Household Knife Sharpener Machine

Final Report
Fundamental of Mechanical Design MS 4101

Created by:
Oky Eldyagusta (OKY) 13106036
Pungky R. Prihono (PRP) 13106108
Oktavianus P. Mulalinda (OPM) 13106138

MECHANICAL ENGINEERING DEPARTMENT

FACULTY OF MECHANICAL ENGINEERING AND AEROSPACE

BANDUNG INSTITUTE OF TECHNOLOGY

2010

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 PREFACE

One of the important skills that must be owned by an engineering student is the ability to
design. Without excellent design, any products will not working properly or even cannot be
manufactured. To achieve good design, the engineers have to consider many aspects, in addition
to technical aspect, that support the design process including manufacturability of the design,
materials selection, cost estimation, etc.

Our topic for this task is “Household Knife Sharpener Machine”. This report will
describe the design process and mechanism of household knife sharpener machine including all
aspects that have already stated.

At last but not least, we want to thank Prof. Dr. Ir. Komang Bagiasna for his guidance
and patience that he gave us during this class. We hope that our report could give benefit for us.

Bandung, January 2010

Authors

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 Table of Contents
Cover .............................................................................................................................................. 1
Preface ............................................................................................................................................ 2
Table of Contents ....................................................................................................................................... 3

Table of Pictures ......................................................................................................................................... 5

Table of Tables ........................................................................................................................................... 6

Chapter 1 Introduction............................................................................................................................... 7

1.1. Background ...................................................................................................................................... 7

1.2. Problem Identification ..................................................................................................................... 7
1.3. Assignment Purpose ........................................................................................................................ 8
1.4. Assignment Benefit .......................................................................................................................... 8
1.5. Research Methodology .................................................................................................................... 8
1.6. Working Diagram Schematic ............................................................................................................ 8
Chapter 2 Design Requirement and Objectives ...................................................................................... 10

2.1. Design............................................................................................................................................. 10
2.1.1. Introduction ............................................................................................................................ 10
2.1.2. Household Knife Sharpener Machine Design ......................................................................... 10
2.2. Requirement and Objectives ......................................................................................................... 16
Chapter 2 Calculation for Safety and Functionality ................................................................................ 17

3.1. Safety Introduction ........................................................................................................................ 17

3.2. Component Safety Evaluation........................................................................................................ 18
3.2.1. Gear Literature........................................................................................................................ 18
3.2.2. Gear Calculation...................................................................................................................... 19
Chapter 4 Main Component Manufacturing ........................................................................................... 28

4.1. Manufacturing Introduction .......................................................................................................... 28

4.2. Main Component Manufacturing and Assembly ........................................................................... 29
4.2.1. Casing ...................................................................................................................................... 29

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 4.2.2. Bevel and Spur Gear ............................................................................................................... 29
4.2.3. Crank ....................................................................................................................................... 30
4.2.4. Feeding Mechanism Tools ...................................................................................................... 31
4.2.5. Sprocket and Chains ............................................................................................................... 31
4.2.6. Shaft, Swing Arm, and Spring.................................................................................................. 31
4.2.7. Grindstone .............................................................................................................................. 32
Chapter 5 Cost Estimation........................................................................................................................ 33

5.1. Cost Introduction ........................................................................................................................... 33

5.2. Cost Evaluation .............................................................................................................................. 33
Chapter 6 Enclosure ................................................................................................................................. 34

6.1. Conclusion ...................................................................................................................................... 34

6.2. Suggestion ...................................................................................................................................... 34
Appendix................................................................................................................................................... 35

Drawing..................................................................................................................................................... 36

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 Table of Pictures

Figure 1.1. Mechanical design flowchart ........................................................................................... 9

Figure 2.1. Knife sharpener mechanism .......................................................................................... 10
Figure 2.2. Feeding mechanism ...................................................................................................... 11
Figure 2.3. Projected view of feeding mechanism (front and side) ................................................... 12
Figure 2.4. Feeding Mechanism (isometric view) ............................................................................. 13
Figure 2.5. Upper position of gear rack ........................................................................................... 14
Figure 2.6. Down position of gear rack............................................................................................ 14
Figure 2.7. Mechanism of rack gear ................................................................................................ 15
Figure 3.1. Top View ...................................................................................................................... 20
Figure 3.2. DAK Engineering’s Spur Gear Calculator......................................................................... 21
Figure 3.3. Geometry factors J for straight bevel gears .................................................................... 24
Figure 4.1. Casing........................................................................................................................... 29
Figure 4.2. Spur and Bevel Gear...................................................................................................... 30
Figure 4.3. Crank ............................................................................................................................ 30
Figure 4.4. Feeding Mechanism Tools ............................................................................................. 31
Figure 4.5. Household Knife Sharpener System ............................................................................... 32

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 Table of Tables

Table 3.1. Dimensional calculation table......................................................................................... 19

Table 3.2. Parameters for bevel gear bending stress ....................................................................... 23
Table 3.3. Bevel gear bending stress calculation ............................................................................. 24
Table 3.4. Mechanical properties for acetal delrin .......................................................................... 25
Table 3.5. Specification for delrin acetal spur gear .......................................................................... 26
Table 3.6. Specification for delrin acetal bevel gear ........................................................................ 27
Table 5.1. Cost Estimation .............................................................................................................. 33

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 CHAPTER I

INTRODUCTION

1.1. Background (OKY)

Knife is one of the tools that are still used up to this day in history of human life.
During the prehistoric time, human used axe as knife to meet the necessities of human
beings. Even today, when the world filled by modern technology, human still use knife.
From that, we just know that the existing of knife is so necessary.

But, as is known, the sharpness and the effectiveness of knife will be decreased
by the time. In order to prevent it, we use a knife sharpener to restore the sharpness of
knife.

A grindstone can process the higher hardness materials, such as hardened steel,
carbide and also process brittle materials such as glass, granite. Grinder can carry out
High-precision grinding and a small surface roughness grinding , also carry out high-
efficiency grinding, such as strong grinding. Therefore, a grinder should be made of
materials that have properties of high hardness, such as sandstone.

Sandstone is a sedimentary rock primarily composed of sand-size mineral or

rock grains. Most sandstone is formed by quartz or feldspar because the minerals are
most numerous in the skin of the earth. Sandstones are resistant to the weather but it is
easy to be formed. In addition, because of the similarity measure of hardness and grain
size, sandstone became very good material to be made into a whetstone (grindstone) and
it is used to sharpen knives and many other purposes.

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1.2. Problem Identification (OKY)

At this time, there are many types of knife sharpener, from the mechanism of work, we
can classify them into two types, manual and automatic. Manual sharpener is cheaper
than automatic sharpener. They need human power to sharp the knife. Meanwhile,
automatic sharpener work more practical than manual sharpener. They using electric
power to drive their components and then sharp the knife. In fact, there is no a sharpener
has been found that can work practically but not expensive.

Start from that, we try to find a technological solution that can solve this problem. And
finally, we have an idea to make a sharpener that created by two expected element from
two type of sharpener, cheap and practically.

1.3. Assignment Purpose (PRP)

Purpose for writing this report is:

1. Complete the assignment of Fundamental of Mechanical Design (MS 4101)
2. Share knowledge about household knife sharpener machine
3. To create a design alternative for household knife sharpener machine that is easier to
use and more energy efficient

1.4. Assignment Benefit (PRP)

1. To know the process of designing a tool and how to analyze

2. To determine the factors that must be considered in designing a tool
3. Recall again about the courses that ever taken
4. Gain more knowledge that we never get in the class
5. Applicate our knowledge to solve problems, especially in this assignment

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1.5. Research Methodology (OPM)

We explore the topic and design the tool by some kind of methods like literature study,
interview, and group discussion.

1.6. Working Diagram Schematic (OPM)

The guideline for mechanical design is showed at mechanical design flowchart below:

START

DESIGN PROBLEM

BRAINSTORMING

GATHER INFORMATION AND DATA

FIND ALTERNATIVE SOLUTIONS

CHOOSE THE DESIRED SOLUTION

ANALYZE AND SYNTHESIZE DESIGN, SUCH AS STRENGTH OF MATERIAL,

MATERIAL SELECTION, PRODUCTION PROCESS

SATISFYING
NO
SOLUTION

YES

DESIGN DETAILS

PRODUCTION, TESTING, AND PROTOTYPE

DEVELOPMENT

FINISH

Figure 1.1 Mechanical design flowchart

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 CHAPTER 2

DESIGN REQUIREMENT AND OBJECTIVE

2.1. Design (OPM & PRP)

2.1.1. Introduction

The selected design in the design of this tool is to use a mechanical drive gear ratio and
uses a swing arm mechanism and the mechanism back and forth on the knife holder.
This design uses millstone for sharpening knives. This design uses alternating
mechanism on the handle of a knife that is expected to facilitate the use of this tool in
sharpening knives. The use of swing arm aims to be pressing millstone surface so as to
hone the knife blade properly.

2.1.2. Household Knife Sharpener Machine Design

Figure 2.1. knife sharpener mechanism

Power from the hand of the operator use to move crank. Transmitted power from the
crank are divided to the two mechanisms, cutting mechanism and feeding mechanism.

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cutting mechanism consists of a combination of spur gear and bevel gear, also pulley
and belt. This is done to turn the grinding speed becomes much higher than the
rotational speed of human hands.

For feeding mechanism can be seen more clearly in the picture below.

Figure 2.2 feeding mechanism

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With the top and bottom teeth then the feeding motion that will occur is back and forth,
while the input is one-way move. Rack gear connected to the iron rod on it. The iron rod
is floating and can move freely against the cylinder casing. This mechanism is inspired
from the in and out mechanism on retractable pen. Below is the overall picture motion
feeding mechanism.

Figure 2.3. projected view of feeding mechanism (front and side)

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Figure 2.4. Feeding mechanism (isometric view)

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 Figure 2.5. Upper position of gear rack

Shown in the picture above the teeth are in a “upper” position. In this condition the knife
(the workpiece) will move forward to the grindstone. Whereas in the picture below is the
condition where the teeth was downstairs. In this case the knife will move back away
from the grindstone.

Figure 2.6. Down position of gear rack

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The declining of rack gear can occur because the elastic rod support colliding with a
casing so that no components that support the rod in the cylinder, consequently the gear
rack will going down.

While the rising mechanism of rack gear can be seen in the picture below.

Figure 2.7. Mechanism of rack gear

Forward movement desired if the tip of the knife has reached the point of grinding. In
this condition there is no longer a pressing force to the spring (because the knife is
backwards), then the potential force of the spring will push the gear rack up, so the gear
rack would be supported by the elastic support again, and also knives will eventually
move forward. Then the cycle will be repeated until the knife sharpened, then the
grinding will stop. Due to the gap between the grinding stones are larger than the blade
thickness.

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2.2. Requirement & Objective (OKY, PRP, & OPM)

Must criteria:

• Can be use to sharpen various types of knives

• Portable

• User friendly

Wish criteria:

• Price should be less than Rp. 500.000,-

• 1 Year life time

• Low weight

• Sharpening process less than one minute

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 CHAPTER 3

CALCULATION FOR SAFETY AND FUNCTIONALITY

3.1. Safety Introduction (OKY)

Safety means freedom from danger, risk, or injury. But, to keep human stay safe from so
many things that could go wrong, they have to be aware because an accident is any
unforeseen or unexpected event that may or may not result in injury or damage to
property or equipment. Educating our self and others about safety issues will not only
keep accidents to a minimum, it will help to save lives. We can do more to protect our
self by constantly thinking and practicing accident prevention than we can by
memorizing all of the rules, regulations, and safeguards ever written or invented. We
must think before we act.

The criteria that’s usually used to represent a machine safe or not, is safety factor.

To achieve condition, minimum safety factor is bigger than one.

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3.2. Component Safety Evaluation (PRP&OPM)

3.2.1. Gear Literature

Gears are machine elements that transmit motion by means successively engaging teeth.
Gears are used to transmit torque and angular velocity in a wide variety of applications.
There are several characteristics of gear:
a. Power transmition
b. Increasing or decreasing torque
c. Increasing or decreasing speed
d. Constant velocity ratio
e. No slip
Gears also have several basic equations that can be used to its analysis, they are:
a. Torque (T)

b. Power (P)

c. Gear Ratio (MG)

Where : NG = Number of teeth on gear

NP = Number of teeth on pinion
d. Module (m)

Gear and pinion have to have same module.

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3.2.2. Gear Calculation

F hand (F) 50 N calculation

r crank ( r ) 0.15 m iteration
6.28318
ω hand (60rpm) 5 rad/s data

specific energy J/mm

3
(u) 68
mm3/
Material Removal Rate=d.w.v 0.6 s
depth of cut (d) 0.005 mm power required=MRR.u 40.8 Watt
width of cut (w) 30 mm
47.1238898
feed rate (v) 4 mm/s power generated=F.r.ω 1 Watt

diameter grind
(d) 0.15 m power grind=d/2.ωg.Ft.2 41.4 Watt
ω grind (ωg) 92 rad/s
F tangential (Ft) 3 N F thrust =1.3Ft 3.9 N
Rotational speed ratio 14.6422547
r gear 1 6 cm =ωgrind/ωhand 6
1.63909181
D bevel 2 1.2 cm r gear 2 9 cm
D bevel 1 4.8 cm
Table 3.1 dimensional calculation table

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 Figure 3.1. Top view

In the first calculation above obtained Material Removal Rate (MRR). With the MRR for the
specific energy and 68 J/mm3 (steel), then get the power needed for grinding operations with
these parameters. Grinding power is used for iteration, thus obtained dimensions and parameters
for grinding.

From the data power and rotational speed of human hand with radius selection of bevel and gear
1, then obtained the gear radius of 1.5 cm 2. Thus calculations using rotational speed ratio.

Calculation of tension in the Spur gear

(mm)

(mm/s)

AGMA bending Stress:

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For bending stress calculation we use the software “DAK Engineering’s Spur Gear Calculator”:

Figure 3.2. DAK Engineering’s Spur Gear Calculator

The results of the calculation from software that can be used for the analysis is:

Power transmitted by the gear pair =6.300268E-02 Hp

Rotational speed of the pinion =225 RPM

Rotational speed of the gear =870.968 RPM

Velocity ratio of the gear pair =0.258

Diametral pitch =12

Number of teeth the in the pinion =120 teeth

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Number of teeth in the gear =31 teeth

Center distance =6.292 inches

Pitchline speed =589.04 feet/min

Transmitted load on the teeth (Wt) =3.53 lb

Torque on pinion shaft =17.65 in-lbs

Face width =0.35 inches

Dynamic factor Kv =0.830

Application factor Ka =1

Load distribution factor Km =2

Enclosure type =Open

Size factor Ks =1

Rim thickness factor Kb, pinion =1

Rim thickness factor Kb, gear =1

Geometry factor J, pinion =0.452

Geometry factor J, gear =0.398

AGMA quality number =8

Computed stress in pinion teeth =645 PSI

Computed stress in gear teeth =732 PSI

Computed contact stress on the teeth =18,531 PSI

The standard method for determining induced bending stresses in bevel gears comes from the
American Gear Manufacturers Association and is based on the equation below.

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Symb Notes / How can we simplify these terms for static loading of
Name
ol normal gears
σ Max bending Compare to gear material strength to determine if the gear will
stress in tooth break
Transmitted Taken at large end of tooth
Wt tangential load
Application Accounts for probability of greater-than-design-load occurrences.
Ka factor This is not something we expect, so neglect this, and set Ka = 1
Accounts for dynamic effects and velocity of tooth contact. For
Kv Dynamic factor static loading, which is an assumption we will make, since we are
dealing with relatively low speeds, neglect this term,and set Kv = 1
P Diametral pitch N/D
F Face width
Accounts for unusually sized gears. Not applicable for normal
Ks size factor gears. Set Ks = 1
Load-
distribution Accounts for shaft misalignment and shaft bending. Build your
Km factor gearbox carefully, so you can neglect this term and set Km = 1.
Geometry factor Similar to Lewis form factor used for spur gears. Obtain from chart
J
based on number of teeth on gear and pinion.
Table 3.2. Parameters for bevel gear bending stress

After setting those factors that do not apply to 1 (see notes above), we can come up with a
simplified AGMA equation.

This equation is highly simplified to allow for fast calculation with minimum table look-ups. It
is not for use on critical applications, high speed gears, or gears of unusual materials.

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 Figure 3.3 Geometry factors J for straight bevel gears.

Preliminary calculations obtained for pinion gear ratio is 4:1. We use a pinion teeth 40 and gear
teeth 10 following the calculation of bending stress for the bevel gear.

Pinion
P 1 σ 33.71593 kPa
F 8.2 mm
J 0.17
Wt 47 watt

Gear
P 1 σ 24.92047 kPa
F 8.2 mm
J 0.23
Wt 47 watt
Table 3.3. Bevel gear bending stress calculation

From the data calculated above, we can choose materials based on the stress data for the pinion
and gear (gear 1 and gear 2).

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We chose to use a polymer material which is Acetal Delrin. Material properties can be seen in
the table below.

Table 3.4. Mechanical properties for acetal delrin

Can be seen in the table that the ultimate tensile strength of 8000 psi. Compared with the
calculated stress (<1000 psi), it is quite sufficient material to be used. Here are the gear products
that we will use.

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 Table 3.5. specification for delrin acetal spur gear

We will use part No. GR1M120 for pinion and GR1M032 for gear.

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 Table 3.6. Specification for delrin acetal bevel gear

We will use bevel gear pair Part No. GB1M410040 (4:1 Ratio)

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 CHAPTER 4

MAIN COMPONENT MANUFACTURING

4.1 Manufacturing Introduction (OKY)

Manufacturing, in its broadest sense, is the process of converting raw material into some
product. There are many things that affect the process of manufacturing a product. The
things that affect the process of manufacturing a product include product design,
component of these products, the selection of raw materials, and intended use of these
products.

The more complicated the design then the manufacturing processes will be more
difficult. So is the component where the more components are used for a product also
requires more manufacturing process. Moreover, the selection of raw materials and
intended use of these products also affect the manufacturing process.

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4.2. Main Component Manufacturing and Assembly (PRP & OPM)

4.2.1. Casing

Figure 4.1 Casing

To reduce the total mass of the tool is then we used casing made of plastic material. This
is because the chassis does not need a very strong material and plastic material has
another advantage that is easy to set up and the price is cheap and also lightweight. The
process of manufacture for casing is by molding in accordance with the desired.

4.2.2. Bevel Gear and Spur Gear

After calculating the stress, then by adjusting the availability of gear on the market, we
choose a gear with Delrin Acetal material. This material selection is based on the need
to reduce manufacturing costs for gears and reduces the total mass of this product.

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 Figure 4.2. Spur and Bevel Gear

4.2.3. Crank

Figure 4.3. Crank

This crank-making process by using the casting and the forming and. After that use
surface finishing.

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4.2.4. Feeding Mechanism Tools

Figure 4.4 Feeding mechanism tools

For feeding mechanism tools, the manufacturing processes there are variety. Gear rack
systems using milling process. In the connecting rod using C45 steel with milling
process. So is the cradle using the same process and using welding and bolt for
connections.

4.2.5. Sprocket and chains

Manufacturing process for sprocket is hobbing. For chain we use standard chain.

4.2.6. Shaft, swing arm and spring

Manufacturing process for swing arm and shaft is milling from C45 plate steel material.
For spring we use standard spring with appropriate stiffness.

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4.2.7. Grindstone

For grindstone we use the grind stone that has been sold commercially.

Figure 4.5. Household knife sharpener system

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 CHAPTER 5

COST ESTIMATION

5.1 Cost Introduction (OKY)

In business, retail, and accounting, a cost is the value of money that has been used up to
produce something, and hence is not available for use anymore. In economics, a cost is an
alternative that is given up as a result of a decision.[1] In business, the cost may be one of
acquisition, in which case the amount of money expended to acquire it is counted as cost.
In this case, money is the input that is gone in order to acquire the thing. This acquisition
cost may be the sum of the cost of production as incurred by the original producer, and
further costs of transaction as incurred by the acquirer over and above the price paid to the
producer. Usually, the price also includes a mark-up for profit over the cost of production.

Costs are often further described based on their timing or their applicability.

5.2 Cost Evaluation (OKY)

Component Price (IDR)

Gear box 200,000
Pulley 50,000
Belt 10,000
Shafts 100,000
Plastic Casing 50,000
Gerindstone 20,000
Bearing 60,000
Spring 12,000
Sprocket 60,000
Chain 40,000
Welding service 50,000
Bolts and nuts 8,000

Total 660,000
Tabel 5.1 Cost estimation

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 CHAPTER 6

ENCLOSURE

(OKY,PRP &OPM)

6.1 Conclusion
1. From the design, we conclude that this mechanism is very complicated. But
relatively cheap and have auto feeding mechanism.
2. This design can sharpened a regular blunt knife for approximately one minute.
3. From our estimation, the price of this design is Rp 660.000

6.2 Suggestion
1. Gear system is not the best design for knife sharpener. So that the others design have
to reconsider.
2. For increasing the efficiency of the system, we suggested for using electrical system.
3. To improve the endurance and reliability of the design, we suggested to reconsider
the material and dimension of the system.

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 APPENDIX

- Callister. 2001. Material Science and Engineering. McGraw-Hill: Singapore.

- Dieter, G. E. 2000. Engineering Design. McGraw-Hill: Singapore.
- Kalpakjian, Serope. 2000. Manufacturing Engineering And Technology Fourth Ed.
Singapore: Addison Wesley Longman
- Norton, Robert L. 2003. Machine Design “An Integrated Approach”.
Prentice Hall : New Jerse
- Shigley, Joseph Edward. 2004. Mechanical Engineering Design Seventh Ed. Singapore:
McGraw Hill

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DRAWINGS

(PRP & OPM)

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