Mini project report

on
Design and Fabrication of Economical Home Lawn Cutter
Submitted in partial fulfilment of the requirement for the award of

Bachelor of Engineering
in
INDUSTRIAL ENGINEERING AND MANAGEMENT
of
Visvesvaraya Technological University, Belgaum
By

Bhograj Prakash 1SI18IM004

Chinmai S Gowtham 1SI18IM007
Milan J Prakash 1SI18IM019
Mohan Kumar NC 1SI18IM020

Under the guidance of

Dr. Jagadeesh P Ganjigatti M.Tech, Ph.D
Professor
DEPARTMENT OF INDUSTRIAL ENGINEERING AND MANAGEMENT
SIDDAGANGA INSTITUTE OF TECHNOLOGY

DEPARTMENT OF INDUSTRIAL ENGINEERING AND MANAGEMENT,

SIDDAGANGA INSTITUTE OF TECHNOLOGY, TUMAKURU-572103
2020- 2021
 SIDDAGANGA INSTITUTE OF TECHNOLOGY
(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi, Approved by
AICTE, New Delhi, Accredited by NAAC with „A‟ Grade, ISO 9001:2015 Certified and Diamond College
Rating QS I-Gauge)
TUMAKURU-572103, KARNATAKA, INDIA
DEPARTMENT OF INDUSTRIAL ENGINEERING AND MANAGEMENT

CERTIFICATE
Certified that the project work entitled “Design and Fabrication of Economical Home Lawn Cutter” is a
bonafide work carried out by

Bhograj Prakash 1SI18IM004

Chinmai S Gowtham 1SI18IM007
Milan J Prakash 1SI18IM019
Mohan Kumar NC 1SI18IM020
in partial fulfillment of the requirement for the award of the degree of Bachelor of Engineering in Industrial
Engineering & Management, Visvesvaraya Technological University, Belagavi during the year 2020-2021. It
is certified that all correction /suggestion indicated for Internal Assessment have been incorporated in the report.
The project report has been approved as it satisfies the academic requirements in respect of project work
prescribed for the Bachelor of Engineering Degree.

Signature of the Guide Signature of the HOD Signature of the Principal

(Dr. Jagadeesh P Ganjigatti) (Dr. R S Kadadevaramath) (Dr. S V Dinesh)

External Viva:
Names of the Examiners Signature with Date

1.

2.

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 2

 DECLARATION

We hereby declare that the work being presented in this report entitled “DESIGN AND
FABRICATION OF ECONOMICAL HOME LAWN CUTTER” submitted by us to Siddaganga Institution
of Technology, in partial fulfillment of the requirement for the award of degree of Industrial Engineering and
Management under the guidance of Dr. Jagadeesh P Ganjigatti, is our original work and the conclusions
drawn are based on the material collected by ourselves.

Project Associates:

Bhograj Prakash 1SI18IM004

Chinmai S Gowtham 1SI18IM007
Milan J Prakash 1SI18IM019
Mohan Kumar NC 1SI18IM020

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 3

 ACKNOWLEDGEMENT

No project or venture is complete without the assistance and guidance by many people who constantly
helped us to reaching the final point. The commendation of the successful completion of the work is to those
hands which stood by us in every small step we took. We use this opportunity to express our gratitude to
everyone who supported us throughout the course of this project. We are thankful for their inspiring guidance,
invaluably constructive criticism, and friendly advice during the project work.

First and foremost, we would like to extend our sincere gratitude to his holiness Dr. Sree Sree Shivakumara
Swamiji, revered founder president of the Siddaganga Math and we offer our pranams to Sree Sree Siddalinga
Swamiji. Everything would have been impossible without their blessings bestowed on us.

We also thank our beloved director Dr. M. N. Channabasappa and the principal Dr. S V Dinesh who are the
founding stones in every endeavors. They are our constant benefactors who stood by us at all obstacles we
faced. We are also grateful to our Head of the IEM Department Dr. Rajeshwar S Kadadevara math for his
encouragement.

We take this opportunity to thank our guide Dr. Jagadeesh P Ganjigatti, Designation of IEM Department, who
constantly encouraged us not to give up on our ideas and helped us improve through their commendable
experience and is supporting at every stage of project.

We thank, Dr. B Adaveesh, Project coordinator, who gave us the opportunity to make this project of our
realization into action and is always eager to help us during progress of the project.

All the teaching staffs who supported us and always made available to clarify even the minor doubts without
any procrastination. Last but not the least, the non-teaching staff who stood by helping us with the non-technical
requirements. It would have been a nightmare without their love and co-operations.

Project Associates:

Bhograj Prakash 1SI18IM004

Chinmai S Gowtham 1SI18IM007
Milan J Prakash 1SI18IM019
Mohan Kumar NC 1SI18IM020

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 4

 ABSTRACT
In current days, a grass cutter machine is operated by fuel and electrical energy which are costly and
requires high maintenance. Hence, in this study, a hand-held operated machine for grass cutting was designed
and fabricated by using locally available materials. Important aspects such as durability, strength, and light
weight were taken into design considerations for better performance characteristics. The lawn mower was
powered by a 12V/1.35A rechargeable battery which drives the DC motor up to a rotational speed of
19,300 RPM. As a result, the generated torque will be transferred to the cutting head mechanism for
efficient grass cutting. The entire configuration set up was mounted on a wooden base which attached together
with a bicycle frame and a set of wheel arrangement. This portable lawn mower can be used to maintain
and trim grass in gardens, home, schools or yards.

Keywords: grass cutter, frame, lawn mower, hand-held, battery, portable.

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 TABLE OF CONTENTS

Chapter Title Page No.

1. Introduction 9

2. Literature survey 11
2.1 Cylinder lawn mowers 11
2.2 Petrol Lawn mowers 11
2.3 Electric lawn mowers 13

3 Objectives 14

4. Methodology 15

5. Components used 16
5.1 DC Motor 16
5.2 Rechargeable battery 17
5.3 BLADE 18
Fabrication and working 20

6. Description 22

6.1 Terminology 22

6.2 Working principle 26

7. Theoretical analysis 28

8. Model 30

9. Advantages of lawn mower 33

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10. Limitations and applications 34

11. Comparison of battery system and fuel system 35

12. Estimation and costing 36

13. Product specifications 37

14. Conclusion 38

15. Gantt chart 39

References 40

LIST OF FIGURES

Figure No. Figure name Page no.

2.1 Cylinder lawn mower 11

2.2 Petrol lawn mower 12

2.3 Electric lawn mower 13

4.1 DC motor 16

4.2 Rechargeable Battery 17

4.5 Blade 18

4.6 Switch 19

4.7 Two Core Wire 19

6.1 Grass cutting on bed knife 23

6.2 2D- Diagram for wheel 24

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6.3 Spiral cutter 24

6.4 Spur gear 26

LIST OF TABLES

Table No. Table name Page no.

11.1 Comparison of battery system and fuel system 35

12.1 Costing 36

13.1 Product specification 37

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CHAPTER-01

INTRODUCTION

Grass cutter machines have become very popular today. Most common machines are used for soft grass
furnishing. In our project grass cutter machine we are aimed to develop for operation and construction. The
main parts of the grass cutting machines are DC motor of 1/12HP capacity, relay switch for controlling motor,
Battery for charging it through solar panel. It is placed in a suitable machine structure. The motor have 7000
rpm and it is connected to the electric supply by the use of a roll of wire. The motor rpm increased by the help
of gears. Motor controlled by an electric switch for easy operation. The wire blades are attached in this
machine.

Grass cutter machines have become very essential to our daily living in maintaining the yards.
Furthermore, environmental awareness on usage of grass cutting machines has caught a great interest among
consumers. As a result, consumers are searching for ways to reduce and solve their own carbon footprints.
Moreover, environmental pollution keeps increasing and it can be experienced in our daily life, particularly in
our homes. Based on a study, it is reported that 70% of Malaysian home citizens are utilizing fuel powered lawn
mowers for their daily grass cutting routine.

The raw materials mainly used are iron, motor, switch, wheel, wire, sheet, paint, insulating material and
other standard item like nuts, bolts and reverts. The machines required for manufacturing includes welding
machine, grinding machine etc.

Working principle of the grass cutter is providing a high speed rotation to the nylon wire blade, which
helps to cut the grass. The wire cutter will get kinetic energy while increasing the rpm. The cutting edges are
very smooth and accurate. Also Grass Cutting Machines are much easier to be used in garden, lawn and grass
fields. In order to enhance the beauty of home-lawns and gardens, Grass cutting machines are the best available
option in the industry. With the help of a lawn mower which is a machine with revolving blades to help us
cutting lawns at even length, people can easily maintain and beautify their lawns and gardens without any
hassle.

Now-a-days, there are plenty of options starting from the simplest push along mower to the most
advanced electric grass cutting machine. According to world energy report, we get around 80% of our energy
from conventional fossil fuels like oil (36%), natural gas (21%) and coal (23%). It is well known that the time is
not so far when all these sources will be completely exhausted. So, alternative sources should be used to avoid
energy crisis in the nearby future.

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 Thus, high maintenance is needed in order to maintain a lawn mower. For instance, one should
change the fuel or oil regularly so that the lawn mower works efficiently during the process of grass cutting.
Furthermore, this will incur extra variable cost since the fuel price has been increased lately.

In order to overcome these issues, an eco-friendly lawn mower needs to be designed and fabricated in
order to support the green technology initiatives. In this study, a newly designed lawn mower was
fabricated which powered through a rechargeable battery. Besides that, the grass cutting machine was
fabricated at low cost by taking consideration on important aspects such as lightweight, durable, and
environmental friendly.

A lawn mower is a machine that uses cutting blades or strings which is used to cut the grass in gardens
or yards at an even length. The working principle of the lawn mower is to provide a high speed rotation to the
blades, which aids in cutting the grass through generated kinetic energy. The main parts of this prototype
lawn mower consist of a DC motor, a pulse width modulation (PWM) device for controlling the
motor, bicycle frame and wheels as the body structure, and a rechargeable battery. For safety operation,
the motor will be controlled by a PWM device as since the motor has a high rotational speed of
19,300 RPM. As for the cutting head, nylon strings will be used as the trimmer instead of traditional
cutting blades due to cost effectiveness, safety, and flexibility. Besides that, since the motor delivers a minimum
torque value, hence nylon strings are much more suitable since it is lighter in weight.

As small engines became more powerful, a new type of lawn mower that could cut larger and stronger
swaths of grass became more popular. Instead of cutting grass like scissors cut paper as a reel mower does, the
rotary mower spins a horizontal blade around fast enough to cut the grass as it hits it. The wire blade sits within
a casing called a deck, which keeps the grass and other objects from flying in all directions when struck.
Typically, the deck rides on four wheels, with a motor sitting on top of it and a bag attached to it to collect the
cut grass.

The basic version of a rotary mower has a handlebar attached to it that the operator stands behind and
pushes to make it move forward. Self-propelled versions have a Tran. The entire model consists of two sections
one controlling section and another designing section of the model.

The controlling section consists of rechargeable battery & relays switches. The system depending on the
charging circuit the motor can be controlled using switch. The system also includes comparator circuit for
checking the temperature of the motor and when it goes beyond the limit the motor gets switched off
automatically using switch. Mission that is turns the wheels using the power of the motor.

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CHAPTER -02

LITERATURE SURVEY

2.1: Cylinder lawn mowers.

Ashishkumarchaudhari: Cylinder lawn mowers consist of a cylinder and a number of horizontal blades that
spiral around it. If adjusted to the correct height a cylinder mower will give the best cut of lawn mower. They
are however, best suited to flat lawns and can be difficult to use on bumpy or tall grass.

Fig 2.1: Cylinder lawn mower.

The number of blades that spiral around the cylinder determines the quality of the finish, the more
blades, and better cut. Cylinder mowers can also be fixed with a roller which flattens the grass giving a smooth
finish. A cylinder mower with a rear roller will give the best striped effect. Some cylinder mowers are entirely
hand driven whereas others may have the blades driven by an engine. Self-propelled cylinder mowers use an
engine to propel themselves forward as well as to turn the blades. This can save the operator a lot of energy as
little effort is required to move the mower around the lawn.

2.2: Petrol Lawn mowers.

Prof. Mrs. S. S. Patil: These lawn mowers fall under the rotary type mowers. They are powered by internal
combustion engines. Such engines can be either two-stroke or four-stroke cycle engines, running on gasoline or

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 11

other liquid fuels. Internal combustion engines used with lawn mowers normally have only one cylinder. Power
generally ranges from two to seven horsepower (1.5 to 5.25 kw).

Fig 2.2: Petrol lawn mower.

The engines are usually carbureted and require a manual pull crank to start them, although an electric
start is becoming a sales feature in some countries. These lawn mowers typically have an opening in the side or
rear of the housing where the cut grass is expelled. Some have a grass catcher attachment at the opening to bag
the grass clippings. The key advantages of petrol lawn mowers are that they are both powerful, and highly
mobile. A basic petrol mower will have at least 3 hp where as an electric mower will only have up to 2 hp. The
other advantages they over electric mowers is that they don‟t require a long power cable to be connected and
dragged behind it. Depending on the size of your lawn this could be quite an important issue.

Petrol lawn mowers come in both the 2 stroke and 4 stroke cycle engines:

1) 2 stroke lawn mowers are more powerful, less expensive, have a better power to weight ratio, and can be
operated in any orientation. However, they are also less fuel efficient, and do not last as long due to the
high revolving engine. They also require the petrol to be mixed with oil prior to use in order to
lubrication to engine.
2) 4 stroke lawn mowers by comparison are not as powerful, but contain an oil sump ( a separate oil
chamber ) and don‟t need the fuel to be pre-mixed. This saves the operate from mixing the fuel but it
DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 12
 also means that the mower cannot be tipped on side as it will cause the oil to fall out of the sump into the
fuel chamber.

2.3: Electric lawn mowers.

Vicky Jain: Rotary mowers powered by electric motors are increasingly popular. Usually, these mowers are
moved by manual power the on-board engine or motor only spins the blades. These have the disadvantages of
requiring a trailing power cord that its range and so these are only useful for relatively small lawns, close to a
power socket. There is the obvious hazard with these machines of mowing over the power cable, which stops
the mower and may put users at risk of electrocution. Installing a residual-current.

Fig 2.3: Electric lawn mower.

Pankaj Malviya: Electric rotary mowers weigh 45-50 pounds. The key advantage of an electric lawn mower is
the price. A basic rotary electric lawn mower will cost you about half the price of a petrol mower, as well as
being lighter, more quiet, and requiring less maintenance. For a small lawn an electric mower should be fine,
provided you mow regularly. If it is any larger or if the grass tends to get out of hand then you will need the
extra power of a petrol mower.

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 13

CHAPTER –03

OBJECTIVES

With reference to current literature availability, there are many variation of lawn mowers that
are exist in the global markets, which may not fulfil the performance and operational cost criteria. The main
concentration of this study is to design and fabricate a lawn mower which is cost effective, feasible and easy
operation. With the help of this portable lawn mower, consumers can easily maintain and beautify their yards
and gardens without any hassle. Nevertheless,

There are few design requirements that must satisfy the study objectives which are:

1. To design and fabricate the lawn mower which is light in weight.

2. To design and fabricate the lawn mower which is feasible in size.
3. To design and fabricate the lawn mower which is cost effective.
4. To design and fabricate the lawn mower which operates around acute areas.
5. To reduce the cost of the grass cutter.
6. It can be operated by unskilled labours.
7. To make it environment friendly.
8. To integrate mower and trimmer that can be used simultaneously.

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CHAPTER – 04

METHODOLOGY

Problem Defination

Design of Model

Drafting & Documentation

Fabrication

Determination

Conclusion

The action of electrons starts an electric current. There are no mechanical parts to wear out.

Electrical energy of the battery is converted to mechanical energy through a set of blades
designed to achieve cutting operation. The electric circuit ensures power transfer from the battery to run
the D.C.motor, The cutting blades get power from the A.C motor. When the power switch is on, the
electrical energy from the battery powers the motor which in turn actuates the blades. The rotating
blades continuously cut the grass as the mower is propelled forward and the cut grass. Height of cut is
adjusted by means of the link mechanism via the lift rod.

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 CHAPTER –05

COMPONENTS USED

4.1. DC MOTOR
4.2 .BATTERY 12V 35AH
4.3 BLADE
4.4 .OTHER ELECTRICAL COMPONENTS LIKE:
a) SWITCHES
b) ELECTRICAL WIRES
Material Selection for the Base There are few materials such as wood, aluminum, mild steel or
composite were considered beforehand for the mower base. However, wood material was selected for the base
since it is cheaper, low in density, corrosion resistance, and locally available in markets. Besides that, since
lightweight criteria are one of the desired requirements, thus wood will be the most suitable candidate.

5.1: DC MOTOR:

Fig 4.1 : DC motor.

An DC motor is an electric motor driven by an direct current (DC). The DC motor commonly consists of
two basic parts, an outside stationary stator having coils supplied with direct current to produce a rotating

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 16

magnetic field, and an inside rotor attached to the output shaft producing a second rotating magnetic field. The
rotor magnetic field may be produced by permanent magnets, reluctance saliency, or DC or AC electrical
windings.

5.2: RECHARGEABLE BATTERY:

Fig 4.2: Rechargeable Battery.

The rechargeable battery and can be further used for the grass cutting machine to run. A rechargeable
battery, storage battery, or dc-accumulator is a type of electrical battery.

It comprises of one or more electrochemical cells, and is a type of energy accumulator. It is known as a
secondary cell because it‟s electrochemical db. To megawatt systems connected to stabilize an electrical
distribution network. Several different combinations of chemicals are commonly used, including: lead-acid,
nickel cadmium (NiCad), nickel metal hydride (NiMH), lithium ion (Li-ion), and lithium ion polymer (Li-ion
polymer).

The electric motor selected was specified to pull 58Amps of electric current at full load. Motor is being
used to rotate a blade at high angular velocities to enable it to cut grass. This action is not expected to load the
motor but will put the motor at approximately half load therefore the motor will only pull about 30 Amps for its

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 17

operation. On average, the amount of time required to move a lawn in a residential area is about forty five
minutes.

A higher capacity battery is selected to provide a safety factor. We picked a 50Amp, 12 Volt deep discharge
battery, which is readily available in the market.

Design of the Cutting Head For the lawn mower cutting head, nylon strings were used instead of
traditional cutting blades since it is flexible, affordable, lighter and easily replaceable. Besides that, since the
stall torque generated by the motor has a minimal output value (Table-1), therefore usage of strings would
provide an optimum result.

The string trimmer also able to operate in acute areas due to its flexibility in nature.

5.3 : BLADE:

Fig 4.5 : Blade.

A blade is that portion of a tool, weapon, or machine with an edge that is designed to cut and/or
puncture, stab, slash,chop, slice, thrust, or scrape surfaces or materials.

A blade may be made from a plastic fiber such as flint, and wire with nylon material or other material.
Here we used two side nylon wire for cutting of grass.

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 a. SWITCH:

Fig 4.6 : Switch.

A switch is an electrical component that can break an electrical circuit, interrupting the current or
diverting it from one conductor to another. The mechanism of a switch may be operated directly by a human
operator to control a circuit (for example, a light switch or a keyboard button), may be operated by a moving
object such as a door- operated switch , or may be operated by some sensing element for pressure, temperature
or flow.

A relay is a switch that is operated by electricity. Switches are made to handle a wide range of voltage and
currents; very large switches may be used to isolate high-voltage circuits in electrical substations.

b. TWO CORE WIRE:

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 Fig 4.7 : Two Core Wire.

Special lighting switch cable can be bought. This is called “twin red core” and is used as switch cable for your
lights. Often this is replaced, by electricians, who use ab ordinary 2 core and earth cable as a switch cable and
place a little red tape around the black wire in the cable.

FABRICATION AND WORKING:

The conceptual design report highlights the design process used for this project. This report contains
useful information with regards to the thought process and techniques used in analysing alternative solutions.
The background and context for this project are discussed in detail in this report. The requirements that have
been defined were established by doing market research and examining the problems that arise while using a
manual mower. Basic and technical requirements have been defined for the project.

Basic requirements include physical characteristics such as weight and dimensions. These are
fundamental to the safe and efficient operation of the mower. Technical requirements have been defined after
initial calculations. A battery powered reel mower would separate the rotation of the blade reel from the rotation
of the wheels, allowing the drum to spin faster and making it less susceptible to jamming. Reel mowers also cut
lawns more evenly and much closer.

MILD STEEL

Wear of material Wear is commonly defined as the undesirable deterioration of a component by the
removal of material from its surface. It occurs by displacement and detachment of particles from surface. The
mechanical properties of steel are sharply reduced due to wear. The wear of material may be due to the friction
of metals against each other, eroding effect of liquid and gaseous media, scratching of solid particles from the
surface and other surface phenomena.

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There are following principle types of wear as described below.

1. Abrasive wear

It results when non-metallic particles penetrate the metal surface and Cause removal of metallic debris.

2. Adhesive wear or metal to metal wear

This wear caused due to relatives sliding or rolling movement of two mating metallic surfaces. Erosive
wear Erosive wear occur as a result of relative movement between metal and liquid or gas.

3. Corrosive wear

The destruction of materials by the action of surrounding medium is called corrosion.

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 21

CHAPTER – 06

DESCRIPTION
The lawn mower is made up of an induction motor, a battery, an alternator, two collapsible blades, and a
link mechanism. Speed of blade shaft is increased by an arrangement of a speed multiplication pulley
system mounted on a steel platform. The power and charging system comprises of an alternator which
charges the battery while in operation.

The DC motor forms the heart of the machine and provides the driving force for the collapsible
blades. A collapsible blade design is used to reduce wear and a grass collection box mounted at the rear collects
cut grasses. This is achieved by the combined effect of mechanical action of the cutting blades and the
forward thrust of the mower. The system is powered by an electrical switch which completes the circuit
comprising the induction motor and the battery. The revolving front wheels ensure easy manoeuvrability
whilst a lift system activates the link mechanism with which the height of cut is altered.

Lawn mower is an essential tool for the maintenance of yards. They vary in size, mode of operation, and
human power. The power source riding mowers for example are usually powered by a gasoline engine and are
ridden and steered by the operator.

It will walk behind mowers are designed to be pushed by the operator and while getting the power from the
wheel rotation. Modern gas powered and electric powered lawn mowers cut grass with a single blade revolving
at a high speed parallel to the ground. In these method there is five blades in cylinder is rotating and achieving
the same power given by the operator. The blade is slightly raised along its rear edge to create draft that lifts the
cutting blades before its cutting operation.

6.1 TERMINOLOGY

The attitude refers to the angle of the bed knife. This reference is in degree differential from the surface of
the turf, (or the line intersecting the bottom of the rollers).The shear point is the point that a reel blade contacts
any given point on the bed knife at a specific point in time. The reel centerline, is the imaginary line drawn
perpendicular to the grass dissecting the reel at its center. This line is used to find the Behind Center Distance
(BCD), this is the distance the shear point lies behind the centerline. There are two rollers. The rear roller trails
the cutting unit, and is usually a solid roller. Some cutting units have a fixed by screws, and the rear roller is
used to set the height of cut. Others, such as the newer DPA design cutting units, have a fixed rear roller, and
the front roller is used to set the height of cut.

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 Fig 6.1: Grass cutting on bed knife

The performance of the machine was evaluated through a field test. A land predominantly covered with
carpet grass was mapped out into plots of 4mx2m. Seven of these plots were selected by randomization process
and mowed. The spiral lawn mower uses multiple cutting blades arranged in form of a cylinder which is turned
by a gear connected to the wheels. The act of pushing the machine makes the cylinder revolve.

The blade is connected to the bevel gear. This gear train increases the speed of the cutting blade. Shafts of
the gears are connected to the bearings. The bearings are used for the shaft stability and frictionless rotation.
The lubricant is used for bearings is ester oil. Straight bevel gear is used in this lawn mower because of its
simple design and low speed. The cutting blade is a low lift blade used for the low speed.

WHEEL

Wheel is the mother part of all the components. Attached to the axle and used to move the entire system.The
main wheels are the contact point with the ground. The ring gear having 63 teeth and it is covered by the frame
need of protection. The circular diameter of wheel is 200 mm. Tire is covered outer side of the wheel which
gives the grip on wheel rotation.

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 Fig.6.2: 2D- Diagram for wheel

SPIRAL CUTTER

The spinning blades of the mower do not actually cut the grass. It manipulates the grass to be cut by the
cutter blade or bed knife. The cutting surface shears the grass as it is caught between the spinning drum and the
cutter blade. A reel mower cuts grass with a scissors like shearing action, as the moving helix shaped blades
pass over the stationary bed knife.

The cutting action requires that the bed knife and reel blades matched, and in close relationship with each
other. This weld is then ground to be a perfect cylinder. The reel is supported by precision bearings held within
the side plates. The side plates are held in place by a frame. This becomes the reel assembly, and is a precision
cutting tool.

Fig.6.3: Spiral cutter

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 24

 The reel assembly is supported by rollers, and pulled along the ground by a carrier frame. Everything comes
together, to make a precision cutting tool. The spinning blades of the mower do not actually cut the grass. It
manipulates the grass to be cut by the cutter blade or bed knife.

The reel consists of five or six helix shaped blades, welded to supports and mounted to a shaft. This weld is
then ground to be a perfect cylinder. The reel is supported by precision bearings held within the side plates. The
side plates are held in place by a frame. This becomes the reel assembly, and is a precision cutting tool. The reel
assembly is supported by rollers, and pulled along the ground by a carrier frame. Everything comes together, to
make a precision cutting tool.

BED KNIFE

The bed knife is held rigidly in position on the bed bar by screws. The bed knife is sharpened to be flat and
square so the sharp edge contacts the reel blades across the entire length. If the bed knife is not flat, or the reel is
not a perfect cylinder, it is impossible to get the bed knife to contact along the entire length of the reel. The
contact between the blade reel and cutter blade provides a shearing force which cuts the grass. It consists of a
horizontal knife screwed to bed knife bar.

SPUR GEAR

The lawn mower shall be driven from both wheels with suitable ratchet action provided on both sides
between the drive wheels and cutting reel. Gears and pinions shall mesh fully and smoothly. Spur gears or
straight-cut gears are the simplest type of gear. They consist of a cylinder or disk with the teeth projecting
radically, and although they are not straight-sided in form of the edge of each tooth is straight and aligned
parallel to the axis of rotation. Geared devices can change the speed, torque, and direction of a power source.
The term is used to describe similar devices even when the gear ratio is continuous rather than discrete, or when
the device does not actually contain any gears, as in a continuously variable transmission.

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 25

 Fig 6.4: spur gear

MECHANISM

A mechanism is a device designed to transform input forces and movement into a desired set of output
forces and movement. The internal spur gear is transfers the torque to the cutter cylinder by gear engagement.
The cutting mechanism is made of a flat blade rigidly fixed to the frame. Mechanisms generally consist of
moving components such as gears and gear trains, belt and chain drives, cam and follower mechanisms, and
linkages as well as friction devices such as brakes and clutches, and structural components such as the frame,
fasteners, bearings, springs, lubricants and seals, as well as a variety of specialized machine elements such as
splines, pins and keys.

6.2 WORKING PRINCIPLE

Electrical energy of the battery is converted to mechanical energy through a set of blades designed
to achieve cutting operation. The electric circuit ensures power transfer from the battery to run the D.C.
Motor, whilst the alternator utilizes the mechanical power to continuously recharge the battery while in
operation. The cutting blades tap power from the DC. Motor. When the power switch is on, the electrical
energy from the battery powers the motor which in turn actuates both the blades and the alternator shafts.
The rotating motion of the alternator shaft generates current to recharge the battery, thereby
compensating for the battery discharge. The rotating blades continuously cut the grass as the mower is
propelled forward and the cut grass is channelled to the collection box/bag attached at the rear of the machine.
Height of cut is adjusted by means of the link mechanism via the lift rod.

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 Working of the lawnmower is depending on the wheel rotation. Wheel is the main component of this
machine. The rotation is transferred from wheel to the spider by gear engagement. Also the rotation of the
spider is controlled in one direction by the ratchet mechanism. It is placed on the pinion inside. Rotating spider
is strike the bed knife and the grass is sheared to applied level of cutting height. Maintenance of the height of
cut is done using support rollers. Reel mowers also cut lawns more evenly and much closer. The cylindrical
drum on a reel mower cuts every individual blade of grass like a pair of scissors. This produces a clean cut,
which will protect the grass from disease and increases the health of the grass. Optimum clip rate is achieved
when the bed knife and reel blades create small, even gatherings that are then cut. The result is a small,
unnoticeable clip and an even after cut appearance.

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CHAPTER – 07

THEORECTICAL ANALYSIS

7.1: Calculation and Methods

The cutting nylon wire, the force required to cut the lawn as well as the force acting on the wire was
considered. The force required by any sharp object to have impact on the grass is less than 10 Newton.

It is also dependent on the height, density an area covered by the object. Therefore, in designing the wire
of the solar powered lawn mower, the force required for effective mowing should be greater than 10
Newton. A nylon wire was used in the cutting blade because of its strength and weight which can transmit
same speed as that of the DC motor or a little less cause of friction.

Weight and torque on the cutting wire.

The weight of the blade, W=Mg
Where, M=mass of the wire=0.014kg
g=acceleration due to gravity=9.8 m/s
Therefore, W=Mg
=0.014×9.81
=0.14N
Hence, the torque produce by the nylon wire is given by,

T=Wr

Where, W is the weight

r is the radius of the wire.

R=450/2=255mm

Therefore, T=Wr

=0.14×225

=31.5Nm

CALCULATIONS AND RESULT.

P=πnt6 WATTS
P=Power

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 N=Speed of motor
T=Torque
Then P=V*I
V=Voltage
I=Current

TORQUE AND POWER OF A MOTOR WITH NO LOAD CONDITIONS.

P=V*I
=12*25=300W
N=7000 RPM
Then
P=πNT60
300=2*π*7000*T60
T=35.8 N-m

TORQUE AND POWER OF A MOTOR WITH LOAD CONDITIONS.

P=V*I
=12*29=348W
N=6000 RPM
Then
P=πNT60
348=2*π*6000*T60
T=55.3 N-m

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CHAPTER – 08

MODEL

2D and 3D CATIA Models of Grass Cutter Machine

ISOMETRIC VIEW FRONT VIEW

BACK VIEW LEFT VIEW

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 RIGHT VIEW TOP VIEW

BOTTOM VIEW ORIGINAL MODEL

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 MULTI VIEWS

2D DRAWING OF GRASS CUTTER

MULTI VIEWS

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CHAPTER – 09

ADVANTAGES OF LAWN MOWER

 They have no moving parts and hence require little maintenance and work quite satisfactorily without
any focusing device.
 It does not cause any environmental pollution like the fossil fuels and nuclear power.
 Easy to operate
 Storage of energy into rechargeable battery.
 Stored energy is used for a longer time and have low running costs
 Low power consumption.
 Conservation of energy
 Motor automation.
 High efficiency can be achieved with relay switch.
 By using this project we can save more power. That is we can reduce the wastage of power.
 Here no need of man. The circuit itself checks the presence of vehicle and also checks weather it is day
or night time. Once we switch on the circuit it automatically performs all this actions without manual
operation.
 At night time also whenever vehicle comes at that time only light brightness increases after few seconds
it will come to normal position that is decreases light brightness.
 It is the most advantage of this project. For these all reasons in future this project may be used in all
streets to save power.

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CHAPTER – 10

LIMITATIONS

 Large time required to remove the grass.

 Manually operated.
 Difficult to operate in rainy seasons.
 Slow working rate compared to engine lawnmower.
 More time required to charging battery.

APPLICATIONS

 The football ground.

 All garden.
 All playgrounds.
 There are several types of mowers, each suited to a particular scale and purpose.
 The smaller types are pushed by human user and are suitable for small residential lawns and gardens.
 Lawn mowers are widely used in all sports grounds. Lawn mowers become a more efficient alternative
to the domesticated grazing animals.
 It is widely used to cut small grasses & it can also be used for cutting small plants and also used for
trimming grass of play grounds and sports ground.

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CHAPTER – 11

COMPARISON OF BATTERY SYSTEM AND FUEL SYSTEM

BATTERY SYSTEM FUEL SYSTEM

 Totally free from pollution  Pollution is a great factor
 No fuel consumption  Fuel is the important need
 No. of reciprocating parts are less  No. of reciprocating parts are more
 Friction is greatly reduced  Frictions between the parts are high
 Low cost and maintenance  Maintenance is difficult & costly
 Load carrying capacity is low  Load carrying capacity is high
 Continuous ride for hours together is  Continuous ride is possible
not possible
 Ratio of speed reduction more when  Speed reduction ratio is less and it does
weight increases very much not vary

Table 11.1: comparison of battery system and fuel system.

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CHAPTER – 12

ESTIMATION AND COSTING

SL no. Component Quantity Estimated cost

1 DC motor 1 1000
2 Battery 1 3000
3 Wire blades 1 600
4 Fabrication & materials 2000
5 Electrical components mechanical 4 1500
Switch =1, wires=20 meters
Holders
Wheels
6 Transportation 1000
Total 9,100/-

Table 12.1: Costing

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CHAPTER – 13

PRODUCT SPECIFICATIONS

Motor power 1/12HP,150W,220V,7000rpm

Battery type Li-on Battery
Battery speciation 12V ,35 Ah
Charging time 5 to 6 Hrs
Wire blade Nylon wire, 3 meter length, 1mm diameter
thick

Table 13.1: Product specification

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CHAPTER – 14

Conclusion

The main advantage of the machine is that the cutting operation can be carried out without stepping on
the lawn, thus reducing human effort. The grass cutting in hilly areas and many other terrains are difficult with
the existing machines, but the automated grass cutting machine rectifies those difficulties. From above analysis
we concluded that conventional lawn mower are occurring more vibration. So we need to damp by using
vibration isolation materials and by locating the place where to damp or fabricate the mower fully balanced.
Further we also concluded that waste collecting is difficult while operating the lawn mower. So we had
provided vacuum cleaner for auto collecting waste. So it reduces the operating time. Moreover, the usage of this
machine makes the grass cutting process faster by reducing the cutting time. Besides that, it is lighter,
environmental friendly and cost effective which is helpful for non-commercial use (home users) in maintaining
and trimming the grass in gardens, home, or yards.

Features

 Weight of machine is less.

 Compact and easy to store machine.
 Mower with mulching feature that gives back grass pieces to your lawn and it works as a natural
fertilizer. You would be at ease and wouldn‟t need to pick up these clippings from your lawn.
 Grass collector (bigger capacity collector would need to be emptied less often during mowing process).
 Rear rolling option that gives you clean finished lawn mowing.

 Packed cables with corded mowers for easy handling.

DESIGN AND FABRICATION OF ECONOMICAL HOME LAWN CUTTER Page 38

CHAPTER – 15

GANTT CHART

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 REFERENCE

1. Ashishkumarchaudhari.(2016) . solar grass robot for grass trimming. International jounal of advance research
and innovative ideas in education.2(3),1246-1251.

2.Prof.Mrs.S.S.Patil.(2015). Solar based wireless grass cutter., international journal of science technology and
engineering.3(4),576-580.

3.Vicky jain.(2014).experimental study of solar grass cutter robot., international journal of advance research and
innovative ideas in education.1(5),68-73.

4.PankajMalviya.(2016).Fabrication of solar grass cutter. International journal of scientific research in science,

engineering and technology. 2(1),892-898.

5.Design, Development and Testing of Low Capital and

6.Operational Cost Shrub Cutting Machine, R. K. MandloiA, Rajesh GuptaB and A. RehmanC,
A,B,CMechanical Engineering Department, Maulana Azad National Institute of Technology, Bhopal

7. Tuned vibration absorber for suppression of hand-arm vibration in electric, grass trimmer, Ko Ying Hao, Lee
Xin Mei, Zaidi Mohd Ripin

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