Proposed Design Analysis of Manual

Molding Machine and Effect of Firing

Temperature and Composition to the
Mechanical Properties
of Fly-ash and Rice Husk-ash Paving Brick

Project Leader:

Presented by: Dr. Liezl M. Jabile

Dave Raphael A. Dumanat Adviser

John Paul M. Relacion Researchers:

BSME – 5A_M1 Consorcio S. Namoco, Jr., Dr.Eng’g

Engr. Jeffrey Ken B. Balangao

 Statement of the Problem

 Large amount of Fly-ash has been produced from the coal-fired in power
plant as waste.

 Philippines, produces 2 million tons of Fly-ash every year.

 Rice husk is generated as waste in agricultural and industrial

procedures in millions of tons per year.
Fly-ash and Rice Husk-ash Paving Brick

Fly-ash Rice Husk-ash

+ Batching

Mixing Water

Molding Unit

=
Fly Ash
Rice Husk Ash
Curing

Drying

Firing

Testing

Final Product
Product
DESIGN ANALYSIS AND DEVELOPMENT OF
A MANUAL BRICK MOLDER MACHINE
FOR
FLYASH AND RICE HUSK ASH PAVING BRICK

Presented by:
Dave Raphael A. Dumanat
Statement of the Problem

 Molder paving brick machines are made by massive and valuable

machine, that this study aims to manufacture a medium – scale,
economical and manual paving brick machine.
OBJECTIVES FOR THIS STUDY

This study generally aims to manufacture a medium – scale, economical

and manual paver brick machine for pedestrian and light traffic application.
It aims in particular for the following objectives:

To design and simulate a manually operated brick

molder machine that uses the mixture of fly ash and
rice husk ash.

To test the molder brick machine that can produce

cube sizes for testing purpose and selected
industrial size of brick at single pressing operation.
THE DESIGN: MANUAL BRICK MOLDER MACHINE

TOPVIEW

ISOMETRIC - FRONT VIEW

ISOMETRIC - BACK VIEW SIDE VIEW BACK VIEW
Motion Study: Animation

Replace the Molder and Compacting Head Molding Motion

THE DESIGN: MANUAL BRICK MOLDER MACHINE

Close up View Brick Size

THE DESIGN: MANUAL BRICK MOLDER MACHINE

Close up View Testing Size

 Concept Design

Design Parameters

Design Requirements

Design Calculation
NO

DESIGN FLOW CHART

Flow Simulation

Proceed to the
expected outcome?

YES

Ready for Fabrication

THEORETICAL FRAMEWORK

Design of the Mold Tension

(Mogaji, 2011) (Faires, 1964)

This determines the volume of the brick: There are two (2) vertical round bars that will support the
compression of the feedbox and compacting head plate.
The compression load applied by the hydraulic
𝑉 =𝐿𝑥𝐵𝑥𝐻 (Eq. 1.1) mechanism is distributed to the supports that will
experience tensile stress.
𝐹
Where: L = length; B = breadth; H = 𝑠𝑡 = (Eq. 1.2)
𝐴𝑡
Where: 𝑠𝑡 = Tensile stress; 𝐹 = force applied; 𝐴𝑡 = Area
height. The brick shape normal to the force applied
𝑠𝑢𝑡
Based on the ultimate stress, 𝑠𝑑𝑡 = (Eq. 1.3)
𝑁𝑠𝑢
Where: 𝑠𝑢𝑡 = ultimate tensile stress
𝑁𝑠𝑢 = design factor for ultimate strength
THEORETICAL FRAMEWORK

Bending stress
Static Fluid Pressure (Vaishnav, 2016)

𝑃𝑠𝑡𝑎𝑡𝑖𝑐 𝑓𝑙𝑢𝑖𝑑 = 𝜌𝑔ℎ (Eq. 1.5) When a static or dynamic load act on any part of the
hydraulic press, along with simple tensile, compressive, and
Where:
shear stress, it also develops bending stress. Consider a
𝜌 = m/V = Fluid density; beam subjected to a bending moment M, the bending
equation is given by,
𝑔 = acceleration gravity; M 𝜎𝑏
= (Eq. 1.6)
I 𝑦
ℎ = depth fluid Where: M = Bending moment at the given section
𝜎𝑏 = Bending stress
I = Moment of inertia of the cross section about the neutral
axis
y = Distance from the neutral surface to the extreme fiber
METHODS

Design Concept Design Parameters

• Molding Unit • Size - The size of the block/brick for this design is 110mm x

• Machine Frame 210mm x 60mm and for testing size is 2 in x 2 in 2 in;

• Compacting Head and Head Plate • Pressing - During pressing operation, the pressure applied

can affect the strength of the brick. The designed pressure is

• Molder
𝒌𝒈 𝒌𝒈
• Feed Box 5-10 MPa or 51 – 101.97 (Lin, 2006).
𝒄𝒎𝟐 𝒄𝒎𝟐

• Feed Box Lever • Time - The designed time for pressing the paving brick is 5-10

• Threaded-End Shaft min.

METHODS

FLOW SIMULATION

Software use: SolidWorks 2017

• Finite Element Analysis (FEA)

• Structural Analysis

• Mass Transport

• Stress Analysis – Measure Stresses,

Strains, and Displacements

Partial Stress Analysis (Brick Size)

Compacting Head (Cast Carbon Steel) Molder(Cast Carbon Steel)

Partial Stress Analysis (Testing Size)

Compacting Head (Cast Carbon Steel) Molder(Cast Carbon Steel)

ESTIMATED COSTS
Specs. No. Item Description Price Quantity Total Price (Php)

1 Hydraulic Jack 10 tons 1,630.00 1 1,630.00

2 Square Tube 40mm x 40mm x 4mm 1,625.00 21ft 3,790.00

(9ft Length)

3 Rectangular Tube 50mm x 30mm x 2.6mm 1,350.00 10ft 1,500.00

(9ft Length)

4 Cold Rolled Shafting 1.5 in. dia. x 9 ft. 1,930.00 5ft 1,100.00
1.0 in. dia. x 9 ft. 1,290.00 7ft 1,000.00

5 Mild Steel Plate 8ft.x 4ft.x12 mm. 10,950.00 3ft x 3ft 3,080.00
8ft.x 4ft.x10 mm. 8,995.00 4ft x 4ft 4,500.00
8ft.x 4ft.x6 mm. 5,315.00 3ft x 3ft 1,000.00

6 Pressure Gauge 3500 psi (max.) 3,800.00 1 3,800.00

7 Galvanized Plain Sheet 8ft.x 4ft.x1.8 mm. 2,580.00 2.5ft x 2.5ft 1300.00

8 Nut 1.5 in Course 90.00 6 540.00

TOTAL P23,240.00
GANNT CHART
September October November December January February March
Task
Week Week Week Week Week Week Week

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

Design Concept

Calculation and
Simulation

Procurement of
Materials

Assembly and
Fabrication

Testing
 EFFECTS OF FIRING TEMPERATURE AND
COMPOSITION TO THE MECHANICAL
PROPERTIES OF PAVING BRICKS MADE FROM
FLY-ASH AND RICE HUSK-ASH

Presented by:
John Paul M. Relacion
Statement of the Problem

Failure of structures or defects is quite relevant

these days, it came up as a result of sub-standard
cement bricks used in building construction.
OBJECTIVES FOR THIS STUDY
This study aims to determine the mechanical properties of paving bricks
from fly ash and rice husk ash to help the readers evaluate the following
sub-objectives;
To determine the effects of the fly ash and rice husk
ash to the mechanical properties of the paving bricks
in terms of:
 Compressive Strength
 Water Absorption
 Abrasion Resistance
 Saturation Coefficient
To determine the best formulation that is appropriate
for paving bricks application.
THEORETICAL FRAMEWORK

Compressive Strength

𝐹 Where:

Sc = Sc = Compressive Strength (MPa)

F = ultimate load (N)
𝐴 A = area (𝒎𝒎𝟐 )
 THEORETICAL FRAMEWORK

Water Absorption

Where:
%WA= % Water Absorption
𝑤2 −𝑤1 W1 = initial weight
%WA = × 100 W2 = final weight
𝑤1
 THEORETICAL FRAMEWORK

Abrasion Resistance

Where:
%AB= % Abrasion Resistance
𝑊𝑐 Wc = cold water absorption
%AB= × 100 Sc = compressive strength
𝑆𝑐
 THEORETICAL FRAMEWORK

Saturation Coefficient

Where:
DS= Degree of Saturation
𝑀1−𝑀2
DS = Ms = material at saturation state
𝑀𝑠−𝑀2 M1 = wet material
M2 = dry material
 FLOW CHART FOR
TESTING OF PAVING
BRICKS
Methods

Composition Percentages of Raw Materials

Methods

Preparation of Materials

• The fly ash will be acquired at Villanueva, Misamis Oriental, while

the rice husk ash will be acquired at Opol, Misamis Oriental.
Methods

Mechanical Testing

Compressive Strength (ASTM C 109)

Water Absorption (IS 3495)
Abrasion Resistance (ASTM C 902)
Saturation Coefficient (ASTM C 902)
Factorial Design for Mechanical Properties
Single Mold Manual Hydraulic 2”x2” Test Sample

(Calixtro 2018)
ESTIMATED COSTS
Specs. No. Item Description Price Quantity Total Price (Php)

1 Hydraulic Jack 10 tons 1,630.00 1 1,630.00

2 Square Tube 40mm x 40mm x 4mm 1,625.00 21ft 3,790.00

(9ft Length)

3 Mild Steel Plate 8ft.x 4ft.x10 mm. 8,995.00 4ft x 4ft 4,500.00

4 Pressure Gauge 3500 psi (max.) 3,800.00 1 3,800.00

5 Nut 1.5 in Course 90.00 6 540.00

TOTAL
GANNT CHART

August September October November December January February March

Task Week Week Week Week Week Week Week Week

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Research and
Conceptualization

Materials
Gathering

Preparation of
Materials

Manufacturing of
Materials

Testing

Data Analysis

Result Evaluation
 Researchers:

THANK YOU!

Dave Raphael A. John Paul M.

Dumanat Relacion

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