INDEX

Chapters

Titles

Page NO

ABSTRACT
1.

INTRODUCTION TO CHOCOLATE
FILLING MACHINE
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12

PREPARATION OF CHOCOLATE AND

STORAGE
2.1
2.2

Various Stages
Melting Chocolate for Moulding

INTRODUCTION TO CADD
3.1

Material Handling Equipment

Engineered Systems
Industrial Trucks
Types Of Material Handling Equipment
Conveyors
Stepper Motor
Solenoid Valves
Actuators
Actuator Types
Examples of actuators
Filler
Types of filler

Types of CADD Software

CAD DESIGN TOOL CREO

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8

Introduction
Core CREO Concepts
Features of CREO Engineering
CREO Basic Design Modes
Assembly in CREO
Degrees of Freedom
Assembly Constraints
CREO Modules

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MODELLING OF CHOCOLATE
FILLING MACHINE FRAME IN CREO
5.1

FINITE ELEMENT ANALYSIS

6.1
6.2
6.3

Introduction
Types of engineering analysis
Results of FEA

7.1
7.2
7.3

Introduction
Benefits
FEM

ANSYS

SIMULATION OF CHOCOLATE
FILLING MACHINE FRAME
8.1
8.2
8.3
8.4

Generating 3D view of a Frame in CREO

Static Analysis Of Ductile Iron At 500N

Static Analysis Of Ductile Iron At 1000N
Static Analysis Of Alloy Steel At 500N
Static Analysis Of Alloy Steel At 1000N

RESULTS AND DISCUSSIONS

9.1
9.2

Comparision Of Results Between

Ductile Iron And Alloy Steel At 500N
Comparision Of Results Between
Ductile Iron And Alloy Steel At 1000N

10 CONCLUSION

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BIBILOGRAPHY

LIST OF FIGURES

Fig. No

1.1
1.2
1.3
1.4

Description

Page. No

Industrial Mezzanine
Engineered System
Industrial Truck
Belt Conveyor

94

1.5
1.6
1.7
1.8
1.9
1.10
1.11

Chute Conveyor
Wheel Conveyor
Roller Conveyor
Gravity Roller Conveyor
Stepper Motor
Solenoid Valve
Pneumatic Rack And Pinion Actuators

1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
2.1
4.1
5.1
5.2
5.3
5.4
5.5
8.1
8.2

For Valve Controls Of Water Pipes

Over Flow Liquid Filler
Working Of Over Flow Liquid Filler
Servo Pump Liquid Filler
Working Of Servo Pump Liquid Filler
Peristaltic Liquid Filler
Working Of Peristaltic Liquid Filler
Time Gravity Liquid Filler
Working Of Time Gravity Liquid Filler
Piston Liquid Filler
Working Of Piston Liquid Filler
Various Chocolate-Making Machinery
Work Space Display of CREO
Modelling Of Supporting Frame
Supporting Frame Assembly
Supporting Frame Assembly
3D View Of Frame [Support]
Detailing Of Frame [Support]
Meshing
Stresses Developed In Frame Of

8.3

Ductile Iron At 500N

Resultant Displacement On The Frame

8.4

Of Ductile Iron At 500N

Final Frame Design Of Ductile Iron At
500N

8.5

Stresses Developed In Frame Of

8.6

Ductile Iron At 1000N

Resultant Displacement On The Frame

8.7

Of Ductile Iron At 1000N

Final Frame Design Of Ductile Iron At
1000N

8.8

Stresses Developed In Frame Of Alloy

steel At 500N

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8.9
8.10

Resultant Displacement On The Frame

Of Alloy steel At 500N
Final Frame Design Of Alloy steel At
500N

8.11

Stresses Developed In Frame Of Alloy

8.12

steel At 1000N
Resultant Displacement On The Frame

8.13

Of Alloy steel At 1000N

Final Frame Design Of Alloy steel At
1000N

LIST OF TABLES

Table No.

Description

2.1

Crystal Forms

5.1

Machine specifications

8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17

Page. No
1

Study Properties of ductile iron

Units
Material Properties of ductile iron
Fixtures
Loads
Stress of Ductile Iron at 500N
Resultant Displacement of Ductile Iron at 500N
Factor of Safety of Ductile Iron at 500N
Stress of Ductile Iron at 1000N
Resultant Displacement of Ductile Iron at 1000N
Factor of Safety of Ductile Iron at 1000N
Material Properties of alloy steel
Stress of Alloy Steel at 500N
Resultant Displacement of Alloy Steel at 500N
Factor of Safety of Alloy Steel at 500N
Stress of Alloy Steel at 1000N
Resultant Displacement of Alloy Steel at 1000N

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8.18

Factor of Safety of Alloy Steel at 1000N

9.1

Comparision of results Between Ductile Iron

and Alloy Steel at 500N
Comparision of results Between Ductile Iron
and Alloy Steel at 1000N

9.2

DESIGN AND ANALYSIS OF CHOCOLATE FILLING MACHINE

FRAME

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ABSTRACT
A chocolate filling machine is a machine which fills the tray of chocolate by
filler. The present work is directed towards the modelling of chocolate filling
machine Frame of overall dimensions of 2m x1m x1.8m .The chocolate filling
machine consists of Belt conveyor ,Motor, Gear box, Frame ,Control
panel,Tray,Tray dropping assembly, Filling tank, Actuators and solenoid
valves. We have modelled Frame of chocolate filling machine in a 3D CAD
tool called CREO 2.0 and assembled. We have also done the structural
analysis on frame by applying three different materials namely Alloy steel and
Ductile iron in ANSYS SIMULATION package of loading 500N and
1000N .The three materials are compared with their results. So the best
material for the frame is going to analysis is done in ANSYS .ANSYS is
dedicated finite element package used for determining the variation of
stresses,and deformation

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CHAPTER 1

94

1. INTRODUCTION TO CHOCOLATE FILLING MACHINE:

Chocolate filling machine consists of different parts

Stepper motor
Solenoid valve
Material handling equipment
Gear box
Belt conveyors
Tray
Tray drop mechanism
Hopper
Actuator

1.1 MATERILAL HANDLING EQUIPMENT:

Fig 1.1.: Industrial mezzanine.

Material-handling equipment is equipment that relate to the movement,

storage, control and protection of materials, goods and products throughout
the process of manufacturing, distribution, consumption and disposal.
Material handling equipment is the mechanical equipment involved in the
complete system.
Material handling equipment is generally separated into four main categories:
storage and handling equipment, engineered systems, industrial trucks, and

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bulk material handling. Storage and handling equipment is a category within

the material-handling industry. The equipment that falls under this description
is usually non-automated storage equipment.
Products such as pallet racking, shelving, casters and carts, among others,
belong to storage and handling
.
1.2 ENGINEERED SYSTEMS:

Fig 1.2.: engineered system.

Engineered systems are typically custom engineered material-handling
systems. Conveyors, Handling Robots, AS/RS, AGV and most other
automated material-handling systems fall into this category. Engineered
systems are often a combination of products integrated to one system. Many
distribution centres will optimize storage and picking by utilizing engineered
systems such as pick modules and sortation systems.
Equipment and utensils used for processing or otherwise handling edible
product or ingredients must be of such material and construction to facilitate
thorough cleaning and to ensure that their use will not cause the adulteration
of product during processing, handling, or storage. Equipment and utensils

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must be maintained in sanitary condition so as not to adulterate or contaminate

product.

1.3 INDUSTRIAL TRUCKS

Fig 1.3. Industrial truck

Industrial trucks usually refer to operator driven motorized warehouse

vehicles powered manually, by gasoline, propane or electrically. Industrial
trucks assist the material-handling system with versatility; they can go where
engineered systems cannot. Forklift trucks are the most common example of
industrial trucks but certainly aren't the extent of the category. Tow tractors
and stock chasers are additional examples of industrial trucks. Their greatest
advantage lies in the wide range of attachments available; these increase the
truck ability to Material handling and efficiency
1.4 Types of material-handling equipment
Bulk material-handling equipment is used to move and store bulk materials
such as ore, liquids, and cereals. This equipment is often seen on farms,

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mines, shipyards and refineries. This category is also explained in Bulk

material handling.
1.4.1 On-rails transfer cart
On-rails transfer cart is a kind of material-handling equipment. It moves on
the rails and can transfer heavy cargoes or equipment with the weight 1-300t
between the workshops or warehouses in the factory. It is widely used in the
line of metallurgy, coal, heavy manufacturing, automotive assembly, etc.
Its power can be AC or DC. DC Power has rail transmit power and battery
power, while AC power includes cable power and slippery touch line power.
In addition, there is the manual rail transfer cart or towed rail transfer cart,
also called motorized transfer trolley.
1.4.2 Cantilevered crane loading platform
Cantilevered crane loading platforms are temporary platforms attached to the
face of multi- storey buildings or structures to allow materials and equipment
to be directly loaded on or shifted off floor levels by cranes during
construction or demolition. They may be fixed or rolling and a variety of
designs are used including fully fabricated and demountable types. The
platforms are supported on needles (cantilevered beams) anchored to the
supporting structure.

1.5 CONVEYORS:
Conveyors are another form of material handling. Conveyors can be used in a
multitude of ways from warehouses to airport baggage handling systems.

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Some types of conveyors are inbuilt, power and free, chain, towline and roller
conveyor.
1.5.1 Belt conveyors

Fig 1.4.: belt conveyor

A conveyor belt is the carrying medium of a belt conveyor system (often
shortened to belt conveyor). A belt conveyor system is one of many types
of conveyor systems. A belt conveyor system consists of two or
more pulleys (sometimes referred to as drums), with an endless loop of
carrying medium - the conveyor belt - that rotates about them. One or both of
the pulleys are powered, moving the belt and the material on the belt forward.
The powered pulley is called the drive pulley while the unpowered pulley is
called the idler pulley. There are two main industrial classes of belt conveyors;
Those in general material handling such as those moving boxes along inside a
factory and bulk material handling such as those used to transport large
volumes

of

resources

and

agricultural

materials,

such

as grain, salt, coal, ore, sand, overburden and more. Today there are different
types of conveyor belts that have been created for conveying different kinds of
material available in PVC and rubber materials.
The belt consists of one or more layers of material. Many belts in general
material handling have two layers. An under layer of material to provide linear

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strength and shape called a carcass and an over layer called the cover. The
carcass is often a woven fabric having a warp & weft. The most common
carcass materials are polyester, nylon and cotton. The cover is often various
rubber or plastic compounds specified by use of the belt. Covers can be made
from more exotic materials for unusual applications such as silicone for heat
or gum rubber when traction is essential
.

Fig 1.5: chute conveyor

Fig 1.6: wheel conveyor

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Fig 1.7: roller conveyor

Fig 1.8 gravity roller conveyor

1.6. STEPPER MOTOR:

A stepper motor (or step motor) is a brushless DC electric motor that divides a
full rotation into a number of equal steps. The motor's position can then be
commanded to move and hold at one of these steps without any feedback
sensor (an open-loop controller), as long as the motor is carefully sized to the
application.

Fig 1.9: stepper motor

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1.7 SOLENOID VALVE:

Fig 1.10: solenoid valve

A solenoid valve is an electromechanically operated valve. The valve is

controlled by an electric current through a solenoid: in the case of a two-port
valve the flow is switched on or off; in the case of a three-port valve, the
outflow is switched between the two outlet ports. Multiple solenoid valves can
be placed together on a manifold.
Solenoid valves are the most frequently used control elements in fluidics.
Their tasks are to shut off, release, dose, distribute or mix fluids. They are
found in many application areas.
Solenoids offer fast and safe switching, high reliability, long service life,
good medium compatibility of the materials used, low control power and
compact design. Besides the plunger-type actuator which is used most
frequently, pivoted-armature actuators and rocker actuators are also used.
1.8 ACTUATOR:

An actuator is a type of motor that is responsible for moving or controlling a

mechanism or system. It is operated by a source of energy, typically electric
current, hydraulic fluid pressure, or pneumatic pressure, and converts that
energy into motion. An actuator is the mechanism by which a control system
acts upon an environment.

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The control system can be simple (a fixed mechanical or electronic system),

software-based (e.g. a printer driver, robot control system), a human, or any
other input.
1.9 ACTUATOR TYPES:

1.9.1. Hydraulic:
A hydraulic actuator consists of a cylinder or fluid motor that uses hydraulic
power to facilitate mechanical operation. The mechanical motion gives an
output in terms of linear, rotary or oscillatory motion. Because liquid is nearly
incompressible, a hydraulic actuator can exert considerable force, but is
limited in acceleration and speed.
The hydraulic cylinder consists of a hollow cylindrical tube along which a
piston can slide. The term double acting is used when pressure is applied on
each side of the piston. A difference in pressure between the two side of the
piston results in motion of piston to either side. The term single acting is used
when the fluid pressure is applied to just one side of the piston. The piston can
move in only one direction, a spring being frequently used to give the piston a
return stroke.

1.9.2 Pneumatic:

Fig 1.11: Pneumatic rack and pinion actuators for valve controls of water pipes

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A pneumatic actuator converts energy formed by vacuum or compressed air at

high pressure into either linear or rotary motion. Pneumatic energy is desirable
for main engine controls because it can quickly respond in starting and
stopping as the power source does not need to be stored in reserve for
operation. Pneumatic actuators enable large forces to be produced from
relatively small pressure changes. These forces are often used with valves to
move diaphragms and so affect the flow of liquid through the valve.

1.9.3 Electric
An electric actuator is powered by a motor that converts electrical energy to
mechanical torque. The electrical energy is used to actuate equipment such as
multi-turn valves. It is one of the cleanest and most readily available forms of
actuator because it does not involve oil. Recently, new type of actuators which
can be actuated by applying thermal or magnetic energy have drawn many
interest and attention and in many commercial applications, due to their
superior and unique properties (i.e. more compact, lightweight, high power
density and economical).[1]These actuators are using shape memory materials
(SMMs), such as shape memory alloys (SMAs) or magnetic shape-memory
alloys (MSMAs)

1.9.4 Mechanical
A mechanical actuator functions by converting rotary motion into linear
motion to execute movement. It involves gears, rails, pulleys, chains and other
devices to operate. An example is a rack and pinion. In engineering, actuators
are frequently used as mechanisms to introduce motion, or to clamp an object
so as to prevent motion. In electronic engineering, actuators are a subdivision
of transducers. They are devices which transform an input signal (mainly an
electrical signal) into motion.
1.10 Examples of actuators

94

Comb drive

Digital micro mirror device

Electric motor

Electro active polymer

1.11 FILLER:
Considerations in selecting a filler
Basics of liquid filling technologies
Types of filler

1.11.1 Considerations in selecting filler

Types of product to be fill..???
Viscosity of liquid
Paste or solid
Stable or unstable
Volatile or non volatile
Explosive or not
Hot or frozen
Large size or small size container (jar) used
Glass bottles or plastic bottles or metal cans
Shape
Neck size

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Way the product is measured to be filled..???

By volumetric method
By weight method
By level controlled filling
Desired speed of the operation..???

Relatively slow manual operation

Semiautomatic
Fully automatic
1.11.2 Basics of liquid filling technologies:
Liquid Volumetric Filling
Dosing filling

Measure Cup filler

Piston filler

Level controlled filling

Gravity Filling

Vacuum Filling

Gravity Vacuum Filling

Time Controlled Filling

1.12 Types of filler:

1. Over Flow Liquid Filler

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2. Servo Pump Liquid Filler

3. Peristaltic Liquid Filler
4. Time Gravity Liquid Filler
5. Piston Liquid filler
1.12.1 over Flow Liquid Filler:
This type of filler is perhaps the most widely used machine in small bottle
filling operations because it handles a wide range of thin, free flowing liquids
as well as liquids with medium viscosity.

Figure 1.12: over flow liquid filler

Working:
The supply side (dark blue) of a two part nozzle is used to pump product into
the container.When the container fills up to the target fill height, the excess
product and foam is forced out of the container (red arrows) via the return side
to the original product source tank.

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Figure 1.13: working of over flow liquid filler

Advantages:
High performance,
Easy to clean,
Easy to operate,
Expandable at low cost,
Offers greatest flexibility at lowest cost.
Examples:

Sauces,
Syrups,
Light gels and shampoos,
Foamy cleansers and chemicals,
Water and other non carbonated aqueous beverages.

Application:
This type of filler is best suited for liquids with low to medium viscosity.
Liquids with solid particulates not exceeding 1/16" can also be filled. Note
that overflow fillers are the machine of choice in handling very foamy
products at higher speeds
.
1.12.2 Servo Pump Liquid Filler:

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This is a very versatile filling machine capable of filling nearly any type of
product that can be pumped. Each nozzle has a dedicated servo controlled
pump that can deliver thin liquids, medium and thick viscosity liquids, and
liquids with large particulates.

Figure 1.14: Servo pump liquid filler

Working:
The filler's master computer independently tracks the rotation of each pump
head so that it knows precisely how much product has been delivered. When
the target fill volume is reached, each pump and nozzle is instantly shut
off; resulting in high accuracy fills of your valuable products. The computer
stores all fill parameters in memory for fast changeovers.

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Figure 1.15: working of servo pump liquid filler

Advantages:
Computer control & Operator setup is greatly simplified. The design also
lends itself very well to sanitary applications due to the ease of automatic
cleaning.
Examples
The servo filler is found in all industries from pharmaceutical, cosmetic, dairy,
chemical, food, etc. Both thin and thick products, and also very large
particulates can all be filled on this machine. Cosmetic creams as well as
thick, chunky sauces at pasteurized temperatures can all be filled.
Application:
It is extremely flexible and designed to fill almost any product in any fill
volume. Even 55 gallon drums can be filled.
1.12.3 Peristaltic liquid filler:

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This filler is the machine of choice for high value; small volume fills at very
high accuracy. It is primarily suitable for aqueous and other light viscosity
products.

Figure 1.16: Peristaltic liquid filler

Working:
The peristaltic pump makes intermittent contact on only the outside of the
surgical (product) tubing so that the product only touches the inside of the
tubing. The filler's master computer independently tracks the # of rotations of
the peristaltic pump head so that it knows precisely how much product has
been delivered.

Figure 1.17: working of Peristaltic liquid filler

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When the target fill volume is reached, the pump stops and the remaining
product fluid does not drip out due to pipette action. The computer stores all
fill parameters in memory for fast changeovers.
Advantages:
Fluid path is disposable; easy cleanup and elimination of cross contamination
problems. Accuracies of 0.5% are achievable for fill volumes less than 1 ml.
Examples:
Pharmaceutical preparations, fragrances, essential oils, reagents, inks, dyes,
and specialty chemicals.

Application:
Specifically designed for high value, small volume fills at very high accuracy.
Suitable for aqueous and other light viscosity products.
1.12.4 Time Gravity liquid filler:
This is the most economical type of filling machine for a limited range of
applications. This filler is best suited for liquids with very thin viscosities that
do not change with ambient temperature or with batch variation.

Figure 1.18: Time gravity liquid filler

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Working:
The product bulk supply is pumped into a holding tank above a set of
pneumatically operated valves. Each valve is independently timed by the
filler's master computer so that precise amounts of liquid will flow by gravity
into the container.

Figure 1.19: working of time gravity liquid filler

Advantages:
This is the most economical type of filling machine for a limited range of
applications. It is especially well suited for corrosive chemicals.
Examples:
Water, solvents, alcohol, specialty chemicals, paint, inks, corrosive chemicals
i.e. acids and bleach.
Application:
This type of filler is best suited for liquids with very thin viscosities that do
not change with ambient temperature or with batch variation. Although this
type of filler is used predominantly on products that do not foam.

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1.12.5 Piston liquid filler:

The piston filler is one of the oldest and most reliable types of fillers used in
the packaging industry. This filling machine is best suited for viscous products
that are paste, semi paste, or chunky with large particulates.

Figure 1.20 : piston liquid filler

Working:

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figure. 1.21 :working of piston liquid filler

The piston is drawn back in its cylinder so that the product is sucked into the
cylinder. A rotary valve then changes position so that the product is then
pushed out of the nozzle instead of back into the hopper.

Advantages:
This lower cost conventional technology is easy to understand for most users.
Fast fill rates are achievable with fairly thick products.Warning: this
technology is nearly obsolete with the advent of servo positive displacement
fillers.
Examples :
Heavy sauces, cosmetic creams, heavy shampoo, gels, and conditioners, paste
cleaners and waxes, adhesives, heavy oils and lubricants.
Application:
These piston fillers are built to meet food grade standards and can also handle
various chemical applications.

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CHAPTER - 2

94

PREPARATION OF CHOCOLATE & STORAGE TEMPARATURE

INVOLVED IN VARIOUS STAGES
2.1 VARIOUS STAGES INVOLVED ARE AS BELOW

Fermentation

Conching

Tempering

Blending

Storage

2.1.1 Fermentation
The dry cocoa beans are poured into baskets, covered with banana leaves, and
left for 56 days with occasional stirring. The heat generated in the basket
causes the beans to ferment with the temperature rising to 50 C and the
chemical content of the beans undergoing complex changes. This is known
as the fermentation process.
As a result the beans lose up to 65% of their original weight and their
moisture content drops to 6%. Their color changes from violet to brown, they
take on a soft, sweetish buttery taste and most important assume the

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characteristic aroma of chocolate. Fermentation is the first and very important

stage in the processing of cocoa beans. The degree to which the beans were
correctly and evenly fermented will largely determine the smell, taste and
quality of the future chocolate.
Off to the factory
The fermented cocoa beans are washed and dried in the sun or with the use
of special equipment. Once dried, they are packed into sturdy sacks of some
natural material, and loaded on boats that are specially designed to carry them.
In this way the cocoa comes on to the world markets. Later the beans will end
up in factories and, soon after, be turned into chocolate.
Whats the use of cocoa
Cocoa beans have a complex chemical composition. They contain proteins,
carbohydrates, organic acids as well as tannic, coloring, mineral and aromatic
substances. These latter determine the specific chocolate aroma of cocoa and
products made from it. Cocoa also contains the alkaloids the bromine and
caffeine.it has a stimulatory effect on the central nervous and cardiovascular
systems. Theo bromine is used in the treatment of coronary heart disease and
headaches, and it has also proved effective in the treatment of coughing
particularly in the early stages.
Thus cocoa and chocolate, which is made from it, have not only
an invigorating effect, but also medicinal uses. For this reason cocoa beans are
a valuable commodity both for chocolate manufacturers and for the
pharmaceutical, cosmetics and perfume industries. Chocolate is created from
the cocoa bean. A cacao tree with fruit pods in various stages of ripening
2.1.2 Blending
Chocolate liquor is blended with the cocoa butter in varying quantities to
make different types of chocolate or covertures. The basic blends of

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ingredients for the various types of chocolate (in order of highest quantity of
cocoa liquor first), are as follows:

Dark chocolate: sugar, cocoa butter, cocoa liquor, and (sometimes)

vanilla

Milk chocolate: sugar, cocoa butter, cocoa liquor, milk or milk powder,
and vanilla

White chocolate: sugar, cocoa butter, milk or milk powder, and vanilla

The texture is also heavily influenced by processing, specifically conching

(see below). The more expensive chocolate tends to be processed longer and
thus have a smoother texture and "feel" on the tongue, regardless of whether
emulsifying agents are added.
Different manufacturers develop their own "signature" blends based on the
above formulas, but varying proportions of the different constituents are used.
The finest, plain dark chocolate covertures contain at least 70% cocoa (both
solids and butter), whereas milk chocolate usually contains up to 50%. Highquality white chocolate covertures contain only about 33% cocoa.
Producers of high quality, small batch chocolate argue that mass production
produces bad quality chocolate. Some mass-produced chocolate contains
much less cocoa (as low as 7% in many cases) and fats other than cocoa
butter. Vegetable oils and artificialvanilla flavor are often used in cheaper
chocolate to mask poorly fermented and/or roasted beans.
2.1.3 Conching

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Figure 2.1 ;Various chocolate-making machinery

The penultimate process is called conching. A conche is a container filled with

metal beads, which act as grinders. The refined and blended chocolate mass is
kept in a liquid state by frictional heat. Chocolate prior to conching has an
uneven and gritty texture. The conching process produces cocoa and sugar
particles smaller than the tongue can detect, hence the smooth feel in the
mouth. The length of the conching process determines the final smoothness
and quality of the chocolate.
2.1.4 Tempering
The final process is called tempering. Uncontrolled crystallization of cocoa
butter typically results in crystals of varying size, some or all large enough to
be clearly seen with the naked eye. This causes the surface of the chocolate to
appear mottled and matte, and causes the chocolate to crumble rather than
snap when broken.The uniform sheen and crisp bite of properly processed
chocolate are the result of consistently small cocoa butter crystals produced by
the tempering process. The fats in cocoa butter can crystallize in six different
forms (polymorphous crystallization). The primary purpose of tempering is to
assure that only the best form is present. The six different crystal forms have
different properties.

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Crystal.

Melting Temp.

17 C (63 F)

Notes
Soft, crumbly, melts too
easily.

II

21 C (70 F)

III

26 C (79 F)

IV

28 C (82 F)

34 C (93 F)

VI

36 C (97 F)

Soft, crumbly, melts too

easily.
Firm, poor snap, melts
too easily.
Firm, good snap, melts
too easily.
Glossy, firm, best snap,
melts
near
body
temperature (37 C).
Hard, takes weeks to
form.

Table 2.1 crystal forms

Making chocolate considered "good" is about forming as many type V crystals
as possible. This provides the best appearance and texture and creates the most
stable crystals so the texture and appearance will not degrade over time. To
accomplish this, the temperature is carefully manipulated during the
crystallization. Generally, the chocolate is first heated to 45 C (113 F) to
melt all six forms of crystals. Next, the chocolate is cooled to about 27 C
(81 F), which will allow crystal types IV and V to form. At this temperature,
the chocolate is agitated to create many small crystal "seeds" which will serve
as nuclei to create small crystals in the chocolate. The chocolate is then heated
to about 31 C (88 F) to eliminate any type IV crystals, leaving just type V.
After this point, any excessive heating of the chocolate will destroy the temper
and this process will have to be repeated. However, there are other methods of
chocolate tempering used. The most common variant is introducing already

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tempered, solid "seed" chocolate. The temper of chocolate can be measured

with a chocolate temper meter to ensure accuracy and consistency. A sample
cup is filled with the chocolate and placed in the unit which then displays or
prints the results.
Two classic ways of manually tempering chocolate are:

Working the molten chocolate on a heat-absorbing surface, such as a

stone slab, until thickening indicates the presence of sufficient crystal
"seeds"; the chocolate is then gently warmed to working temperature.

Stirring solid chocolate into molten chocolate to "inoculate" the liquid

chocolate with crystals (this method uses the already formed crystal of
the solid chocolate to "seed" the molten chocolate).

Chocolate tempering machines (or temperers) with computer controls can be

used for producing consistently tempered chocolate, particularly for large
volume applications.
2.1.5 Storage:
Chocolate is very sensitive to temperature and humidity. Ideal storage
temperatures are between 15 and 17 C (59 and 63 F), with a relative
humidity of less than 50%. Chocolate is generally stored away from other
foods as it can absorb different aromas. Ideally, chocolates are packed or
wrapped, and placed in proper storage with the correct humidity and
temperature. Additionally chocolate is frequently stored in a dark place or
protected from light by wrapping paper. Various types of "blooming" effects
can occur if chocolate is stored or served improperly. If refrigerated or frozen
without containment, chocolate can absorb enough moisture to cause a whitish
discoloration, the result of fat or sugar crystals rising to the surface. Moving
chocolate from one temperature extreme to another, such as from a
refrigerator on a hot day, can result in an oily texture. Although visually

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unappealing, chocolate suffering from bloom is perfectly safe for

consumption.
2.2 Melting chocolate for moulding in a classroom:
The simple chocolate melting equipment shown below will, if used carefully, produce satisfactory chocolate for moulding chocolate shapes. It
illustrates the variables needing to be controlled in order to produce a
consistently high-quality product, and indicates the major cost factors in
making chocolates (e.g. quality of processing from the raw materials, careful
tempering and moulding, good packaging and presentation, appropriate
storage, marketing, care during transport, etc.).The best method of melting
chocolate is to use a water-bath. A simple chocolate-melter made from a 2l
plastic ice-cream container is shown below.

hole cut in the ice-cream container lid just large enough for the body of a
500g plastic pot (with lid), Payless Plastics item 126/16 make sure the rim
of the pot does not fit through the hole 2l plastic ice-cream container
insulation (e.g. Corf lute, closed-cell foam) Long-handled teaspoon bent
upwards by about 60.Although chocolate can be melted in a microwave oven,
the kinds of chocolate vary in their melting rates, and much care is required to
avoid overheating or scorching it.

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Milk chocolate seems especially prone to scorching. The water-bath method

takes longer but needs less monitor-ing and can maintain the melted
chocolate in moulding condition during a moulding session. Note that
chocolate pieces may retain their shape even when melted, so always stir the
chocolate and check the temperature before further heating.
The appearance of the chocolate is not a sufficient guide to its melted state. If
the moulding of chocolate is concurrent with the plastic mould forming
(assuming there are sufficient adult supervisors), the chocolate moulding area
needs to be well separated from the plastics area. Apart from safety and
supervision issues, there is the need to ensure that the pupils have minimum
exposure to the fumes, and to reduce the chance of the chocolate being
tainted.

The moulds and all utensils in contact with chocolate must always be
completely dry. A small spoon is needed to ladle chocolate into the mould.
The draw-ing of the chocolate-melter above shows a long-handled teaspoon
with the spoon-end bent so it becomes more of a ladle. While miniature ladles
and parfait spoons suitable for bending are available they tend to be
expensive.
Tap the chocolate-filled mould gently on the table a few times to makethe
chocolate flow fully into the mould and to bring any air bubbles to the
surface. Melted chocolate can maintain its shape, and vibrating or tapping it
makes it flow; professional chocolatiers use vibrating tables. When moulding,
it is best if a refrigerator is available in which to place the moulds with their
soft, warm chocolate.
Cooling makes it easier for the chocolate to be removed from the mould, but

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it is important to not leave the chocolate too long in the refrigerator. If too
cold, condensation on the surface when it is removed from the mould can
cause blooming. As chocolate contracts as it cools it usually separate easily
from a clean mould (lack of separation indicates it may have been overheated
in the melting stage).
Decoration can also be added after the chocolates have been removedfrom
the moulds. Some of the moulds provide opportunity to use different kinds of
chocolate for different parts, such as white chocolate for eyes and buttons,
milk/dark chocolate for parts of clothing, etc. Small blobs of chocolate can be
placed in the mould with toothpicks. When wanting discrete colours for
different parts, the mould and chocolate must be cooled before the next lot of
chocolate is added.

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CHAPTER 3

INTRODUCTION TO CAD
Computer-aided design (CAD), also known as computer-aided design and
drafting (CADD), is the use of computer technology for the process of design
and design-documentation. Computer Aided Drafting describes the process of
drafting with a computer. CADD software, or environments, provides the user
with input-tools for the purpose of streamlining design processes; drafting,
documentation, and manufacturing processes.
CADD output is often in the form of electronic files for print or machining
operations. The development of CADD-based software is in direct correlation
with the processes it seeks to economize; industry-based software
(construction, manufacturing, etc.) typically uses vector-based (linear)

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environments whereas graphic-based software utilizes raster-based (pixilated)

environments.
CADD environments often involve more than just shapes. As in the manual
drafting of technical and engineering drawings, the output of CAD must
convey information, such as materials, processes, dimensions, and tolerances,
according to application-specific conventions.CAD may be used to design
curves and figures in two-dimensional (2D) space; or curves, surfaces, and
solids in three-dimensional (3D) objects.
CAD is an important industrial art extensively used in many applications,
including automotive, shipbuilding, and aerospace industries, industrial and
architectural design, prosthetics, and many more. CAD is also widely used to
produce computer animation for special effects in movies, advertising and
technical manuals.
The modern ubiquity and power of computers means that even perfume
bottles and shampoo dispensers are designed using techniques unheard of by
engineers of the 1960s. Because of its enormous economic importance, CAD
has been a major driving force for research in computational geometry,
computer graphics (both hardware and software), and discrete differential
geometry.
The design of geometric models for object shapes, in particular, is often called
computer-aided geometric design (CAGD).Current computer-aided design
software packages range from 2D vector-based drafting systems to 3D solid
and surface modellers. Modern CAD packages can also frequently allow
rotations in three dimensions, allowing viewing of a designed object from any
desired angle, even from the inside looking out. Some CAD software is
capable of dynamic mathematic modeling, in which case it may be marketed

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as CADD - computer-aided design and drafting.CAD is used in the design of

tools and machinery and in the drafting and design of all types of buildings,
from small residential types (houses) to the largest commercial and industrial
structures (hospitals and factories).
CAD is mainly used for detailed engineering of 3D models and/or 2D
drawings of physical components, but it is also used throughout the
engineering process from conceptual design and layout of products, through
strength and dynamic analysis of assemblies to definition of manufacturing
methods of components. It can also be used to design objects.CAD has
become an especially important technology within the scope of computeraided technologies, with benefits such as lower product development costs
and a greatly shortened design cycle. CAD enables designers to lay out and
develop work on screen, print it out and save it for future editing, saving time
on their drawings.
3.1 Types of CAD Software
3.1.1 2D CAD
Two-dimensional, or 2D, CAD is used to create flat drawings of products and
structures. Objects created in 2D CAD are made up of lines, circles, ovals,
slots and curves.
2D CAD programs usually include a library of geometric images; the ability
to create Bezier curves, splines and polylines; the ability to define hatching
patterns; and the ability to provide a bill of materials generation.
3.1.2 3D CAD
Three-dimensional (3D) CAD programs come in a wide variety of types,
intended for different applications and levels of detail. Overall, 3D CAD
programs create a realistic model of what the design object will look like,
allowing designers to solve potential problems earlier and with lower
production costs. Some 3D CAD programs include Autodesk Inventor, Co

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Create Solid Designer, Pro/Engineer Solid Edge, Solid Works, Unigraphics

NX and VX CAD, CATIA V5.
3.1.3 3D Wireframe and Surface Modeling
CAD programs that feature 3D wireframe and surface modeling create a
skeleton-like inner structure of the object being modeled. A surface is added
on later. These types of CAD models are difficult to translate into other
software and are therefore rarely used anymore.
3.1.4 Solid Modeling
Solid modeling in general is useful because the program is often able to
calculate the dimensions of the object it is creating. Many sub-types of this
exist. Constructive Solid Geometry (CSG) CAD uses the same basic logic as
2D CAD, that is, it uses prepared solid geometric objects to create an object.
However, these types of CAD software often cannot be adjusted once they are
created.

94

CHAPTER - 4

CAD-DESIGN TOOL
Computer Aided Design & Drafting
CREO-Parametric

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4.1 INTRODUCTION:
4.1.1 CAD
Computer aided design (cad) is defined as any activity that involves
the effective use of the computer to create, modify, analyze, or document an
engineering design. CAD is most commonly associated with the use of an
interactive computer graphics system, referred to as cad system. The term
CAD/CAM system is also used if it supports manufacturing as well as design
applications.

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The design software used to design the Single & Four Bolted Joints in CREO
4.1.2 Introduction to CREO
CREO is a suite of programs that are used in the design, analysis, and
manufacturing of a virtually unlimited range of product. In CREO we will be
dealing only with the major front end module used for pan and assembly
design and model creation, and production of engineering drawings. There are
wide ranges of additional modules available to handle tasks ranging from
sheet metal operations, piping layout mold design, wiring harness design, NC
machining and other operations.
In a nutshell, CREO is a parametric, feature-based solid modeling system,
Feature based means that you can create part and assembly by defining
feature like extrusions, sweep, cuts, holes, slots, rounds, and so on, instead of
specifying low-level geometry like lines, arcs, and circle& features are
specifying by setting values and attributes of element such as reference planes
or surfaces direction of creation, pattern parameters, shape, dimensions and
others.
4.2 core CREO wildfire 2.0 concepts:
Those are

solid modelling

Feature based

Parametric

Parent/child relationships

Associative

modelclinic

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4.2.1 Parametric means that the physical shape of the part or assembly is
driven by the values assigned to the attributes (primarily dimensions) of its
features. Parametric may define or modify a features dimensions or other
attributes at any time.
For example, if your design intent is such that a hole is centered on a block,
you can relate the dimensional location of the hole to the block dimensions
using a numerical formula; if the block dimensions change, the centered hole
position will be recomputed automatically.
4.2.2 Solid Modelling means that the computer model to create it able to
contain all the information that a real solid object would have. The most
useful thing about the solid modeling is that it is impossible to create a
computer model that is ambiguous or physically non-realizable.
PTC was founded in 1985, by Samuel Peisakhovich Ginsberg, who previously
worked at Prime Computer, Computer vision (CV) and Applicon.
Pro/ENGINEER (a.k.a. Pro/E), the company's first product, shipped in 1988.

Figure 4.1 Work Space Display of CREO

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4.2.3 Capabilities and Benefits:

1.

Complete 3D modeling capabilities enable you to exceed quality arid

time to arid time to market goals.

2. Maximum production efficiency through automated generation of

associative C tooling design, assembly instructions, and machine code.
3. Ability to simulate and analysis virtual prototype to improve
production performance and optimized product design.
4. Ability to share digital product data seamlessly among all appropriate
team members
Compatibility with myriad CAD tools-including associative data
exchange and industry standard data formats.
4.3 Features of CREO Engineering
CREO is a one-stop for any manufacturing industry. It offers effective feature,
incorporated for a wide variety of purpose. Some of the important features are
as follows:

Simple and powerful tool

Parametric design

Feature-based approach

Parent child relationship

Associative and model centric

4.3.1 Simple and Powerful Tool

CREO tools are used friendly. Although the execution of any operation
using the tool can create a highly complex model
4.3.2 Parametric Design

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CREO designs are parametric. The term parametric means that the design
operations that are captured can be stored as they take place. They can be used
effectively in the future for modifying and editing the design. These types of
modeling help in faster and easier modifications of design.
4.3.3. Feature-Based Approach
Features are the basic building blocks required to create an object. CREO
wildfire models are based on the series of feature. Each feature builds upon
the previous feature, to create the model (only one single feature can be
modified at a time). Each feature may appear simple, individually, but
collectively forms a complex part and assemblies.
The idea behind feature based modeling is that the designer construct on
object, composed of individual feature that describe the manner in which the
geometry supports the object, if its dimensions change. The first feature is
called the base feature.

4.3.4 Parent Child Relationship

The parent child relationship is a powerful way to capture your design intent
in a model. This relationship naturally occurs among features, during the
modeling process. When you create a new feature, the existing feature that are
referenced, become parent to the feature.
4.3.5 Associative and Model Centric
Pro/Engineering wildfire drawings are model centric. This means that
Pro/Engineering models that are represented in assembly or drawings are

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associative. If changes are made in one module, these will automatically get
updated in the referenced module.
4.4 Creo Basic Design Modes
When a design from conception to completion in creo, the design information
goes through three basic design steps.
1.

Creating the component parts of the design

2. Joining the parts in an assembly that records the relative position

of the parts.
3. Creating mechanical drawing based on the information in the
parts and the assembly.
4.5 Assembly in CREO:
Bottom-Up Design (Modeling):
The components (parts) are created first and then added to the assembly file.
This technique is particularly useful when parts already exist from previous
designs and are being re-used.
Top-Down Design (Modeling):
The assembly file is created first and then the components are created in the
assembly file. The parts are building relative to other components. Useful in
new designs
In practice, the combination of Top-Down and Bottom-Up approaches is used.
As you often use existing parts and create new parts in order to meet your
design needs.
4.6 Degrees of Freedom:
An object in space has six degrees of freedom.

94

Translation movement along X, Y, and Z axis (three degrees of

freedom)

Rotation rotate about X, Y, and Z axis (three degrees of freedom)

4.7 Assembly Constraints:

In order to completely define the position of one part relative to another, we
must constrain all of the degrees of freedom.Mate, Align, and Insert
4.7.1 Mate
Two selected surfaces become co-planar and face in opposite directions. This
constrains 3 degrees of freedom (two rotations and one translation)
4.7.2 Mate Offset
Two surfaces are made parallel with a specified offset distance.
4.7.3 Align Coincident
Two selected surfaces become co-planar and face in the same direction. Can
also be applied to revolved surfaces. This constrains 3 degrees of freedom
(two rotations and one translation). When Align is used on revolved surfaces,
they become coaxial (axes through the centers align).
4.7.4 Align Offset
This can be applied to planar surfaces only; surfaces are made parallel with a
specified offset distance.
4.7.5Align Orient
Two planar surfaces are made parallel, not necessarily co-planar, and face the
same direction (similar to Align Offset except without the specified distance).

94

4.7.6 Insert
This constrain can only be applied to two revolved surfaces in order to make
them coaxial (coincident
4.8 CREO Modules:

Sketcher (2D)

Part (3D)

Assembly

Drawing and Drafting

Sheet Metal

Rendering

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CHAPTER 5

MODELING OF CHOCOLATE FILLING MACHINE FRAME IN

CREO 2.0
5.1 Machine specifications:

Pneumatic system
electric power
dimensions
l x w x h (m/m)

100mm,350mm,25mm
ac 230v 1/2hp
three phase 120 rpm
2x1x1.8

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Table: 5.1 Machine specifications

5.2 MODELING OF FRAME IN CREO 2.0

Figure 5.1: Supporting frame

Figure 5.2: Supporting frame Assembly

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Figure 5.3: Supporting frame Assembly

Figure 5.4: 3D view of frame [support]

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Figure 5.5: Detailing of Frame [support]

Frame is modelled by using weldment feature in CREO 2.0 with the help of
3D sketches.

CHAPTER - 6
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6.1 INTRODUCTION TO FEA

Finite Element Analysis (FEA) was first developed in 1943 by R. Courant,
who utilized the Ritz method of numerical analysis and minimization of
variational calculus to obtain approximate solutions to vibration systems.
Shortly thereafter, a paper published in 1956 by M. J. Turner, R. W. Clough,
H. C. Martin, and L. J. Topp established a broader definition of numerical
analysis. The paper centered on the "stiffness and deflection of complex
structures".
By the early 70's, FEA was limited to expensive mainframe computers
generally owned by the aeronautics, automotive, defense, and nuclear
industries. Since the rapid decline in the cost of computers and the
phenomenal increase in computing power, FEA has been developed to an

94

incredible precision. Present day supercomputers are now able to produce

accurate results for all kinds of parameters.
FEA consists of a computer model of a material or design that is stressed and
analyzed for specific results. It is used in new product design, and existing
product refinement. A company is able to verify a proposed design will be
able to perform to the client's specifications prior to manufacturing or
construction. Modifying an existing product or structure is utilized to qualify
the product or structure for a new service condition.In case of structural
failure, FEA may be used to help determine the design modifications to meet
the new condition.
There are generally two types of analysis that are used in industry: 2-D
modeling, and 3-D modeling. While 2-D modeling conserves simplicity and
allows the analysis to be run on a relatively normal computer, it tends to yield
less accurate results. 3-D modeling, however, produces more accurate results
while sacrificing the ability to run on all but the fastest computers effectively.
Within each of these modeling schemes, the programmer can insert numerous
algorithms (functions) which may make the system behave linearly or nonlinearly. Linear systems are far less complex and generally do not take into
account plastic deformation. Non-linear systems do account for plastic
deformation, and many also are capable of testing a material all the way to
fracture.
FEA uses a complex system of points called nodes which make a grid called a
mesh. This mesh is programmed to contain the material and structural
properties which define how the structure will react to certain loading
conditions. Nodes are assigned at a certain density throughout the material
depending on the anticipated stress levels of a particular area.

94

Regions which will receive large amounts of stress usually have a higher
node density than those which experience little or no stress. Points of interest
may consist of: fracture point of previously tested material, fillets, corners,
complex detail, and high stress areas.
The mesh acts like a spider web in that from each node, there extends a mesh
element to each of the adjacent nodes. This web of vectors is what carries the
material properties to the object, creating many elements.
A wide range of objective functions (variables within the system) are available
for minimization or maximization:

Mass, volume, temperature

Strain energy, stress strain

Force, displacement, velocity, acceleration

Synthetic (User defined)

There are multiple loading conditions which may be applied to a system.

Some examples are shown:

Point, pressure, thermal, gravity, and centrifugal static loads

Thermal loads from solution of heat transfer analysis

Enforced displacements

Heat flux and convection

Point, pressure and gravity dynamic loads

Each FEA program may come with an element library, or one is constructed
over time. Some sample elements are:

94

Rod elements

Beam elements

Plate/Shell/Composite elements

Shear panel

Solid elements

Spring elements

Mass elements

Rigid elements

Viscous damping elements

Many FEA programs also are equipped with the capability to use multiple
materials within the structure such as:

Isotropic, identical throughout

Orthotropic, identical at 90 degrees

General anisotropic, different throughout

6.2 Types of Engineering Analysis

6.2.1 Structural analysis
This consists of linear and non-linear models. Linear models use simple
parameters and assume that the material is not plastically deformed. Non-

94

linear models consist of stressing the material past its elastic capabilities. The
stresses in the material then vary with the amount of deformation as in.
6.2.2 Vibrational analysis
This is used to test a material against random vibrations, shock, and impact.
Each of these incidences may act on the natural vibrational frequency of the
material which, in turn, may cause resonance and subsequent failure.
Fatigueanalysis helps designers to predict the life of a material or structure by
showing the effects of cyclic loading on the specimen. Such analysis can show
the areas where crack propagation is most likely to occur. Failure due to
fatigue may also show the damage tolerance of the material.
6.2.3 Heat Transfer analysis
This models the conductivity or thermal fluid dynamics of the material or
structure. This may consist of a steady-state or transient transfer. Steady-state
transfer refers to constant thermo properties in the material that yield linear
heat diffusion.
6.3 Results of Finite Element Analysis
FEA has become a solution to the task of predicting failure due to unknown
stresses by showing problem areas in a material and allowing designers to see
all of the theoretical stresses within. This method of product design and testing
is far superior to the manufacturing costs which would accrue if each sample
was

actually

built

and

tested.

In practice, a finite element analysis usually consists of three principal steps:

6.3.1

Pre processing:

The user constructs a model of the part to be analyzed in which the geometry
is divided into a number of discrete sub regions, or elements," connected at
discrete points called nodes." Certain of these nodes will have fixed
displacements, and others will have prescribed loads. These models can be

94

extremely time consuming to prepare, and commercial codes vie with one
another to have the most user-friendly graphical preprocessor" to assist in
this rather tedious chore. Some of these preprocessors can overlay a mesh on a
preexisting CAD file, so that finite element analysis can be done conveniently
as part of the computerized drafting-and-design process.
6.3.2

Analysis:

The dataset prepared by the preprocessor is used as input to the finite element
code itself, which constructs and solves a system of linear or nonlinear
algebraic equationswhere u and f are the displacements and externally applied
forces at the nodal points. One of FEA's principal advantages is that many
problem types can be addressed with the same code, merely by specifying the
appropriate element types from the library
.
6.3.3

Post processing:

In the earlier days of finite element analysis, the user would pore through
reams of numbers generated by the code, listing displacements and stresses at
discrete positions within the model. It is easy to miss important trends and hot
spots this way, and modern codes use graphical displays to assist in
visualizing the results. Typical postprocessor display overlays colored
contours representing stress levels on the model, showing a full field picture
similar to that of photo elastic or moir experimental results.

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CHAPTER - 7

7.1 ANSYS

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ANSYS

is

an

Engineering

Simulation

Software

(computer

aided

Engineering). Its tools cover Thermal, Static, Dynamic, and Fatigue finite
element analysis along with other tools all designed to help with the
development of the product.
The company was founded in 1970 by Dr. John A. Swanson as Swanson
Analysis Systems, Inc. SASI. Its primary purpose was to develop and market
finite element analysis software for structural physics that could simulate
static (stationary), dynamic (moving) and heat transfer (thermal) problems.
SASI developed its business in parallel with the growth in computer
technology and engineering needs. The company grew by 10 percent to 20
percent each year, and in 1994 it was sold. The new owners took SASIs
leading software, called ANSYS, as their flagship product and designated
ANSYS, Inc. as the new company name
7.2 BENIFITS OF ANSYS:

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 The ANSYS advantage and benefits of using a modular simulation

system in the design process are well documented. According
to studies performed by the Aberdeen Group, best-in-class companies
perform more simulations earlier. As a leader in virtual prototyping,
ANSYS is unmatched in terms of functionality and power necessary to
optimize components and systems. The ANSYS advantage is welldocumented.
ANSYS is a virtual prototyping and modular simulation system that is
easy to use and extends to meet customer needs, making it a low-risk
investment that can expand as value is demonstrated within a
company. It is scalable to all levels of the organization, degrees of
analysis complexity, and stages of product development.

7.3 Finite Element Method

7.3.1 General Description of the Finite Element Method:
In the finite element method, the actual continuum or body of matter like
solid, liquid or gas is represented as assemblage of sub divisions called finite
elements. These elements are considered to be interconnected at specified
joints, which are called nodes or nodal points. The nodes usually lie on the
element boundaries where adjacent elements are considered to be connected.
Since the actual variation of the field variable (like displacement, stress,
temperature, pressure and velocity) inside the continuum is not known, we
assume that the variation of field variable inside a finite element can be
approximated by a simple function. These approximating functions (also
called interpolation models) are defined in terms of the values at the nodes.
7.3.2 Structural Analysis:

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Structural analysis is probably the most common application of the finite

element method. The term structural (or structure) implies not only civil
engineering structures such as ship hulls, aircraft bodies, and machine
housings, as well as mechanical components such as pistons, machine parts,
and tools.
7.4 Types of Structural Analysis:
Different types of structural analysis are:

Static analysis

Modal analysis

Harmonic analysis

Transient dynamic analysis

Spectrum analysis

Bucking analysis

Explicit dynamic analysis

7.4.1. Static Analysis:

A static analysis calculates the effects of steady loading conditions on a
structure, while ignoring inertia and damping effects, such as those caused by
time varying loads.
A static analysis can, however, include steady inertia loads (such as gravity
and rotational velocity), and time-varying loads that can be approximated as
static equivalent loads (such as the static equivalent wind arid seismic loads
commonly defined in many building codes).

94

Static analysis is used to determine the displacements, stresses, strains, and

forces in structural components caused by loads that do not induce significant
inertia and damping effects. Steady loading and response are assumed to vary
slowly with respect to time.
The kinds of loading that can be applied in a static analysis include:
Externally applied forces and pressures
Steady-state inertial forces (such as gravity or rotational
velocity)
Imposed (non-zero) displacements
Temperatures (for thermal stain)
Fluences (for nuclear swelling)
A static analysis can be either linear or non-linear. All types of non-linearities
are allowed-large deformations, plasticity, creep, stress, stiffening, contact
(gap) elements, hyper elastic elements, and so on.

7.4.2 Over-view of steps in a static analysis:

The procedure for a modal analysis consists of three main steps:
1. Build the model.
2. Apply loads and obtain the solution.
3. Review the results

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7.5 BASIC STEPS IN ANSYS (Finite Element Software):

7.5.1 Pre-Processing (Defining the Problem):

The major steps in pre-processing are given below
Define key points/lines/ areas/volumes.
Define element type and material/geometric properties
Mesh lines/ areas/volumes as required.

The amount of detail required will depend on the dimensionality of the

analysis (i.e., 1D, 2D, axi-symmetric, 3D).

7.5.2 Solution (Assigning Loads, Constraints, And Solving): Here the loads
(point or pressure), constraints (translational and rotational) are specified and
finally solve the resulting set of equations.

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7.5.3 Post Processing: In this stage, further processing and viewing of the
results can be done such as:
Lists of nodal displacements
Element forces and moments
Deflection plots
Stress contour diagram

7.5.4 Advanced Post-Processing:

ANSYS provides a comprehensive set of post-processing tools to display
results on the models as contours or vector plots, provide summaries of the
results (like min/max values and locations). Powerful and intuitive slicing
techniques allow to get more detailed results over given parts of your
geometries. All the results can also be exported as text data or to a spreadsheet
for further calculations. Animations are provided for static cases as well as for
nonlinear or transient histories. Any result or boundary condition can be used
to create customized charts

94

7.6 Exploring design:

A single simulation just provides a validation of a design. ANSYS brings you
to the next level with designxplorer a tool designed for fast and efficient
design analysis. You will not need more than a few mouse clicks to get a
depper understanding of your design, whether you want to examine multiple
scenarios or create full response surfaces of your model and get sensitivities to
design parameters, optimize your model or perform a Six Sigma analysis.
7.7 Communicating results:
ANSYS lets you explore your design in multiple ways. All the results you get
must then be efficiently documented: ANSYS will provide you instantaneous
report generation to gather all technical data and pictures of the model in a
convenient format (html, MS Word, MS PowerPoint).Capturing the
knowledge:
7.8 INDIVIDUAL COMPONENT ANALYSIS:IMPORTING THE COMPONEENT FROM CAD (CRE0) TOOL TO CAE
TOOL (ANSYS)
After creating part models in creo we can directly import the files from CREO
to ANSYS by converting .prt files into the followed file format. For these
go to save as select any one of below listed file formats.
1. IGES- Initial Graphics Exchange Specification
2. STP- STandard for the Exchange of Product model data
3. STL- standard tri angular Language
4. Para solid

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CHAPTER -8

94

SIMULATION OF CHOCOLATE FILLING MACHINE

FRAME
The structural analysis of the frame is done by applying, Ductile iron and
Alloy steel the material which yielded less stresses than their yield strength is
preferred.
8.1 STATIC ANALYSIS OF FRAME BY APPLYING DUCTILE IRON
BY APPLYING 500N:
On the frame by calculating the weight of the conveyor, fasteners, tray
dropping mechanism the total weight on the frame will be 500N.

8.1.1 STUDY PROPERTIES:

Study name
Analysis type
Mesh type
Solver type
Inplane Effect:
Soft Spring:
Inertial Relief:
Incompatible bonding options
Large displacement
Compute free body forces

Static 1
Static
Beam Mesh
Direct sparse solver
Off
Off
Off
Automatic
Off
On

Table: 8.1 Study Properties of ductile iron

94

8.1.2 Units
Unit system:
Length/Displacement
Temperature
Angular velocity
Pressure/Stress

SI (MKS)
mm
Kelvin
Rad/sec
N/m^2
Table 8.2: Units

8.1.3 MATERIAL PROPERTIES:

Model Reference

Properties
Name:
Model type:

Ductile Iron
Linear Elastic

Default failure

Isotropic
Max von Mises

criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion

Stress
5.51485e+008 N/m^2
8.61695e+008 N/m^2
1.2e+011 N/m^2
0.31
7100 kg/m^3
7.7e+010 N/m^2
1.1e-005 /Kelvin

coefficient:

94

Table 8.3 Material Properties of ductile iron

8.1.4 LOADS AND FIXTURES:

Fixture
name

Fixture Image

Fixture Details
Entities: 4 Joint(s)
Type: Fixed

Fixed-

Geometry

Table 8.4: Fixtures

Load
name

Load Image

Load Details
Entities: 1 plane(s), 14

Force1

Reference:
Type:
Values:
Moments:

Beam (s)
Front Plane
Apply force
---, -500, --- N
---, ---, --- N.m

Table 8.5: Loads

94

8.1.5 MESHING

Fig: 8.1: Meshing

Name
Stress1

Type
TXY: Shear in Y

Min
0.178789

Max
54.4028 N/mm^2

Dir. on YZ Plane

N/mm^2 (MPa)

(MPa)

Element: 75

Element: 18

Table 8.6 : Stress of Ductile Iron At 500N

94

Figure 8.2: stresses developed in Frame of Ductile iron at 500N

Name
Displacement1

Type
URES: Resultant

Min
0 mm

Max
1.80113 mm

Displacement

Node: 19

Node: 203

Table 8.7: Resultant Displacement of Ductile Iron At 500N

Figure 8.3: Resultant Displacement on the frame Of Ductile Iron At 500N

Name
Factor of
Safety1

Type
Automatic

Min
10.1371

Max
1509.46

Node: 19

Node: 76

94

Table 8.8: Factor of Safety of Ductile Iron at 500N

Figure 8.4: Final Frame Design of ductile iron at 500N

A factor of safety less than 1 at a location indicates that the material at that
location has failedA factor of safety greater than 1 at a location indicates that
the material at that location is safe.
As our FOS is greater than 1 it indicates that our design is safe.
8.2 STATIC ANALYSIS OF FRAME BY APPLYING DUCTILE IRON
BY APPLYING 1000N:

94

Name
Stress1

Type
TXY: Shear in Y Dir.

Min
0.357578 N/mm^2

Max
108.806 N/mm^2

on YZ Plane

(MPa)

(MPa)

Element: 75

Element: 18

Table 8.9 Stress of Ductile Iron At 1000N

8.14

Fig 8.5: Stresses Developed In Frame Of Ductile Iron At 1000N

Name
Displacement1

Type
URES: Resultant

Min
0 mm

Max
6.78768 mm

Displacement

Node: 19

Node: 203

Table 8.10: Resultant Displacement of Ductile Iron At 1000N

94

Figure 8.6: Resultant Displacement On The Frame Of Ductile Iron At

1000N

Name
Factor of
Safety1

Type
Automatic

Min
0.488734

Max
75.4732

Node: 19

Node: 76

Table 8.11: Factor of Safety of Ductile Iron at 1000N

94

Fig 8.7 Final Frame Design of ductile iron at1000N

A factor of safety less than 1 at a location indicates that the material at that
location has failed. A factor of safety of 1 at a location indicates that the
material at that location has just started to fail. A factor of safety greater than 1
at a location indicates that the material at that location is safe.
As our FOS is Less than 1 it indicates that our design is not safe..

94

8.3 STATIC ANALYSIS OF FRAME BY APPLYING ALLOY STEEL BY

APPLYING 500N:
8.3.1 Material Properties
Model Reference

Properties
Name:
Model type:

Alloy Steel
Linear Elastic

Default failure

Isotropic
Max von Mises

criterion:
Yield strength:

Stress
6.20422e+008

Tensile strength:

N/m^2
7.23826e+008

Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion

N/m^2
2.1e+011 N/m^2
0.28
7700 kg/m^3
7.9e+010 N/m^2
1.3e-005 /Kelvin

coefficient:

Table 8.12: Material Properties of alloy steel

Name
Stress1

Type
TXY: Shear in Y Dir.

Min
0.178789

Max
56.425 N/mm^2

on YZ Plane

N/mm^2 (MPa)

(MPa)

Element: 75

Element: 18

Table 8.13: Stress of Alloy Steel at 500N

94

Fig 8.8: Stress developed In Frame Of Alloy steel At 500N

Name
Displacement1

Type
URES: Resultant

Min
0 mm

Max
1.11536 mm

Displacement

Node: 19

Node: 203

Table 8.14: Resultant Displacement of Alloy Steel at 500N

94

Fig 8.9: Resultant Displacement On The Frame Of Alloy steel At 500N

Name
Factor of
Safety1

Type
Automatic

Min
10.9955

Max
1698.15

Node: 19

Node: 76

Table 8.15: Factor of Safety of Alloy Steel at 500N

94

Figure 8.10: Final Frame Design Of Alloy Steel At 500N

8.4 STATIC ANALYSIS OF FRAME BY APPLYING ALLOY STEEL

BY APPLYING 1000N:

Name
Stress1

Type
TXY: Shear in Y

Min
0.357578

Max
112.85

Dir. on YZ Plane

N/mm^2 (MPa)

N/mm^2 (MPa)

Element: 75

Element: 18

Table 8.16: Stress of Alloy Steel at 1000N

94

Fig 8.11: Stress developed in Frame Of Alloy Steel at 1000N

Name
Displacement1

Type
URES: Resultant

Min
0 mm

Max
2.23072 mm

Displacement

Node: 19

Node: 203

Table 8.17: Resultant Displacement of Alloy Steel at 1000N

94

Fig 8.12: Resultant Displacement On The Frame Of Alloy steel At 1000N

Name
Factor of Safety1

Type
Automatic

Min
5.49776

Max
849.076

Node: 19

Node: 76

Table 8.18: Factor of Safety of Alloy Steel at 1000N

94

Fig 8.13: Final Frame Design Of Alloy steel At 1000N

94

CHAPTER - 9

94

RESULTS AND DISCUSSIONS

The structural analysis of the chocolate machine frame is done by applying
three different materials namely Ductile iron and Alloy steel for 500N and
1000N loading conditions.
9.1 Comparision of results for load of 500N:
S.no

Ductile iron

Alloy steel

Stresses developed[Mpa]

54.4028

56.425

Resultant displacement

1.80113

1.1153

Table 9.1: Comparision of results Between Ductile Iron and Alloy Steel at
500N
9.2 Comparision of results for load of 1000N:
S.no
Stresses developed[Mpa]

Ductile iron
108.8

Alloy steel
112.85

Resultant displacement

3.6026

2.23072

Table 9.2: Comparision of results Between Ductile Iron and Alloy Steel at
1000N
From the above results we infer that the Ductile iron has obtained less stresses
compared to the other materials .As 6061 alloy is failed for both the loads
because the stresses induced are greater than the material yield strength.The
ductile iron is cheap compared to alloy steel. So the best material for the
frame would be ductile iron.

94

CHAPTER - 10

CONCLUSION

94

The chocolate filling machine overall dimensions are 2m x 1m x 1.8m.The

chocolate filling machine components like Belt conveyor ,frame ,motor ,Gear
box, Tray dropping assembly, filling tank assembly with actuators and
solenoid valve are modelled in a 3D CAD tool called CREO 2.0.

All the parts were modelled and assembled in creo 2.0

The automation of chocolate filling machine is done with ansys motion

analysis.
The tray assembly , Belt conveyor assembly ,fasteners are mounted on
the frame so the structural analysis of frame is done by applying three
different materials namely Ductile iron, 6061 alloy and Alloy steel for

500N and 1000Nloading conditions.

The Ductile iron has obtained less stresses compared to the other

materials.
The ductile iron is cheap compared to alloy steel. So the best material
for the frame would be ductile iron.

FUTURE SCOPE
As chocolate filling machine is modelled the next step would be the modeling
of coolers and packaging set up for the chocolates.The thermal analysis can be
carried for heat stacking mechanism of chocolate machine. The structural
analysis of tray could also be carried out while heat staking load will be on
tray.

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94

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94