Full Cone is a very common shape in fabrication industry as it is most frequently used shape in fabrication so it is very necessary that every fabrication engineer or professionals in fabrication field must have knowledge of Cone layout Development if you have detailed knowledge of cone fabrication it is very useful to you while working in fabrication daily activities. So, in this post, we are covering all the Points related to Full Cone Layout Development so that you can learn in-depth and used this method in daily fabrication activity.

We are going to explain this Cone layout in both Geometrical and Numerical Methods and at the end of learning this method, we have taken one practical Example of Full Cone Fabrication Layout Development to understand the use of this method for layout Development. We had also provided you example solution checking method using our Fabrication Calculator tool so that you can verify your calculation with some tested tools and make you confident in the fabrication layout. You can practice this method by taking more examples yourself and verify your answer by our tools and become an expert in Full Cone Fabrication Layout Development.

Geometrical Method or Marking Method for Full Cone Layout

Geometrical Method of Full Cone Fabrication Layout Development is also called Graphical Method of Full Cone Layout Development, in this layout, Method layout markings are developed using direct measuring of the Geometrical shape of Full Cone. This Method is Basic Method for fabrication Layout but it required much time to draw the Geometry of actual size and it also has limitation for Bigger Sizes to avoid this limitation you have to use computerized tool Such as Auto Cad Software and to the developed layout using this software also required skilled manpower to generate layout it cost us more in terms of extra skilled manpower and extra time for drawing layout. If the fabrication layout shape is complex then it is not economical. Now, we will move towards learning Full Cone Fabrication Layout Development using Geometrical Method in Step by Step process.

We recommend you that always use mean dimensions for Fabrication layout development it gives more Accuracy of fabrication Layout Marking Compared to Outside or Inside Dimensions.

Step 1: Draw Elevation View & Plan View for Full Cone Shape.

Step 2: Divide Top View Circle of Cone in equal no. of Parts.

Step 3: Measure Slant Height of the Cone in elevation view.

Step 4: Draw Development Circle with Radius as Slant Height.

Step 5: Measure Dividing Distance (L) From the Top view of Divided Circle.

Step 6: Mark the Development Circle with Dividing Distance (L) in to equal no of parts in top view.

Step 7: Trim the remaining part to get layout of the Full Cone.

In this way we can generate fabrication layout of Full Cone using Geometrical Method or Graphical Method of Fabrication Layout Development.

Numerical Method or Calculation Method for Full Cone Layout

Numerical Method for Full Cone layout Development is a very faster and time-saving method for layouting, you can calculate the values of layout dimension by solving manually on a scientific calculator or you can use any computerized tool for solving such as MS Excel or any other tool for Calculates Values in a faster way.

Now we will move towards learning Numerical Method for Full Cone fabrication layout development in this Method We are Discussing Two Cases for Layout Development.

Case 1: Cone Angle and Cone Diameter Given

Step 1: Define Generalized Diagram of Full Cone Layout Development.

Step 2: Define Variables for Full Cone Layout.

Let,

D = Base Mean Diameter of Cone.

α = Cone Angle

β = Cone Included Angle.

R = Development Radius.

Θ = Development Angle.

X = Cone Cord Length.

Step 3: Calculate Development Radius R of Full Cone.

If α is given then,

R = ( D/2 ) / Cos (α)

If β is given then,

R = ( D/2 ) / Sin (β/2)

Step 4: Calculate Development Angle Θ.

Θ = ( (D/2) / R ) x 360

Step 4: Calculate Cone Cord Length X

X = 2 x R x Sin (Θ/2)

Step 5: Development of Cone Layout.

In this way we can develop fabrication Layout when we had problem like case-1 where Cone angle and Cone Diameter is Given. Now we will see Case-2 type problem of fabrication layout Development.

Case 2: Cone Diameter and Cone Height Given

Step 1: Define Generalized Diagram for Full Cone Layout Development.

Step 2: Define Variables for Full Cone Layout

Let,

D = Base Mean Diameter of Cone.

H = Cone Height.

R = Development Radius.

Θ = Development Angle.

X = Cone Cord Length.

Step 3: Calculate Development Radius R.

R = √ ( H² + (D/2)² )

or

α = Tan^-1 ( H / (D/2) )

R = ( D/2 ) / Cos (α)

Step 4: Calculate Development Angle Θ.

Θ = ( (D/2) / R ) x 360

Step 5: Calculate Cone Cord Length X.

X = 2 x R x Sin (Θ/2)

Step 6: Development of Cone Layout.

So, by using Numerical Formulae you can generate fabrication Layout Development of Full Cone in a very faster and efficient way.

 In the above Two Methods, we learn How to Layout Full Cone Using Geometrical and Numerical Methods, now we will see one Practical Example Solution Using Numerical Method so that we can understand in better layouting by practicing it Practically.

Practical Example Solution by Numerical Method or Calculation Method

Example: Generate Fabrication Layout Development Markings of Full Cone for Following Sizes:

Solution:

Step 1: Note Down the Given Data of the Example.

Given Data:

D = 500

H = 750.

Step 2: Calculate Development Radius R

R = √ ( H² + (D/2)² )

R = √ ( 750² + (500/2)² )

R = √ ( 562500 + (62500) )

R = 790.56 mm.

Step 3: Calculate Development Angle Θ.

Θ = ( (D/2) / R ) x 360

Θ = ( (500/2) / 790.56 ) x 360

Θ = 113.84 Degree.

Step 4: Calculate Cone Cord Length X.

X = 2 x R x Sin (Θ/2)

X = 2 x 790.56 x Sin (113.84 / 2)

X = 1324.84 mm.

Step 4: Mark Development Layout Using Above Dimensions.

This is Final Fabrication Layout Markings of Full Cone for Given Example solved by using Numerical Method. You have practice this method to become master in this type of layout and after practicing you will have confidence in your layouts and in the latter part after becoming expert you reduce your work by using the method with the help of computerizes numerical tools, for increase your accuracy and save the time of calculations.

Now we will see this example Solution checking process so that you can be assured about your calculation and verify your result with some standard tested reference.

Example Solution Checking for Full Cone Layout using Fabrication Calculator

We are providing this example solution Checking Method to you so that you can easily verify your calculated values with some standard tested tool so that become more confident while layouting and easily practice using this method till you become an expert in layouting by Numerical method. We had already tested is Tool with advanced Computer Tool so that you can trust this tool and become more accurate in calculating values.

Now we will see the example solution checking Method, First You have to Download our Mobile Application from Our Website or Google play store or Apple App Store.

Download Links for Our Fabrication Calculator App :

Fabrication Calculator App from Our Website.

Fabrication Calculator App from Google Play Store.

Fabrication Calculator App from Apple App Store.

Solution Checking Process: Download above Mobile Application to your mobile check example Result Values with App results in Value. Follow below Steps of Checking Solution of Full Cone Layouts we had also added Screen Shots for Better Understanding of this Checking Methods.

Step 1: Select Full Cone Option from Application Home Screen as shown in the below image for step 1.

Step 2: Enter Input data of Cone Diameter as 500 mm and Cone Height as 750 mm in the input Fields and Press Calculate Button as shown in the below image of step 2.

Step 3: Check Result Values with your Calculated Values if your calculated values Match with this Result Page Value then you are correct if your values are not matching with result page values then recheck your calculation and Find out Correct values for Accurate Result. Refer to step 4.

In such a way that You can check your Result by using this Fabrication Calculator App, you can also check using any methods you known. We are using this method we had already tested the result of this app so we are testing our result using this application.

Now, we learn all Cone Layout development process using all methods, similarly if you want to learn fabrication layout development of all fabrication shapes in detailed then you can join our 70 days Video Course on Fabrication Layout Development Click here to Know Course Details.

If you are working in the field of fabrication then we have simplified your day to day fabrication activity by developing various calculators so that you can minimize your time and cost of fabrication also increase the accuracy of your fabrication works and improve your workmanships, so let’s try our free apps, Click here for more details…

If you want to learn fabrication layout or flat pattern layout development of various fabrication shapes by your own then you can buy our book “Master in Fabrication Layout Development “ or Click here to learn about our books.

We hope you learn all methods of cone layout development in all aspects.

The post Cone Layout Development by Marking and Calculation Method with Practical Example appeared first on Let'sFab.

Agitation is a means mixing of phases can be accomplished and by which mass and heat transfer can be enhanced between phases or with external surfaces. the process of mixing is concerned with combinations of phases.

1. Gases with gases.
2. Gases into liquids such as dispersion.
3. Gases with Granular solids such as fluidization, pneumatic conveying, drying.
4. Liquids into gases such as spraying and atomization.
5. Liquids with liquids such as dissolution, emulsification, dispersion.
6. Liquids with granular solids such as suspension.
7. Pastes with each other and with solids. 8. Solids with solids such as mixing of powders.

Hydraulically, mixers behave like pumps. Mixing applications can be either a batch or a continuous process. Although the terms agitation and mixing are often used interchangeably, there is a technical difference between the two.

Agitation creates a flow or turbulence as follows:

1. Mild agitation performs a blending action.
2. Medium agitation involves a turbulence that may some gas absorption.
3. Violent agitation creates emulsification.

Mechanical mixers are used as follows:

1. To mix two or more no homogeneous materials.
2. To maintain a mixture of materials that would separate if not agitated.
3. To increase the rate of heat transfer between materials.

Mixers are Designed to achieve one of the following.

• Blending: combines miscible materials to form a homogeneous Mixture.
• Dissolving: the dissipation of a solid into a liquid.
• Dispersion: the mixing of two or more non-miscible materials.
• Solid Suspension: suspends insoluble solids within a liquid.
• Heat Exchange: promotes heat transfer through forced convection.
• Extraction: separation of a component through solvent Extraction.

Agitator or Mechanical Mixer usually consists of a shaft-mounted Impeller connected to a drive unit.

General Arrangement of Industrial Agitators or Mixers:

Typical arrangement of agitator is shown in above has consist of Dished Vessel, Stirrer, Cooling Coils, Baffle plate, Foam breaker, Seal, Bearing assembly, Gear Box, Motor Drive.

Selection of an efficient agitation depends on Nature of Liquids, Operating Condition, intensity of circulation and shear. Factor to be considered are Type of agitator, Circulation pattern, Location of agitator, Shape and size of the tank, Diameter and Width of agitator, Method of baffling, Power required for Agitation, Shaft Over hang, Types of Stuffing box,, Seal, Bearing, Drive System etc.

Terminology Used in Industrial Agitator or Mixer:

• Agitator: The assembly consisting of impeller, impeller shaft and drive including other parts such as gland, and bearing used in conjunction with the above.
• Impeller: The actual element which imparts movement to the charge (fluid).
• Propeller: A high speed impeller which essentially imparts axial thrust to the fluid.
• Turbine: An impeller with essentially constant blade angle with respect to a vertical plane, over its entire length or over finite sections, having blades either vertical or set at an angle less than 90” with the vertical.
• Paddle: – An impeller with four or fewer blades, horizontal or vertical, and essentially having a high impeller to vessel diameter ratio.
• Anchor: Basically a paddle type impeller which is profiled to sweep the wall of the containing vessel with a small clearance.
• Baffle: An element fixed inside the vessel to impede swirl.
• Draught Tube: A tubular fitting which is arranged to direct the liquid flow produced by the impeller.
• Filling Ratio: The ratio of liquid depth in the Vessel to Vessel Diameter.
• Swirling: The Continuous Rotation of liquid about a Fixed Axis.
• Vortex: A depression in the surface of a liquid produced by swirling.
• Fully Baffled Condition: A condition when any further increase in baffling causes no significant increase in power consumption, this may be considered as a state where the liquid swirl in the vessel has become negligibly small and when all the power input to the impeller expended to create turbulence.

General Guideline of Mixers or Agitators

1. All mixers/agitators rotate clockwise.
2. 2. In general, agitators are sized on the basis of the required torque per unit volume. Other factors that affect size and torque are:

• Viscosity > 100 cP (viscosity can affect blend times).
• Critical speeds.
• Tip speed.
• Impeller diameter.
• The required degree of agitation

3. Each shaft is designed for mechanical loads and critical shaft speed. Motor size and shaft design are related. A larger shaft to take the torque will require more horsepower to eliminate wobble.

4. To prevent solid buildup on the bottom, a radial-blade impeller may be used. If elected, then place the blade one blade width off the bottom.

5. Power consumption:

• Operating speed is back-calculated to ensure delivery of the proper power for a given impeller diameter.
• The speed and horsepower define the torque required for the system. The torque in turn sets
• the shaft size and gear box size.
• Impeller power consumption determines the horsepower and impeller diameter required for a given mixing process.

6. Mixing parameters:

• Shaft angle.
• Time.
• Impeller type and diameter.
• RPM (pumping capacity).
• Power.
• Viscosity, specific gravity.

7. A steady rest bearing may be utilized at the bottom of the tank if the mixing application allows.

8. Other applicable data:

• Types of seals or packing.
• Metallurgy.
• Drain location.
• Man way size.
• Indoor/outdoor.
• Mixed agitator run times.
• Head room required above tank.

This all above are the basics of Industrial Agitator or Mixer.

If you are working in the field of fabrication then we have simplified your day to day fabrication activity by developing various calculators so that you can minimize your time and cost of fabrication also increase the accuracy of your fabrication works and improve your workmanships, so let’s try our free apps, Click here for more details…

If you want to increase your knowledge by learning from us then you can join our various video course in the field of fabrication, Click here for more details.

The post Basics of Industrial Agitators or Mixers appeared first on Let'sFab.