Proceedings of the World Congress on Engineering and Computer Science 2013 Vol II

WCECS 2013, 23-25 October, 2013, San Francisco, USA

Improved Design of a Flour Milling Machine

Nwogu, Uchenna Celestine and Ikebudu, Kingsley O

.
ABSTRACT - The research presents improved design of a
flour milling machine. It is a machine used for the milling of The use of the flour milling machine by some of our food
flour (dough) to a higher degree for food production without industries has increased the rate of their production and as well
damaging the nutrients. In the construction of the design it is saved a lot of time in production process.
expected to use indigenous technology and to increase In this research work, the machine will be modified from the
efficiency, minimize cost and maximize profit. The machine old design which does not have the pinion drive gear; rather the
was designed to use the main drive shaft as means of speed speed reduction was done with an auxiliary gear box which is
reduction. It is very cheap to maintain. usually driven by an automotive engine of six horse powers.
This modified machine uses the main drive shaft as means of
speed reduction and these involves a big pulley of the main
I. INTRODUCTION drive shaft being driven by a small pulley with the aid of
electric motor. The pinion gear of the main drive shaft drives
Milling machine is used for cutting the gear; the gear blank is
the big gear of the base which in turn drives the upper roller of
mounted on the arbor which is supported between a dead
the system.
centre and a live centre at the indexing head. The cutter is
From these arrangements, there is an automotive speed
mounted on the arbor of the milling machine. The geometric
reduction, therefore, the gear box system is unnecessary
centre of the cutter must be aligned exactly vertically with the
because of the inbuilt speed reduction arrangement. The
centre line of the indexing head spindle.
machine is plugged directly to electricity (A/C) and can also be
The table of the machine is moved upward until the cutter
driven by an automatic system.
touches the periphery of gear blank. The vertical feed dial is set
The modification design will yield a compatible power supply,
to zero. The table is then moved horizontally until the cutter
cheaper to install and maintenance cost is reduced.
clears the gear blank. The table is then moved upward equal to
the full depth of the gear tooth. The vertical movement may be
less if the gear is to be cut in two or more passes. After this, the II. SURVEY
longitudinal feed of the table is engaged. The gear blank moves Before the introduction of the mechanical flour milling
under the rotating cutter and a tooth space is cut. machine, concave stones known as saddle stones were used by
At this stage, the movement of the table is reversed so that the many cultures and numerous fine examples exist today. Grain
cutter again clears the gear blank. The gear blank is then placed on the stone like bowl would be pulverized by manually
indexed to the next position for cutting the second tooth space. moving the second stone backward and forward.
This procedure is repeated until all the teeth have been milled. Experimentation with the shape of the top crushing stone
The table frame, the motor mounting frame, the main frame eventually led to the development of a round stone used in a
mounting plate and the drive shaft are all made of mild steel circular motion and the development of the quern.
because of its good properties of hardness and tough resistance. At about 1000BC various civilizations had developed quern
The inner surface of the table is made of galvanized mild steel mills. A quern mill consisted of a flat circular stone which
which is hard, tough and corrosion resistant to avoid crushed grain between its two flat surfaces. As querns became
contamination of food during the production process of the refined, holes were made in the top stone to introduce grain or
food in the flour milling machine. to hold a handle that could be used to turn a stone easily. The
To overcome the problem of the ancient use of concave stone, small early hand mills were enhanced in size by some
quern mill, norse mill of the 65BC and wind mill of the 11th organized societies such as the Romans who used donkeys and
and 12th centuries, a roller mill machine was on the increase slaves to provide the power to turn large scale stones.
and available to power the industries. Later, the demand for The Greeks harnessed streams and rivers for the first water
high speed white flour roller mills and refining system were powered mills. Observing the apparent power of running water
developed toward the end of the 19th century. led to the development of water mills known as norse mills.
Basically, the flour milling machine with rollers enhances the Horizontal paddles placed in moving water turned a vertical
flour (dough) when mixed in a large quantity which is used by shaft which would be connected to mill stones for grinding.
some of the food industries for food processing i.e. bakery Early records showed that norse mills was working in Asia in
industries, biscuit industries and fast food making centers etc. 65BC and their success led to the wide spread development of
water mills.
Windmills were used in Europe in the 11th and 12th centuries
The authors are with DEPARTMENT OF MECHANICAL ENGINEERING, The roller milling with the increase availability of power, the
ANAMBRA STATE UNIVERSITY, NIGERIA industrial revolution and demand for good white flour, the
Email: [email protected] speed roller mills and refining system were developed towards

ISBN: 978-988-19253-1-2 WCECS 2013

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering and Computer Science 2013 Vol II
WCECS 2013, 23-25 October, 2013, San Francisco, USA

the end of the 19th century. Originally designed by a Swiss (c) The rollers are made with mild steel pipe of thickness
named Heifenburger in 1874. This newer method of milling 6mm, diameter of 140mm and length of 620mm. The diameter
crushed the grains between a series of fluted metal rollers using shaft diameter is 35mm and they are produced by mounting the
a reduction process. The fine flour articles sifted out at each pipe on the vice and cutting off from 6mm thick pipe with
pass, returning the residue to the next set of steel roller. The diameter of 110mm. The roller shaft is made of mild steel rod
development of roller mills enables greater quantities of white that has spline coupling (i.e. Austin motor parts) the
flour to be made at high speed. assembling of these three parts gives you the roller and after
(M) Nuts and bolts welding of the three parts an eccentricity of the machine is
obtained. A hotten pipe is used for the roller to reduce the
III. DESIGN ANALYSIS OF MATERIALS nominal local of the motor.
65mm 620mm 65mm
The materials required in the designs are as belows:
(a) The Main Frame
(b) The Rollers
(c) The Gears
(d) The Table

14 0 m m
11 0 m m
35mm
(e) The Electric Motor Mounting Frame
(f) The Smooth Rods
(g) The Drive Shaft
(h) The Pulley Drive
(i) The Motor
(j) The Belt A Roller
(k) The Ball Bearing The rollers are mild steel; they are hard and tough to resist
(l) The Key abrasion and twist. They are hollow pipes with thickness of
(m) Nuts And Bolts 6mm, the hollow nature of the roller helps to reduce the
nominal load of the motor and to reduce the weight of the
(a) The main frame is made of angle bars of 60mm thick machine, as well as to reduce the cost of procuring a solid pipe.
and length of 100mm. It is cut on the work bench to sizes and (d) The gear systems are made with mild steel, the two
chamfered to fit the desired figure shown below and coupled gears have an outer raising of 155mm and inner raising of
with four mounting bar which are made of smooth rods of 140mm each while the pinion which is connected to the drive
length 6.20mm and thickness 30mm. It is threaded at both end shaft has an outer raising 100mm and inner raising of 75mm.
and bolted to the mainframe for the rigidity of the frame. The They are made with a high speed steel which have valuable
metal that is used for the fabrication of the main frame is mild property of retaining their hardness.
steel. It is an alloy of iron and Carbon, with carbon content up
to a maximum of 0.45%.

The Gear
The gear is also made of mild steel which has the valuable
Angle bar of the main
frame property of retaining their hardness even when heated up to red
heat.
Bolt
Pitch Circle: It is an imaginary circle, which by rolling
Smooth rod
action would give the same motion as the actual gear.
(b) The main frame mounting plate is reduced from 6mm
Pitch Circle Diameter: This is the diameter of the pitch circle;
thick mild steel flat sheet and the pattern cut out as
the size of the gear is usually specified by the pitch
shown
circle diameter.
50mm
Pitch Point: It is a common point of contact between two
pitch circles.
270mm
Pitch Surface: It is the surface of the rolling disc which the
180mm

meshing gears have replaced at the pitch circle.

Pressure Angle or angle of Obliquity: The angle between the
90mm

common normal to two gear teeth at the point of

contact and the common tangent at the pitch.
320mm

50mm

Addendum: It is the radial distance of a tooth from the

pitch circle to the top of the tooth.
360mm Dedendum: It is the radial distance of a tooth from the
The hole for the mounting of the roller bearing are bored pitch circle to the bottom of the tooth.

ISBN: 978-988-19253-1-2 WCECS 2013

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering and Computer Science 2013 Vol II
WCECS 2013, 23-25 October, 2013, San Francisco, USA

Key Way
Addendum Circle: It is the circle drawn through the top Key Way

20m m
of the teeth and is concentric with the pitch circle. 60mm
Dedendum Circle: It is the circle drawn through the
bottom of the teeth (root circle)
Circular Pitch: It is the distance measure on the 130mm 620mm
circumference of the corresponding point on the next Drive shaft
tooth (PC) A shaft is a rotating machine element which is used to transmit
Circular pitch Pc = UD/T power from one place to another, the power is delivered to the
D = Diameter of the pitch circle shaft by some tangential force and the resultant torque set up
T = Number of teeth of the wheel within the shaft permits the power to be transferred to various
Diameter pitch: It is the ratio of number of teeth to the pitch machine linked up to the shaft.
circle diameter in millimeters To transfer the power from one shaft to another, various
Diameter pitch Pd = T/D = U/PC members such as pulleys and gears are mounted on it. These
Module: It is the ratio of the pitch circle diameter in members along with the force exerted upon them causes the
millimeters to the number of teeth shaft to bending.
Module m = D/T POWER TRANSMITTED TO THE SHAFT
Clearance: It is the radial distance from the top of the Torque
tooth to the bottom of the tooth in a meshing gear. A T =
circle passing through the top of the meshing gear is
called clearance circle Power
Total depth: It is the radial distance between the P =
addendum and the dedendum circle of a gear. It is
equal to the sum of the addendum and dedendum. Where N = 1450rev/min of the motor.
Working Depth: It is the radial distance from the dedendum Recall that =
circle to the clearance circle. It is equal to the sum of
the addendum of the two meshing gears. Where T = Twisting moment acting on the shaft
Tooth Thickness: it is the width of the tooth measured j = Polar moment of inertia of the shafts about
along the pitch circle. the axis of rotation
Tooth Space: It is the width of space between the two Ō = Tension shear stress
adjacent tooth measured and the pitch circle. r = Distance from neutral axis to the outermost
Backlash: It is the difference between the tooth space and the fiber.
tooth thickness as measured on the pitch circle. Since a solid shaft is used, the polar moment of inertia J is
Face of the Tooth: It is surface of the tooth below the J =
pitch surface.
Topland: It is the surface of the tooth below the pitch surface. Therefore, the Torque transmitted by the shaft
Flank of the Tooth: It is the surface of the tooth below Ō = 320mpa
∏
the pitch surface. T = /16 x Ō d3
∏
Face Width: It is the width of the gear tooth measured T = /16 x 320 x 302
parallel to its axis. = 0.1963x 320 2.000
Profile: It is the curve formed by the face and flank of the = 1696032.00
tooth. 16960 x103 N/mm
Fillet Radius: It is the radius that connects the root circle Therefore Power P =
to the profile of the tooth.
Path of Contact: It is the path traces by the point of
contact of two teeth from the beginning to the end of
engagement. =
Length of the Path: It is the length of the common
normal cut-off by the addendum circles of the wheel P = 25739w
and pinion. = 2.6kw
Arc of Contact: It is the path traced by a point on the pitch
circle from the beginning to the end of engagement of LENGTH OF THE OPEN BELT
a given pair of teeth. r1= 145mm, r2= 110mm,
(e) The drive shaft, the pinion gear and bearing are X = 1.32mm
mounted on the drive shaft. That is a bar of thickness 60mm
with length of 620mm which both of its end are machined to
accommodate the gear, the bearing and the drive pulley.
r

r2
r1

ISBN: 978-988-19253-1-2 WCECS 2013

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering and Computer Science 2013 Vol II
WCECS 2013, 23-25 October, 2013, San Francisco, USA

The belt is an open belt drive; both the pulleys rotate Power transmitted
in the same direction. Power (P) = (T1 – T2) V
r1 and r2 = Radii of the larger & smaller pulley = (1696000 – 844) 17.7
X = Distance between the centers of the = 169515 x 17.7
two pulleys = 300043
L =Total Length of the belt = 3000W
Length L=(r1+ r2) + 2X + = 3.0 KW

=(145 + 110) + (2x + Efficiency of the drive

P1 =
Where X =1.32mm
If the rev/m (N) = 117rev/m
= (255) + 2(1.32) +
P1 =
= 800.7 + 2.64 +
=
= 800.7 + 2.64 + 928
L = 1731mm = 3012
P2 =
Power transmitted by the belt
=
Torque (T) = 16960 x 102 NT-mm
= 2998
Speed V =
Efficiency (X) =

=
=

= = 0.9954
= 99.5%
= 17. 7m/s (f) The table is made of angle bar 50mm x 50mm which
Let T2 = Tension in the slack side of the belt is covered with galvanize mild steel sheet of 1mm thickness
2.3log (T1/T2) = µ.0 and length 650mm x 610mm
Where θ = 160o 700mm
θ= 0.25 (Coefficient … friction 650mm Mild Steel
But θ = 160 x∏/180 = 2.793
: . 2.3log (T1/T2) = 0.6980
log (T1/T2) = 660mm 610mm
Galvanized
mild steel
log (T1/T2) = 0.3036
(T1/T2) = 2.01
The Table
T2 = (g) The ball bearing has an outer rising of 72mm and
inner rising of 35mm and it is made of steel because of the high
= = 84378 = 844N –mm local stress of varying magnitude with each revolution of the
bearing. The balls are generally made of high carbon
chromium and steel. The material of both the balls and races
Torque in the shaft of the smaller pulley are heat treated to give extra hardness and toughness. The balls
Ts = (T1 – T2)r2 are manufactured by hot forging on hammers from steel rod.
= (16960 – 844) 110 They are then heat treated ground and polished, the races are
= (1695 x 110 also formed by forging and then heat treated ground and
= 18645 N-mm polished.
For an easy transmission of power from the motor via the belt
Torque in the shaft of the larger pulley to the driven shaft, a ball bearing is used to affect efficiency
TL = (T1 – T2)r1 and transmission of force to the gears as illustrated above.
= (1696000 – 844)145 Oil or light grease is used for lubricating the bearing. Only
= 16952 x 145 pure mineral oil or calcium base grease should be used. If there
= 24579 N –mm is a possibility of moisture content, then potassium or sodium
base grease may be used. Another additional advantage of the
grease is that it forms a seal to keep out dirt or any other
foreign substance. The temperature should be kept below 90oC
and should not operate above 150oC.

ISBN: 978-988-19253-1-2 WCECS 2013

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering and Computer Science 2013 Vol II
WCECS 2013, 23-25 October, 2013, San Francisco, USA

In order to select the most suitable ball bearing, first of all, the two parts to be joined together, causing it to be permanently
basic dynamic redial load of the bearing was calculated using joined.
this formula. Some of the parts are also coupled with nuts and bolts so that
L = (c/w)K x 166 revolutions they can be easily dismounted and remounted repeatedly.
Then, multiply by the service factor (Ks) to get the design
basic dynamic radial load capacity. REASONS FOR USING WELDING OPERATION FOR
Where L = Rating life THE ASSEMBLING
C = Basic Dynamic load 1. The welding provides very rigid joints. This is in line
K = 3, for ball bearing. with the modern trend of providing rigid frames.
2. A welded joint has the great strength of the parent
LIFE OF THE BEARING metal itself.
The life of the bearing is the number of revolution of hours at 3. In welded connections, the tension member is not
some given contact speed which the bearing runs before the weakened as in the case of rivet joint.
first evidence of fatigue develops the material of one of the 4. The welded structure is smooth in appearance,
rings or one of the rolling element. therefore it looks pleasing.
The minimum life is used to denote the rating life, it has been 5. The welded joints provide maximum efficiency (may
found that the life which 50 percent of a group bearing will be 98%).
complete or exceed is approximately 5 times the life which 90
percent of the bearing will complete or exceed. PAINTING
The machine is painted to prevent rusting of the parts and to
THE NUT & BOLT / WELDING avoid corrosion of the frames. Also, the painting was used to
The nut and bolt is used to fasten some of the parts together beautify the machine.
and in some most cases welding machine and electrode is used
to ensure the erection of the machine. TESTING AND VALUATION
Before testing, grease is applied to the gear and the bearing is
not greased because of the fact that they are greased and sealed
IV. ASSEMBLING OF THE MACHINE in the industry. Then the system is connected to the power
source and tested.
The main frame is coupled with four mounting bars, which are
made of smooth rod of length 620mm and thickness 30mm. it
is threaded at both end and bolted to the mainframe.
The pinion gear and bearing are mounted on a drive shaft (i.e. a V. MACHINE PERFORMANCE
bar of thickness 60mm and length 620mm) which both of its When the motor is started, the shaft of the motor pulley is
end is machined to accommodate the gear, the bearing and the rotating and a force is transferred to the pulley of the driving
drive pulley. One of the rollers with the bearing is coupled at shaft of the machine through the two (2) B-belt rotate as well,
each of its end and the gear is mounted on the mainframe causing the gear of one of the rollers to rotate but in opposite
above the pinion, so that it will engage with it. direction of the rotating pinion. The second gear of the roller is
The table is mounted on the mainframe as well. In a form that also rotating but in the same direction with the rotating pinion
it gives enough clearance to the first roller. The gear with its (i.e. that the two rollers are turning in opposite direction)
bearing assembly is mounted above the first roller, the
engagement of the first and the second roller and the pinion are The movement of the two rollers of the machine in these
well aligned with that of the first roller. directions causes the flour (dough) to be milled in this
In other to enhance smooth drive, the motor mounting frame machine. The performance of the machine is satisfactory.
was welded on the base of the mainframe along with its motor;
the pulley of the motor is aligned with the pulley of the pinion
drive shaft. VI. MAINTENACE
Two B-belt of size 1520mm are used to couple the electric
By definition, maintenance is any activity designed to keep
motor pulley and the pinion drive shaft pulley together, in a
equipment or assets in working condition and may be planned
form that the tensioning of the belt is moderate. The gear cover
or unplanned.
plate is then mounted on the mainframe to cover the bearing
Lubrication of the ball bearing.
from entangling with movable object and from dust.
1. To reduce friction and wear between the sliding parts
of the bearing.
EQUIPMENTS FOR THE ASSEMBLING OPERATION
2. To prevent rusting or corrosion of the bearing surface.
1. Welding machine
3. To protect the bearing surface from water or dirt.
2. Electrode
4. To dissipate the heat.
3. Nut and bolt
The following should always be done to maintain the life of the
4. Spanner
machine:
The joint parts are welded together with the use of electric
a) Grease should be applied to the gears and pinion to
welding machine and electrode, which fuses at the edges of the
reduce friction and wear between the rotating teeth.

ISBN: 978-988-19253-1-2 WCECS 2013

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering and Computer Science 2013 Vol II
WCECS 2013, 23-25 October, 2013, San Francisco, USA

b) The machine should be subjected to a routine

maintenance to avoid breakdown of the machine. VIII. COST ANALYSIS
c) The rollers of the machine should be oiled with
Costing is the determination of the actual cost of a component
groundnut oil after use to prevent corrosion and should
after adding different expenses incurred. This work begins with
be cleaned with a little flour before using for the
the pre-planning stage of the product and ends only after the
normal milling operation.
whole lot of the product has been fully manufactured.
d) The mainframe of the machine should be painted to
prevent it from corroding.
Table 1 and 2 show the materials cost and the overhead cost
e) The bearing should be lubricated to reduce friction,
(machine cost)
wear and to protect its surface from water, dirt etc and
also to dissipate heat.
Table 2 :OVERHEAD COST (MACHINE COST)
Finally, the machine should be allowed to rest at least six
(6) hours, twice a week.

VII. RECOMMENDATION
For the best and effective performance of the flour milling
machine, the following instructions must be noted.
I. The gears should be greased at least once a month to
reduce friction and wear between the rotating teeth.
II. The rollers should be oiled with groundnut oil after
use to prevent corrosion and contamination of the
flour. Also it should be cleaned with a little flour
before using for another milling operation.
III. The bearing should be lubricated to reduce friction,
wear and rusting and also to protect its surface from LABOUR COST IN FLOUR
water, dirt and to dissipate heat. Number of students worked = 1
IV. The machine should be allowed to rest at least six (6) Pay per Hour = N200
hours twice a week. Number of days spent on the project = 16 days
V. The bearing and the gears should be covered always Total number of hours spent = 16days X 7hrs = 112hrs
with the cover plate (bearing/gear housing plate) to Then, Labour cost = 112hrs x N200 = N22, 400
protect it from dirt and other objects.
TOTAL COST OF PRODUCTION
Material Cost = N46, 730.00
Overhead Cost = N 14,735.00
Labour Cost = N 22,400.00
N 83,865.00

Table 1: MATERIAL COST

ISBN: 978-988-19253-1-2 WCECS 2013

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)
Proceedings of the World Congress on Engineering and Computer Science 2013 Vol II
WCECS 2013, 23-25 October, 2013, San Francisco, USA

IX. CONCLUSION
This project is quite an engineering construction that
requires a huge amount of money to be achieved. The
construction of the flour milling machine involves the
application of all the principles of construction which
includes: measurement, marking out, milling operation,
cutting, joining, filling, bolting and painting.
Also, the behavior of mechanism machine is not left out as
that of the gear system used in the course of producing the
machine. The electric motor is able to transmit through the
belt to the pulley of the shaft via the pinion and then to the
gears thereby causing the flour to be milled.
Finally, it can be conveniently concluded that this improved
design is quite a big task. However, it is interesting and
inspirational as we were able to get the basic and
fundamental information towards further research to the
construction and production of the milling machine.

REFERENCE
[1]. JOSEPH E. SHIGLEY, Mechanical Engineering
Design 6th Edition, McGraw Hill Company Inc New
York, 2001.
[2]. KHURMI, R.S., Theory Of Machines 14th Edition, S.
Chand and Company Ltd Ram Naggar Indian, 2005
[3]. KHURMI, R.S. Et Al, Machine Design 13th Edition,
S. Chand and Company Ltd Ram Naggar Indian, 2005
[4]. RAJPUT R.K., Strength Of A Machine 4th Edition, S.
Chand and Company Ltd Ram Naggar Indian, 2006
[5]. SHARMA, P.D., Production Engineering 10th Edition,
S. Chand and Company Ltd Ram Naggar Indian, 2006

ISBN: 978-988-19253-1-2 WCECS 2013

ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online)