DESIGN, DEVELOPMENT, AND EXPERIMENTAL INVESTIGATION OF A PORTABLE MULTI-BLOCK MAKING MACHINE

Abstract

This thesis presents the design, development, and experimental investigation of a Portable MultiBlock Making Machine, aimed at overcoming the limitations of existing single-block and multiblock machines. The innovative design combines portability with high output efficiency and reduced energy consumption, making it suitable for small to medium-scale manufacturers in diverse construction environments. The developed prototype demonstrates the capability to produce five hollow cement blocks simultaneously, adhering to industry standards for block quality and structural integrity. Finite Element Analysis (FEA) was employed to validate the structural reliability and production efficiency of the machine. Key findings from the FEA indicate that stress distribution, displacement, and strain levels remain well within acceptable limits. The von Mises stress analysis confirms that all components experience stress values significantly below the yield strength of ASTM A36 mild steel, ensuring that the machine operates within the elastic deformation range, thereby preventing permanent failure. Additionally, the displacement analysis reveals minimal deformation across all structural components, indicating robust mechanical stability during operation. The strain analysis further validates effective stress distribution, demonstrating that material selection and design choices mitigate localized strain concentrations, enhancing overall durability. The Factor of Safety (FOS) analysis provides a minimum safety margin of 1.5, reinforcing the design's compliance with industrial safety standards and its ability to withstand operational loads. The successful fabrication and testing of the prototype confirm that the Portable Multi-Block Making Machine offers a high-output, energy-efficient alternative to conventional block-making methods, significantly improving productivity and lowering operational costs. Looking ahead, future enhancements should focus on fatigue analysis, structural reinforcement in high-stress areas, and optimization of mold alignment to further boost efficiency and lifespan. The integration of automated control systems and renewable energy sources could also enhance sustainability and operational flexibility.