𝑥 ) is determined by:
wl4
δ𝑚𝑎𝑥 =
384EI
From the results of the calculation above, the allowable mould thickness = 18mm
3.6.3 Mould Dimensions

The mould size was determined based on the size of the brick to be produced and the amount of
clay mix needed to produce such a brick.
Factors considered;

Brick Dimensions (L x W x H) = 222mm x 90mm x 73mm

Thickness of Plate = 5mm
Added Tolerance = 2mm
Thus, the mould dimension
Width = width of brick + add tolerance + thickness of plate = 97mm

Length = length of brick + thickness of side grooves
Length = 222 + (2 x 5) = 234mm
Height = height of brick + added tolerance + thickness of two stamping plate
Height = 73mm + 2mm + 10mm = 85mm
Therefore, dimension of mould (L x W x H) = 234mm x 92mm x 85mm
The volume of one of the cavity can be calculated as;
V= l×w×h
V = 234mm × 92mm × 85mm
V = 1,829,880mm3
The total volume of the mold cavity can be;

VT = 4 × 1829880mm3 = 7319520mm3 = 0.0073 m 3
𝑽𝑻 = 𝟎. 𝟎𝟎𝟕𝟑 𝒎 𝟑

Figure 3:9 Moulding Chamber

3.6.4 Feeder design
The following were determined for the Feeder:
Volume of the Feeder

The feeder is designed to accommodate the entire volume of mix needed to produce a brick at each
compression. Since the feeder function is to take mix from the hopper and deposit to the mould, a
thickness of 3mm mild steel will be used.
Volumeofmould (LxWxH) = 234mmx 92mmx 85mm

Since Volume of the feeder must be at least equal the Volume of mould,
Factors considered include:
➢ Thickness of the mould = 10mm
➢ length of the mould = 234mm
Thus, the Feeder dimensions are:
Width of the feeder = width of the rectangular base of the hopper = 92mm
Length of the feeder = 234mm + 10mm = 244mm
Height of the feeder = height of brick + added tolerance = 85 + 2mm = 87mm
Therefore, dimension of feeder (L x W x H) bc4 × (234mm x 92mm x 87mm)

Figure 3:10 3D View of Feeder.
WeightofmixintheFeeder (Kg) = 2.5 kg

Volumeofmixinthefeeder(m3 ) = 4 × (234mm x 92mm x 87mm)
Volumeofmixinthefeeder(m3 ) = 4 × (0.234 m × 0.092 m × 0.087 m) = 4 × 0.001873 m3
Volumeofmixinthefeeder(m3 ) = 0.007492m3
weight of mix in the Feeder (Kg)
Weight Density of the mix (N⁄m3 ) =
volume of mix in the feeder (m3 )
4 × 2.5 kg
Weight Density of the mix (N⁄m3 ) = = 5340 kg⁄m3
4 × 0.001873 m3
Weight Density of the mix (N⁄m3 ) = 5340 kg⁄m3
3.6.5 Design of Hopper

The Hooper will be designed to accommodate the volume of mix required to make at least 80
bricks at a run. The hopper will have a shape of a truncated right-angle Pyramid as the large
container supplying the feeder needed volume of mix for each brick production operation.
Therefore, the Dimension of the rectangular base section of the hopper;

Figure 3:11 3D View of Hooper

Selection of material for container (charge) is based on the following consideration:
❖ Availability of material
❖ Its tensile strength, toughness and hardness
❖ Its machinability
Based on the above criteria we select mild steel for mixture feeder.
To calculate the total area of side view, from trapezoidal formula,
1
As = (a + b2 ) h
2 2
Where, a 1 = 300mm
a 2 = 500mm
b1 = 92mm
b2 = 234 mm
h = 400mm
1
As = (500mm + 234mm)400mm = 146800mm2
2

𝐂𝐚𝐥𝐜𝐮𝐥𝐚𝐭𝐞 𝐭𝐡𝐞 𝐚𝐫𝐞𝐚 𝐨𝐟 𝐟𝐫𝐨𝐧𝐭 𝐯𝐢𝐞𝐰;

1
Af = (a + b1 ) h
2 1
where, a1 = 300mm
b1 = 92mm
1
Af = (300mm + 92mm) 400mm
2
Af = 78400mm2
There is two side and front of the hopper, so the total area become;
AT = 2(As + Af)
AT = 2(146800mm2 + 78400mm2 )
AT = 450400mm2
The volume of the hopper become,

Vh = AT × h
Vh = (5404800 × 400) mm3
Vh = 180160000mm3 = 0.18m3
Design of structural parts
3.6.6 U - Channel (Main Frame)

The main frame of the machine is shown in figure below. The main frame is characterized by the
following parameters:
Material used: mild steel; and
Density: 7.84 kg/m3 .
Figure 3:12 The main frame of the machine.

The sectional view of the main frame and the dimensions of the U-section
Figure 3:13 Sectional view of the main frame.
3.6.7 Design of bricks

Volume = Length × Breadth × Height
Figure 3:14 brick

The structural parts include all supporting beams at the two side of punch plate. These structures
are subjected to carry all load applied on it such as; hydraulic force due piston rod, the weight of
the mold cavity and the mixture of the material.

The sum of all load applied on the beam is 16.3𝑘𝑁/𝑚 and this uniformly distributed on the beam.
From the free body diagrams of the entire beam, we determine the magnitude of the reaction at the
supports.
∑ FA = 0
R A = R B × 0.5 mm − 16.3 × 0.25 mm

R A = 8.15KN
∑ FB = 0
R B = R A × 0.5 mm − 16.3 × 0.25 mm

R B = 8.15KN
The material needed for structural beams should have the following properties;
✓ It should have high strength
✓ It should have good heat treatment material
✓ It should have high wear resistant material
Material properties of mild steel
Ultimate tensile stress = 450Mpa
Ultimate yield stress = 250Mpa
Maximum tensile stress = 128Mpa
Maximum shear stress = 78Mpa

Width of the beam = 500mm

Height of the beam = 700mm
ultimate yield strength
Design stress =
safety factor
Design stress = 250/3
Designstress = 83.33Mpa
Area of the section
𝐴 = (700𝑚𝑚 × 500𝑚𝑚) − (480 − 690)
𝐴 = 18,800 𝑚𝑚2
Compressive stress
𝑃 16300𝑁
𝜎= = 2
= 0.867𝑁/𝑚𝑚2
𝐴 18800𝑚𝑚
𝜎 = 0.867𝑁/𝑚𝑚2
3.6.8 Design of Bolt

The bolts are used as fasteners at the various joints of the members. The existence of the machine
will depend on the ability of the bolt not to fail under sudden shear, tensional and check all these
effects to avoid failure of compressive forces. It is made up of mild steel.
Figure 3:15 bolt

The material for this pin is grey cast iron type which is available with the following mechanical
property.
Yield strength = 310 N/mm2
Tensile strength= 139 N/mm2
Compressive strength = 604 N/mm
Shear strength = 192 N/mm2
Thickness of pin head, t2 = 0.5d
We know that ultimate tensile strength of cast iron is 139N/mm and ultimate yield strength is
310N/mm (from mechanical property of cast iron)
Let we take factor of safety =2
We know that the allowable tensile stress
σult 139 N⁄mm

σall = = = 46.3 N⁄mm
F. S 2
τult 310 N⁄mm

τall = = = 55 N⁄mm
F. S 2
Since the pin is in double shear, therefore cross-sectional area of the pin under shearing Shear
strength of the pin
P 16300 N⁄mm
τ= π = = 36 N⁄mm
2 × ⁄4 × d2 2 × π⁄4 × 152
The value of maximum bending moment is given by
P t1 t 16300 10 100
M= ( + )= ( + ) = 230,916 Nmm
2 3 4 2 3 4
Section modulus
π π
Z = 32 (d3 ) = 32 (153 ) = 331mm3
Maximum bending (tensile) stress
M 70,833
σt = = = 214 N⁄mm2
Z 331

Finally, checking the maximum shear stress induced in the pin we have,
√σ2 + 4τ2 √2142 × 4(14.22 )

τmax = = = 107 N⁄mm2
2 2
τmax=107N⁄mm2 ,Which is less than 155N ⁄ mm , (τall )thus it is safe!
L t = length of threaded portion of grip

Ld = length of unthreaded portion in grip
L t = 2d + 6mm, L ≤ 125, d ≤ 48
= 2d + 12mm, 125 ≤ L ≤ 200
= 2d + 25mm, L ≤ 200
𝐼𝑛 𝑜𝑢𝑟 𝑐𝑎𝑠𝑒 𝑤𝑒 ℎ𝑎𝑣𝑒 𝐿𝑑 = 120𝑚𝑚 𝑎𝑛𝑑 𝑑 = 15𝑚𝑚
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑟𝑒𝑎𝑑𝑒𝑑 𝑝𝑜𝑟𝑡𝑖𝑜𝑛 𝑜𝑓 𝑔𝑟𝑖𝑝
𝐿𝑡 = 2𝑑 + 6𝑚𝑚 = 2𝑥15𝑚𝑚 + 6𝑚𝑚 = 36𝑚𝑚
𝑇𝑜𝑡𝑎𝑙𝑙𝑒𝑛𝑔𝑡ℎ𝑜𝑓𝑡ℎ𝑒𝑝𝑖𝑛
𝐿 = 𝐿𝑑 + 𝐿𝑡 = 120𝑚𝑚 + 36𝑚𝑚 = 156𝑚𝑚
From table 8.1 the pitch for our selected diameter is 2mm and the bolt designation is M15x2
By using the value of the pitch from (table 8.1) P = 2mm
Nominal diameter will be dn
Dn = D − P = 15mm − 2mm = 13mm
To calculate the number of teeth
P 5
n=π =π = 9mm
(d2 − dn 2 )Pb (152 − 132 ) × 17.5
4 4
𝐧 = 𝟗𝐦𝐦

3.6.9 Design of nut

A screw thread is formed by cutting a continuous helical groove on a cylindrical surface. A
screwed joint is mainly composed of two elements i.e., a bolt and nut. The material for this nut is
grey cast iron type which is available with the following mechanical property.
Yield strength = 310 N/mm2
Tensile strength= 139 N/mm2
Compressive strength = 604 N/mm2
Shear strength = 192 N/mm2
Allowable bearing pressure = 17.5N/mm2
Figure 3:16 Nut view
We know that the allowable tensile stress
σult 139 N⁄mm2

σall = = = 46.3 N⁄mm2
F. S 2
τult 310 N⁄mm2
τall = = = 155 N⁄mm2
F. S 2
P 5
n=π =π = 9mm
(d2 − dn 2 )Pb (152 − 132 ) × 17.5
4 4
n = 9mm
Also, the height of the nut will be considered the product of pitch and number of threads
H = p × n = 2 × 7 = 14mm

The width of the nut (w) is taken as

W = 1.5Dn = 1.5 × 13 = 19.5mm = 20mm
To calculate the maximum shear stress in the nut,
P P 2
τall = , where t = = = 1mm
πndc t 2 2
16300 16300
τmax = = = 57 N⁄mm2
π × 7 × 13 × 1 286
Which is much less than 155N/mm2 (τall ), thus the design is safe!
3.7 Working principle of hydraulic mini brick machine

The hydraulic mini brick machine is a mechanical function that acts though hydraulic
pressure. Mechanical motion is generated by pumped liquid contained mineral oil, typically
by moving the cylinders of pistons. To do these, rectangular brick with the help of hydraulic
mini brick machine requires the following successive steps. First, the proportion amount of
sand, clay and water should be mixed together correctly. Second, the mixed mixture is feed
to the cavity (mold cavity) by moving box prepared. Third, now this is going to compressed
or compact between upper and lower die. Fourth, the lower die moves upward and compact
mixture in the mold cavity. This movement of lower die is due to the piston rod in the cylinder
move upward and downward by the created pressure. Last, after this mixture got some
strength with rectangular shape it will be allowed to taken out of the mold cavity by some
means. Finally, this brick is going to dry by any means and used for different purpose like
for construction house and compound.
Mix
Clay,sa Mold
Hopper Feeder Brick
nd and cavity
water
Figure 3:17 Working step

Figure 3:18 assembly drawing
3.8 Various Testing of the Brick

Once after the brick is produced, it is mandatory to test it for using it in multiple applications.
Compressive Strength of the Brick Test
The compressive strength of a brick is nothing but the ability to resist upon crushing it. In general,
some 3 to 5 specimens are considered for performing this test. Firstly, one of the examples is put
on the crushing machine, and pressure is applied until it breaks. The maximum value of pressure
at which it breaks is nothing but the compressive strength of the brick.
Water Absorption Test
Initially, the bricks are weighed in dry condition and then immersed in water for a whole day. After
24 hours, the blocks are taken out and again weighed. The difference in weights gives the water
absorbed by the bricks. Thus, the percentage of water consumed is calculated. The block that
absorbs less water is of better quality.
Efflorescence Test
It helps in finding out the presence of alkalis in bricks, which is harmful and forms a white layer
on its surface by absorbing moisture. For this, the blocks are immersed in fresh water for 24 hours
and then dried. After drying, they are examined for the formation of white layer indicating the
presence of alkalis.

Hardness Test
A scratch is made on the brick surface with a hard thing. If it doesn’t leave any mark, then it is of
good quality.
Size, Shape and Color Test
A group of bricks is stacked together along the length width and height to verify the size and shape.
If all the bricks appear the same in shape and size, then they can be used for construction. Also, if
they possess a bright & uniform color, they are of good quality.
Soundness Test
A good quality brick gives a clear metallic ringing sound when it is struck with other brick of the
same kind.
Structure Test: If a broken brick has any flaws, cracks, or holes on the broken face, then the brick
is not of good quality.
3.8.1 Determination of the Mechanical and Physical Properties of the Bricks

The mechanical properties such as the compressive strength, bulk density, moisture content, etc.
are examined as per the ISS: 1077-1970 [21]. The physical properties such as the shape, size, color,
soundness, structure, etc. were investigated. For the bulk density determination four bricks were
used, while for the compressive strength, three sets of five bricks were used in both wet and dry
conditions. The results of bulk density and the physical characteristics have been presented in
below.
Volume = Length × Breadth × Height
V = 222mm × 90mm × 73mm
V = 1.146 × 10−3 m3
Weight
Bulk density = Kg/m3
Volume
2.5
Bulk density = Kg/m3
1.146 × 10−3

Bulk density = 1712 Kg/m3
Max load
Compressive strength = N/mm 2
Area of compression
25
Compressive strength = N/mm 2
90 × 222
Compressive strength = 1.25 × 10−3 N/mm 2
3.9 Limitation of the project

❖ Pressure applied on the machine should not exceed 20Mpa.
❖ It doesn’t work without electrical power. That means the motor requires electric power as
source of energy in order to run the machine.
❖ At one complete cycle the machine doesn’t produce more than four bricks.
❖ It doesn’t automate and it needs human power for operation of the machine.
❖ It doesn’t capable of moving from one place to another.
3.10 Overall efficiency of machine

Expected rate of production = 160 bricks per min.
960
Average bricks produced per hr = = 120bricks per minute.
8
Total bricks produced = 120 units;
Total time used = 1 hr

Therefore, the average rate of brick production is given by:
The efficiency (ƞ) of the machine can be calculated as:
output
ƞ = x 100
input
120
ƞ = x 100 = 75 %
160
ƞ = 𝟕𝟓 %

Chapter four
4 Result and discussion
4.1 Result
After identifying the problems of the current design, literature review is uses to get the basic idea
of the existing solution concepts. The proposed concepts are then generated according to the
problem and establishment of customer needs and specification.
❖ So, the challenge is to design rectangular brick making machine that fulfilling the target
product specification. The knowledge in mechanical and hydraulic systems is crucially
needed for generating the design concept. During the coverage of the design so many
results are obtained. Improvement of production rate by using mineral oil for fluid power
system.
❖ Reduction of human power waste by using actuator that convert hydraulic energy into
mechanical energy. Force produced by actuators used to moves external loads.
❖ Strength of product is sufficient by increase pressure for properly compression of bricks
in mold cavity.
Table 4:1 results
Force push piston 16.48 𝐾𝑁

Stroke length 350𝑚𝑚
Bore diameter 32 mm
Extending speed 11.67 mm⁄s
Mass flow rate 0.008 Kg⁄s
Pump displacement 1.9 cm3 ⁄rev
4536 Nm
Shaft Torque
Pump efficiency 80 %
Drive power 1.1 kw

Pump power 860 W

4.2 Discussion
This type of project involves a major modification effort to enhance the current design to become
automated and high production rate. The new optimized machine must have an excellent working
principle compared to current machine used. This phase begins with the site visit, and observing
the product in use. From customer, the statements are interpreted in terms of customer needs. These
interpret data are organize into a hierarchical list where consist of a set of primary and secondary
needs. The target specifications for rectangular brick making machine are established after back
ground and literature review have been analyzed. A good way to generate considers what precise,
measurable characteristic of the product will reflect the degree to which the product satisfies the
need. The units of measurement are most commonly conventional engineering units. After
identifying a set of customer needs and establishing target product specifications, the machine
modification concept is being generated.
The generated concept for modification which are rectangular brick making machine that have
cantilever structure holding compaction cylinder, feeding the mold cavity, method of removing
the brick from the mold cavity and method of creating hole in the brick where needed. The current
machine design used has been chosen to become reference concept, against which all other
concepts are rated.
Final product specification then being refine according to the chosen concept before developing
the detail design of the rectangular brick making machine with bridge supporting compaction
cylinder system.

Chapter 5
Conclusion and recommendation
5.1 Conclusion
A mini hydraulic brick machine was designed and modified. in order to maximize their production
efficiency every enterprise modified machine plant with new feature system. Therefore,
implementing this project can achieve high profit for the enterprise by avoiding several problems
on the current machine. The machine can produce 960 of bricks per day, day, but this also depends
on the performance of the operators involved in the production of bricks. The design product that
helps a user to maximize the production of the rectangular bricks in the minimum cost. Reduction
of human power waste by using actuator that convert hydraulic energy into mechanical energy.
Force produced by actuators used to moves external loads. Strength of product is sufficient by
increase pressure for properly compression of bricks in mold cavity. The production efficiency of
the machine is high not only by reducing the wastage of bricks due to lack of sufficient strength
but also by minimizing the human power consumption those done in the enterprise producing
bricks. A major objective of the modified design of in rectangular brick making machine was to
be able to ensure that the brick productivity increase compare to the current machine design. The
machine is designed with its manually feeding features and having the hydraulically system in
order to make mold compacted by pressurized mineral oil. The cost of producing the machine was
48,645 ETB only. This is very cheap compared to the similar machine.

4.2 Recommendation
❖ The machine was designed in such a simple way that it requires little training for the
operators of the machine.
❖ The entrepreneurs will be more beneficial if they use this system way for brick production.
❖ One can increase the rate of production by increasing number of mold cavity.
❖ The current ways of house building of the country people is more depend on trees plant
and this brings deforestation leading to global warming or un favorable living conditions
is created for human live. So, we recommend those people to use bricks produced by this
machine for their house construction because this machine gives for the brick, high
strength, high durability, make the brick us it stands with variable climatic conditions and
etc.
❖ In order to be able to produce hollow the mould has to be modified to a movable mould
that will accommodate pallet.
❖ The machine could be automated especially the feeding and evacuation components
(mechanism). This will improve its performance and the safety of the operator.
❖ This machine can be modified such that it can have bigger mould and a means of feeding
and compaction of the mix in lifts, preferably automatically. This should be made simple
and not expensive.

Reference
[1]. Jimma university, institute of technology, department of mechanical engineering, project
done manual mini brick making machine during TCBTP phase four,2006.
[2] Hasluck, P. N. (1906). Bricks and brickmaking: Varieties and qualities of bricks; brick earths
and clays; brick kilns; hand-manufacture of bricks; machine-manufacture of bricks; manufacture
of roofing tiles, ridging, quarries, coping, etc. London: Cassell & Co.
[3]. H.C. Sumpf, Brick Machine, United States Patent Office, Application December 16, 1946,
Serial No. 716,564, Cl. 25-41.
[4] R. C Wolansky and Akers 1988, Akers et al. 2006.
[5] Hasluck, P. N. (1906). Bricks and brick making.
[6] Judson A. Hereford, Brick making apparatus, 1991.
[7] R.S. Khurmi and J.K. Gupta, A text book of machine design, New Delhi: Eurasia Publishing
House, 2005.
[8] Beamish and Will, 1988

Appendixes





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WOLLEGA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

A THESIS SUBMITTED TO WOLLEGA UNIVERSITY IN PARTIAL FULFILLMENT

NAME OF STUDENTS ID .NO

2. CHALA SHEBERA .............................................................................. 0267/15

3. NAOL ALEMU ..................................................................................... 0871/15

4. BALACHEW ABDETA ....................................................................... 0189/15

5. GELANE BEDESA .............................................................................. 0494/15

ADVISORS NAME: Mr. JABESA A. (MSc). Mr. SHIMALIS M. (MSc)

SUBMITTED DATE: FEBRUARY 03, 2021

1. Dawit Tekele ________ ________

2. Chala Shebera ________ ________

3. Naol Alemu ________ ________

4. Belachew Abdeta ________ ________

5. Gelane Bedesa ________ ________

Jabesa A. ________ ________

Coadvisor Name Signature Date

Shimelis M. ________ ________

Examiner Name Signature Date

Key words: bricks, raw material

Q ......................................................................................... Flow rate

Np .......................................................................................Pump shaft speed

ƞvp .......................................................................................Pump volumetric efficiency

σm ....................................................................................... Maximum allowable stress

Figure 1:1 Classification of bricks .................................................................................................. 2

Table 3:1 components ..................................................................................................................... 7

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 1

1.1 Back ground

1. first class bricks 1. facing bricks 1. sun dried

Figure 1:1 Classification of bricks

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 2

1.2 Statement of Problem

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 3

1.5 Scope of study

❖ Reduction of number of operators

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 4

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 5

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 6

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 7

3.2 Conceptual design

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 8

3.3 Selecting fluids for hydraulic pumps

Figure 3:1 The optimum operating of a hydraulic system depends viscosity.

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 9

Table 3:2 major functions of a hydraulic fluid and the properties

Pump efficiency • Proper viscosity to minimize internal leakage

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 10

3.3.1 Light Mineral oil

3.4 Design Calculations

t = thickness of the brick

L = length of the brick

UTS = ultimate tensile strength of the clay material

UTS = 0.28 Mpa = 0.28 × 106 N⁄m2

F = 0.7 × 0.073 m × 0.222 m × 0.28 × 106 N⁄m2

WU. DEPARTMENT OF MECHANICAL ENGINEERING. FINAL THESIS 11

i. What is the specification of the job?

Force requirement = 16.48kN

Stroke length = 350mm

1. Dawit Tekele

2. Chala Shebera

3. Naol Alemu

4. Belachew Abdeta

5. Gelane Bedesa

Jabesa A.

Shimelis M.