Henok Shiferaw Best

ADDIS ABABA UNIVERSITY
ADDIS ABABA UNIVERSITY INSTITUTE OF

TECHNOLOGY SCHOOL OF MECHANICAL AND
INDUSTRIAL ENGINEERING
Design and Development of Self-Prospered Riding Reapers Machine.
Thesis Submitted to the Addis Ababa University Institute of Technology

School of Mechanical and Industrial and Engineering
In Partial Fulfillment of the Requirements for the Degree Master of Science in
Mechanical
Engineering)
By
Henok Shiferaw
Advisor: Daniel Tilahun (PhD)
Co-Advisor: Siraj K. (PhD Candidate)
Dec,2018
ADDIS ABABA, ETHIOPIA
Acknowledgement
Any accomplishment requires the effort of many people and this work is no different. The
author would not be able to complete this thesis paper without the support of all those around
us and The author to give the credit to whom it’s due.
The author would like to thank Department of Mechanical and industrial Engineering, Addis
Ababa Technology University, for their supervision, support, guidance and encouragement
throughout this study. The author would like to thank Daniel T.(PhD) and Siraj Kedir (PhD
candidate) for their comments and kindness.
Design and development of Self-Prospered Riding Reapers Machine. AAIT /2018
Abstract
Harvesting is the process of collecting the mature crop from the field. Harvesting
operation includes cutting, laying, gathering, transporting, stacking the cut crop. The
mechanization of harvesting operation is essential to minimize the cost of harvesting, crop
production cost, crop loss, turnaround time, weather risk, and to increase benefit by
appropriate technology. In order to achieve the above goal, a manually controlled reaper
machine is designed and developed which are support to the Farmers and it will reduce
the cost of crop cutting and collecting in field and it will achievable highest performance
under the given constraints.
Research methodology consists of series of actions or steps necessary to effectively
carry out research and the desired sequencing of these steps. Identify Statement of the
problems, Studying the present design of the reaper machine, Review the literature,
Product development generic design process steps for reaper harvesters machine,
planning, concept development, system-level design, detail design, testing and refinement
and product ramp-up, in this step it’s define the material properties according to the
design. to model the reaper machine by using Catia software, Prototype development,
testing for validation and Interpret and report.
Material are selected on the basis of strength requirement of various components of the
Reaper machine. The machine is constructed from locally available materials. This self-
propelled reaper is operated at forward speed of 2.54 m/s. It has 120 cm size of cutter bar
and dropped bundling mechanism. The field capacity 0.306 ha/hr, respectively. The
required labor for harvesting one hectare of wheat and rice reaper harvesting field
operation are needs 2 man-hr/ha. The quantity of fuel required to fill the tank fully after
harvesting the plot was measured to determine the quantity of fuel consumed for reaping
the test plot and fuel consumption 1.17 l/h.
1
Table of Contents
CHAPTER ONE .................................................................................................................................................... 8
1 Introduction: .............................................................................................................................................. 8
1.1 Background and justification: ..................................................................................................... 8
1.2 Statement of the problems: ...................................................................................................... 10
1.3 General objectives: ....................................................................................................................... 10
1.4 Specific objectives: ....................................................................................................................... 10
1.5 Motivation ....................................................................................................................................... 10
1.6 Scope of the Research: ................................................................................................................ 11
1.7 Significance of the study: ........................................................................................................... 11
1.8 Thesis Outline ................................................................................................................................ 11
CHAPTER TWO................................................................................................................................................ 13
2 Literature review................................................................................................................................... 13
2.1 Study on design and develop a reaper harvesting ........................................................... 13
2.2 Study on comparative field performance of deferent reaper machines ................. 14
2.3 Study on tested and evaluated field performance of reaper machine ..................... 14
2.4 Product development.................................................................................................................. 18
CHAPTER THREE ........................................................................................................................................... 19
3 Product development .......................................................................................................................... 19
3.1 Planning............................................................................................................................................ 19
3.1.1 Focus area ............................................................................................................................... 20
3.1.2 What is the mission of this machine ............................................................................. 20
3.2 Concept Design .............................................................................................................................. 21
3.2.1 Overall function .................................................................................................................... 22
3.2.2 Concept generation ............................................................................................................. 23
3.2.3 Concept selection ................................................................................................................. 26
3.3 System Design ................................................................................................................................ 31
3.4 Embodiment design ..................................................................................................................... 33
3.4.1 Definition................................................................................................................................. 33
3.5 Framework of Methodology ..................................................................................................... 34
3.5.1 Materials:................................................................................................................................. 34
3.5.2 Material used for various components ........................................................................ 34
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3.5.3 Frame structure design ..................................................................................................... 36

3.5.4 Design Chassis Frame ......................................................................................................... 36
3.5.5 Self-Prospered Riding Reapers Machine structure................................................. 47
3.5.6 Engine selection(standard) .............................................................................................. 54
3.5.7 design and select Belt ......................................................................................................... 55
3.5.8 design and select Pulley .................................................................................................... 66
3.5.9 design and select Chain ..................................................................................................... 74
3.5.10 Shaft design ............................................................................................................................ 82
3.5.11 Bearing Selection ................................................................................................................. 96
3.5.12 design and select cutter bar and cutter guard lips................................................100
3.5.13 Finger Conveyor design and developed ....................................................................108
3.5.14 design spring on hinder ...................................................................................................114
3.5.15 Steering ..................................................................................................................................116
3.6 Production Ramp-Up.................................................................................................................125
3.6.1 Prototype development ...................................................................................................125
3.6.2 Modeling of Reaper machine .........................................................................................125
3.6.3 Manufacturing process of machine components ...................................................127
3.6.4 Assembly and disassembly procedure ......................................................................129
CHAPTER FOUR ............................................................................................................................................133
4 Results and Discussion ......................................................................................................................133
4.1 Working principle of self-prospered reapers harvesting machine .........................133
4.2 Harvesting process in filed operation.................................................................................135
4.3 Test procedure: ...........................................................................................................................135
4.3.1 Laboratory tests: ................................................................................................................135
4.3.2 Specifications: .....................................................................................................................135
4.4 Machine performance ...............................................................................................................136
4.5 Workability ...................................................................................................................................136
4.6 Field capacity................................................................................................................................136
4.6.1 Theoretical field capacity: ..............................................................................................138
4.6.2 Actual field capacity ..........................................................................................................138
4.6.3 Field efficiency ....................................................................................................................139
4.7 Energy requirements ................................................................................................................139
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4.8 Cutting efficiency ........................................................................................................................141

4.9 reapers machine efficiency with respect to other similar production ..................144
CHAPTER FIVE ..............................................................................................................................................146
5 Conclusion and Recommendation ................................................................................................146
5.1 Conclusion .....................................................................................................................................146
5.2 Recommendation ........................................................................................................................146
Budget Breakdown/details of expenditure: ......................................................................................147
REFERENCES .................................................................................................................................................150
Appendix..........................................................................................................................................................153
4
List of table
Table 1 the weighted Concept selection objective method ........................................................... 29
Table 2 Material property of RHS and angle iron steel grade...................................................... 35
Table 3 material and component ............................................................................................................. 35
Table 4The mechanical properties of these grades of carbon steel ........................................... 86
Table 5 uses of process sheet ..................................................................................................................127
Table 6 Specification of this reaper harvesting machines ...........................................................134
Table 7 Comparative performance characteristics of reaper with this new reaper ..........145
Table 8 Material cost...................................................................................................................................147
Table 9 Equipment ......................................................................................................................................149
Table 10 Consumables ...............................................................................................................................149
Table 11Travel & Subsistence (Destination, No. of persons and days) Equipment ...........149
Table 12 Personnel and other costs ......................................................................................................149
5
List of figure
Figure 1 vertical conveyer reapers ......................................................................................................... 14
Figure 2 field area .......................................................................................................................................... 16
Figure 3 Reaping method of left turn ..................................................................................................... 16
Figure 4 Reciprocating reaping method................................................................................................ 16
Figure 5 field edge ......................................................................................................................................... 17
Figure 6 Generic Design Process .............................................................................................................. 19
Figure 7 Planning process ......................................................................................................................... 19
Figure 8 concept generation structured ............................................................................................... 21
Figure 9 overall function ............................................................................................................................. 22
Figure 10 working structure...................................................................................................................... 22
Figure 11 Concept one ................................................................................................................................. 23
Figure 12concept two ................................................................................................................................... 24
Figure 13 concept three ............................................................................................................................... 24
Figure 14 concept four ................................................................................................................................. 25
Figure 15 concept five .................................................................................................................................. 25
Figure 16 concept six .................................................................................................................................... 26
Figure 17 self-prospered riding reaper machine .............................................................................. 30
Figure 18 processing tree ........................................................................................................................... 32
Figure 19 Embodiment design step structure .................................................................................... 33
Figure 20 frame and chaise structure .................................................................................................... 37
Figure 21(a)overhung beam , (b)Support reactions. (c, d) Segment AF................................... 38
Figure 22 shear stress .................................................................................................................................. 41
Figure 23 beandin g moment .................................................................................................................... 42
Figure 29 Parking with a wheel on a curb high enough to lift one wheel off the ground .. 49
Figure 30 reaper lateral force ................................................................................................................... 50
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Figure 31 lateral force known grip characteristics ........................................................................... 51

Figure 32 Load transfer between the rear and front axle during braking ............................... 53
Figure 33 Engine ............................................................................................................................................ 54
Figure 34 Angle of contact between the belt and each pulley ...................................................... 61
Figure 35 Angle of contact between the belt and each pulley ................................................ 64
Figure 36 steel chains and sprocket wheels. ....................................................................................... 74
Figure 37 Bending, torque and load diagram of shaft ..................................................................... 88
Figure 38 Bending, torque and load diagram of shaft ..................................................................... 95
Figure 39 bearing ........................................................................................................................................... 96
Figure 40cutter bar .....................................................................................................................................100
Figure 41 cutter bar and cutter guard lips ........................................................................................100
Figure 42 reciprocating knife type cutter bar ...................................................................................104
Figure 43 Finger Conveyor .......................................................................................................................109
Figure 44 Finger Conveyor angular velocity .....................................................................................110
Figure 45 angular velocity ........................................................................................................................110
Figure 46 angular acceleration ...............................................................................................................111
Figure 47 crop binder spring design ....................................................................................................114
Figure 48 The steering angle ...................................................................................................................117
Figure 49 Deflection of the rolling tire by a lateral cornering force ........................................119
Figure 50 Over-steer (left) and Under-steer (right) .......................................................................122
Figure 51 Isometric front view of reaper machine by CATIA V5 ..............................................126
Figure 52 Manufacturing process ..........................................................................................................131
Figure 53 Manufacturing process ..........................................................................................................132
Figure 54 binding mechanism.................................................................................................................137
Figure 55 harvest area ...............................................................................................................................141
Figure 56 new modified cutter bar .......................................................................................................142
Figure 57 After cut the corps ...................................................................................................................143
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CHAPTER ONE
1 Introduction:
1.1 Background and justification:

Today agriculture plays an important role in countries like Ethiopia. Wheat and Rice is
one of the most important crop and staple food of millions of people which is grown in
many countries of the world include our country.
Harvesting of crops is an important field operation, it is the process of collecting the
mature rice and wheat crop from the field. Harvesting operation includes cutting, laying,
gathering, transporting, stacking the cut crop. Harvesting methods being used are
manual harvesting (traditional harvesting) and mechanical harvesting.
I. traditional harvesting: - is manual mowing method using sickles.
The harvesting of crops is traditionally done by manual methods. Harvesting of major
cereals, pulse and oilseed crops are done by using sickle whereas tuber crops are
harvested by country plough or spade. All these traditional methods involve drudgery
and consume long time.
II. Mechanical harvesting: - is modern mowing method using machine.
Timeliness of harvest is of prime importance. During harvesting season, often rains and
storms occur causing considerable damage to standing crops. Rapid harvest facilitates
extra days for land preparation and earlier planting of the next crop. The use of machines
can help to harvest at proper stage of crop maturity and reduce drudgery and operation
time. Considering these, improved harvesting tools, equipment, combines are being
accepted by the fanners.
Mechanized agriculture is the process of using agricultural machinery to mechanize the
work of agriculture, greatly increasing farm worker productivity.
In modern times, powered machinery has replaced many jobs formerly carried out by
manual labor or by working animals such as oxen, horses and mules. The history of
agriculture contains many examples of tool use, such as the plough. Mechanization
involves the use of an intermediate device between the power source and the work. This
intermediate device usually transforms motion, such as rotary to linear, or provides some
sort of mechanical advantage, such as speed increase or decrease or leverage. Current
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mechanized agriculture includes the use of tractors, trucks, combine harvesters,

airplanes (crop dusters), helicopters, and other vehicles.
Until the nineteenth century, most grain was harvested by cutting with a sickle or scythe.
During the nineteenth century, mechanical reapers were developed to cut and windrow
grain for field drying. Reaper is a wheat and rice harvesting machine which reaps crops
and gather Manually. Manually operated vertical conveyor reaper, Self-propelled vertical
conveyor reaper, Tractor front mounted vertical conveyor reaper and Self-propelled
binding reaper are available.
Reapers are used for harvesting of crops mostly at ground level. It consists of crop-row
divider, cutter bar assembly, feeding and conveying devices. Reapers are classified on the
basis of conveying of crops as given below:
1. Vertical conveying reaper windrower: - This type of machines cut the crops and
conveys vertically to one end and windrows the crops on the ground uniformly. Self-
propelled walking type, self-propelled riding type and tractor mounted type reaper-
windrowers are available.
2. Horizontal conveying reapers: -This type of reapers is provided with crop dividers
at the end, crop gathering reel, cutter bar and horizontal conveyor belt. They cut the
crop, convey the crop horizontally to one end and drop it to the ground in head-tail
fashion. It’s suitable for wheat, rice, soybean, and gram.
3. Bunch conveying reapers: -This type of reapers is similar to horizontal conveying
reapers except that the cut crop is collected on a platform and is being released
occasionally to the ground in the form of a bunch by actuating a hand lever.
4. Reaper binders: -The cutting unit of this type of reapers may be disc type or cutter
bar type. After cutting, the crop is conveyed vertically to the binding mechanism
and released to the ground in the form of bundles. Reaper binders are suitable for
rice and wheat.
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1.2 Statement of the problems:
In the field operation of most self- propelled reapers machine problems are, before
operation it needs to prepare the field by using manually cropping on the four sides of
field with width of 20cm and on four corners of field with square of 2 x 2 m and the
machine can smoothly turn in field, when the reaper machine changes its direction
during harvesting, which drives backward without function and turning round reaping,
there is tiredness of farmers because during harvesting the farmer guides the machine
by waking and handling .
To overcome these problems, in order to achieve the need for highest performance under the
given constraints with reduced tiredness of crop gathering, the hardness of grains harvesting,
manual efforts, fuel consumption and cost.
1.3 General objectives:

The general objective of this project is to design and develop Self-Prospered Riding
Type Reapers Machine by adding binding mechanism.
1.4 Specific objectives:
 To use product development generic process
 To design and develop Self-Prospered Riding Reapers frame structure
according to binding mechanism.
 To design and develop riding and finger conveyor mechanism.
 To design and Select Proper Self-Prospered Riding Reapers Machine
component engine, power transmit ion, shaft, bearing and crop cutter knife
 Model 3D of Self-Prospered Riding Reapers Machine by using CATIA V5-R19
software.
 Prototype development
 Testing
1.5 Motivation
The motivation of this research is to minimize the technology gap from the developed
countries and to reach the maximum by developing the Self-Prospered vertical conveyor
Riding Type Reapers Machine.
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1.6 Scope of the Research:

The ability to contribute the scope in design and develop significant to make it new
understanding and conclusion. It can be the standard for the development of the
material of Design and development Self-Prospered Riding Reapers. The study will
only be limited on The scope will extend to cover the design and developed prototype
and specification test Design and development Self-Prospered Riding Reapers.
1.7 Significance of the study:
The present study is to address specific problems occurred during crops seed
harvesting. The study will be helpful to make harvesting crop seeds to be economical,
qualitative and shares world market. It will change the traditional way of harvesting
system to a technological way, our traditional harvesting system was by traditional
equipment’s, so this ways of harvesting system wastes time, man power and also
money, so this thing affects the profitability of the farmer’s. As we all know our
economy bases are the farmers, so the profitability of these farmers directly affects the
economic development of our country. But if we proceed to the new machine it will
save man power, money and time, so that our general objectives will fulfill through
time.
1.8 Thesis Outline
The thesis contents six chapters.
In Chapter 1 discussed introduction about Harvesting Machine, Statement of the
problems, General objectives, Specific objectives and Scope of the Research.
In Chapter 2 discussed Literature review, to consider how past designs for reaper
harvesters machine may be applicable to this project, examined databases such as,
journals, farm books and engineering village. After finding the above literature
reference, their associated reference number was further researched to gain more
insight into the design. This was used to develop a list of equipment used previously in
the reference. Using this reference and adapt some of them. To Use the data that
obtained from the references to help design reaper machine. And this chapter contains
literature summery.
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Chapter 3 discuses Product development generic design process steps for reaper
harvesters machine, planning, concept development, system-level design, detail
design, testing and refinement and product ramp-up, in this step it’s define the material
properties according to the design. Embodiment design for each component and
developed 3D Model and analysis of Self-Prospered Reapers Harvesting Machine by
using Catia software
Chapter 4 puts the whole result from the Self-Prospered Reapers Harvesting Machine
output and provides a detailed discussion on the results.
Chapter 5 finally summaries the results and give conclusion of this research work and
recollects the main influences to the area of crop harvesting method and give
recommendation and future work.
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CHAPTER TWO
2 Literature review
This chapter deals with research work done in past by various investigation on the
performance, the mechanization of harvesting operation is essential to minimize the cost of
harvesting, crop production cost, crop loss, turnaround time, weather risk, and to increase
benefit by appropriate technology. crop harvesting is the important part in agricultural
mechanization, it is the process of collecting the mature crop from the field. Harvesting
operation includes cutting, laying, gathering, transporting, stacking the cut crop. Harvesting
methods being used traditional and mechanical harvesting. And also deals about Product
development generic design process steps for reaper harvesters machine, planning, concept
development, system-level design, detail design, testing and refinement and product ramp-
up, in this step it’s define the material properties according to the design.
2.1 Study on design and develop a reaper harvesting
Devani and Pandey (1985), designed and developed a vertical conveyor belt windrower for
harvesting wheat crop. They concluded that, field capacity achieved with 1.6 m wide unit was
0.269 ha/h and for 2.09 m wide unit was 0.337 ha/h. The costs of operation with tractor and
power tiller models were low as compared to manual method by 20 to 30 %.
El-Sahrigi et.al. (1992), developed a front mounted reaper. The design features included a
flat belt mechanism conveying the crop to the side of machine, improve cutter bar star wheel
assembly to minimize clogging, a bevel gear drive for power transmission, a robust frame, a
header provide design that will not dig in to the soil and provision to covert the flat belt
conveyor drivers to chain without frame modification.
J Prasad et. al. (2001-2002) development of a self-propelled riding type reaper windrower
powered by small diesel engine. The result of test conducted on 4 varieties of wheat crop,
the mean values of plant height, effective field capacity, fuel consumption & total machine
loss were 84.6 cm, 0.336 ha/h, 1.35 l/h & 0.610%, respectively.
13
D.N Sharma and S. mukesh (2010) they studied on the designing of self-propelled vertical
conveyer reapers and tractor operated vertical conveyer reaper harvesting machines.
1. tractor operated vertical conveyer reaper b) self-propelled vertical conveyer reapers

Figure 1 vertical conveyer reapers
2.2 Study on comparative field performance of deferent reaper machines
El-Sharabasy (1997) compared four different machines (small combine harvester, power
reaper, self-propelled mower and rear mounted mower) in wheat and rice fields. He found
the followings: -
1. The minimum grain loss of 1.66 % was obtained under small combine harvester.
2. The highest efficiency of 78.04 % was obtained under self-propelled mower.
3. The highest field capacity of 1.64 fed/h was obtained under tractor power reaper.
4. Harvesting by self-propelled mower + threshing with stationary thresher recorded
minimum energy of 25.38, wk./fed.
2.3 Study on tested and evaluated field performance of reaper machine

Ni Ni Aung, Win Pa Pa Myo and Zaw Moe Htet (2012), Field Performance Evaluation of
vertical conveyor paddy reaper. The actual field capacity of the reaper was 0.24 ha/hr with a
field efficiency of 92 % at an average operating speed of 2.18 km/h.
Mahrous (1995), tested and evaluated a horizontal flat conveyor belt for improving the
efficiency of a rear mounted mower. The mower was operated at wheat crop under forward
speeds of 3, 4, 5 and 6 km/h. The average field capacity, field efficiency, cutting efficiency
14
and cost requirements were 1.18 fed/h, for the developed rear-mounted mower,
respectively.
Habib et.al (2002) stated that the parameters affecting cutting process are related to the
cutting tool, machine specifications and plant materials properties. They added that, the
cutting energy consumed in harvesting process.
Sahar (1988), reported that, the use of a large scale machine is inappropriate for the
following reasons: -it needs high technical experience for operation and maintenance, high
capital requirements. Low field efficiency is in small holding and losses of straw are high on
irregular furrowed soils. The use of small machines is appropriate for small holdings, low
capital requirements and low technical operations and maintenance experience.
Prof. P.B. Chavan, Prof. D.K. Patil and Prof. D.S. Dhondge (2015) are identified that the
Reaper are generally selected on the land holding of the farmer, greater the land holding,
tractor operated vertical conveyer reaper is choosing, for medium land holding self-
prospered vertical conveyer reapers are preferred and for small land holding Manually
operated vertical conveyor reaper are preferred.
Manjunatha et. al. (2008) field performance evaluation of vertical conveyor paddy reaper.
The actual field capacity of the power reaper was 0.3 ha/hr with a field efficiency of 73 % at
an average operating speed of 3.2 km/h. The cost of cultivation of paddy crop could be
reduced through mechanization of harvesting operations.
Ni Ni Aung, Win Pa Pa Myo and Zaw Moe Htet (2012) Field Performance Evaluation of a
Power Reaper 4GL-120A for Rice Harvesting and stated the Preparation of in order to
minimize the loss in reaping, before operation, it is necessary to prepare the field.
 Manually cropping on the four sides of field with width of 20cm to prevent the loss due
to the fact that machine can’t reach the sides in reaping.
 Manually cropping on four corners of field with square of 2X 2 m, so that machine can
smoothly turn in field as shown in Fig. 2
15
20 cm
2 m X 2m
Figure 2 field area
Operation Method, when coming across with protruded part of field land where power reaper
cannot operate, as field condition is different, it is necessary to field edge reaping method,
which is adaptable to conditions.
 Reaping method of left turn is the field standard operation method as shown in Fig.3
Figure 3 Reaping method of left turn
 Reciprocating reaping method is suited to right angled quadrilateral long and narrow
field as shown in Fig.3
Figure 4 Reciprocating reaping method
16
Field Performance Evaluation of a Power Reaper for Rice Harvesting Fig.3. When changing
the direction of power reaper in small sized field, driving backward and turning round
reaping method can be used, and gear shifting and through “driving forward”,” reversing”.
Changing the direction using “driving forward” method is a good method. The turning round
reaping method needs no gear shifting, but field edge area is larger than that of using the
“reversing”. In the wet field, the turning round reaping method is more effective, however,
the field edge is wider as shown in Fig.5
Figure 5 field edge
In the process of harvesting by using self-prospered reaper machine Before it needs to

prepare the field or manually cropping which can perform the following operations, Easy
harvesting of grains, Less manual efforts, Low cost and less maintenance.
In the field operation of most self- prospered reapers machine problems are: -
1. Before operation it needs to prepare the field, manually cropping on the four sides of
field with width of 20cm and on four corners of field with square of 2 x 2 m, so that
machine can smoothly turn in field.
2. During harvesting, when the reaper machine changes its direction, which drives
backward without function and turning round reaping.
3. There is tiredness of farmers, because during harvesting he guides the machine by
waking and handling.
17
2.4 Product development

Karl Ulrich and Steven D. Eppinger (2016). are identified that the six phases of the
generic development process are:
1. Planning (Phase 0)
2. concept development (phase 1)
3. system-level design (phase 2)
4. detail design (phase 3)
5. testing & refinement (phase 4)
6. production ramp-up (phase 5)
Roozenburg, N. and Eekels, J. (1998). are stated that the weighted objectives method, this
method is an evaluation method for comparing design concepts based on an overall value per
design concept.
R.S. Khumi and J.K. Gupta (2010). are stated that manufacturing process steps through
which raw materials are transformed into a final product. The manufacturing process begins
with the product design, and materials specification from which the product is made.
Generally, From the literature survey is studied to recommend the appropriate system for
medium land holding self-prospered vertical conveyer reapers harvesting machine, the
system was evaluated according to the technical parameters: knife speed, operating speed,
actual field capacity, theoretical field capacity, field efficiency, cutting efficiency, cost
economics and percentage of grain losses. To consider how past designs for crop harvesting
reaper machine may be applicable to this project and the Literature review is done to solve
the above problems which are identified in studying the present machine.
18
CHAPTER THREE
3 Product development
Product development is the process of creating a new product to be sold by a business or

enterprise to its customers. In the document title, Design refers to those activities involved
in creating the styling, look and feel of the product, deciding on the product's mechanical
architecture, selecting materials and processes, and engineering the various components
necessary to make the product work. Development refers collectively to the entire process of
identifying a market opportunity, creating a product to appeal to the identified market, and
finally, testing, modifying and refining the product until it is ready for production.
Generic Design Process
Figure 6 Generic Design Process

3.1 Planning
 Planning: -is a systematic search for, and selection and development of product ideas but is
not a part of production design process but it is pushes the process
 focus area
 To make mission statement
 To get approval for management
 Rough idea about the product
Figure 7 Planning process

19
Identify opportunities: - is called as opportunities funnel, the source of identifies are

mention in below
 Marketing and sales personal

 Resource and technology development organization
 Current production development team
 Manufacturing and operations organizations
 Current or potential customers
 Third parties such as supplies, mentors and business
Evaluate and prioritize projects: - On the basis of four strategies you will evaluate the
project
1. Competitive strategy
2. Market segmentation
3. Technological trajectory
4. Produce plate form planning
Complete pre-project planning

1 Technical leader ship
2 Cost-leader ship
3 Customer focus
4 Imitative
3.1.1 Focus area
agricultural on crop harvesting
3.1.2 What is the mission of this machine?
The mission of this thesis is to develop crop harvesting machine for wheat and rice. the
purpose of this machine is to harvest and binding the cut crops without tiredness and by
minimum cost. The mission of this harvesting machine is to solve the following problems.
This problem is
 difficult to harvesting and collecting the crops

 tiredness of farmers
 high west production
 more time taken
 high cost of operation
Primary Market
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 Do-it-yourself consumer
Secondary Markets
 Casual consumer
 Light-duty professional
Stakeholders
 User
 Retailer
 Sales force
 Service center
 Production
 Legal department
3.2 Concept Design

Designers and engineers develop a number of product concepts to illustrate what types of
products are both technically feasible and would best meets the requirements of the target
specifications. A product concept is a general description of the working principal and form
of the product. It is usually expressed as a sketch or as a rough three dimensional model with
some brief description The concept generation process begins with a set of customer needs
and target specifications and results in a set of product concepts from which the final concept
is chosen. The structured approach to concept generation consists of the following five steps:
search for solution

firm up into concept
Specification principal to satisfy
variants
sub-function
abstract to combine solution evaluat concept

identiufy principles to fulfill the variant technical &
the problem overall-function economic criteria
estabish function
structure overall- select suitable concept
functions & sub- combination
function
Figure 8 concept generation structured
21
This is the stage where the feature of the crop harvesting is preset as a stepping stone for the
rest of the design process. Here, many alternatives and different features are discussed,
compared and specified based on geometrical consideration and expected mechanical,
ergonomic and aesthetic requirements.
3.2.1 Overall function
objective of harvesting operation is to harvesting and binding. for different agro-climatic
conditions to achieve optimum yields.
input process output
 Reaper machine and Deiseal fuel crop harvesting crops

 Matured Crop plant
process
 Operator
Figure 9 overall function

Definitely the main concern of the design of harvest is to find a simple, with easy
manufacturability and relative cost method of metering root seed harvesting so that to meet a
specific requirement. Hence the following are some of the competitive mechanisms anticipated
to meet the quality and feature needed. After completing the task clarification phase, the
conceptual design phase determines the principle solution. This is achieved by abstracting the
essential problems, establishing function structures, searching for suitable working principles
and then combining those principles into a working structure.
weakling
engine feul wheel
machine
pulley power chain &

operator
and belt transmition sproket
cutter & crop crop

control conveyor and
conveyor cutter
binding
crops
Figure 10 working structure

22
3.2.2 Concept generation

 Concept one crop harvesting conveyor and collector by belt leg digger
 The purpose of this simple machine is crop harvesting and drop on surface of the
ground by belt leg conveyor mechanism.
 This type of machines cut the crops and conveys vertically to two side end and
windrows the crops on the ground uniformly in both direction according to forward
reaper direction.
 It has crop cutter knife, star wheel and belt leg conveyor
 complex mechanism
 Used 4 horse power gasoil engine.
Figure 11 Concept one
 Concept two crop harvesting conveyor and binding
 The purpose of this simple machine is crop harvesting and conveys vertically to one end
and windrows the crops on the ground by binding mechanism.
 It has crop cutter knife, star wheel, belt leg conveyor and binding mechanism devise in
to right side windrow.
23
Figure 12concept two
 Concept three crop harvesting by simple reaper bundle machine

 this types of reaper machine cutting the crop and release the cut crop in the middle of
the
machine at ground.
 Self-waking riding machine.
 Simple operation.
Figure 13 concept three

Concept four crop harvesting by tractor attached binding reaper machine
 tractor attached reaper and it has two small wheel.
 This machine harvest wheat and rice crop.
 The mechanism of crop conveyor and binding.
24
 Used tractor transmit ion power.
Figure 14 concept four

 Concept five Self-Prospered Riding Reapers with binding mechanism
 the purposes of this machine is to harvest and binding crop like, wheat and rice crops in
modern why.
 three-wheel driving mechanism Used 5 horse power diesel engine and the speed of the
machine is 2.54 km/h.
 In harvesting process of Self-prospered riding reaper machines is cut the crops and
collects crop from on both left and right side and pushes towards the middle position of
machine for dropping to the ground between in the form of bundles.
Figure 15 concept five
25
 Concept six harvesting by Self-Prospered Riding Reapers Machine

 The purpose of this harvesting machine is crop cutting and binding the cutter
crops and drop on surface of the ground by binding mechanism devise.
 Over all activity finished one all in all.
 This machine powered by 5 horse power.
Figure 16 concept six

3.2.3 Concept selection
Through the process of evaluation and tradeoffs between attributes, a final concept is
selected. The selection process may be confined to the team and key executives within the
company, or customers may be polled for their input. Candidate appearance models are often
used for additional market research; to obtain feedback from certain key customers, or as a
centerpiece of focus groups. The concept selection method in this section is built around the
use of decision matrix for evaluating each concept for toilet seat cleaner with respect to a set
of selection criteria.
3.2.3.1 Evaluating and selecting alternatives

The procedure is, therefore, first setting criteria for each sub functions, then comparing the
given possible solutions for each sub functions with a reference based on the sated criteria
26
finally selecting the best alternative from the given based on their result. The following are
the steps to be used in the selection process.
3.2.3.2 Concept Selection Process

 Prepare the Matrix
 Criteria
 Rate of Concept
 Weightings Rate Concepts
 Rank the concepts
 Sum Weighted Scores Combine and Improve
 Remove Bad Features
 Combine Good Qualities Select Best Concept
 Reflect on results and process
3.2.3.3 Generating Alternatives Design
To select one of the superlative choices given for each component, there are steps to be
followed.
1. Setting Criteria
2. Calculating a weighting factor for each criterion
3. Evaluating each design with respect to the selected criteria by using a decision matrix.
4. Select the preeminent design based on the decision matrix.
The type and number of criteria are determined by individual judgment. There are no proper
set of rules for setting design criteria, since it depends on the type and application of design
and its complication.
Concept selection for root seed harvesting machine Concept Scoring Matrix. The generic
steps involved in concept selection using concept scoring matrix are:
1. Develop evaluation criteria
2. Assign importance rate to each criterion
3. Rate each concept with respect to each evaluation criterion
4. Rank the concepts

27
5. Combine and improve the concepts
6. Select one or more concepts
7. Reflect on the results and process
3.2 Concept Selection Criteria
The following selection criteria for root seed harvesting machine was finalized
by taking into consideration the customer needs:
1. Performance 6. Simple Design

2. Inexpensive 7. Easy of Manufacture
3. Easy to operate 8. Simple Assembly
4. Durability 9. Ease of Maintenance
5. Ergonomic
The next task was assigning weights to each selection criteria in the scoring matrix. Several
different schemes can be used to weight the criteria such as assigning the importance value
from concepts for root seed harvesting with respect to selection criteria was done on a scale
of 1-6 with following definitions for each scale.
3.2.3.4 The weighted objective method

The weighted objective method for crop harvesting machine is shown in Table. The method
uses a weighted sum of the ratings to determine concept ranking. The reference points for
each criterion are signified by bold rating values.
The weighted objectives method is an evaluation method for comparing design concepts
based on an overall value predesign concept and it involves assigning weights to the different
criteria. The weighted objectives method is best used when a decision has to be between a
select number of design alternatives, design concepts or principle solution.
28
Table 1 the weighted Concept selection objective method
All concept
Concept
Concept
Concept
Concept
Concept
Concept
four
two
three
five
one
Customer requirements
six
Weight score
Weight score
Weight score
Weight score
Weight score
Weight score
weight
rating
rating
rating
rating
rating
rating
performance 15 1 15 2 30 2 30 3 45 5 75 7 105
cost 15 5 75 5 75 4 60 4 60 4 60 2 30
Easy to 10 3 30 2 20 3 30 3 30 4 40 5 50
OPERATION
Simple Design 10 5 50 4.5 45 4 40 3 30 3 30 2 20
Easy of 12 4 48 4 60 4 48 4 48 3 36 2 24
Manufacture
Simple Assembly 8 4 32 4 32 3.5 28 3 24 3 24 2 16
Ease of 10 6 60 4 40 5.5 55 5 50 4 40 3 30
Maintenance
Fuel consumption 5 3 30 4 40 5 50 4.5 45 4 40 2 20
Life time 4 3 12 3 12 2.5 10 2.5 10 4 16 10 40
Total score 353 354 351 342 361 335
rank 3 2 4 5 1 6
Sum, total score no no no no yes no
29
The weighted objective method indicates that Concept five in which “Self-Prospered Riding Reapers Machine” received the highest
score of 361. All other concepts remained below the score of concept number five. Therefore, Concept five was finally chosen as
the best design for crop harvesting modern reaper harvesting.
Figure 17 self-prospered riding reaper machine
30
3.3 System Design

System-level design, or the task of designing the architecture of the product, is the subject of
this stage. In prior stages, the designer was focused on the core product idea, and the
prospective design was largely based on overviews rather than in-depth design and
engineering. The goal of a system approach to reaper machine design (system design) is to
define the technical specification, so each component in such a way that the machine as a
whole performs its functions according to assigned procedures and objectives.
Technical specifications mean a set of physical measurements that define each part
completely, without the use of detailed drawings; sometimes technical specifications are a
complement to a conventional detailed drawing, but can be used as a substitute.
Detailed drawings are needed solely to explain how apart must be manufactured, while
technical specifications explain the function of apart, how its performance can be measured
together with the acceptable values for this performance. Clearly, coherence between
detailed drawings and technical specifications is necessary, but only the latter guarantee that
the performance targets can be reached.
31
design and develop Self-Prospered Riding Reapers Machine processing tree
 Cutting mechanism
design and develop
 Conveyor mechanism
Reaper Machine
 Binding mechanism
mechanism and
system  Walking mechanism
Design and Develop Self- design and

develop Reapers  Frame structure
Prospered Riding Reapers
Machine body’s  Conveyor structure
Machine
 Chaise structure
 Cutting structure
Optimized Reapers
Machine filled
Construct static
operation
Reaper Machine
component
construct the
Reaper Machine  Front Frame
Construct dynamic  Chaise frame
Reaper Machine  Handel
component
 Cutting bar
Specification  Finger conveyor
checking  Belt and pulley
testing
Visual observation
Figure 18 processing tree
32
3.4 Embodiment design

3.4.1 Definition
Embodiment design is that part of the design process in which, starting from the principle
solution or concept of a technical product, the design is developed in accordance with
technical and economic criteria and in the light of further information, to the point where
subsequent detail design can lead directly to production.
Embodiment design step structure
frame design Engine

selection
steer design Belt design & selection
cutter bar design Pulley design & selection
cutter guide design Chain design & selection
Shaft design bearing selection
Make proto type
Part assemble
Figure 19 Embodiment design step structure
33
3.5 Framework of Methodology

This thesis Research methodology consists of series of actions or steps necessary to
effectively carry out research and the desired sequencing of these steps. The first part of the
research is a frame of reference in a literature study. The second part of the study focuses on
mathematical and theoretical method The three part of the study focuses on model and prototype
of Self-Prospered Reaper Harvesting Machine by using CATIA software. which 3D model are
made using part modeling and assembly design module generated in CATIA software.
3.5.1 Materials:
In choosing equipment and materials for the design harvesting reaper machine, certain
factors/elements needed to be considered in order to ensure that this machine will be
successfully fabricate.
3.5.2 Material used for various components
Material as selected on the basis of strength requirement of various components of the
mechanism. The machine is expected to be constructed from locally available materials;
The component of the machine will be: -
1. Engine with support frame 6. Frame structure
2. Machine body 7. Steering and handle
3. Cutting bar and cutting lip. 8. finger conveyor
4. Crop divider 9. Power transmission belt
5. Ground wheel 10. Bolt and nut
The materials include standard parts and manufactured parts used in the above component
the machine. The reaper machine structure is made with steel beams of rectangular hollow
section (RHS), and angle iron with different size. The sizes of RHS used are RHS 40X40X4 mm,
30X30X2.5 mm, 25X25X2 mm, 20X20X1.5 mm and angle iron 40X40X4mm and 30x30x3mm.
34
Table 2 Material property of RHS and angle iron steel grade C450L0/C350L0 [DURACAL(2003)].
No. Material property Structural steel

1. Tensile yield strength 350 MPa
2. Compressive yield strength 350 MPa
3. Tensile ultimate strength 430 MPa
4. Density 7850 kg/m3
5. Young’s modulus 200 GPa
6. Elongation in degree 260
Table 3 material and component

NO Component(part of DESCRIPTION Material used
the machine)
1. 5 hp engine gasoil engine
Engine with support Square Bar 4*40mm RHS st.37.2
Angle bar 4*40mm Angle iron St.
37.2
2. Frame Square Bar 4*40mm RHS st.37.2
Square Bar 3*40*40mm <<
3. Machine body 0.8 mm thk sheet metal <<
angle Bar 25*30mm Angle iron St.
37.2
Square bar 20*20*1mm and RHS st.37.2
3*30*3mm
4. Cutting bar and Flat bar 100*5mm St. 37.2
cutting lip. Flat bar 100*3mm St. C 45
Angle bar 4*40mm Angle iron St.
37.2
angle Bar 3*30mm <<
Square Bar 2*20mm RHS st.37.2
1mm sheet metal <<
5. painting Painting spray anti-reset and silver Shin spray
6. Ground wheel 35mm Ø Round bar shaft St. C 45
Apollo 165/80 tire rubber
Apollo 165/80 chercke Mild steel
Deep groove ball brg, (30X62X16) standard
7. Steering wheel Apollo 165/80 chercke standard
Apollo 165/80 tire rubber
35
Hex. Head bolt, m30øx3x200mm long standard

Breaking and fuel injecting control
wire Rope wire
Bicycle breaking and fuel injecting
control standard
8. Finger conveyor ‘8 mm round bar St. 37.2
Pulley Cast iron
Double bearing holder (20x42x14mm) standard
9. Power transmit ion v-Belt for 1st stage (A 39) rubber
belt v-Belt for 3rd stage (A 24) <<
v-Belt for 4th stage (A 52) <<
10. Power transmit ion Chain 2nd stage (pitch=12.5,center to
chain and sprocket center=400 mm) standard
sprocket 2nd stage driver, (ID. 20 mm, <<
OD. 60 mm). driven (ID. 22 mm, OD.
150mm)
Chain 3rd stage (pitch=12.5,center to
center=450 mm) <<
sprocket 3rd stage driver, (ID. 35 mm, <<
OD. 60 mm). driven (ID. 22 mm, OD.
150mm)
11. Bolt and nut Hexagonal head M5,m8,m10,m12 <<
3.5.3 Frame structure design

The Frame structure design according to binding mechanism. frame element is formulated to
model a straight bar of an arbitrary cross-section, which can deform not only in the axial
direction but also in the directions perpendicular to the axis of the bar. The bar is capable of
carrying both axial and transverse forces, as well as moments. Therefore, a frame element is
seen to possess the properties of both truss and beam elements. In fact, the frame structure
can be found in most of our real world structural problems, for there are not many structures
that deform and carry loadings purely in axial directions nor purely in transverse directions.
[Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia and Andrea Tonoli (2011)].
3.5.4 Design Chassis Frame
Determine the bending moment and shear force diagrams for a simply supported beam with
an overhang as shown in fig.20 the beam is 150cm. long with a 10 cm. overhang. It is subjected
to a standard human weight 65 kg along the center 10 cm of its span.
36
65 kg
90 kg 60kg
0.30m
0.4m
RA RB 0.4m
Figure 20 frame and chaise structure

𝑃 𝑙𝑜𝑎𝑑 1 = 𝑚𝑚𝑖𝑑𝑑𝑙𝑒 ∗ 𝑔 (3.1)
𝑃 𝑙𝑜𝑎𝑑 1 = 90 𝑘𝑔 ∗ 9.81 𝑚/𝑠 2
𝑃 𝑙𝑜𝑎𝑑 1 = 882.9 𝑁
𝑃 𝑙𝑜𝑎𝑑 2 = 𝑚𝑓𝑟𝑜𝑛𝑡 ∗ 𝑔 (3.2)
𝑃 𝑙𝑜𝑎𝑑 2 = 60 𝑘𝑔 ∗ 9.81 𝑚/𝑠 2
𝑃 𝑙𝑜𝑎𝑑 2 = 588.6 𝑁
𝑃𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑 = 882.9 𝑁 + 588.6 𝑁
𝑃 3 = 65 𝑘𝑔 ∗ 9.81 𝑚/𝑠 2
𝑃 3 = 637.65 𝑁
𝑃 𝑡𝑜𝑡𝑎𝑙 = 2109.15 𝑁
637.65 N 2207.25 N/m 1471.5 N/m
0.4m 0.4m
48.8 Nm/1m=48.8 N
RA RB
37
(a)overhung beam
V(x) M(x)
RA
(b)Support reactions.
a. Segment AF
2207.25 (x- V(x)

1m) M(x)
RA
Fig 21 (c)Segment AF
b. Segment FG
882.9 N V(x)
M(x)
RA Fig 21 (d)Segment FG
Figure 21(a)overhung beam , (b)Support reactions. (c, d) Segment AF
Step 1 calculation of reactions
The two reaction (RA and RB) of the beam are obtained from a transverse EE and a rotational
EE written at E, which is the midpoint of the distributed load p.
∑ 𝑀: 𝑅𝐴 + 𝑅𝐵 − 𝑃𝑦𝑡𝑜𝑡𝑎𝑙 = 0 (3.3)
𝑦
𝑅𝐴 + 𝑅𝐵 − 𝑃1 − 𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 1 − 𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 2 −𝑃 3 = 0 (3.4)

38
𝑅𝐴 + 𝑅𝐵 − 2109.15 𝑁 = 0
∑ 𝑀: 0 ∗ 𝑀𝑅𝐴 + 1.1𝑀𝑅𝐵 −0.01𝑚𝑃1 − 1𝑚𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 1 − 1.4𝑀 ∗ 𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 2 = 0

𝑎
0 + 1.1𝑀𝑅𝐵 − 0.01𝑚 ∗ 637.65 𝑁 − 1𝑀 ∗ 882.9 𝑁 − 1.4𝑀 ∗ 588.6 𝑁 = 0

1.1𝑀𝑅𝐵 − 6.3765 𝑁𝑀 − 882.9 𝑁𝑀 − 824.04 𝑁𝑀 = 0
1.1𝑀𝑅𝐵 = 1713.3165𝑁𝑀
𝑅𝐵 = 1713.3165𝑁𝑀/1.1𝑀
𝑅𝐵 = 1557. 56 𝑁
AND
𝑅𝐴 + 𝑅𝐵 − 2109.15 𝑁 = 0
𝑅𝐴 + 1557. 56 𝑁 − 2109.15 𝑁 = 0
𝑅𝐴 = 551.59 𝑁
The accuracy of the reaction can be checked by writing the moment EE at any convenient
location.select locations at A and B because the moment is 0 at these points (𝑀𝐴 = 𝑀𝐵 = 0).
∑ 𝑀: 0 ∗ 𝑀𝑅𝐴 + 1.1𝑀𝑅𝐵 −0.01𝑚𝑃1 − 1𝑚𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 1 − 1.4𝑀 ∗ 𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 2 = 0

𝑎
0 + 1.1𝑀𝑅𝐵 − 0.01𝑚 ∗ 637.65 𝑁 − 1𝑀 ∗ 882.9 𝑁 − 1.4𝑀 ∗ 588.6 𝑁 = 0
1.1𝑀𝑅𝐵 − 6.3765 𝑁𝑀 − 882.9 𝑁𝑀 − 824.04 𝑁𝑀 = 0
1713.316 − 6.3765 𝑁𝑀 − 882.9 𝑁𝑀 − 824.04 𝑁𝑀 = 0
0=0
AND
∑ 𝑀: 1.1𝑀𝑅𝐴 + 0 ∗ 𝑀𝑅𝐵 −1.09𝑚𝑃1 − 0.1 ∗ 𝑚𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 1 + 0.4𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 2 = 0

𝑏
1.1 ∗ 551.59 𝑁 − 1.09𝑚 ∗ 637.65 𝑁 − 0.1𝑀 ∗ 882.9 𝑁 + 0.4𝑀 ∗ 588.6 𝑁 = 0

0=0
Step 2-bending mmoent and shear force diagrams
39
Because of the nature of load disrtibution, the BM and SF diagrams have to be constructed
separately for four segment: AF, FG, GB, and BC as shown in fig (c1) to (c4). The BM and SF
for each segment follow.
Segment AF (0 ≤ 𝑥 ≤ 1𝑀)
𝑉(𝑥) = −𝑅𝐴 = −551.59 𝑁
𝑀(𝑥) = 551.59 𝑁 ∗ 𝑋
Segment FG
𝑉(𝑥) = −551.59 𝑁 + 𝟐𝟐𝟎𝟕. 𝟐𝟓(𝑥 − 0.4𝑀)
𝑉(𝑥) = −551.59𝑁 − 𝟐𝟐𝟎𝟕. 𝟐𝟓 ∗ 𝑥 − 882.9 𝑁𝑀)
𝟐𝟐𝟎𝟕. 𝟐𝟓
𝑀(𝑥) = 551.59𝑁 ∗ 𝑋 − (𝑥 − 1𝑚)2 = 551.59𝑋 − 1103.6(𝑥 − 1𝑚)2 )
2
Segment GB
𝑉(𝑥) = −551.59𝑁 + 588.6𝑁 = 37.01 𝑁
𝑉(𝑥) = −551.59 𝑥 − 588.6𝑁(𝑥 − 1.4)
𝑉(𝑥) = −1140.2 𝑁 ∗ 𝑥 + 824.04 𝑁
Segment GB: for simplicity, the calculation for, this section uses the loads in the
overhang. 𝑉(𝑥) 𝑎𝑛𝑑 𝑉(𝑥) are positive as marked in Fig 9-1
𝑉(𝑥) = −1557. 56 𝑁
𝑀(𝑥) = −1557. 56 𝑁(0.4 − 𝑋)
The SF and BM are verified for few locations in bbeam:
Location F: The SF and BM callculated at F(x=1m) from segments AF and FG must be in
agreement.
Segment AF
𝑉𝐹 = −𝑅𝐴 = −551.59 𝑁
𝑀𝐹 = 551.59 𝑁 ∗ 1 𝑚
𝑀𝐹 = 551.59 𝑁. 𝑚
Segment FG
𝑉𝐹 = 𝑉(𝑥 = 0.4𝑚) = −551.59 𝑁 + 2207.25(𝑥 − 0.4𝑀) = −551.59 𝑁
40
𝑀𝐹 = 𝑉(𝑥 = 0.4𝑚) = 2207.25 𝑁 ∗ 𝑥

𝑀𝐹 = 2207.25𝑁 ∗ 0.40𝑀
𝑀𝐹 = 882.9 𝑁. 𝑚
Segment G
𝑉𝐺 = 𝑉(𝑥 = 1.4𝑚) = −551.59 𝑁 + 882.9𝑁 = 331.31 𝑁
𝑀𝐺 = 551.59 𝑥 − 882.9𝑁(𝑥 − 1.4)
𝑀𝐺 = 551.59 𝑥 𝑁 − 882.9𝑥 + 1236.06 𝑁
𝑀𝐺 = 1236.06 𝑁 − 331.31 𝑁. 𝑚 ∗ 𝑥
Segment B
𝑉𝐵 = 𝑉(𝑥 = 0.4𝑚) = 𝑉(𝑥) = −588.6 𝑁
𝑀𝐵 = −588.6 𝑁(0.4 − 𝑋)
𝑀𝐵 = 235.44𝑁 − 588.6 𝑁 ∗ 𝑥
235.44 𝑁 − 588.6 𝑁 ∗ 0.4
𝑀𝐵 = 0
𝑉𝐵 = 𝑉(𝑥 = 0) = 𝑉(𝑥) = −1557. 56 𝑁 + 588.6 𝑁 = −968.96 𝑁
𝑀𝐵 = −588.6 𝑁(0.4 − 𝑋)
𝑀𝐵 = −235.44 𝑁
Figure 22 shear stress
41
Figure 23 beandin g moment
shear stress on the middle rectangular mild steel
Determine the shear stress along the z-plane of the edges of the 40*40*4 rectangular cross
section and the load apply on the four rectangular RHS is 882.9 N.
given: h = 40 mm, b = 40 mm , t =4 mm , 𝑉𝑑 = 882.9 N/4 = 220.725N
20 mm
40 mm
4 mm
mm
40 mm
𝑏 ∗ ℎ3 (𝑏 − 𝑡) ∗ (ℎ − 𝑡)3
𝐼𝑍 = − ( 3.5)
12 12
40 ∗ 403 36 ∗ 363 404 364 2560000 − 1679616

𝐼𝑍 = − = − =
12 12 12 12 12
𝐼𝑍 = 73365.33 𝑚𝑚4
𝑦̅ = 20 𝑚𝑚
𝑄 = ∆𝐴 ∗ 𝑦̅ = 4 ∗ 4 ∗ 20 = 320 𝑚𝑚3
42
𝑉𝑄 220.725N 𝑁 ∗ 320 𝑚𝑚3

𝑞= = = 0.963 𝑁/𝑚𝑚
𝐼 16278.67 𝑚𝑚4
q is the total shear flow acting on the particle with two cutting planes)
𝑆ℎ𝑒𝑎𝑟 𝐹𝑙𝑜𝑤 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑙𝑒𝑛𝑔𝑡ℎ (𝜏)
1 𝑞 1 0.963𝑁/𝑚𝑚
𝜏= = ∗ = 0.12 𝑁/𝑚𝑚2
2𝑡 2 4 𝑚𝑚
section and the load apply on the four rectangular RHS is 882.9 N.
given: h = 30 mm, b = 30 mm , t =2.5 mm , 𝑉𝑑 = 882.9 N/4 = 220.725N
14 mm
30 mm
2.5mm
mm
30 mm
𝑏 ∗ ℎ3 (𝑏 − 𝑡) ∗ (ℎ − 𝑡)3
𝐼𝑍 = − (3.6)
12 12
30 ∗ 303 28 ∗ 283 304 283 810000 − 614656

𝐼𝑍 = − = − =
12 12 12 12 12
𝐼𝑍 = 16278.67 𝑚𝑚4
𝑦̅ = 14 𝑚𝑚
𝑄 = ∆𝐴 ∗ 𝑦̅ = 2 ∗ 2 ∗ 14 = 56 𝑚𝑚3
43
𝑉𝑄 220.725N 𝑁 ∗ 56 𝑚𝑚3
𝑞= = = 0.76 𝑁/𝑚𝑚
𝐼 16278.67 𝑚𝑚4
1 𝑞 1 0.76𝑁/𝑚𝑚
𝜏= = ∗ = 0.19 𝑁/𝑚𝑚2
2𝑡 2 2 𝑚𝑚
shear stress on the chair supporter RHS
section and the load apply on the two rectangular mild steel is 637.65 N.
given: h = 30 mm, b = 30 mm , t =2.5 mm , 𝑉𝑑 = 882.9 N/4 = 318.825N
14 mm
30 mm
2.5mm
mm
30 mm
𝑏 ∗ ℎ3 (𝑏 − 𝑡) ∗ (ℎ − 𝑡)3
𝐼𝑍 = − (3.7)
12 12
30 ∗ 303 28 ∗ 283 304 283 810000 − 614656
𝐼𝑍 = − = − =
12 12 12 12 12
𝐼𝑍 = 16278.67 𝑚𝑚4
𝑦̅ = 14 𝑚𝑚
𝑄 = ∆𝐴 ∗ 𝑦̅ = 2 ∗ 2 ∗ 14 = 56 𝑚𝑚3
𝑉𝑄 318.825 𝑁 ∗ 56 𝑚𝑚3
𝑞= = = 1 𝑁/𝑚𝑚
𝐼 16278.67 𝑚𝑚4
44
1 𝑞 1 1𝑁/𝑚𝑚
𝜏= = ∗ = 0.25 𝑁/𝑚𝑚2
2 𝑡 2 2 𝑚𝑚
shear stress on the conveyor supporter rectangular mild steel
section. and the load apply on the four rectangular RHS is 588.6 N.
N
given: h = 25 mm, b = 25 mm , t =2 mm , 𝑉𝑑 = 588.6 4 = 147.15N
25 mm 11.5 mm
2mm mm
25 mm
𝑏 ∗ ℎ3 (𝑏 − 𝑡) ∗ (ℎ − 𝑡)3
𝐼𝑍 = − (3.8)
12 12
25 ∗ 253 23 ∗ 233 254 233 390625 − 279841
𝐼𝑍 = − = − =
12 12 12 12 12
𝐼𝑍 = 9232 𝑚𝑚4
𝑦̅ = 11.5 𝑚𝑚
𝑄 = ∆𝐴 ∗ 𝑦̅ = 2 ∗ 2 ∗ 11.5 = 46 𝑚𝑚3
45
𝑉𝑄 147.15 𝑁 ∗ 46 𝑚𝑚3
𝑞= = = 0.73 𝑁/𝑚𝑚
𝐼 9232 𝑚𝑚4
1 𝑞 1 0.73𝑁/𝑚𝑚
𝜏= = ∗ = 0.18 𝑁/𝑚𝑚2
2𝑡 2 2 𝑚𝑚
Determine the shear stress along the z-plane of the edges of the 20*20*1.5 mm rectangular
cross section.
given: h = 20 mm, b = 20 mm , t =1.5 mm , 𝑉𝑑 = 250 N
20 mm 9.25 mm
1.5mm
mm
20 mm
20 ∗ 203 18.5 ∗ 18.53 204 18.53 160000 − 279841

𝐼𝑍 = − = − =
12 12 12 12 12
𝐼𝑍 = 3572 𝑚𝑚4
𝑦̅ = 11.5 𝑚𝑚
𝑄 = ∆𝐴 ∗ 𝑦̅ = 2 ∗ 2 ∗ 9.25 = 37 𝑚𝑚3
𝑉𝑄 250 𝑁 ∗ 37 𝑚𝑚3
𝑞= = = 0.56 𝑁/𝑚𝑚
𝐼 16278.67 𝑚𝑚4
46
1 𝑞 1 0.56𝑁/𝑚𝑚
𝜏= = ∗ = 0.14 𝑁/𝑚𝑚2
2𝑡 2 2 𝑚𝑚
3.5.5 Self-Prospered Riding Reapers Machine structure

3.5.5.1 internal and External Loads
A Reapers Harvesting Machine is stressed by loads which typically are determined by the
dynamic interaction between the excitation and the Reaper. During the initial stages of
design, the data available regarding the Reaper and its subsystems may not be enough to
model such dynamic interactions. In this phase an evaluation of the loads is necessary never
the less in order to identify an initial design. In a following stage a dynamic condition check
is performed generating a more refined design. On basis of these considerations, the objective
of the following paragraph is to illustrate some load conditions useful for the initial design of
the components of the structural body. Loads in the following conditions will be considered:
[Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia and Andrea Tonoli (2011)].
Parking on flat road
the Reapers Harvesting Machine parked on a flat road, with the maximum payload possible,
is not in an extreme load condition. Never the less flat road parking is interesting because the
other conditions can be determined by calculating the variations with respect to This case.
Given the mass and the position of the center of gravity, the vertical Loads 𝐹𝑧𝑎 and 𝐹𝑧𝑃 acting
on the front and rear axles are simply: machine mass (𝑚) = 250 𝑘𝑔, 𝑝 = 2𝑚, 𝑎 = 0.35𝑚, 𝑏 =
0.65𝑚
𝐹𝑧𝑎 = mg b/p (3.9)
𝐹𝑧𝑎 = 250 kg ∗ 9.81 m/s ∗ 0.65m /1.1 = 1450 N
𝐹𝑧𝑃 = mg − 𝐹𝑧𝑎 (3.10)
𝐹𝑧𝑃 = 250 𝑘𝑔 ∗ 9.81 𝑚/𝑠 − 1450 = 1000 𝑁
car weighing = 𝐹𝑧𝑎 + 𝐹𝑧𝑃 = 145 N + 100.25 𝑁 = 2452.5 KN
Parking with a wheel on a curb

47
Referring to Fig. 28 it is assumed that the car has a wheel on a curb high enough to cause one
of the other three wheels to lift off the ground. If the height of the curb is negligible with
respect to the wheelbase, with one wheel lifted, the car is supported in astatically determined
way by the ground. Since the wheel contact points are not symmetric with respect to the
middle plane (on which the center of gravity is assumed toile) the structure becomes twisted.
To understand which wheel leaves the ground, I tis sufficient to consider the maximum torque
that can be balanced by the front or rear axle. The sketch of Fig. 29 shows one axle isolated
from the rest of the vehicle. Applying a torque Mt determines a vertical load transfer between
the two wheels with track:
∆𝐹𝑧 = Mt/t (3.11)
Since the wheel-ground contact is mono lateral, the maximum torque which Can be balanced
by the axle is that which completely unloads the wheel:
𝐹
𝑀𝑡𝑚𝑎𝑥 = 2𝑧𝑖 𝑡 (3.12)
Where Fzi represents the load on the axle and the subscript i=a, p denotes the Front and rear
axle respectively. Higher torque values cannot be balanced and Would cause capsizing. When
the car in Fig. 27 rises on to the curb, the front Axle applies a torque to the rear one.
When one of the four wheels leaves the ground (in the figure the front right or the rear left)
the torque cannot increase further. Therefore, the maximum torque
48
CG
𝐹𝑍2
𝐹𝑍1
𝐹𝑍3
Figure 29 Parking with a wheel on a curb high enough to lift one wheel off the ground
so that the car is supported by three wheels only.
During parking with a wheel on a curb is the minimum between the moments
that can be balanced by the two axles:
𝐹𝑧𝑎 𝐹𝑥𝑎
𝑀𝑡𝑚𝑎𝑥 = 𝑀𝑚𝑖𝑛 𝑡 , 𝑡 3.5
2 𝑎 2 𝑝
𝑀𝑡𝑚𝑎𝑥 = 𝑀𝑚𝑖𝑛 𝑡 , 𝑡
2 𝑎 2 𝑝
If the torque transmissible by the front axle is lower than the rear axle,
𝑡𝑎 < 𝑡 (3.13)
2 2 𝑝
the first wheel to rise is a front one;
vice versa if:
𝑡𝑎 > 𝑡 (3.14)
2 2 𝑝
the first wheel to rise is a rear one.
For the sole purpose of evaluating the order of magnitude of the static moment,
49
consider a car weighing FF=2452.5 N, with the center of gravity located at half
of the wheel base a=b=p/2. In this case 𝐹𝑧𝑎 =1450 N, 𝐹𝑧𝑝 = 1002.5 N. If the two front wheel
rack are equal 𝑡𝑎 =1m, the result is:
1450 𝑁
𝑀𝑡𝑚𝑎𝑥 = ∗ 1𝑚 = 725 𝑁𝑚
2
The considerable magnitude of the torque requires a design intended to avoid the material
yielding, the welds pots to break (static or fatigue failure) and, above all, excessive
deformations
𝑀𝑡
𝐹1
𝐹2
𝐹3
Figure 30 reaper lateral force
Load transfer due to a torque Mt applied to an axle isolated from the reaper lateral
force (𝐹𝑦𝑚𝑎𝑥 ) When a car maneuvers a constant radius corner, the maximum lateral
force(𝐹𝑦𝑚𝑎𝑥 )on the vehicle is limited by two conditions:
1)reaching the tires maximum lateral adhesion, or

2)the incipient capsizing.
The condition of tires maximum lateral adhesion is given by:
𝐹𝑦𝑚𝑎𝑥 𝜇 = 𝜇𝑦 𝑚𝑎𝑥 𝐹𝑧 (3.14)
50
Where 𝐹𝑧 is the total weight and 𝜇𝑦 𝑚𝑎𝑥 is the maximum lateral adhesion coefficient that can
be produced by the whole vehicle. Its value does not only depend On the tires features and on
the road surface characteristics (dry surface, wet, snow), but is also influenced by vehicle
dynamics issues, such as the features of the suspension system, its stiffness, the presence of
antiroll bars, the center of gravity position, just to list the principal factors. The incipient
capsizing condition is reached when the Resultant of the inertia force and the weight force
(both applied on the center of gravity) crosses the contact patch of the external wheel. In this
case, the lateral load transfer cancels the vertical force on the wheels inside the corner:
ℎ 𝐹𝑧
∆𝐹𝑧 = 𝐹𝑦 𝑚𝑎𝑥 𝑅 = (3.15)
𝑡 2
ℎ
𝐹𝑦𝑚𝑎𝑥
𝐹𝑧
𝐹𝑧
Figure 31 lateral force known grip characteristics
So a maximum lateral grip force 𝐹𝑦 𝑚𝑎𝑥 𝑅 is obtained which corresponds to the Incipient
capsizing:
𝑡 ∗ 𝐹𝑧
𝐹𝑦 𝑚𝑎𝑥 𝑅 = (3.16)
ℎ∗2
1 ∗ 2452.5 𝑁
𝐹𝑦 𝑚𝑎𝑥 𝑅 = = 4905
0.25 ∗ 2
51
Maximum lateral force due to the incipient capsizing for a reaper travelling on a road with
known grip characteristics, the maximum lateral force is given by the lowest of the limit loads.
1𝑡
𝐹𝑦 𝑚𝑎𝑥 =min(𝜇𝑦 𝑚𝑎𝑥 𝐹𝑧 , 𝐹) (3.17)
2ℎ 𝑧
In the case of a road with good grip conditions 𝜇𝑦𝑚𝑎𝑥 ≈ 0.8 ÷ 0.9, depending On the ratio 2h/t
between the height h of the center of gravity and the semi track (t/2), the limit of the lateral
force is given by the tires or by the incipient capsizing. Considering a vehicle with track t =1.2
relatively low center of gravity: h=0.5m, so the ratio t/(2h)=1.2> 𝜇𝑦 𝑚𝑎𝑥. The maximum
lateral force is then imposed by 𝜇𝑦 𝑚𝑎𝑥 . (capsizing):car weighing= 𝐹𝑧 =2452.5 N For a small
commercial vehicle with the same track and a higher center of gravity h=0.8mt/2h=0.75, the
maximum lateral force is imposed by the capsizing condition.
1𝑡 1
𝐹𝑦 𝑚𝑎𝑥 = 𝐹𝑧 = ∗ 2452.5 𝑁 = 4905 𝑁
2ℎ 2∗0.25
Longitudinal limit
The maximum longitudinal force conditions can be reached during braking or Accelerating to
the limit of tires adhesion. For common vehicles the maximum torque produced by the brakes
is much higher than the torque given by transmission, so the braking condition features
higher longitudinal forces; if Fz is the total weight then:
𝐹𝑥 𝑚𝑎𝑥 𝜇=𝜇𝑥 𝑚𝑎𝑥 𝐹𝑧 , (3.18)
Where𝜇𝑥 𝑚𝑎𝑥 is the maximum longitudinal adhesion coefficient that can be produced by the
whole vehicle.
52
𝐶𝐺
ℎ
𝐹𝑎𝑥
𝐹𝑥𝑝
𝑃
𝐹𝑧𝑎 𝐹𝑧𝑝
Figure 32 Load transfer between the rear and front axle during braking
Similarly, to the case of limit transversal forces, the incipient capsizing condition can be
taken in to account. The load transfer in the braking condition is:
ℎ
∆𝐹𝑧 = 𝐹 𝑅 (3.19)
𝑝 𝑥 𝑚𝑎𝑥
The incipient capsizing is reached when the load transfer cancels the vertical load On the
rear axle (Fig. 32):
𝑎
∆𝐹𝑧 = 𝐹𝑧𝑝 = 𝐹 (3.20)
ℎ 𝑧
In this case the whole car is completely weighing on the front axle. Therefore:
𝑎
𝐹𝑥 𝑚𝑎𝑥 𝑅 = 𝐹 (3.21)
ℎ 𝑧
1𝑚
𝐹𝑥 𝑚𝑎𝑥 𝑅 = ∗ 2452.5 𝑁
0.25 𝑚
𝐹𝑥 𝑚𝑎𝑥 𝑅 = 9810 𝑁
The maximum longitudinal force is given by the lowest of the loads defined by equations
3.11 and 3.14:
𝑎
𝐹𝑥 𝑚𝑎𝑥 𝜇=𝑚𝑖𝑛 (𝜇𝑥 𝑚𝑎𝑥 , ℎ 𝐹𝑧 ) (3.22)
Since usually a>h the maximum longitudinal force is commonly given by Reaching the limit
of tires adhesion.
53
3.5.6 Engine selection(standard)

Engine, machine for converting energy into motion or mechanical work. the internal
combustion engines (briefly written as I. C. engines) are those engines in which the
combustion of fuel takes place inside the engine cylinder. The I.C. engines use either petrol or
diesel as their fuel. The operating cycle of an I.C. engine may be completed either by the two
strokes or four strokes of the piston. Four stroke diesel engine is suitable to this machine
according to the propose. Diesel engines are more efficient than gasoline-powered engines
and do not require spark plugs. Relatively to the previous harvesting machine select 5 kw
single cylinder 4 stroke, air cooled, Diesel engines and the speed of engine shaft is 970 rpm
(102.4 rad/s) an engine delivers 5 kilowatts; express this power in horsepower. D. N Sharma;
S. Mukesh (2008 and 2010)]
P = 5 kw x 1.36 = 6.8 hp.
calculate the engine torque
T = P/ ω (3.23)
P: engine power, expressed in n W
T: engine torque, expressed in Nm
ω: angular velocity, expressed in rad/s
T = 5000 w /102.4 rad/s = 48.8 Nm
Figure 33 Engine [D. N Sharma; S.mukesh (2008 and 2010)]
54
3.5.7 design and select Belt

The belts or ropes are used to transmit power from one shaft to another by means of
pulleys which rotate at the same speed or at different speeds. The amount of power
transmitted depends upon the following factors:
1. The velocity of the belt.
2. The tension under which the belt is placed on the pulleys.
3. The arc of contact between the belt and the smaller pulley.
4. The conditions under which the belt is used.
3.5.7.1 Selection of a Belt Drive
Following are the various important factors upon which the selection of a belt drive depends:
[16].
1. Speed of the driving and driven shafts, 5. Positive drive requirements,

2. Speed reduction ratio, 6. Shafts layout,
3. Power to be transmitted, 7. Space available, and
4. Centre distance between the shafts, 8. Service conditions
3.5.7.2 Types of Belts

Though there are many types of belts used these days, yet the following are important from
the subject point of view [D. N Sharma; S. Mukesh (2008 and 2010)].
1. Flat belt. is mostly used in the factories and workshops, where a moderate amount of
power is to be transmitted, from one pulley to another when the two pulleys are not
more than 8 meters apart.
2. V-belt. is mostly used in the factories and workshops, where a great amount of power
is to be transmitted, from one pulley to another, when the two pulleys are very near
to each other.
55
3. Circular belt or rope. is mostly used in the factories and workshops, where a great
amount of power is to be transmitted, from one pulley to another, when the two
pulleys are more than 8 meters apart.
3.5.7.2.1 Types of Belt Drives

The belt drives are usually classified into the following three groups: [D. N Sharma; S. Mukesh
(2008 and 2010)].
1. Light drives. These are used to transmit small powers at belt speeds up to about 10
m/s as in agricultural machines and small machine tools.
2. Medium drives. These are used to transmit medium powers at belt speeds over 10
m/s but up to 22 m/s, as in machine tools.
3. Heavy drives. These are used to transmit large powers at belt speeds above 22 m/s
as in compressors and generators.
3.5.7.3 Material used for flat and v-belts

The material used for belts and ropes must be strong, flexible, and durable. It must have a high
coefficient of friction. The belts, according to the material used, are classified as follows:
1. Leather belts.
2. Cotton or fabric belts.
3. Rubber belt.
4. Balata belts.
select rubber belt because simple to get and not expensive. The rubber belts are made of layers
of fabric impregnated with rubber composition and have a thin layer of rubber on the faces. These
belts are very flexible but are quickly destroyed if allowed to come into contact with heat, oil or
grease. One of the principle advantages of these belts is that they may be easily made endless.
These belts are found suitable for saw mills, paper mills where they are exposed to moisture.
Mass density in kg / m3 is 1140 Belt Speed. A little consideration will show that when the speed
of belt increases, the centrifugal force also increases which tries to pull the belt away from the
pulley. This will result in the decrease of power transmitted by the belt. It has been found that
for the efficient transmission of power, the belt speed 20 m/s.
56
3.5.7.4 Standard Belt Thicknesses and Widths

The standard flat belt thicknesses are 5, 6.5, 8, 10 and 12 mm. The preferred values of
thicknesses are as follows:
1. 5 mm for nominal belt widths of 35 to 63 mm
2. 6.5 mm for nominal belt widths of 50 to 140 mm,
3. 8 mm for nominal belt widths of 90 to 224 mm,
4. 10 mm for nominal belt widths of 125 to 400 mm, and (e) 12 mm for nominal belt
widths of 250 to 600 mm.
The standard values of nominal belt widths are in R10 series, starting from 25 mm up to 63
mm and in R 20 series starting from 71 mm up to 600 mm. Thus, the standard widths will be
25, 32, 40,50, 63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250, 280, 315, 355, 400,
450, 500, 560 and 600 mm. [R.S. KHURMI and J.K. GUPTA (2005)].
3.5.7.5 Types of Flat Belt Drives for this machine
The power from one pulley to another may be transmitted by any of the following types of
belt drives.
1. Open belt drive: - is used with shafts arranged parallel and rotating in the same
direction.
2. Crossed or twist belt drive: - is used with shafts arranged parallel and rotating in the
opposite directions.
3. Quarter turn belt drive (also known as right angle belt drive): - is used with shafts
arranged at right angles and rotating in one definite direction. In order to prevent the
belt from leaving the pulley, the width of the face of the pulley should be greater or
equal to 1.4 b, where b is width of belt.
4. Belt drive with idler pulleys (also known as jockey pulley drive): - is used with shafts
arranged parallel and when an open belt drive cannot be used due to small angle of
contact on the smaller pulley.
5. Compound belt drive: - is used when power is transmitted from one shaft to another
through a number of pulleys.
6. Stepped or cone pulley drive. is used for changing the speed of the driven shaft while
the main or driving shaft runs at constant speed.
57
7. Fast and loose pulley drive. is used when the driven or machine shaft is to be started
or stopped whenever desired without interfering with the driving shaft.
Select v-belt and Open belt drive V-belts are the most common means of driving light loads
between short range pulleys. V-belts are small in cross-sectional to reduce friction and
heating. They have a greater load capacity at high speeds than do flat belts.
3.5.7.6 Calculate length and thickness Frist stage belt
 calculate belt length

; - assume the distance between driver pulley and driven pulley, 400mm according to frame
structure.
Center - to - center distance (C) between driven pulleys is given by:
C = 60/2 + 400 + 200/2 =530 mm
The length of belt is given by
L = 2C + π (D + d)/2 + (D – d) 2/4C
L = 2 X 530 + π (200 + 60)/2 + (200 – 60) 2/4C
L = 1468.4 mm
 calculate belt tension and width

Design a rubber v-belt to drive a gasoil engine 5 kW at 970 r.p.m. and fitted with a pulley 60
mm diameter.
Allowable stress for belt = 2.1 MPa
Density of rubber = 1000 kg / m3
Angle of contact driver pulley = 165°
Coefficient of friction between belt and pulley = 0.3
Given: P= 5 kW = 5 × 103
W; N= 970 r.p.m.; d= 60 mm = 0.06 m; η, d = 85% = 0.85; σ= 2.1 MPa = 2.1 × 106N/m2
58
ρ= 1000 kg/m3; θ= 165° = 165 × π/180= 2.88 rad; μ= 0.3
T1= Tension in the tight side of the belt, and
T2= Tension in the slack side of the belt.
We know that velocity of the belt,
π. d. N πX0.06X970 M
V= 1+ =1+ = 4.05
60 60 S
And power transmitted (P)
10 × 103 = (T1 – T2 ) v
10 × 103 = (T1 – T2 )X4.05
10 × 103 = 4.05 (T1 – T2 )
∴ T1 – T2 = 5 x103 /4.05 = 1234.57 N (3.24)
We know that
T1
2.3 log = μ. θ = 0.3 x 2.88 = 0.864
T2
T1 0.864
log = = 0.3756
T2 2.3
T1
= 2.375 (3.25)
T2
... (Taking antilog of 0.3756)
From equations (3.24) and (3.25), we find that
T1 = 2132.435 N; and T2 = 897.87 N
Let b= Width of the belt in meters, and
t = Thickness of the belt in meters.

59
Assuming thickness of the belt, t= 10 mm = 0.01 m, we have
Cross-sectional area of the belt= b x t = b x 0.01 = 0.01 bm2
We know that mass of the belt per meter length,
m= Area x length x density = = 0.01 b x 1 x 1000 = 10 bkg / m
∴Centrifugal tension,
TC = m. v 2 = 10 b(3.05)2 = 283.726 bN
We know that maximum tension in the belt,
T = σ. b. t = 2.1 × 106 × b × 0.01 = 21 000 bN
And tension in the tight side of belt (T2 ),
897.87 N = T– TC = 21 000 b– 283.726 b = 20716.274b∴
b= 897.87 N / 20716.274 = 0.0435 m = 43.5 mm
The standard width of the belt (b) is 50 mm. Ans.
3.5.7.7 Calculate length and thickness 3rd stage belt

; - assume the distance between driver pulley and driven pulley, 200 mm according to frame
structure.
C = 60/2 + 200 + 70/2 =270 mm
L = 2C + π (D + d)/2 + (D – d) 2/4C
L = 2 X 270 + π (60 + 70)/2 + (60 + 70) 2/4C
L = 540 + 204.2 + 15.64
L = 759.5~760 mm
60
𝛼 70 mm
θ H
60 mm
θ
260 mm
Figure 34 Angle of contact between the belt and each pulley
 Angle of contact between the belt and each pulley

Let θ =Angle of contact between the belt and each pulley.
We know that for a crossed belt drive,
𝑟1 + 𝑟2 30 + 35
sin 𝛼 = = = 0.24
𝑐 240
𝛼 = 8.830
𝜃 = 180𝑜 + 2𝛼 = 180𝑜 + 2(8.830 ) = 188.830
𝜋
𝜃 = 188.83 = 3.3 𝑟𝑎𝑑
180

Design a rubber v-belt to drive a gasoil engine 5 kW at 1/3 x 970 r.p.m. and fitted with a
pulley 60 mm diameter.
pulley angle of contact = 188.830
Given: P= 5 kW = 5 × 103
61
W; N= 323.33 r.p.m.; d= 60 mm = 0.06 m; η= 85% = 0.85; σ= 2.1 MPa = 2.1 × 106N/m2
ρ= 1000 kg/m3; θ= 188.830 = 188.83 × π/180= 3.3 𝑟𝑎𝑑; μ= 0.3
π. d. N πX0.06X1/3 x970 M
V= 1+ =1+ = 1.35
60 60 S
10 × 103 = (T1 – T2 ) v
= (T1 – T2 )X1.35
= 1.35 (T1 – T2 )
∴ T1 – T2 = 5 x103 /1.35 = 3707.7 N (3.26)
We know that
T1
2.3 log = μ. θ = 0.3 x 3.3 = 0.9
T2
T1 0.9
log = = 0.39
T2 2.3
T1
= 2.375 (3.27)
T2
T1 = 13579.1 N; and T2 = 9871.4 N
62
TC = m. v 2 = 10 b(1.35)2 = 18.225 bN
T = σ. b. t = 2.1 × 106 × b × 0.01 = 21 000 bN
9871.4 N = T– TC = 21 000 b– 18.225 b = 20716.274b∴
b= 9871.4 N / 20981.775 = 0.047 m = 47mm
3.5.7.8 Calculate length and thickness 4th stage belt

; - assume the distance between driver pulley and driven pulley, 600mm according to frame
structure.
C = 60/2 + 600 + 60/2 =660 mm
L = 2C + π (D + d)/2 + (D – d) 2/4C
L = 2 X 660 + π (60 + 60)/2 + (60 + 60) 2/4C
L = 1122 mm
63
M
H
𝛼
θ
60 mm 𝛼 θ
660 mm
Figure 35 Angle of contact between the belt and each pulley
 Angle of contact between the belt and each pulley

Let θ =Angle of contact between the belt and each pulley.
We know that for a crossed belt drive,
𝑟1 + 𝑟2 30 + 30
sin 𝛼 = = = 0.091
𝑐 660
𝛼 = 5.2160
𝜃 = 180𝑜 + 2𝛼 = 180𝑜 + 2(5.2160 ) = 185.2160

𝜋
𝜃 = 193.3 = 3.23 𝑟𝑎𝑑
180

Design a rubber v-belt to drive a gasoil engine 5 kW at 1/3 x 6/7 x970 r.p.m. and fitted with
a pulley 60 mm diameter.
pulley angle of contact = 193.30

64
Given: P= 5 kW = 5 × 103
W; N= 277.14 r.p.m.; d= 60 mm = 0.06 m; η= 85% = 0.85; σ= 2.1 MPa = 2.1 × 106N/m2
ρ= 1000 kg/m3; θ= 185.2160 = 185.216× π/180= 3.23 𝑟𝑎𝑑; μ= 0.3
π. d. N πX0.06X1/3 x6/7x970 M
V= 1+ =1+ = 1.157
60 60 S
10 × 103 = (T1 – T2 ) v
= (T1 – T2 )X1.157
= 1.35 (T1 – T2 )
∴ T1 – T2 = 5 x103 /1.157 = 4321 N (3.28)
We know that
T1
2.3 log = μ. θ = 0.3 x 3.23 = 0.97
T2
T1 1
log = = 0.39
T2 2.3
T1
= 2.375 (3.29)
T2
T1 = 7463.54N; and T2 = 3142.54 N
65
TC = m. v 2 = 10 b(1.157)2 = 13.38 bN
T = σ. b. t = 2.1 × 106 × b × 0.01 = 21 000 bN
9871.4 N = T– TC = 21 000 b– 13.38 b = 20986.62b∴
b= 7463.54N / 20986.62b = 0.0355 m = 35.5 mm
3.5.8 design and select Pulley

The pulleys are used to transmit power from one shaft to another by means of flat belts, V-
belts or ropes. Since the velocity ratio is the inverse ratio of the diameters of driving and
driven pulleys, therefore the pulley diameters should be carefully selected in order to have
a desired velocity ratio. The pulleys must be in perfect alignment in order to allow the belt
to travel in a line normal to the pulley faces. The pulleys may be made of cast iron, cast
steel or pressed steel, wood and paper. The cast materials should have good friction and
wear characteristics. The pulleys made of pressed steel are lighter than cast pulleys, but in
many cases they have lower friction and may produce excessive wear. [D. N Sharma; S.
Mukesh (2008 and 2010)].
66
3.5.8.1 types of pulleys for v-belt and flat-belt

Following are the various types of pulleys for flat belts:
1. Cast iron pulleys

2. Steel pulleys
3. Wooden pulleys
4. Paper pulleys, and
5. Fast and loose pulleys.
3.5.8.1.1 Cast iron pulleys
The pulleys are generally made of *cast iron, because of their low cost. The rim is held in
place by web from the central boss or by arms or spokes.
3.5.8.1.2 Steel Pulleys

Steel pulleys are made from pressed steel sheets and have great strength and durability.
These pulleys are lighter in weight (about 40 to 60% less) than cast iron pulleys of the
same capacity and are designed to run at high speeds. They present a coefficient of friction
with leather belting which is at least equal to that obtained by cast iron pulleys
3.5.8.1.2.1 Wooden pulleys

Wooden pulleys are lighter and possess higher coefficient of friction than cast iron or steel
pulleys. These pulleys have 2/3rd of the weight of cast iron pulleys of similar size. They are
generally made from selected maple which is laid in segments and glued together under
heavy pressure
3.5.8.1.3 Paper pulleys

Paper pulleys are made from compressed paper fiber and are formed with a metal in the
center.
These pulleys are usually used for belt transmission from electric motors, when the center
to center shaft distance is small.
3.5.8.2 FAST AND LOOSE PULLEYS

A fast and loose pulley, used on shafts enables machine to be started or stopped at will. A
fast pulley is keyed to the machine shaft while the loose pulley runs freely. The belt runs
over the fast pulley to transmit power by the machine and it is shifted to the loose pulley
67
when the machine is not required to transmit power. By this way, stopping of one machine
does not interfere with the other machines which run by the same line shaft.
According to the strength, cost of pulley, and also the availability of pulley in local market
we select cast iron.
3.5.8.3 Calculate of Cast Iron Pulleys
The following procedure may be adopted for the design of cast iron pulleys.
Dimensions of pulley
The diameter of the pulley (D) may be obtained either from velocity ratio consideration or
centrifugal stress consideration. We know that the centrifugal stress induced in the rim of the
pulley, σt = ρrv 2
Where ρ = Density of the rim material= 7200 kg/m3 for cast iron, V = Velocity of the rim =
πDN/ 60, D being the diameter of pulley and Nis speed of the pulley.
The following are the diameter of pulleys in mm for flat and V-belts.
20, 22, 25, 28, 32, 36, 40, 45, 50, 56, 63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250,
280, 315, 355, 400, 450, 500, 560, 630, 710, 800, 900, 1000, 1120, 1250, 1400, 1600, 1800,
2000, 2240, 2500, 2800, 3150, 3550, 4000, 5000, 5400. The first six sizes (20 to 36 mm) are
used for V-belts only. [D. N Sharma; S. Mukesh (2008 and 2010)].
If the width of the belt is known, then width of the pulley or face of the pulley (B) is taken
25% greater than the width of belt.
∴ B = 1.25 b; where b= Width of belt.
According to Indian Standards, IS: 2122 (Part I) – 1973 (Reaffirmed 1990), the width of
pulley is fixed as given in the Standard width of pulley table III in appendix.
3.5.8.3.1 Frist stage drive pulley

A cast iron pulley transmits 5 kW at 1:1 of 970 r.p.m. The diameter of pulley is 60 mm and
has smooth straight arms of elliptical straight arms of cross-section in which the major axis
is twice the minor axis. Find the dimensions of the arm if the allowable bending stress is 15
MPa. Mention the plane in which the major axis of the arm should lie.
68
Let b1 = Minor axis, and
b1 = Major axis = 2b1
We know that the torque transmitted by the pulley,
PX60 5x103 X60 30x104

T= = = = 49.25 N. M
2XπXN 2XπX970 6091.6
Maximum bending moment at the hub end,
2T 2x49.25 N. M
M= = = 98.5 N. M
n 1
And section modulus,
π π π(b1 )3
Z= Xb1 X(a1 )2 = Xb1 X(2b1 )2 = (3.30)
32 32 8
We know that the bending stress σb
M 98.5X8X103 788X103
15 = = =
Z π(b1 )3 π(b1 )3
3
788X103
(b1 ) = = 25.57 mm
15Xπ
a1= 2b1 = 2x25.57 mm = 51.14 mm
3.5.8.3.2 Frist stage driven pulley

A cast iron pulley transmits 5 kW at 1/3 of 970 r.p.m. The diameter of pulley is 200 mm and
has full arms of elliptical straight arms of cross-section in which the major axis is twice the
minor axis. Find the dimensions of the arm if the allowable bending stress is 15 MPa. Mention
the plane in which the major axis of the arm should lie.
69
σb = 15mpa = 15N/mm2
PX200 5x103 X200 10x105

T= = = = 492.3 N. M
2XπXN 2XπX323.33 2031.35
Maximum bending moment per arm at the hub end,
2T 492.3 N. M
M= = = 984.6 N. M
n 1
π π π(b1 )3
Z= Xb1 X(a1 )2 = Xb1 X(2b1 )2 =
32 32 8
M 984.6 N. MX8X103 7876.8X103

15 = = =
Z π(b1 )3 π(b1 )3
3
7876.8X103
(b1 ) = = 55 mm
15Xπ
a1 = 2b1 = 2x55 mm = 110 mm
3.5.8.3.3 Second stage drive pulley (double sprocket pinion)

A steel sprocket pinion transmits 5 kW at 1/3 of 970 r.p.m. The diameter of sprocket pinion
is 60 mm and has full arms of elliptical straight arms of cross-section in which the major axis
is twice the minor axis. Find the dimensions of the arm if the allowable bending stress is 35
MPa. Mention the plane in which the major axis of the arm should lie.
σb = 35mpa = 35N/mm2
70
PX60 5x103 X60 30x104

T= = = = 147.69 N. M
2XπXN 2XπX323.33 2031.35
2T 147.69 N. M
M= = = 295.37 N. M
n 1
π π π(b1 )3
Z= Xb1 X(a1 )2 = Xb1 X(2b1 )2 = (3.31)
32 32 8
M 295.37 N. M X8X103 2362.96X103

25 = = =
Z π(b1 )3 π(b1 )3
2362.96X103
(b1 )3 = = 27.8 mm
35Xπ
a1= 2b1 = 2x27.8 mm = 55.6mm
3.5.8.3.4 Second stage driven pulley (sprocket gear)

A steel sprocket pinion transmits 5 kW at1/3 x 1/3 of 970 r.p.m. The diameter of sprocket
pinion is 120 mm and has three arms of elliptical straight arms of cross-section in which the
major axis is twice the minor axis. Find the dimensions of the arm if the allowable bending
stress is 15 MPa. Mention the plane in which the major axis of the arm should lie.
PX120 5x103 X120 12x105

T= = = = 886 N. M
2XπXN 2XπX107.78 677.2
71
2T 2 ∗ 886 N. M
M= = = 590.67 N. M
3 3
π 2
π 2
π(b1 )3
Z= Xb X(a1 ) = Xb X(2b1 ) = (3.32)
32 1 32 1 8
M 590.67 N. M X8X103 47725.33X103

15 = = =
Z π(b1 )3 π(b1 )3
3
47725.33X103
(b1 ) = = 46.46mm
15Xπ
a1= 2b1 = 2x46.46 mm = 92.9 mm
3.5.8.3.5 Second stage driven pulley (sprocket gear)
A steel sprocket pinion transmits 5 kW at1/3 x 6/7 of 970 r.p.m. The diameter of sprocket
pinion is 70 mm and has full arms of elliptical straight arms of cross-section in which the
major axis is twice the minor axis. Find the dimensions of the arm if the allowable bending
stress is 15 MPa. Mention the plane in which the major axis of the arm should lie.
PX70 5x103 X70 35x104

T= = = = 201 N. M
2XπXN 2XπX277.14 1741.34
2T 2 ∗ 201 N. M
M= = = 402N. M
1 1
72
π 2
π 2
π(b1 )3
Z= Xb X(a1 ) = Xb X(2b1 ) = (3.33)
32 1 32 1 8
M 402 N. M X8X103 3215.9X103

15 = = =
Z π(b1 )3 π(b1 )3
3215.9X103
(b1 )3 = = 29.47mm
15Xπ
a1= 2b1 = 2x29.47 mm = 58.9 mm
3.5.8.3.6 Third stage drive pulley

A cast iron pulley transmits 5 kW at 1/3 x 1/2 of 970 r.p.m. The diameter of pulley is 60 mm
and has smooth straight arms of elliptical straight arms of cross-section in which the major
axis is twice the minor axis. Find the dimensions of the arm if the allowable bending stress is
15 MPa. Mention the plane in which the major axis of the arm should lie.
PX60 5x103 X60 30x104

T= = = = 295.34 N. M
2XπXN 2XπX161.67 1815.67
2T 2x295.34N. M
M= = = 590.678 N. M
n 1
π π π(b1 )3
Z= Xb1 X(a1 )2 = Xb1 X(2b1 )2 = (3.34)
32 32 8
73
M 590.678X8X103 47.25X105
15 = = =
Z π(b1 )3 π(b1 )3
47.25X105
(b1 )3 = = 46.45 mm
15Xπ
a1= 2b1 = 2x46.45 mm = 92.9 mm
3.5.9 design and select Chain

The chains are made up of number of rigid links which are hinged together by pin joints in
order to provide the necessary flexibility for wrapping round the driving and driven wheels.
These wheels have projecting teeth of special profile and fit into the corresponding recesses
in the links of the chain as shown in Fig. in below. The toothed wheels are known as *sprocket
wheels or simply sprockets. The sprockets and the chain are thus constrained to move
together without slipping and ensures perfect velocity ratio. The reason of using chain is
because of In order to avoid slipping. [D. N Sharma; S. Mukesh (2008 and 2010)].
Figure 36 steel chains and sprocket wheels [D. N Sharma; S. Mukesh (2008 and 2010)].
The chains are mostly used to transmit motion and power from one shaft to another, when
the center distance between their shafts is short such as in bicycles, motor cycles, agricultural
machinery, conveyors, rolling mills, road rollers etc. The chains may also be used for long
center distance of upto8 meters. The chains are used for velocities up to 25 m / s and for
power up to 110 kW. In some cases, higher power transmission is also possible. [16]
74
3.5.9.1.1 Second stage chain
Harvesting machine operated by 5 kW diesel engines and the speed of engine shaft is 970
rpm and that of rotary is to be 1/3 x 970 rpm. The maximum distance between driver
sprocket and driven sprocket gear 450 mm. calculate a suitable chain drive for the rotary.
Since the speed of diesel engine in the present case is not very high, so we may take lower
chain velocity and a roller chain is selected for the drive. Determine velocity ratio (VR): the
velocity ratio of drive can be determined by following equation [D. N Sharma; S. Mukesh (2008
and 2010)].
RPM 970 323.33

𝑉R = RPMe = 1 = 277.14 = 3
r
3
∗970
Now, from the chain table which is available in the design handbook for a velocity ratio of
3. The number of teeth in the pinion is equal to 20.
Number = 20
Nr = Ne x V.R = 20 X 3 =60 teeth
Calculate of chain pitch
c 450
P= = = 15 from the to 7.5 mm
30 to 60 30 to 60
From the table in design data book we may select standard chain pitch = 12.7 mm
Chain velocity
P RPM m
V = 1000 X XNe (3.35)
60 s
12.7 323.33 m
V= X X20 = 1.3 m/s
1000 60 s
3.5.9.1.2 Calculate of load on chain
𝐹𝑐ℎ𝑖𝑎𝑛 = 𝐹 + 𝐹𝐶 + 𝐹𝑓 Ff = Frictional force chain
75
P(KW)X1000
F = FC = centrifugal load on chain
V
1000
F = 5 kW X = 3652.9 KN F = load due to power transmission
1.3
W x V2
Fc = , where; W = 13.6 N/m for duplex chain from design data book
g
13.6 x 1.32
FC = = 2.34 N
9.81
F𝑓 = 𝐾𝑓 ∗ 𝑊 ∗ 𝐶, where; (3.36)
c = center to center distance (450 mm)
𝐾𝑓 = kinematics friction
For inclined drive (𝐾𝑓 ) =2.0
For horizontal drive (𝐾𝑓 ) = 4.0
For vertical drive (𝐾𝑓 ) = 1.0
𝐾𝑓 = 2 X 13.6 X0.45 m = 12.24 N
𝐹𝐶 = 3652.9 N+ 2.34 N+ 12.24 N = 3667.48 N
New check the loading strength of chain from the chain table which is available in design
hand book for duplex chain minimum breaking load = 431 KN
Fu breaking load 431X103 N

Fos = = = = 117.52
c chain load 3667.48 N
When it is greater than 117.52 >11.00 the chain selection for rotary is safe.
Chain length = LC = m x p, when p =chain pitch and m = number of chain link
2𝑐 𝑁𝑟 − 𝑁𝑒 𝑝(𝑁𝑟 − 𝑁𝑒)2
𝑀= + + (3.37)
𝑝 𝑝 4𝜋 2 𝑐
76
2 x 450 20 + 60 12.7(60 − 20)2

𝑀= + +
12.7 2 4π2 (450)
M = 70.866 + 40 + 1.133 = 135.63 pitches
LC = m x p = 135.63x 12.7 =1200.15mm
3.5.9.2 Center to center distance between sprockets
p Ne+Nr (Ne+Nr)2 1/2 p(Nr−Ne)2 1/2

c = (m − + [{m − } −8 ] (3.38)
4 2 4π2 c 2π
12.7 20 + 60 (20 + 60)2 1/2 12.7(60 − 20)2 1/2

c = (135.63 − + [{135.63 − } −8 ]
4 2 4π2 c 2π
c = 303.53 + [11.63 − 160.85]
c = 452.75 mm
3.5.9.3 Power transmit ion chain in to wheel shaft

Harvesting machine operated by 5 kW diesel engines and the speed of engine shaft is 970
rpm and that of rotary is to be 1/3 x 1/3 of 970 rpm. The maximum distance between drive
pulley and rotary shaft is to be 300 mm. calculate a suitable chain drive for the rotary. Since
the speed of diesel engine in the present case is not very high, so we may take lower chain
velocity and a roller chain is selected for the drive. Determine velocity ratio (VR): the velocity
ratio of drive can be determined by following equation
RPM 323.3
VR = RPMe = 107.78 = 3
r
Now, from the chain table which is available in the design handbook for a velocity ratio of 3
say 3. The number of teeth in the pinion is equal to 20.
Number = 20
Nr = Ne x V.R = 20 X 3 =60 teeth
Calculate of chain pitch
c 400
P= = = 13.33 from the to 6.667 mm
30 to 60 30 to 60
77
From the table in design data book we may select standard chain pitch = 12.7 mm
Chain velocity
P RPM m
V = 1000 X XNe (3.39)
60 s
12.7 107.78 m
V= X X20 = 0.45 m/s
1000 60 s
Calculate of load on chain
𝐹𝑐ℎ𝑖𝑎𝑛 = 𝐹 + 𝐹𝐶 + 𝐹𝑓 Ff = Frictional force chain
P(KW)X1000
F = FC = centrifugal load on chain
V
1000
F = 5 kW X = 11111.11 N F = load due to power transmission
0.45
W x V2
Fc = , where; W = 13.6 N/m for duplex chain from design data book
g
13.6 x 0.452
FC = = 0.62 N
9.81
F𝑓 = 𝐾𝑓 ∗ 𝑊 ∗ 𝐶, where;
c = center to center distance (400 mm)
𝐾𝑓 = kinematics friction
For inclined drive (𝐾𝑓 ) =2.0
For horizontal drive (𝐾𝑓 ) = 4.0
For vertical drive (𝐾𝑓 ) = 1.0
𝐾𝑓 = 2 X 13.6 X0.4 m = 10.88 N
𝐹𝐶 = 11111.11 N+ 0.62N+ 10.88 N = 11122.6 N
78
New check the loading strength of chain from the chain table which is available in design
hand book for duplex chain minimum breaking load = 431 KN
Fu breaking load 431X103 N

Fos = = = = 38.75 N
c chain load 11122.6 N
When it is greater than 38.75 N >11.00 N the chain selection for rotary is safe.
Chain length = LC = m x p, when p =chain pitch and m = number of chain link
2𝑐 𝑁𝑟 − 𝑁𝑒 𝑝(𝑁𝑟 − 𝑁𝑒)2
𝑀= + + (3.40)
𝑝 𝑝 4𝜋 2 𝑐
2 x 400 20 + 60 12.7(60 − 60)2

𝑀= + +
12.7 2 4π2 (400)
M = 63 + 40 + 2 = 105 pitches
LC = m x p = 115 x 12.7 =1437.5mm
3.5.9.4 Center to center distance between sprockets
p Ne + Nr (Ne + Nr)2 1/2 p(Nr − Ne)2 1/2

c = (m − + [{m − } − 8 ] (3.41)
4 2 4π2 c 2π
12.7 20+60 (25+60)2 1/2 12.7(60−20)2 1/2
c = (105 − + [{105 − } −8 ]
4 2 4π2 c 2π
c = 374 mm
3.5.9.5 Design chain tension

Design a chain to drive a dynamo generating 5 kW at1/3 0f 970 r.p.m. and fitted with a
sprocket pinion 60 mm diameter.
Allowable stress for belt = 20 MPa
Angle of contact for dynamo pulley = 165°
79
Given: P= 5 kW = 5 × 103 W;
N= 323.33 r.p.m.; d= 60 mm = 0.06 m; η, d = 85% = 0.85; σ= 20 MPa = 20 × 106N/m2
ρ= 1000 kg/m3; θ= 165° = 165 × π/180= 2.88 rad; μ= 0.3
T1= Tension in the tight side of the chain, and
T2= Tension in the slack side of the chain.
We know that velocity of the chain,

π. d. N πX0.06X323.33 M
V= 1+ =1+ = 2.07
60 60 S
5 × 103 = (T1 – T2 ) v (3.42)
= (T1 – T2 )X2.07
= 2.07 (T1 – T2 )
∴ T1 – T2 = 5 x103 /2.07 = 2415.46 N (3.43)
We know that
T1
2.3 log = μ. θ = 0.3 x 2.88 = 0.864
T2
T1 0.864
log = = 0.3756
T2 2.3
T1
= 2.375 (3.44)
T2
From equations ((3.43)) and (3.44), we find that

T1 = 4172.16 N; and T2 = 1756.7 N
3.5.9.6 Design chain tension
Design a chain to drive a dynamo generating 5 kW at1/3 0f 970 r.p.m. and fitted with a
sprocket pinion 120 mm diameter.
80
Allowable stress for belt = 20 MPa

Angle of contact for dynamo pulley = 165°
Given: P= 5 kW = 5 × 103 W;
N= 323.33 r.p.m.; d= 60 mm = 0.06 m; η, d = 85% = 0.85; σ= 20 MPa = 20 × 106N/m2
ρ= 1000 kg/m3; θ= 165° = 165 × π/180= 2.88 rad; μ= 0.3
T1= Tension in the tight side of the chain, and
T2= Tension in the slack side of the chain.
We know that velocity of the chain,
π. d. N πX0.12X323.33 M
V= 1+ =1+ = 3.03
60 60 S
5 × 103 = (T1 – T2 ) v
= (T1 – T2 )X2.07
= 3.03 (T1 – T2 )
∴ T1 – T2 = 5 x103 /2.07 = 1650.16 N (3.45)
We know that
T1
2.3 log = μ. θ = 0.3 x 2.88 = 0.864
T2
T1 0.864
log = = 0.3756
T2 2.3
T1
= 2.375 (3.46)
T2
T1 = 2850.28N; and T2 = 1200.11 N
81
3.5.10 Shaft design

A shaft is a rotating machine element which is used to transmit power from one place to
another. The power is delivered to the shaft by some tangential force and the resultant torque
(or twisting moment) set up within the shaft permits the power to be transferred to various
machines linked up to the shaft. The shafts are usually cylindrical, but may be square or cross-
shaped in section. They are solid in cross-section but sometimes hollow shafts are also used.
But my shaft is cylindrical shape. The design of shaft material, the design of shaft material
will be: -
1. It has high strength.

2. It has good machinability.
3. It has low notch sensitivity factor.
4. It has good heat treatment properties.
5. It has high wear resistant properties.
3.5.10.1 General layout of shaft

The general layout of the shafts, including axial location of pulleys, sprocket gear and
bearings, must now is specified in order to perform a free-body force analysis and to obtain
shear force and bending moment diagrams. If there is no existing design to use as a starter,
then the determination of the shaft layout may have many solutions. A free-body force
analysis can be performed without knowing shaft diameters, but cannot be performed
without knowing axial distances between pulley (sprocket gears) and bearings. Strength of
shaft, in designing shafts on the basis of strength.
(a) Shafts subjected to twisting moment or torque only,
When the shaft is subjected to a twisting moment (or torque) only, then the diameter of the
shaft may be obtained by using the torsion equation.
T = Twisting moment (or torque) acting upon the shaft,

J = Polar moment of inertia of the shaft about the axis of rotation,
Ʈ= Torsional shear stress, and
82
r = d / 2; where d is the diameter of the shaft.
T/Ʈ=Ʈ/r (3.47)
T=(πX Ʈ X d^3)/(16 ) (3.48)
J=π/(16 X d^3 ) (3.49)
3.5.10.2 Frist stage pulley support shaft design

A shaft is supported by two bearings placed 0.7 m apart. A 200 mm diameter pulley is
mounted at a distance of 150 mm to the right of left hand bearing and this drives a pulley
directly below it with the help of belt having tension T11 = 2132.435 N and T12 =
897.87 N [1st stage of belt]. Another Sprocket pinion 60 mm diameter is placed 78 mm to the
left of right hand bearing and is driven with the help of diesel engine and belt having
tension T21 = 4172.16 𝑁 AND T22 = 1756.7 N [2nd stage of belt tension] , which is placed
horizontally to the right and third pulley 120 mm diameter is placed 323 mm to the right hand
bearing a belt having tension T31 = 2850.28N AND T32 = 1200.11 N [2nd stage of belt 2
tension], The angle of contact for both the pulleys is 180° and μ =0.24. Determine the suitable
diameter for a solid shaft, Ultimate tensile strength, 670 MPa. Factor of safety is 2. Assume
that the torque on one pulley is equal to that on the other pulley. Vertical load acting on the
shaft at A, T1 = 2132.435 N; and T2 = 897.87 N
WC1 = T11 + T12 = 2132.435 N + 897.8 N = 3030.235 N And horizontal load on the
shaft at A=0
The vertical load diagram is shown in Fig. 15 (c).
We know that torque acting on the pulley A,
T = (T11 − T12 )R A = (2132.435 N − 897.8 N )0.1 = 123.46 N. M
The torque diagram is shown in Fig. 15 (b).
Vertical load acting on the shaft at B,

WC2 = (T31 + T32 ) = (4172.16 N + 1756.7 N ) = 5928.86 N
83
We know that torque acting on the pulley b,
T = (T21 − T22 )R B = (2850.28N − 1200.11 N )0.3 = 495.051 N. M
We know that torque acting on the pulley C,
WC3 = (T21 + T22 ) = (2850.28N + 1200.11 N ) = 4050.39N
We know that torque acting on the pulley C,
T = (T31 − T32 )R B = (4172.16 N − 1756.7 N )0.3 = 724.638 N. M
The maximum torque at B or C pulley is 289.85 N. M
The torque diagram is shown in Fig. 15 (b).
First of all, considering the vertical loading at C. Let RAV and RBV be the reactions at the
bearings A and B respectively. We know that
R XV + R YV = 3030.235 N + 5928.86 N. M − 4050.39N = 4908.705 N
84
Taking moments about X,
R YV × 0.4 = 4908.705 N × 0.15
R YV = 1840.76 N
and R XV = 3030.235 N – 1840.76 N = 1189.47 N
We know that B. M. at Aand B,
MXV = MYV = 0
B. M. at A, MCV
MAV = R XV × 0.1 = 1189.47 N × 0.1 = 118.9 N. M
B. M. at B, MDV
MBV = R XV × 0.12 = 1189.47 N × 0.12 = 142.7 N. M
B. M. at B, MDV
MCV = R YV × 0.323 = 1840.76 N × 0.323 = 594.56 N. M
The bending moment diagram for horizontal loading is shown in Fig. 16 (f).
horizontal loading is on there fore MXh = 0 and MYh = 0 shown in Fig. 15 (e).
Resultant B.M. at A, √(MAV 2 + MAh 2 = √1189.472 + 02 = 1189.47 N. M
Resultant B.M. at B, √(MBV 2 + 𝑀𝐵ℎ 2 = √142.72 + 02 = 142.7 𝑁. 𝑀
Resultant B.M. at B, √(𝑀𝐶𝑉 2 + 𝑀𝐶ℎ 2 = √594.562 + 02 = 594.56 𝑁. 𝑀
Maximum bending moment
The resultant B.M. diagram is shown in Fig. 16 (g).
85
We see that the bending moment is maximum at B, therefore Maximum B.M,
𝑀 = 𝑀𝐴 = 1189.47 𝑁. 𝑀 𝐴𝑛𝑠.
𝐿𝑒𝑡 𝑑 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡.
𝑊𝑒 𝑘𝑛𝑜𝑤 𝑡ℎ𝑎𝑡 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑡𝑤𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡,
𝑇𝑒 = √𝑀2 + 𝑇 2 = √1189.47 2 + 123.46 2 = 1195.86 𝑁. 𝑀 = 1195.86 𝑋103 𝑁. 𝑚𝑚
𝑊𝑒 𝑎𝑙𝑠𝑜 𝑘𝑛𝑜𝑤 𝑡ℎ𝑎𝑡 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑡𝑤𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡 (𝑇𝑒 ),
Table 4The mechanical properties of these grades of carbon steel Richard G. Budynas and J.
Keith Nisbett (2011)
standard designation Ultimate tensile strength, MPa Yield strength, MPa

40 C 560 - 670 320
45 C 610 - 700 350
50 C 640 - 760 370
50 C 700 Min 390
𝜏 = 0.3 𝜎𝑒𝑙 𝑜𝑟 0.18 𝜎𝑢
478.344 478.344
𝜏 = 0.3 𝑋 1195.86 𝑁. 𝑀 = = = 239.172 𝑚𝑝𝑎
𝑓 1.5
𝜋 ∗ 𝜏 ∗ 𝑑3
𝑇𝑒 =
16
3
𝜋 ∗ 60.3 𝑀𝑃𝑎 ∗ 𝑑 3
1195.86 𝑋10 𝑁. 𝑚𝑚 =
16
16 𝑥 𝑋 1195.86 𝑋103 𝑁. 𝑚𝑚 = 𝜋 ∗ 239.172 𝑚𝑝𝑎 ∗ 𝑑 3
𝑑 3 = 25464.8
𝑑 = 29.42 𝑚𝑚 𝑠𝑎𝑦 30 𝑚𝑚
86
𝐴𝑔𝑎𝑖𝑛 𝑤𝑒 𝑘𝑛𝑜𝑤 𝑡ℎ𝑎𝑡 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡,
𝑀𝑒 = 1/2(𝑀 + √𝑀2 + 𝑇 2 = 1/2(𝑀 + 𝑇𝑒 )
𝑀𝑒 = 1/2( 1189.47 𝑁. 𝑀 + 1195.86 𝑁. 𝑀)
𝑀𝑒 = 1192.665 𝑁. 𝑀
𝑊𝑒 𝑎𝑙𝑠𝑜 𝑘𝑛𝑜𝑤 𝑡ℎ𝑎𝑡 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡 (𝑀𝑒
𝜎𝑏 = 0.6 𝜎𝑒𝑙 𝑜𝑟 0.36 𝜎𝑢

429.3594 429.3594
𝜎𝑏 = 0.36 𝑋 1192.665 = = = 214.67 𝑚𝑝𝑎
𝑓 2
𝜋 ∗ 𝜎𝑏 ∗ 𝑑3
𝑀𝑒 =
16
𝜋 ∗ 214.67 𝑀𝑃𝑎 ∗ 𝑑 3
1192.665 𝑁. 𝑀 𝑋103 𝑁. 𝑚𝑚 =
16
16 𝑋 1192.665 𝑋103 𝑁. 𝑚𝑚 = 𝜋 ∗ 214.67𝑀𝑃𝑎 ∗ 𝑑 3
𝑑 3 = 28295.5
𝑑 = 30 𝑚𝑚
87
Bending, torque and load diagram of Frist stage pulley support shaft design
A C 𝑇11 A
0.2 m B 0.06 m 𝑇31
XY
B
0.1 M 0.02m 0.08m 0.323m 𝑇12 𝑇21 𝑇22 𝑇32

(a) torque diagram
289.85 289.85
3030.6 𝑁 0 5928.86 N (𝒃)𝒗𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝒍𝒐𝒂𝒅
0 4050.4 N 0 (𝒄)𝒉𝒐𝒓𝒛𝒐𝒏𝒕𝒂𝒍 𝒍𝒐𝒂𝒅
1189.47 𝑁. 𝑀 594.56 𝑁. 𝑀
(𝑑)𝒗𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑩. 𝑴 𝒅𝒊𝒂𝒈𝒓𝒂𝒎
142.7 𝑁. 𝑀
𝒉𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑩. 𝑴 𝒅𝒊𝒂𝒈𝒓𝒂𝒎
1189.47 N. M 142.7 N. M 594.56 N. M 𝒓𝒆𝒔𝒖𝒍𝒕𝒂𝒏𝒕 𝑩. 𝑴 𝒅𝒊𝒂𝒈𝒓𝒂𝒎
Figure 37 Bending, torque and load diagram of shaft
88
3.5.10.3 Second stage Pulley support shaft design
Shafts subjected to twisting moment or torque only,

A shaft supported at the ends in ball bearings carries a straight tooth spur gear at its mid span
and is to transmit 5 kW at 161.67 r.p.m. The pitch circle diameter of the pulley is 150 mm. The
distances between the center line of bearings and pulley are 100 mm each. If the shaft is made
of steel and the Ʈ u = 610MPa = 610 N/mm2, determine the diameter of the shaft. Show in a
sketch how the gear will be mounted on the shaft; also indicate the ends where the bearings
will be mounted? Factor of safety is 4
L= 40 mm = 0.04 m; Ʈ u = 610MPa = 610 N/mm2
𝜏𝜇 610
𝜏= = = 152.5𝑁/𝑚𝑚2
𝑓 4
Let d = Diameter of the shaft.
𝑃 ∗ 60 5000𝑤 ∗ 60 300000
𝑇1 = = = = 295.33 𝑁. 𝑚 = 295333 𝑁. 𝑚𝑚
2𝜋𝑁 2𝜋𝑁 2𝜋 ∗ 161.67
𝑇 = 295.33𝑁. 𝑚𝑚
We also know that torque transmitted by the shaft (T),

3 3
𝜋𝑋 𝑋 𝑑 𝜋𝑋 152.5 𝑋 𝑑
295333 𝑁. 𝑚𝑚 = =
16 16
d 3=295333 𝑁. 𝑚𝑚 4/29.94 N.mm
d3 =9863𝑚𝑚 3
d =21.44 mm say 25 mm shaft diameter
3.5.10.3.1Shafts Subjected to Bending Moment Only

𝑃 ∗ 60 5000𝑤 ∗ 60 300000
𝑇1 = = = = 295.33 𝑁. 𝑚 = 295333 𝑁. 𝑚𝑚
2𝜋𝑁 2𝜋𝑁 2𝜋 ∗ 161.67
𝑇1 = 295333 𝑁. 𝑚𝑚
89
Since the sprocket is mounted at the middle of the shaft, therefore maximum bending
moment at the center of the sprocket,
𝑊𝐿 4050.39 𝑁 ∗ 800 𝑚𝑚
𝑀= =
4 4
M = 810078 N.mm
We know that equivalent twisting moment.
Te = √𝑀2 + 𝑇 2 =√(810078 𝑁. 𝑚𝑚)2 + (295333 𝑁. 𝑚𝑚)2
Te = 862234.3 N.mm
862234.3N.mm = π /16 x Ʈ x do 3(1-k4) = π /16 x 40 Mpa x d 3 x (1-0.84)
𝜋𝑋 Ʈ 𝑋 𝑑3 𝜋𝑋 152.5 𝑋 𝑑3
862234.3 N. mm = =
16 16
d 3=862234.3N.mm 4/29.943 N.mm
d3 =28795.8 𝑚𝑚 3
d =30 mm shaft diameter

3.5.10.4 Wheel shaft design subjected to twisting moment or torque
The design of cylindrical key way Shaft rotating at 107.78 r.p.m. is to transmit 5 KW. The shaft
may be assumed to be made of mild steel with an Ultimate tensile stress of 610 MPa. A shaft
is supported by two bearings placed 1 m apart. A 300 mm diameter sprocket is mounted at a
distance of 160 mm to the right of left hand bearing and this drives a sprocket directly below
it with the help of chain having maximum tension of 11.92 KN. The angle of contact for both
the pulleys is 180° and μ =0.24. Determine the diameter of the shaft, neglecting the bending
moment on the shaft. Assume a factor safety as 4
N = 107.78 r.p.m.;
P = 5,000 W;
90
Ʈ u = 610MPa = 610 N/mm2
𝜏𝜇 610
𝜏= = = 152.5𝑁/𝑚𝑚2
𝑓 4
𝑃 ∗ 60 5000𝑤 ∗ 60 300000
𝑇1 = = = = 443 𝑁. 𝑚 = 443008 𝑁. 𝑚𝑚
2𝜋𝑁𝐺 2𝜋𝑁𝐺 2𝜋 ∗ 107.78
𝑇 = 443008 𝑁. 𝑚𝑚
We also know that torque transmitted by the shaft (T),
𝜋𝑋 Ʈ 𝑋 𝑑3 𝜋𝑋 152.5 𝑋 𝑑3
443008 𝑁. 𝑚𝑚 = =
16 16
d 3=443008𝑁. 𝑚𝑚 4/29.943 N.mm

d3 =14795.06 𝑚𝑚 3
d =24.5mm say 25 mm shaft diameter
(b) Shafts subjected to bending moment only,
(c) Shafts subjected to combined twisting and bending moments, and
(d) Shafts subjected to axial loads in addition to combined torsional and bending loads.
We shall now discuss the above cases, in detail, in the following pages.
3.5.10.5 Shafts Subjected to Bending Moment Only
When the shaft is subjected to a bending moment only, then the maximum stress (tensile or
compressive) is given by the bending equation.
M = Bending moment,
I = Moment of inertia of cross-sectional area of the shaft about the axis of rotation,
𝛿𝑏 = Bending stress, and
y = Distance from neutral axis to the outer-most fiber.
We know that for a round solid shaft, moment of inertia
91
y=d/2
𝜋 𝑋 𝑑4 𝑑
𝑇= 𝑦=
64 2
𝜋 ∗ 𝛿𝑏 ∗ 𝑑3
𝑀=
16
3.5.10.6 The design of Shafts Subjected to Bending Moment
The design of cylindrical key way Shaft rotating at 107.78 r.p.m. is to transmit 5 KW. The shaft
may be assumed to be made of mild steel with an Ultimate tensile stress of 610 MPa. A shaft
is supported by two bearings placed 1 m apart. A 120 mm diameter sprocket is mounted at a
distance of 160 mm to the right of left hand bearing and this drives a sprocket directly below
it with the help of chain having maximum tension of 11.92 KN. If the shaft is made of steel and
the allowable shear stress is 152.5 MPa, determine the diameter of the shaft. Show in a sketch
how the gear will be mounted on the shaft; also indicate the ends where the bearings will be
mounted? The pressure angle of the gear may be taken as 20°.length of shaft is 1000 mm.
N = 107.78 r.p.m.;
P = 5,000 W;
Ʈ u = 610MPa = 610 N/mm2
𝜏𝜇 610
𝜏= = = 152.5𝑁/𝑚𝑚2
𝑓 4
𝑃 ∗ 60 5000𝑤 ∗ 60 300000
𝑇1 = = = = 443 𝑁. 𝑚 = 443008 𝑁. 𝑚𝑚
2𝜋𝑁𝐺 2𝜋𝑁𝐺 2𝜋 ∗ 107.78
𝑇 = 443008 𝑁. 𝑚𝑚
2𝑇 443008 𝑁. 𝑚𝑚
𝐹= = 𝑇𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑡ℎ𝑒 𝑆𝑝𝑟𝑜𝑐𝑘𝑒𝑡 𝑔𝑒𝑎𝑟
𝐷 120
Ft = 3691.73 N
W = Ft/COS α =3691.73 N/COS 200
92
𝐹𝑡 3691.73 N 𝑁
𝑊= =
𝐶𝑂𝑆 𝛼 𝐶𝑂𝑆 200
W = 3928.6 N
Since the sprocket is mounted at the middle of the shaft, therefore maximum bending
moment at the center of the sprocket,
𝑊𝐿 = 3928.6 𝑁 ∗ 1000 𝑚𝑚
𝑀= =
4 4
M = 982165.14 N.mm
We know that equivalent twisting moment.
Te = √𝑀2 + 𝑇 2 =√443008 𝑁. 𝑚𝑚2 + 982165.14 N. mm2
Te = 1077452.76 N.mm
1077452.76 N.mm = π /16 x Ʈ x do 3(1-k4) = π /16 x 40 Mpa x d 3 x (1-0.84)
𝜋𝑋 Ʈ 𝑋 𝑑3 𝜋𝑋 152.5 𝑋 𝑑3
1077452.76 𝑁. 𝑚𝑚 = =
16 16
d 3=1077452.76 N.mm 4/29.943 N.mm

d3 =35983.46 𝑚𝑚 3
d =33 mm say 35 mm shaft diameter
Step 1 calculation of reactions
The two reaction (RA and RB) of the beam are obtained from a transverse EE and a rotational
EE written at E, which is the midpoint of the distributed load P. distributed load P1 which is
found on the middle part of the machine and distributed load P2 which is found on the front
part of the machine
𝑃 𝑙𝑜𝑎𝑑 = 𝑚 ∗ 𝑔
mass on the middle part of the machine 90kg and front part of the machine 60 kg
𝑃𝑑 𝑙𝑜𝑎𝑑 1 = 𝑚𝑚𝑖𝑑𝑑𝑙𝑒 ∗ 𝑔
93
𝑃 𝑙𝑜𝑎𝑑 1 = 90 𝑘𝑔 ∗ 9.81 𝑚/𝑠 2
𝑃𝑙𝑜𝑎𝑑 1 = 882.9 𝑁
𝑃 𝑙𝑜𝑎𝑑 2 = 𝑚𝑓𝑟𝑜𝑛𝑡 ∗ 𝑔
𝑃𝑙𝑜𝑎𝑑 2 = 60 𝑘𝑔 ∗ 9.81 𝑚/𝑠 2
𝑃𝑑 𝑙𝑜𝑎𝑑 2 = 588.6 𝑁
𝑃𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑 = 882.9 𝑁 + 588.6 𝑁
𝑃𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑 = 1471.5 𝑁
∑ 𝑀: 𝑅𝐴 + 𝑅𝐵 − 𝑃𝑦𝑡𝑜𝑡𝑎𝑙 = 0
𝑦
𝑅𝐴 + 𝑅𝐵 − 𝑃 𝑙𝑜𝑎𝑑 1 − 𝑃 𝑙𝑜𝑎𝑑 2 = 0
𝑅𝐴 + 𝑅𝐵 − 1471.5 𝑁 = 0
∑ 𝑀: 0 ∗ 𝑀𝑅𝐴 + 1 ∗ 𝑀𝑅𝐵 − 0.1𝑚 ∗ 𝑃𝑑 𝑙𝑜𝑎𝑑 1 − 0.99𝑚 ∗ 𝑃𝑑𝑖𝑠 𝑙𝑜𝑎𝑑 2 = 0

𝑎
0 + 1𝑀𝑅𝐵 − 0.1𝑚 ∗ 882.9 𝑁 − 0.99𝑚 ∗ 588.6 𝑁 = 0
1.1𝑀𝑅𝐵 − 88.29𝑁𝑚 − 582.714 𝑁𝑀 = 0
1.1𝑀𝑅𝐵 = 671 𝑁𝑚
𝑅𝐵 = 671 𝑁𝑚/1.1 𝑚
𝑅𝐵 = 610 𝑁
𝑡ℎ𝑒 𝑟𝑒𝑠𝑢𝑙𝑡 𝑜𝑓 𝑅𝐴 𝑖𝑠
𝑅𝐴 + 𝑅𝐵 − 1471.5 𝑁 = 0
610 𝑁 + 𝑅𝐵 − 1471.5 𝑁 = 0
𝑅𝐵 = 861.5 𝑁
94
Bending, torque and load diagram of wheel shaft design
A C 𝑇21 𝑇21
0.4 m B 0.15 m
X Y
B
0.2m 0.6m
(a) torque diagram
142.7 N. m
(𝒃)𝒗𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝒍𝒐𝒂𝒅
861.5 𝑁 N 1650.17 N 610 N (𝒄)𝒉𝒐𝒓𝒛𝒐𝒏𝒕𝒂𝒍 𝒍𝒐𝒂𝒅
(𝑑)𝒗𝒆𝒓𝒕𝒊𝒄𝒂𝒍 𝑩. 𝑴 𝒅𝒊𝒂𝒈𝒓𝒂𝒎
142.7 𝑁. 𝑀
𝒉𝒐𝒓𝒊𝒛𝒐𝒏𝒕𝒂𝒍 𝑩. 𝑴 𝒅𝒊𝒂𝒈𝒓𝒂𝒎
142.7 N. M 𝒓𝒆𝒔𝒖𝒍𝒕𝒂𝒏𝒕 𝑩. 𝑴 𝒅𝒊𝒂𝒈𝒓𝒂𝒎
Figure 38 Bending, torque and load diagram of shaft
95
3.5.11 Bearing Selection

Bearing is used to support a load while permitting relative motion between two elements of
a machine. The term rolling contact bearings refers to the wide variety of bearings that use
spherical balls or some other type of roller between the stationary and the moving
elements. The most common type of bearing supports a rotating shaft, resisting purely
radial loads or a combination of radial and axial (thrust) loads. Some bearings are designed
to carry only thrust loads. Most bearings are used in applications involving rotation, but
some are used in linear motion applications. According to the design Ball select bearing
[Richard G. Budynas and J. Keith Nisbett (2011)].
The main advantages of ball bearings are
1. Low starting and running friction except at very high speeds.
2. Ability to withstand momentary shock loads.
3. Accuracy of shaft alignment.
4. Low cost of maintenance, as no lubrication is required while in service.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.
8. Cleanliness.
Figure 39 bearing[Richard G. Budynas and J. Keith Nisbett (2011)
96
select six different ball bearings according to the shaft diameter

 Four 30mm bearings (20mm is internal diameter of bearing or the shaft diameter)
 One 35mm bearing
3.5.11.1 Bearing selection for input shaft
By selecting ball bearings for the intermediate shaft for above reason with a reliability of 99
percent. The problem specifies a design life of 12 000 h. The intermediate shaft speed
is1250 rev/min. The estimated bore size is 35mm and the estimated bearing width is
30mm. From the free-body diagram of above first shaft;
RAV = 3030.6 N RAH = 1189.47N RAR = 3255.67N
RBV = 4050.39 𝑁 RBH = 594.56 N RBR = 4093.8 N
At the shaft speed of 250rev/min, the design life of 12 000 h correlates to a bearing life of
LD = (12 000 h) (60 min/h) (1250 rev/min) = 9 × 108 rev.
Since the average life of the bearing is 5 years at 10 hours per day, therefore life of the
bearing in hours,
LH = 5 × 300 × 10 = 15 000 hours ... (Assuming 300 working days per year) and life of the
bearing in revolutions,
L = 60 N × LH = 60 × 1250 × 15 000 = 1.125 × 107 rev
𝐶
F=CO =R𝑓 [𝑋 ] 1/b (3.50)
𝑂 +(𝜃−𝑋𝑂 )(1−𝑅𝑒)
Where F = Basic static load rating or, the design load
RF =reaction force at the bearing
C = Basic dynamic load rating,
97
Re = reliability
x = life measure dimensionless vitiate, L/L10
X0 = guaranteed, or “minimum,’’ value of the vitiate x0 = 0.02
Characteristic parameter corresponding to the 63.2% value of the vitiate, which is
(θ − x0) =4.439 from Richard G. Budynas and J. Keith Nisbett (2011)
b = shape parameter that controls the skew mess for ball bearing b = 1.483.
𝐿𝐷 9 × 108
C= = = 1.125 × 107 = 80
𝐿
Since the maximum reaction force is at point A we must do the design load this reaction
force
RA =6264.83N
𝐶
F=CO =R𝑓 [𝑋 ] 1/b (3.51)
𝑂 +(𝜃−𝑋𝑂 )(1−𝑅𝑒)
80
F=CO =6264.83N[0.02+(4.439)(1−0.99)] 1/1.483 =764498.45N =764.5KN
From Table VI, the bearing number 200 having C = 43Kn with bore diameter=10mm, outside
diameter=35mm, and width of 13mm may be selected, and the bearing number 202 having C
= 160kN, which bore diameter=15mm, outside diameter=35mm, and width of 11mm may be
selected.
3.5.11.2 Bearing selection for intermediate shaft

By selecting ball bearings for the intermediate shaft, for above reason with a reliability
of 99 percent The problem specifies a design life of 12 000 h. The intermediate shaft speed
is 250 rev/min. The estimated bore size is 60mm and the estimated bearing width is 30mm.
From the free-body diagram of above wheel shaft;
RAH = 90 N RBH = 60 N RBR = 108.16 N
98
From the free-body diagram of above;

RAV = 775N RAH = 316N RAR = 946.65N
RBV = 1200N RBH = 446N RBR = 1466.35
At the shaft speed of 250rev/min, the design life of 12 000 h correlates to a bearing life of
LD = (12 000 h) (60 min/h) (250 rev/min) = 1.8 × 108 rev.
Since the average life of the bearing is 5 years at 10 hours per day, therefore life of the
bearing in hours,
LH = 5 × 300 × 10 = 15 000 hours ... (Assuming 300 working days per year) and life of the
bearing in revolutions,
L = 60 N × LH = 60 × 250 × 15 000 = 22.5 × 106 rev
𝐶
F=CO =R𝑓 [𝑋 ] 1/b (3.52)
𝑂 +(𝜃−𝑋𝑂 )(1−𝑅𝑒)
Where F = Basic static load rating or, the design load
RF =reaction force at the bearing
C = Basic dynamic load rating,
Re = reliability
x = life measure dimensionless variate, L/L10
X0 = guaranteed, or “minimum,’’ value of the variate x0 = 0.02
Characteristic parameter corresponding to the 63.2121 percentile value of the variate,

which is (Θ − x0) =4.439
b = shape parameter that controls the skew ness for ball bearing b = 1.483.
𝐿𝐷 1.8 × 108
C= = = 22.5 × 106 = 80
𝐿
Since the maximum reaction force is at point B we must do the design load by this reaction
force
99
RB =1466.35
1/b
𝐶
𝐹 = 𝐶𝑂 = R𝑓 = [ ]
𝑋𝑂 + (𝜃 − 𝑋𝑂 )(1 − 𝑅𝑒)
𝟏/𝟏.𝟒𝟖𝟑
80
𝐹 = 𝐶𝑂 = 1466.35 [ ] = 178939N = 179KN
0.02 + (4.439)(1 − 0.99)
From Table above, the bearing number 204 having C = 160kN, width bore
diameter=20mm, outside diameter=47mm, and width of 14mm may be selected, and the
bearing number 206 having C = 160kN, with bore diameter=30mm, outside diameter=62mm,
and width of 16mm may be selected.
3.5.12 design and select cutter bar and cutter guard lips.
The cutter bar consists of a single action cutter bar, which has 28 knifes triangular in shape
located above fixed one has the same number of guards. The cutter bar is 140 cm in length
takes its reciprocating motion from the machine engine through transmission system.
Figure 40cutter bar
Figure 41 cutter bar and cutter guard lips [D. N sharma; S.mukesh (2008 and 2010).]
100
3.5.12.1 Size and shape of knife section:

It is selected based on following parameters: [D. N sharma; S. mukesh (2008 and 2010).]
(i) Gripping of stalk by cutting pair: The crop is cut by impact and shear action between
the knife section and guard lip. Owing to the deflection of the crop, the height of
stubble is somewhat greater than the height of the cutter bar above ground surface.
For normal cutting action, the stalk should be pinched between cutting edge of knife
and guard lip as given in Fig. 41 This condition is satisfied when
< 𝛼 + < 𝛽 ≤< 𝜑1 +< 𝜑2 (3.53)
where, < 𝛼 = angle between cutting edge and axis of knife section
< 𝛽 = angle between cutting edge and axis of twin guard
< 𝜑1 & < 𝜑2 = angles of friction between the crop and cutting edge of knife and
guard lip respectively
(ii) Rake angle, sharpness and thickness of cutting edge: According to Klenin (1985) the
knives of rake angle of 22 0 are sharp for longer time but force requirement for
cutting is higher as compared to rake angle of 19 0, But, with the existing tool
grinders the rake angle obtained varies from 22-25 0. So, rake angle of 22 0 with
sharp cutting edges is selected for the knife section. Thickness of knife section
should not exceed 120-130 um for most of the cereals.
(iii) Pitch of serrated knives: In order to avoid slipping off the stalks, the knife section
should be serrated. The pitch of serrated knives is selected two or three times
smaller than the diameter of paddy and wheat stalk i.e. the pitch should be 1-1.2
mm.
(iv) Clearance between knife section and twin guard: Best results are obtained when
clearance between knives and ledger plates is maintained at 0.3 mm. So, a clearance
of 0.5-1.0 mm is selected.
(v) Velocity of knife section: The cutting of stalk is greatly affected by knife speed. The
velocity of knife section is expressed as:
𝑉𝑘 = 𝑅 ∗ 𝑉𝑚 (3.54)
101
where, 𝑉𝑘 = average knife velocity, m/s

𝑉𝑚 = forward speed of machine, m/s
R = velocity ratio
Type of cutter bar: A reciprocating type cutter bar having standard knife section of 76.2 mm
stroke length and two cuts per stroke is selected. Number of knife sections required for the
cutter bar of Reaper machine would be:
On the basis of above discussed design parameters, the dimensions of different components
of crop cutting unit selected.
𝑁𝐶 = 𝐿𝑐 /𝐿𝑘 (3.55)
𝑁𝐶 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑢𝑡𝑡𝑒𝑟 𝑏𝑎𝑟
𝐿𝐾 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑘𝑛𝑖𝑓𝑒(7.62 cm)
𝐿𝐶 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡𝑡𝑒𝑟 𝑏𝑎𝑟(120 𝑐𝑚)
120
𝑁𝐶 = = 15.77 ~15
7.62
𝑁𝐶 = 15
3.5.12.2 Calculate knife velocity

For best results, according to Klenin (1985) for cc of 3 1 0 the knife velocity should be .5
m/s. The value of R ranges from 1.3 to 1.4 with available cutter knives (Bansal, 1989).
Taking 'R' as 1 .3 and 𝑉𝑚 -of 5.0 km/hr (l .39 m/s) and putting values in eqn. 4.3, we get
𝑉𝑘 = 1.3 x 1.17 m/s = 1.52 m/s Also,
we know that
𝑁𝑘
𝑉𝑘 = 𝑋 ∗ (3.56)
30
𝑤ℎ𝑒𝑟𝑒,
𝑋 = 𝑠𝑡𝑟𝑜𝑘𝑒 𝑙𝑒𝑛𝑔𝑡ℎ 7.62 𝑚𝑚
𝑁𝑘 = 𝑅𝑃𝑀 𝑜𝑓 𝑘𝑛𝑖𝑓𝑒 𝑠𝑒𝑐𝑡𝑖𝑜𝑛
102
30 30
Therefor, 𝑁𝑘 = 𝑉𝑘 ∗ 𝑋 = 1.52 𝑚/𝑠 (100 𝑐𝑚/𝑚 ∗ 7.62)
𝑁𝑘 = 598.42 𝑟𝑝𝑚
𝑁𝑘 = 598.42 𝑟𝑝𝑚 𝑜𝑟 𝑠𝑎𝑦 600 𝑟𝑝𝑚.
For a standard 76.2 mm knife section, the above velocity translates into 1280 strokes/min
or 640 rpm of knife section. Now, we know that engine rpm = 3200 rpm. Assume a speed
reduction of 1: 2 from engine to intermediate shaft and I: 3 from intermediate
shaft to cutter bar shaft. Therefore, Knife rpm ( 𝑁𝑘 ) is given by
7.4 1
𝑁𝑘 = 970 𝑟𝑝𝑚 ∗ ∗ ∗ 3 = 598.16 𝑟𝑝𝑚 𝑜𝑟 𝑠𝑎𝑦 600 𝑟𝑝𝑚.
12 3
Assume 10% slippage in belt drives
Therefore,
90
𝑁𝑘 = 485 𝑟𝑝𝑚 ∗ = 540 𝑟𝑝𝑚
100
The actual average knife speed of cutter bar of self-propelled reaper would be
7.62
𝑁𝑘 = 540 𝑟𝑝𝑚 (30∗100) = 1.372 𝑚/𝑠
For this knife speed rake angle of 190-220 is selected.
3.5.12.3 Forward speed of self-prospered riding reaper machine

Check for self-propelled riding reaper forward speed: The power tiller is powered by a 5 hp,
970 rpm diesel engine. It is fitted with iron wheels with outside diameter of 40 cm. The engine
is fitted with 6 cm diameter pulley and there is speed reduction at two stages and overall
transmission speed ratio of 18: l.
Therefore, theoretical forward speed of power tiller is
𝑉𝑚 = 𝐷𝑤 𝑥 970 / (60 𝑥 6) = 𝜋 𝑥 40 𝑥 970/ (60𝑥100𝑥6) = 3 .386 𝑚/𝑠 Assuming 15-25%-

wheel slippage during motion of reaper.
𝑚 75
Therefore, actual speed of VCR𝑉𝑚1 = 3 .386 ∗ 100 = 2.56 𝑚/𝑠 or 9.14 km/hr.
𝑠
103
3.5.12.4 Forces acting on cutter bar of a reaper
Figure 42 reciprocating knife type cutter bar [N sharma; S. mukesh (2008 and 2010)]
𝑝 = 𝑝𝑐 + 𝑝𝑓 + 𝑝𝑖 (3.57)
𝑝 − 𝑡𝑜𝑡𝑎𝑙 𝑟𝑒𝑠𝑖𝑠𝑡𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒 𝑖𝑛 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑏𝑎𝑟, 𝑁 𝑜𝑟 𝐾𝑔
𝑝𝑐 − 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑜 𝑐𝑢𝑡𝑡𝑖𝑛𝑔, 𝑁 𝑜𝑟 𝐾𝑔
𝑝𝑓 − 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑁 𝑜𝑟 𝐾𝑔
𝑝𝑖 − 𝑖𝑛𝑒𝑟𝑡𝑖𝑎 𝑓𝑜𝑟𝑐𝑒 𝑜𝑓 𝑘𝑛𝑖𝑓𝑒 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑁 𝑜𝑟 𝐾𝑔
Where,
Resistance to cutting (Pc): To estimate resistance to cutting for cereal crops, it is

assumed that the plants are uniformly distributed in the rows and two rows will be cut by
manually operated machine.
𝑃𝐶 = 𝐸. 𝐹1 𝑁⁄𝑋 (3.58)
𝐶
𝐸 = 1.25𝑁 − 𝑐𝑚/𝑐𝑚2 𝑓𝑜𝑟 𝑤ℎ𝑒𝑎𝑡 𝑎𝑛𝑑 2.0𝑁 − 𝑐𝑚/𝑐𝑚2 𝑓𝑜𝑟 𝑟𝑖𝑐𝑒
𝐹𝑙 = 𝑘𝑛𝑖𝑓𝑒 𝑙𝑜𝑎𝑑 𝑎𝑟𝑒𝑎; 41.9 𝑐𝑚2 𝑓𝑜𝑟 𝑎 𝑠𝑖𝑛𝑔𝑙𝑒 𝑠𝑡𝑟𝑜𝑘𝑒 𝑐𝑢𝑡𝑡𝑒𝑟 𝑤𝑖𝑡ℎ 5.5 𝑐𝑚 𝑘𝑛𝑖𝑓𝑒 𝑠𝑤𝑒𝑒𝑝
Where, length of knife (x)=7.62 cm
𝑘𝑛𝑖𝑓𝑒 𝑙𝑜𝑎𝑑 𝑎𝑟𝑒𝑎 = 7.62 cm ∗ 5.5 cm = 41.9 𝑐𝑚2
𝑁 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑘𝑛𝑖𝑓𝑒 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑠 𝑖𝑛 𝑐𝑢𝑡𝑡𝑒𝑟 𝑏𝑎𝑟, 15 𝑓𝑜𝑟 120 𝑐𝑚 𝑐𝑢𝑡𝑡𝑒𝑟 𝑏𝑎𝑟
104
𝑋𝑐 = 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝑜𝑓 𝑘𝑛𝑖𝑓𝑒 𝑓𝑟𝑜𝑚 𝑠𝑡𝑎𝑟𝑡 𝑡𝑜 𝑒𝑛𝑑 𝑜𝑓 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 (2.811 𝑐𝑚 𝑓𝑜𝑟 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑
𝑘𝑛𝑖𝑓𝑒 𝑠𝑒𝑐𝑡𝑖𝑜𝑛)
𝑃𝐶 = 𝐸. 𝐹1 𝑁⁄𝑋 𝑃𝐶 = 1.25 ∗ 41.9 ∗ 15⁄2.81

𝐶
PC = 279.58 N in wheat crop
𝑃𝐶 = 𝐸. 𝐹1 𝑁⁄𝑋 𝑃𝐶 = 2 ∗ 41.9 ∗ 15⁄2.81

𝐶
PC =447.33 N in rice crop
3.5.12.4.1Inertia force (Fl): the inertia is governed by the mass (Mk) of reciprocating
cutter bar which is given by [(3.58)]

𝑃𝑙 = 𝑟. 𝜔2 . 𝑀𝑘 (1 − 𝑥⁄𝑟 ) (3.59)
Where,
𝑀𝑘 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑘𝑛𝑖𝑓𝑒 𝑠𝑒𝑐𝑡𝑖𝑜𝑛, 𝑘𝑔
𝑟 = 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑐𝑟𝑟𝑎𝑛𝑘, 𝑐𝑚
𝑟𝑎𝑑
𝜔 = 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, , 0.84
𝑠
𝑥 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠𝑡𝑟𝑜𝑘𝑒, 𝑐𝑚
𝑃𝑙 = 𝑟. 𝜔2 . 𝑀𝑘 (3.60)
For reaper weight of cutter bar per meter length is 20-22 Weight (𝑀𝑘 ) of 120 cm long 28 N.
at V m/sec and r= 3.81 cm of a 120 cm long cutter bar.
𝑃𝑙𝑚𝑎𝑥 = 3.81 𝑐𝑚 ∗ (0.84)2 ∗ 21 𝑁
𝑃𝑙𝑚𝑎𝑥 = 56.45 𝑁
Frictional force(𝑝𝑓 ): it acts on the knife as it slides over the finger bar and is given by
𝑝𝑓 = 𝑝𝑓1 + 𝑝𝑓2 (3.61)
105
𝑝𝑓1=force due to weight of cutter bar, N
𝑝𝑓2 = 𝑓𝑜𝑟𝑐𝑒 𝑑𝑢𝑒 𝑡𝑜 𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑛𝑔 𝑟𝑜𝑑, 𝑁
𝑝𝑓1 = 𝑀𝑘 ∗ 𝑓 (3.62)
𝑓 = 0.2 𝑡𝑜 0.3 𝑡𝑎𝑘𝑒 𝑎𝑠 0.25
𝑝𝑓1 = 28 ∗ 0.25
𝑝𝑓1 = 7 𝑁
𝑝𝑓2 𝑖𝑠 𝑡ℎ𝑒 𝑓𝑜𝑟𝑐𝑒 𝑐𝑎𝑢𝑠𝑒𝑑 𝑏𝑦 𝑛𝑜𝑟𝑚𝑎𝑙 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑜𝑓 𝑖𝑡𝑠 𝑓𝑜𝑟𝑐𝑒 𝑒𝑥𝑒𝑟𝑡𝑒𝑑 𝑏𝑦 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑛𝑔
𝑟𝑜𝑑 𝑜𝑛 𝑘𝑛𝑖𝑓𝑒 𝑎𝑠 𝑢𝑛𝑑𝑒𝑟:
For wheat crops , r =3.81 cm and l 10 cm,𝑡𝑎𝑛 𝛽 = 0.22 𝑎𝑛𝑑 𝑝𝑐 = 335.5 𝑁 )
𝑡𝑎𝑛 𝛼
𝑝𝑓2 = {(𝑝𝑐 + 𝑝𝑙𝑚𝑎𝑥 + 𝑝𝑓1 ) − }∗𝑓 (3.63)
𝑙 − 𝑓 𝑡𝑎𝑛 𝛽
𝑡𝑎𝑛 290
𝑝𝑓2 = {( 279.58 N + 56.45 𝑁 + 7 𝑁) − ( )} ∗ 0.25
𝑙 − 0.25 𝑡𝑎𝑛 220
𝑝𝑓2 = {343.03 − (0.616)} ∗ 0.25
𝑝𝑓2 = 85.6035 𝑁
For rice crops , r =3.81 cm and l 10 cm,𝑡𝑎𝑛 𝛽 = 0.22 𝑎𝑛𝑑 𝑝𝑐 = 536.8 𝑁 )
𝑡𝑎𝑛 290
𝑝𝑓2 = {(447.33 N + 56.45 𝑁 + 7 𝑁) − ( )} ∗ 0.25
𝑙 − 0.25 𝑡𝑎𝑛 220
𝑝𝑓2 = {510.78 − (0.63)} ∗ 0.25
𝑝𝑓2 = 127.5 𝑁
Therefore, the total friction force (𝑝𝑓 ) for wheat crops is
𝑝𝑓 = 𝑝𝑓1 + 𝑝𝑓2
𝑝𝑓1 = 7 𝑁
106
𝑝𝑓2 = 85.6035 𝑁
𝑝𝑓 = 7 𝑁 + 85.6035 𝑁 = 92.6 𝑁
Therefore, the total friction force (𝑝𝑓 ) for rice crops is 𝑝𝑓 = 𝑝𝑓1 + 𝑝𝑓2
𝑝𝑓1 = 7 𝑁
𝑝𝑓2 = 127.5 𝑁
𝑝𝑓 = 7 𝑁 + 127.5 𝑁 = 134.54 N
Therefore, the total resisting the motion cuter bar for wheat crop is
𝑝 = 𝑝𝑐 + 𝑝𝑓 + 𝑝𝑖 (3.64)
𝑝 = 279.58 𝑁 + 92.6 𝑁 + 56.45 𝑁 = 298.1 𝑁
Therefore, the total resisting the motion cuter bar for rice crop is
𝑝 = 𝑝𝑐 ∗ 𝑝𝑓 ∗ 𝑝𝑖 𝑝
𝑝 = 447.33 N ∗ 134.54 N ∗ 56.45 𝑁 = 638.32 N
Power requirement of reaper machine: Total power required for operation of self-
propelled harvesting machine (𝑊𝑚 ) is given by the equation [(3.63)
where, 𝑊𝑚 = 𝑊𝑟 + 𝑊𝑛 + 𝑊𝑤 (3.65)
𝑊𝑟 =power for rolling machine,
𝑊𝑛 = power for no-load working of parts of machine,
𝑊𝑤 = power required for full load working of machine, w
Power for rolling of machine (𝑊𝑟 ) is given by
𝑊𝑟 = 𝑝 ∗ 𝑣/(𝜂𝑡𝑟 ∗ 𝜂𝑠 ) (3.66)
where, P = resistance to rolling of machine,
𝜂𝑡𝑟 = transmission efficiency, percentage
𝜂𝑠 = coefficient of skidding of machine
107
According to Devnani (1985), the power required for cutting crop at a knife speed of 1.372
m/s of cutter bar can be taken as 0.513 hp/m length of cutter bar and power required for
conveying cut crop as 50% of the cutting' power.
Therefore, power required for full load working of machine 𝑊𝑤 = 𝑊𝑐 + 𝑊𝑐𝑜𝑛
𝑊𝑤 = 0.513 ℎ𝑝 + 50% 𝑜𝑓 0.513 ℎ𝑝
𝑊𝑤 = 0.513 𝑘𝑊 + 0.2565 ℎ𝑝
𝑊𝑤 = 0.7695 ℎ𝑝
Power for rolling of machine (𝑊𝑟 ) is estimated as: W F P, v/75.
Let the coefficient of rolling resistance be 0.2 and weight of machine as 250 kg operating at a
forward speed of 2.54 m/s.
Therefore, 𝑊𝑟 = 250 𝑘𝑔 ∗ 0.2 ∗ 2.54 /75 = 1.7 ℎ𝑝
Total power W = 𝑊𝑤 + 𝑊𝑟 = 0.7695 hp + 1.7 hp = 2.47 hp.
Assuming 90% power transmission efficiency at each stage and there would be three
reductions from engine to cutting and conveying unit and two reductions from engine to
drive wheels of power tiller. Let us assume, the average efficiency as 70%.
Therefore, power requirement of self-propelled riding reaper = 2.47 /0.70 = 3.53 hp.
Therefore, 5 hp. diesel engine will be adequate to operate the machine in the actual field
conditions for harvesting of crop.
3.5.13 Finger Conveyor design and developed

In a pin jointed four bar mechanism, as shown in Fig. 4.23, AB = 325 mm, BC = 300, CD =
100mm, and AD = 320 mm. The angle BAD = 60°. The crank AB rotates uniformly at 138.57
r.p.m. Locate all the instantaneous centers and find the angular velocity of the link BC. [R.S.
KHURMI and J.K. GUPTA (2005)].
138.57
𝑁𝐴𝐵 = 138.57 r. p. m or 𝜔𝐵𝐴 = 2π ∗ = 14.51 rad/s
60
108
Since the length of crank AB = 325 mm = 0.325 m, therefore velocity of point B on link AB,
Figure 43 Finger Conveyor
𝑉𝐵 = 𝜔𝐵𝐴 ∗ AB = 14.51 rad/s ∗ 0.325 = 4.716 m/s
Location of instantaneous centers

The instantaneous centers are located as discussed below: [Richard G. Budynas and J. Keith
Nisbett (2011)].
1. Since the mechanism consists of four links (i.e. n = 4), therefore number of instantaneous
centers,
𝑛(𝑛 − 1) 4(4 − 1)
𝑁= = =6
2 2
2. For a four bar mechanism, the book keeping table may be drawn as discussed in Art. 6.10.
3. Locate the fixed and permanent instantaneous centers by inspection. These centers are
I12, I23, I34 and I14, as shown in Fig. 35.
109
4. Locate the remaining neither fixed nor permanent instantaneous centers by Aron hold
Kennedy’s theorem. This is done by circle diagram as shown in Fig. 36. Mark four points
(equal to the number of links in a mechanism) 1, 2, 3, and 4 on the circle
Figure 44 Finger Conveyor angular velocity
5. Join points 1 to 2, 2 to 3, 3 to 4 and 4 to 1 to indicate the instantaneous centers already

located i.e. I12, I23, I34 and I14.
6. Join 1 to 3 to form two triangles 1 2 3 and 3 4 1. The side 13, common to both triangles,
is responsible for completing the two triangles. Therefore, the instantaneous center I13
lies on the intersection of the lines joining the points I12I23 and I34 I14 as shown in Fig. 36.
Thus center I13 is located. Mark number 5 (because four instantaneous centers have
already been located) on the dotted line 1, 3.
7. Now join 2 to 4 to complete two triangles 2 3 4 and 1 2 4 The side 2 4, common to both
triangles, is responsible for completing the two triangles. Therefore, center I24 lies on the
intersection of the lines joining the points I23 I34 and I12 I14 as shown in Fig. 37. Thus center
I24 is located. Mark number 6 on the dotted line 2 4. Thus all the six instantaneous
centers are located.
Figure 45 angular velocity

110
Angular velocity of the link BC

Let 𝜔𝐵𝐶 = Angular velocity of the link BC.
Since B is also a point on link BC, therefore velocity of point B on link BC,
𝑉𝐵 = 𝜔𝐵𝐴 ∗ I13 (3.67)

By measurement, we find that I13 B = 480 mm = 0.48 m
𝑉𝐴 4.716 m/s
𝜔𝐵𝐶 = = = 9.825 𝑟𝑎𝑑/𝑠
B ∗ I13 0.48
a Space diagram (All dim. in mm). b, Velocity diagram c, Acceleration diagram.

Figure 46 angular acceleration
Since the length of crank CD = 100 mm = 0.1 m, therefore velocity of B with respect to A or
velocity of B, (because A is a fixed point),

m
vectors ab = 𝑉𝐵𝐴 = 𝑉𝐵 = 𝜔𝐵𝐴 ∗ 𝐶𝐷 = 4.716 ∗ 0.1mm
s
𝑉𝐵 = 0.4716 𝑚/𝑠
First of all, draw the space diagram to some suitable scale, as shown in Fig. 46 (a). Now the
velocity diagram, as shown in Fig. 46 (b), is drawn as discussed below: [R.S. KHURMI and J.K.
GUPTA 2005]
111
1. Since the link AD is fixed, therefore points a and d are taken as one point in the velocity
diagram. Draw vector ab perpendicular to BA, to some suitable scale, to represent the
velocity of B with respect to A or simply velocity of B (i.e. VBA or VB) such that
vector ab = VDC = VC = 0.4716 m/s
2. Now from point b, draw vector bc perpendicular to CB to represent the velocity of C with
respect to B (i.e. VCB) and from point d, draw vector dc perpendicular to CD to represent
the velocity of C with respect to D or simply velocity of C (i.e. VCD or VC). The vectors bc
and dc intersect at b. By measurement, we find that
𝑉𝐴𝐵 = 𝑉𝐵 = vectors ab = 0.361 𝑚/𝑠
We know that BA = 325 mm = 0.325 m
∴Angular velocity of link BA,
𝑉𝐴𝐵 0.361 𝑚/𝑠

𝜔𝐵𝐴 = = = 1.11 𝑟𝑎𝑑/𝑠(𝑠clockwise about 𝐴)
BA 0.325 m
We know that angular velocity of link BC=300mm=0.3mm, the vectors bc and ba intersect at
𝑚 𝑚
c. By measurement, we find that 𝑉𝐵𝐶 = vectors bc = 0.251 𝑎𝑛𝑑 𝑉𝐵𝐶 = 0.321
𝑠 𝑠
𝑉𝐵𝐶 0.251 𝑚/𝑠

𝜔𝐵𝐶 = = = 0.83735 𝑟𝑎𝑑/𝑠(Anticlockwise)
BC 0.3 m
and angular velocity of link AB,
𝑉𝐵𝐴 0.251 𝑚/𝑠

𝜔𝐴𝐵 = = = 0.772 𝑟𝑎𝑑/𝑠(Clockwise)
BA 0.325 m
Angular acceleration of links CB and BA
Since the angular acceleration of the crank DC is not given, therefore there will be no
tangential component of the acceleration of C with respect to D.
112
We know that radial component of the acceleration of C with respect to D (or the
acceleration of C),
𝑉 2 𝐶𝐷 0.47162 m/s
𝜔𝑟 𝐶𝐷 = 𝜔𝐶𝐷 = 𝜔𝐶 = = = 2.224 𝑟𝑎𝑑/𝑠
CD 0.1 m
Radial component of the acceleration of B with respect to C,
𝑉 2 𝐶𝐵 0.251 𝑚/𝑠
𝜔𝑟 𝐶𝐵 = = = 0.837 𝑟𝑎𝑑/𝑠
CB 0.3 m
and radial component of the acceleration of B with respect to A (or the acceleration of B),
𝑉 2 𝐵𝐴 0.321 𝑚/𝑠
𝜔𝑟 𝐶𝐵 = = = 0.99 𝑟𝑎𝑑/𝑠
BA 0.325 m
The acceleration diagram, as shown in Fig. 46 (c) is drawn as follows:
1. Since d and a are fixed points, therefore these points lie at one place in the acceleration
diagram. Draw vector d'c' parallel to DC, to some suitable scale, to represent the radial
component of acceleration of C with respect to D or acceleration of C i.e aCr d or aQ such that
vectors D′ C′ = 𝑎𝑟 𝐶𝐷 = 0.4716 m/s
2. From point c', draw vector c' x parallel to CB to represent the radial component of
acceleration of B with respect to C i.e. 𝑎𝑟 𝐵𝐶 such that
vectors C′ 𝑥 = 𝑎𝑟 𝐶𝐵 = 0.251 𝑚/𝑠
3. From point x, draw vector xb' perpendicular to QR to represent the tangential component
of acceleration of B with respect to c i.e BC at whose magnitude is not yet known.
4. Now from point A', draw vector A'y parallel to AB to represent the radial component of the
acceleration of B with respect to A i.e. BA ab such that
vectors A′ 𝑥 = 𝑎𝑟 𝐵𝐴 = 0.321 𝑚/𝑠
5. From point y, draw vector yb' perpendicular to AB to represent the tangential component
113
of acceleration of B with respect to A i.e. 𝑎𝑟 𝐵𝐴 at.

6. The vectors xb' and yb' intersect at b'. Join d 'b and d' b'. By measurement, we find that
𝑎𝑡 𝐵𝐶 = vectors B′ 𝑥 = 0.64 rad/𝑠 2 , 𝑎𝑡 𝐵𝐴 = vectors b′ 𝑦
We know that angular acceleration of link CB,
𝑎𝑡 𝐵𝐶 0.251 𝑚/𝑠
𝑎𝑡 𝐵𝐶 = = = 0.772 𝑟𝑎𝑑/𝑠
CB 0.3 m
and angular acceleration of link BA,
𝑎𝑡 𝐵𝐴 0.251 𝑚/𝑠
𝑎𝑡 𝐵𝐶 = = = 0.772 𝑟𝑎𝑑/𝑠
BA 0.325 m
3.5.14 design spring on hinder
In a spring loaded reaper binding as shown in Fig. 38, the cutting crops binding put on the
vertical arms of the binder lever, the horizontal arms of which lift the sleeve against the
pressure exerted by a spring. The mass of binding crops is 10 kg and the lengths of the vertical
and horizontal arms of the binding crank lever are 400 mm and 150 mm respectively. Design
a suitable close coiled round section spring for the governor. From Table IV Assume
permissible stress in spring steel as 420 MPa, modulus of rigidity 84 kN/mm2 and spring
index 8. Allowance must be made for stress concentration, factor of which is given by [R.S.
KHURMI and J.K. GUPTA 2005].
4𝐶 − 1 0.615
+ 𝑤ℎ𝑒𝑟𝑒 𝐶 𝑖𝑠 𝑡ℎ𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 𝑖𝑛𝑑𝑒𝑥
4𝐶 − 4 𝐶
r1 r
r
r2
crop 0.4M δ
crop
δ1
1
0.1M 1 11 δ2
1111
11 211 m
211
21
Figure 47 crop binder spring design
114
We know that the spring force.

𝑥 𝑚 0.5𝑚
𝑆1 = 𝑀𝑥𝑔 𝑥 𝑟1 𝑥 = 10 𝑘𝑔 𝑥 9.81 2 0.9𝑚 𝑥
𝑦 𝑠 𝑥 0.1𝑚
𝑆 = 441.45 𝑁
𝑥 𝑚 0.5𝑚
𝑆2 = 𝑀𝑥𝑔 𝑥 𝑟2 𝑥 = 10 𝑘𝑔 𝑥 9.81 2 0.5𝑚 𝑥
𝑦 𝑠 𝑥 0.1𝑚
𝑆1 = 245.25𝑁
compression of the spring,
𝑦 𝑦
𝛿 = (𝑟1 − 𝑟)𝑥 + (𝑟2 − 𝑟)𝑥 (3.68)
𝑥 𝑥
0.1 0.1
𝛿 = (0.9 − 0.5)𝑥 + (0.5 − 0.5) 𝑥 0.08𝑚 = 80𝑚𝑚
0.5 0.5
Diameter of the spring wire
Let d = Diameter of the spring wire in mm.
We know that Wahl’s stress factor,
4𝐶 − 1 0.615 4𝑥8 − 1 0.615
𝑘= + = + = 1.184
4𝐶 − 4 𝐶 4𝑥8 − 4 4
We also know that maximum shear stress (𝜏)
8𝑥𝑤𝑥𝑐 8𝑥441.45 𝑁𝑥8
𝜏 = 𝑘𝑥 = 1.184 𝑥 (𝑆𝑢𝑏𝑠𝑡𝑖𝑡𝑢𝑡𝑖𝑛𝑔 𝑊 = 𝑆, 𝑡ℎ𝑒 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑠𝑝𝑟𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒)
𝜋𝑑 2 𝜋𝑑2
𝑑 2 = 10647.9/420 = (25.35)2 = 5.035𝑚𝑚
From Table V, we shall take the standard wire of size SWG 1 having diameter
(d) = 5.38 mm Ans.
Mean diameter of the spring coil
Let D = Mean diameter of the spring coil. We know that the spring index,
C = D/d or D = C.d = 8 × 5.38 = 46.64 mm Ans.
Number of turns of the coil
Let n = Number of active turns of the coil.
We know that compression of the spring (δ),
8𝑥𝑤𝑥𝑐 3 𝑥𝑛
𝑠= (3.69)
𝐺𝑥𝑑 2
115
8𝑥196.2𝑥83 𝑥𝑛
80𝑚𝑚 = . . . (𝑆𝑢𝑏𝑠𝑡𝑖𝑡𝑢𝑡𝑖𝑛𝑔 𝑊 = 𝑆1 − 𝑆2 )
84𝑥103 𝑥5.382
𝑛 = 44.4~45
and total number of turns using squared and ground ends,
n' = n + 2 =45 + 2 = 47
Free length of the coil
Since the compression produced under a force of 245.25𝑁 is 80 mm, therefore maximum
compression produced under the maximum load of 441.45 N is,
80 𝑚𝑚
𝛿𝑚𝑎𝑥 = 𝑥441.45 = 144𝑚𝑚
245.25
We know that free length of the coil,
𝐿𝐹 = 𝑛, 𝑥𝑑𝑥𝛿𝑚𝑎𝑥 + 0.15𝛿𝑚𝑎𝑥 = 144𝑚𝑚
𝐿𝐹 = 47, 𝑥5.3𝑥144 + 0.15𝑥144 = 418.46 𝑚𝑚
Pitch of the coil
We know that pitch of the coil
free length 418.46

pitch of the coil = ,
= = 9.1
𝑛 −1 47 − 1
3.5.15 Steering
When the vehicle is moving straight on a flat surface, the direction of the center of gravity
(CG) keeps the same with the orientation of the vehicle. When the reaper turns, the yaw rate
causes the change of the orientation. The reaper demonstrates a velocity component
perpendicular to the orientation, known as the lateral velocity. Then, the orientation of the
vehicle and the direction of the travel are no longer the same. The vehicle is moving under
the influence of different forces. If a lateral force is acting on the tire, an angle is formed
between the direction of movement of the tire and the tire straight line. This angle is called
116
the sideslip angle 𝛼 (shown in Fig. 48). Reason for this sideslip angle or the tire slip is the
elastic lateral deflection of the rolling tire in the tire contact area under the effect of the
lateral force between tire and road. For analyzing the motion behaviors of a single track
model, a linearization of the tire lateral force and the tire slip angle is assumed via a tire
stiffness 𝐶𝑎 [Lorenzo Morello, Lorenzo Rosti Rossini, Giuseppe Pia and Andrea Tonoli (2011)].
𝐹𝑎
𝐶𝑎 = (3.69)
𝛼
When the vehicle moves at low speed, the wheels roll without a tire slip angle since the
lateral cornering force, 𝐹𝑎 , is small and can be ignored. The vehicle model can be seen as the
assumption of Rudolf Ackermann with the elongations of all wheel center lines intersecting
at one point, the center of the turning curve (Fig. 48).
The steering angle, 𝛿 , can be simply calculated as:
𝑙
𝛿 = 𝑎𝑟𝑐𝑡𝑎𝑛 ( )
𝑟
r: radius of the curve (r=10)
𝑙
𝛿 = 𝑎𝑟𝑐𝑡𝑎𝑛 ( ) = 0.11 𝑟𝑎𝑑 = 6.30
10 𝑚
𝑙 𝛿
𝑐
Figure 48 The steering angle
117
However, when the lateral force appears, the vehicle front wheel orientation and the vehicle
movement direction is no longer the same. A simplified description of the vehicle lateral
dynamics is demonstrated in a reaper wheel model (Fig.49). The tire contact points are in
the center of tires. Longitudinal forces in the tire contact points as well as wheel load
fluctuations are not considered. The height of the center of gravity is zero. The Newton’s law
equation of the motion for the vehicle lateral direction is: [Lorenzo Morello, Lorenzo Rosti
Rossini, Giuseppe Pia and Andrea Tonoli [2011].
𝑚𝛼𝑦 = 𝐹𝐼𝑓 + 𝐹𝐼𝑟 (3.70)
The force of inertia acting on the vehicle center of gravity, 𝑚𝛼𝑦 , corresponds to the
centrifugal force:
𝑣2 𝑣
𝑚𝛼𝑦 = 𝑚 + 𝐹𝐼𝑟 + 𝑚 𝑣̇ 𝑟 = 𝑚𝑣(Ψ̇ − 𝛽̇ ) (3.71)
𝑟 𝑟
𝑣2
𝐹𝑐𝑒𝑛𝑡 = 𝑚 (3.72)
𝑟
Where;
m = mass of the machine (250 kg)
v = velocity (2.54 m/s)
r: radius of the curve (r=10)

2.54 m/s 2
𝐹𝑐𝑒𝑛𝑡 = 250 𝑘𝑔
10 𝑚
𝐹𝑐𝑒𝑛𝑡 = 63.5 𝑁
Moment balance in front point,
𝐹𝑐𝑒𝑛𝑡 𝑙𝑓 = 𝐹𝐼𝑟 𝑙 (3.73)
𝑙𝑓 0.6
𝐹𝐼𝑟 = 𝐹𝑐𝑒𝑛𝑡 = 63.5 𝑁 ∗
𝑙 1.1
𝐹𝐼𝑟 = 34.63 𝑁
𝑙𝑟 0.5
𝐹𝐼𝑓 = 𝐹𝑐𝑒𝑛𝑡 = 63.5 𝑁 ∗
𝑙 1.1
𝐹𝐼𝑟 = 28.86 𝑁
118
Where;
𝑙𝑓 = 0.6 𝑚
𝑙𝑟 = 0.5 𝑚
𝑙 = 1.1 𝑚
Ψ 𝛼𝑟
𝛽 𝐹𝑐𝑒𝑛𝑡 𝑙𝑓 𝐹𝑙𝑓
𝑙𝑟
𝛼𝑟 𝐹𝐿𝑟 𝑙
Figure 49 Deflection of the rolling tire by a lateral cornering force

where, 𝑣 : Vehicle velocity, 𝜔 : Vehicle angular velocity, r : radius of curve, Ψ : Yaw angle, 𝛽 :
Side slip angle, 𝛿 : Steering angle, a : Tire slip angle, l : Wheel base. And the gyroscopic effect
on the z-axis at the vehicle center of gravity:
𝐽Ψ̈ = 𝐹𝐼𝑓 𝑙𝑓 + 𝐹𝐼𝑟 𝑙𝑓 (3.74)
where J is the vehicle moment of inertia on z-axis. The tire side forces can be calculated from
the given tire slip rigidity, 𝑐𝑎 , in equation ((3.74)) for the front wheel:
𝐹𝐼𝑓 = 𝑐𝑎𝑓 𝑎𝑓 (3.75)

And for the rear wheel
𝐹𝐼𝑟 = 𝑐𝑎𝑟 𝑎𝑟 (3.76)
and from the rear tire slip, 𝑎𝑟 :
119
𝐹𝐼𝑟
𝑎𝑟 = (3.77)
𝑐𝑎𝑟
Assume;
𝑐𝑎𝑟 = 𝑐𝑎𝑓 = 𝑓𝑜𝑟 𝑠𝑚𝑎𝑙𝑙 𝑡𝑖𝑟𝑒 30,000N/rad
34.63 𝑁
𝑎𝑟 =
30,000N/rad
180𝑜 ∗ 0.00115 𝑟𝑎𝑑

𝑎𝑟 = 0.00115 𝑟𝑎𝑑 = = 0.066 𝑜
𝜋
𝐹𝐼𝑓
𝑎𝑓 = (3.78)
𝑐𝑎𝑓
28.86 𝑁 𝑁
𝑎𝑓 =
30,000N/rad
180𝑜 ∗ 0.000962 𝑟𝑎𝑑

𝑎𝑓 = 0.000962 𝑟𝑎𝑑 = = 0.055 𝑜
𝜋
The side slip angle for the vehicle at the center of gravity, 𝛽 , can be formulated from the
front tire slip, 𝑎𝑓 :
𝑙𝑓 Ψ̇
𝑎𝑓 = 𝛿 + 𝛽 − (3.79)
𝑣
𝑙𝑓 Ψ̇
𝛼𝑟 = 𝛽 + (3.80)
𝑣
It is noted that the tire slip rigidity or the sideslip stiffness, 𝑐𝛼 , is an elastic property for
each rubber tires, normally in the range of 30,000-50,000 N/rad.
3.5.15.1 STEERING IN STEADY STATE
In steady state condition, the vehicle speed, v, is a constant, then, the yaw velocity Ψ̇ , and
the sideslip, 𝛽, are also constant, i.e, Ψ̈ = 0 and 𝛽̇ = 0. The torque balance equations can be
formulated at the rear contact point:
120
𝐹𝐿𝑓𝑙 = 𝑚𝛼𝑦 𝑙𝑟 (3.81)
Replaced with the tire slip rigidity in equation (3.81):
𝑙𝑓 Ψ̇ 𝑙𝑟
𝑐𝑎𝑓 [ 𝛿 + 𝛽 − ] = 𝑚𝑎𝑦 (3.82)
𝑣 𝑙
And in equation (3.81):
𝑙𝑟 Ψ̇ 𝑙𝑓
𝑐𝛼𝑟 [𝛽 + ] = 𝑚𝛼𝑦 (3.83)
𝑣 𝑙
𝑣
Because in the steady state, 𝛽 = 0 , then from equation (3.80),Ψ = 𝑟. The transformation
from equation ((3.86)) and ((3.87)) leads to:
𝑙 𝑚 𝑙𝑟 𝑙𝑓
𝛿= + [ − ]𝑎 (3.84)
𝑟 𝑙 𝑐𝛼𝑓 𝑐𝛼𝑟 𝑦
From the above equation, the necessary steering angle, 𝛿 , during the steady state driving
𝑙
along a curve composes of two parts. The first part, 𝑟, or Ackermann angle, depends on the
𝑚 𝑙 𝑙
vehicle geometrical parameters. And the second part, [𝑐 𝑟 − 𝑐 𝑓 ] 𝑎𝑦 , is characterized by the
𝑙 𝛼𝑓 𝛼𝑟
𝑙 𝑙
influences of the lateral acceleration and the tire rigidities, which can increase, if [𝑐 𝑟 > 𝑐 𝑓 ],
𝛼𝑓 𝛼𝑟
𝑙𝑟 𝑙𝑓
or reduce, if [𝑐 < 𝑐 ], the steering angle.
𝛼𝑓 𝛼𝑟
From equation ((3.83)) and ((3.84)), the sideslip angle difference between the front and the
rear wheel is:
𝑙𝑓 Ψ̇
∆𝛼 = 𝛼𝑓 − 𝛼𝑟 = 𝛿 − (3.85)
𝑣
𝑙
With 𝑣 = Ψ̇𝑟 , then,. ∆𝛼 = 𝛿 − 𝑟 Replace with 𝛿 in equation ((3.85)):
𝑚 𝑙𝑟 𝑙𝑓
∆𝛼 = [ − ]𝑎 (3.86)
𝑙 𝑐𝛼𝑓 𝑐𝛼𝑟 𝑦
Calculate 𝛽
121
𝑙𝑟 Ψ̇ 𝑙𝑟
𝛽= − 𝛼𝑟 = 𝛼𝑟 − (3.89)
𝑣 𝑟
0.6
𝛽 = 0.0136 𝑟𝑎𝑑 −
10
0
𝛽 = −2.66
From equation ((3.84)) Calculate 𝛿
𝑙𝑓
𝛿 = 𝑎𝑓 − 𝛽 + (3.90)
𝑟
𝛿 = 00.055 + 2.660 + 2.8660
𝑜
𝛿 = 5.570
Assess the stationary steering behavior of this vehicle.
∆𝛼 = 𝛼𝑓 − 𝛼𝑟
∆𝛼 = 0.055 𝑜 − 0.066 𝑜
∆𝛼 = −0.011 𝑜
Then, the difference of the sideslip angles depends on the vehicle and the tire parameters.
The driver has to compensate the sideslip angle difference, ∆𝛼 , with the steering angle, 𝛿 .
This forms a basic knowledge of oversteer and under-steer definition: Over-steer is if ∆𝛼 =
𝛼𝑓 − 𝛼𝑟 < 0, neutral is if ∆𝛼 = 𝛼𝑓 − 𝛼𝑟 = 0 and under-steer is if ∆𝛼 = 𝛼𝑓 − 𝛼𝑟 > 0 fig ()
Go out
Go in
Figure 50 Over-steer (left) and Under-steer (right)
Under-steer and over-steer are vehicle dynamic characteristics used to demonstrate the
sensitivity of a vehicle steering system. The under-steer happens if the vehicle turns less
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than the steering control of the driver. Conversely, over-steer happens if the vehicle turns
more than the steering control of the driver.
3.5.15.2 Steering in Transient Response
Transformation of equations ((3.80)-(3.86)) can lead to the following expressions:
𝑙𝑓 Ψ̇ 𝑙𝑟 Ψ̇
𝑚𝑣(Ψ̇ − 𝛽̇ ) = 𝑐𝑎𝑓 [ 𝛿 + 𝛽 − ] + 𝑐𝑎𝑟 [𝛽 + ] (3.91)
𝑣 𝑣
And
𝑙𝑓 Ψ̇ 𝑙𝑟 Ψ̇
𝐽𝑧 Ψ̈ = 𝑐𝑎𝑓 [ 𝛿 + 𝛽 − ] 𝑙𝑓 + 𝑐𝑎𝑟 [𝛽 + ]𝑙 (3.92)
𝑣 𝑣 𝑟
Equation ((3.92)) can be represented by yaw velocity,
𝑚𝑣𝛽̇ + 𝑐𝑎𝑓 ( 𝛿 + 𝛽) + 𝑐𝑎𝑟 𝛽

Ψ̇ = (3.93)
𝑙𝑓 𝑙
𝑚𝑣 − 𝑐𝑎𝑟 𝑣 + 𝑐𝑎𝑓 𝑣𝑟
For the steady state, v = const., then, Ψ̈:
𝑚𝑣𝛽̈ + 𝑐𝑎𝑓 ( 𝛿̇ + 𝛽̇ ) + 𝑐𝑎𝑟 𝛽̇

Ψ̈ = (3.94)
𝑙𝑓 𝑙
𝑚𝑣 − 𝑐𝑎𝑟 𝑣 + 𝑐𝑎𝑓 𝑣𝑟
Replace Ψ̇ and Ψ̈ in equation (3.91):
𝑐𝑎𝑓 + 𝑐𝑎𝑟 𝑐𝑎𝑓 𝑙𝑓2 + 𝑐𝑎𝑟 𝑙𝑟2 𝑐𝑎𝑓 𝑙𝑟 + 𝑐𝑎𝑟 𝑙𝑓 𝑐𝑎𝑓 𝑙𝑓2 + 𝑐𝑎𝑟 𝑙𝑟2
̈
𝛽+[ + ̇
]𝛽 + [ + ]𝛽 (3.94)
𝑚𝑣 𝑣𝐽𝑧 𝐽𝑧 𝐽𝑧 𝑚𝑣 2
𝑐𝑎𝑓 𝑙𝑓 𝑐𝑎𝑓 𝑐𝑎𝑟 (𝑙𝑓 𝑙𝑟 + 𝑙𝑟2 𝑐𝑎𝑓

=[ + ] 𝛿 − 𝛿̇ (3.95)
𝐽𝑧 𝐽𝑧 𝑚𝑣 2 𝑚𝑣
The characteristic polynomial of the dynamic equation in ((3.95)) can be represented in an

inhomogeneous linear differential equation of 2nd order for the vehicle slip angle 𝛽 . The
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homogeneous part of this differential equation has the form of a simple oscillating motion
with damping:
𝛽̈ + 𝐴𝛽̇ + 𝐵𝛽 = 0
or in the vibrated frequency form:
𝜔𝑜2 + 2𝐷𝜔𝑜 𝑠 + 𝑠 2 = 0
Thus, the differential equation for the slip angle 𝛽 can be viewed with a yaw undamped
natural frequency, 𝜔𝑜 :
𝑐𝑎𝑟 𝑙𝑟 − 𝑐𝑎𝑓 𝑙𝑓 𝑐𝑎𝑓 𝑙 2

𝜔𝑜 = √ +
𝐽𝑧 𝐽𝑧 𝑚𝑣 2
Where:
𝐽𝑧 = 1960 𝑘𝑔𝑚2
30,000 ∗ (0.6) − 30,000(0.5) 30,000(1.1)2

𝜔𝑜 = √ +
1960 1960 ∗ 250(2.54)2
𝜔𝑜 = √1.53
𝜔𝑜 = 1.24
𝑐𝑎𝑓 𝑙𝑟 + 𝑐𝑎𝑟 𝑙𝑓 𝑐𝑎𝑓 𝑙𝑓2 + 𝑐𝑎𝑟 𝑙𝑟2
+
𝐽𝑧 𝐽𝑧 𝑚𝑣 2
𝐷=
2𝜔𝑜
30,000 ∗ (0.6) + 30,000(0.5) 30,000(0.6)2 + 30,000(0.5)2
+
1960 1960 ∗ 250(2.54)2
𝐷=
2(1.24)
165.115
𝐷=
2(1.24)
165.115
𝐷=
2(1.24)
𝐷 = 66.58
Then, the dynamic yaw frequency, 𝜔𝑜𝑚𝐷 , 𝑖𝑠:
124
𝜔𝑜𝑚𝐷 = √1 − 𝐷2 𝜔𝑜
𝜔𝑜𝑚𝐷 = √1 − 66.582 ∗ 1.24
𝜔𝑜𝑚𝐷 = 82.56
The yaw natural frequency and damping rate can be represented for the movement of the
vehicle around the vertical axis (z).
3.6 Production Ramp-Up

3.6.1 Prototype development
Before a new machine is built, it must be researched, designed, and developed into a workable
product. Researchers analyze market trends, consumer surveys, and buying patterns to
determine what consumers want, and then suggest what kinds of cars to make. Designers
work to shape these new ideas into tangible parts or products. Engineers adapt existing parts
for the new model and draw up new plans for the prototype. A prototype is a custom-built
working example of a new design. Manufacturers begin by building a few prototypes before
they set up a factory to build the new car. Product planners monitor the process along the
way and make sure that an approved new car program finishes on time and within budget.
3.6.2 Modeling of Reaper machine
Before going to making prototype, the modeling of the Self-Prospered Reaper Harvesting
Machine should be made. The figure given below shows the model of the Reaper machine
made in CATIA V5-R19 software. For the designing of the reaper prototype, factors such as
working width, minimum ground clearance were taken into consideration, finger conveyor
and binding mechanism along with the harvesting methods. The designed prototype
consisted of a cutter, a driving and braking system, a steering system, and a drive train, such
that it was able to cut two rows of soybean stalks with a single cut and combine the cut
portions into a single row. The prototype drove with three wheels (a two front wheel and one
rear wheels). The rear wheels provided the driving function and the front wheel provided the
steering function.
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Figure 51 Isometric front view of reaper machine by CATIA V5

126
3.6.3 Manufacturing process of machine components
manufacturing process are the steps through which raw materials are transformed into a final
product. The manufacturing process begins with the product design, and materials
specification from which the product is made. These materials are then modified through
manufacturing processes to become the required part. For manufactured parts process
procedure, better to use process sheet method.
3.6.3.1 Uses of process sheet

A process sheet is a very important document which forms a basis for all Methodology, scheduling
and dispatching function; also it helps in advance planning and for purchase of raw materials,
design and manufacture of special tools, jigs, fixtures and inspection devices. Its helps in estimating
the cost of the product before is an actually manufactured. It also helps in planning for man power
required for doing the job.
Table 5 uses of process sheet
No of Description of Machine tool Positioning Measuring tool

jobs operation and clamping
1. Inspection of row blank Measuring tool Reference Venire caliper, and
Size and material type point spectrometer
2. Profile cutting and hole Lathe machine Reference profile gauge and
making Fixture angle gauge
3. Burrs removing Bench work Vise Visual inspection
4. Profile cutting Milling lathe Fixture Visual inspection
5. tampering Electric Packing Surface hardens
furnace container inspection
6. welding Arc welding - Angle gauge
7. Surface treatment Bath Fixture Visual inspection
(cleaning and coloring) and coloring
thickness
tester
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3.6.3.2 Frame and body Manufacturing process

 First prepare a biller material from a sheet metal to the specified sheet material
by primary process
 Second: - measure and cots frame material to the require dimensions
 Bending and welding
 Joint support material with bending by using rivet or bolt with nut
3.6.3.3 Finger conveyor Manufacturing process
 First prepare a biller material from a cast material according to the specified
finger conveyor material by primary process.
 Second: - Bending and welding billet material to the require.
 Pin joint movable material for conveyor mechanism.
3.6.3.4 Crop Binder Manufacturing process

 First prepare a biller material from a cast material according to the specified
finger conveyor material by primary process.
 Second: - Bending and welding billet material to the require.
 Pin joint movable material for conveyor mechanism.
 Connect with spring.
3.6.3.5 Shafts Manufacturing process

 First prepare a biller material from a cast material according to the specified shaft
material by primary process
 Second: - roll the billet material to the require dimensions either by hot rolling
and subsequent turning to the correct size or by cold rolling to the final size
 Finally provide generous filet radius in stepped point and surface finish by
machining in order to reduce stress concentrations.
3.6.3.6 Pulley Manufacturing process

The pulley can be manufactured by
 Permanent mold casting
128
 pulley cutters
But it is proffered that the pulley must me manufactured with CNC gear hobbling machine
with the specified pulley materials.
3.6.3.7 Keys Manufacturing process
 Keys can be manufacture in a milling machine to the required dimensions
3.6.3.8 Tapestry driver sit Manufacturing process

 First prepare a biller material from a foam and synthetic lather to the specified
dimensions.
 Cover driver sit by foam and synthetic lather
3.6.3.9 Standard parts

Standard parts of the reaper machine like, sprocket gear, chain, bolts, nuts and bearings can
be manufactured by the standard manufacturing procedures.
3.6.4 Assembly and disassembly procedure
3.6.4.1 Assembly
When assembling the reaper harvesting machine
All necessary bolts, screws, rivets, nuts, washers and locking devices are to be furnished as
assembly material for the equipment. All bolts and screwed rods shall be galvanized including
the threaded portions. All nuts shall be galvanized with the exception of the threads, which
shall be oiled.
Where for any type of reaper machine parts tensile steel bolts are employed then bolts of this
type shall be used for all connections for every type of reaper machine parts on that line in
order to avoid the use of mild steel bolts in error where high tensile type should be employed.
High tensile steel bolts shall bear a mark on the heads to allow identification of grades.
All type of washers shall be included under this Contract, including locking devices and anti-
vibration arrangements, which shall be subject to the approval of the Engineer. Taper
washers shall be fitted where necessary. Nuts shall be finger tight on the bolt and will be
129
rejected if they are, in the opinion of the Engineer, considered to have an excessively loose or
tight fit. Nuts and bolts of the same size shall be interchangeable and supplied from one
manufacturer. The Manufacturer shall supply the net quantities plus 5 percent of all
permanent bolts, screws, nuts and other similar items and materials required for installation
of the works at the site.
3.6.4.2 Disassembly
When disassembling the reaper harvesting machine
1. Remove the assembly wheel using proper tools for removing the bolts
2. Remove the belt in the engine pulley and first stage pulley
3. Remove the engine on the engine supporter
4. Remove the chain and sprocket gear using proper tools for removing the bolts
5. Remove the shaft where service is needed by smoothly rotating it to disengage the
meshing gear on it. Then Remove the bearing.
6. Remove the gears by sliding over the shaft to a direction where a lower diameter is found.
and finally remove the keys to finalize the overall disassembly.
130
Finger conveyor
Crop Binder
Figure 52 Manufacturing process
131
Figure 53 Manufacturing process
132
CHAPTER FOUR
4 Results and Discussion
In this study, the discussions will cover the effect of harvesting systems as function of
machines forward speeds and crop collecting on total grain losses, cutting efficiency, field
capacity and efficiency, energy consumed and total cost. requirements for harvesting wheat
crop. The mechanization of self-prospered riding reapers machine operation is essential to
increase performances of field capacity, field efficiency, cutting efficiency by reduce manual
effort, the hardness of collecting crops or making bundles. During harvesting of the crop the
cutting unit collects the harvest crop from on both left and right side and pushes towards the
middle position of machine for dropping or released to the ground in the form of bundles the
bundles where the machine powered by 5 kW, single cylinder, water cooled diesel engine
having rated engine speed of 970rpm. the Reaper machine frame structure designed and
developed according to crop binding mechanism.
4.1 Working principle of self-prospered reapers harvesting machine

Working width of the reaper machine 120 cm and length of the reaper machine are 200 cm
and100 cm Height of the machine. the crop is conveyed vertically by finger conveyor to the
binding mechanism and released to the ground in the form of bundles. During harvesting of
the crop the cutting unit collects the harvest crop from on both left and right side and pushes
towards the middle position of machine for dropping the bundles where the machine
powered by 5 kW, 4 cylinder, water cooled diesel engine having rated engine speed of
970rpm. It has reciprocating cutter bar of cutting width about 120 cm which get rotary
motion powered also from the diesel engine and this engine provided two driving wheels in
the front pneumatic wheels. Other systems include brakes, steering, mechanism, and power
transmission and an operator seat is available to make the machine riding type.
133
Table 6 Specification of this reaper harvesting machines
NO. Descriptions Details
1. Name of the harvesting machine reaper
2. Working width 120cm
3. Cutting bar width 110 cm
4. Color of the machine Light blue
5. Height of the machine 125 cm
6. Length of the machine 200cm
7. Weight of the machine 250 kg
8. Source of power 4 cylinder gas oil engine
9. engine power 5 hp
10. Source of manufacture Local(Ethiopia, Addis Ababa university 5

kilo)
11. Cost of equipment, Birr 25,000 birr
12. Types of vehicle Three wheel vehicle
13. steer control handle bar
14. Position of steer Back wheel steer
15. Number of machine Operator One man
16. Speed of operation 2.54 m/s
134
4.2 Harvesting process in filed operation

The cutting unit of reaper harvesting machine is reciprocating cutter bar type. After cutting,
the crop is conveyed vertically to the binding mechanism and released to the ground in the
form of bundles.
4.3 Test procedure:
The testing of experimental self-propelled riding type vertical conveyor reaper was done.
4.3.1 Laboratory tests:
The main objectives of laboratory tests were to confirm the dimensions and to study the
performance of the components designed. Such a study assisted the modifications and
improvement in the design of machine.
4.3.2 Specifications:
Self-propelled riding type Reaper was kept on firm level and horizontal surface of the
workshop floor and various dimensions were measured.
4.3.2.1 Visual observations and checking provision for adjustment:
The reaper was inspected thoroughly paying attention in particular to the power
transmission components, moving parts, correctness and ease of operations along with
various adjustments, tightness of bolts and nuts, etc.
4.3.2.2 Field test:
The observations on header loss and conveyance loss were recorded for constant speed of
vertical conveyor reaper. Pre-harvesting loss from header and also conveyance loss was
measured using 1 m x 1 m size area. The grains were collected from 1m2 area. Time and diesel
required for the operations were calculated with the help of stopwatch and measuring
cylinder, respectively (Bukhari and Nawaz, 1991).
135
4.4 Machine performance

The machine performances for all different types under study were evaluated
measuring machine capacity and the labor requirement.
4.5 Workability
The second parameter is workability, which is calculated measuring the two mean factors,
mainly, the length of harvesting period and potential harvesting hours. The economic
evolution is dun calculating fixed costs, operating costs and optimal harvesting capacity
4.6 Field capacity

Field capacity of a machine is the actual rate of land preparation/harvested or crop
processing in a given time, based on total field time. In other words, effective field capacity
of a machine is a function of the rated width of the machine. The percentage of rated width
actually utilized the speed of travel and the amount of field time lost during the operation. In
order to determine effective field capacity, the rated width of the implement (cutting width),
speed of travel and field efficiency were measured. Field capacity and field efficiency were
calculated using the following formula (Hunt, 1973):
During harvesting of the crop the cutting unit collects the harvest crop from on both left and
right side and pushes towards the middle position of machine for dropping or released to the
ground between six meter in the form of bundles it shows in figure 54-55. This Crop gathering
mechanism is use to increased Field capacity and field efficiency.
136
Figure 54 binding mechanism

137
4.6.1 Theoretical field capacity:

The theoretical field capacity was also calculated as per- equation
ℎ𝑎 e∗v
𝑇. 𝐹. 𝐶 ( ) =
ℎ𝑟 10
v is the working speed (km/h), 9.144km/h = 2.54 m/s
e is the effective working width (m), 1.2m

ℎ𝑎 1.2 m ∗ 9.144𝑘𝑚/ℎ
𝑇. 𝐹. 𝐶 ( ) = = 1.1ℎ𝑎/ℎ𝑟
ℎ𝑟 10
4.6.2 Actual field capacity
The actual field capacity was also calculated as per equation
ℎ𝑎 b∗L
𝐴. 𝐹. 𝐶 ( )=
ℎ𝑟 𝑇𝐶0 ∗ 10,000
Where; 𝑇𝐶0 time to covering total area ,
𝑇𝐶0 = ((𝑝 ∗ 𝑛) + 𝑘 + 𝑚 + 𝑠 + 𝑐)(1 + q)
𝑇𝐶0 = ((0.656 ∗ 83.33) + 20 + 30 + 30 + 30)(1 + 5%)
𝑇𝐶0 = 3 ℎ𝑟
b is the field width (m), 100 m
L is the field length (m), 100 m
100 𝑚
p is the time for turning (min), 𝑝 = 2.54𝑚 /𝑠 = 39.37 𝑠 = 0.656 𝑚𝑖𝑛
100 𝑚
n is the number of turnings, 𝑛 = = 83.33
1.2𝑚
Assume;
k is the turnings on treatment of headland (min), k= 20 min
S the time of adjustments, control, tending of machine, etc. (min), s = 30 min
m is the preparation for unloading (min), m = 30 min
c is the net unit of unloading time (min), and 30 min
138
ℎ𝑎 100 ∗ 100
𝐴. 𝐹. 𝐶 ( )=
ℎ𝑟 3 ℎ𝑟 ∗ 10,000
ℎ𝑎
𝐴. 𝐹. 𝐶 ( ) = 0.33 ℎ𝑎/ℎ𝑟
ℎ𝑟
4.6.3 Field efficiency
The field efficiency is the ratio of actual field capacity (ha/h) to the theoretical field capacity
(ha/h).
𝐴. 𝐹. 𝐶
𝐹𝑖𝑒𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
𝑇. 𝐹. 𝐶
0.33
𝐹𝑖𝑒𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
1.09
𝐹𝑖𝑒𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 0.306
4.7 Energy requirements

The power consumption (Er, kW) for different systems were calculated according to the
following equation (Hunt- 1995)
1 1 1
𝐸𝑟 = 𝐹𝑐 ( ) 𝑃. 𝐹 ∗ 𝐿. 𝑉. 𝐶 ∗ 427 ∗ 𝜂𝑡ℎ ∗ 𝜂𝑚 ∗ ∗
60 ∗ 60 75 1.36
1 1 1
𝐸𝑟 = 18 ( ) 0.85 ∗ 11000 ∗ 427 ∗ 35% ∗ 80% ∗ ∗
60 ∗ 60 75 1.36
𝐸𝑟 = 54.8 𝑘𝑤
Fuel flow calculation:
engine: 5 kW diesel engine at full power
Assume fuel 40.6MJ/kg, thermal efficiency 0.42:
5 𝑘𝑤
𝐹𝑢𝑒𝑙 𝑖𝑛𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟 = = 12𝑘𝑊
0.42
𝑠
3600 ( )
𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑓𝑢𝑒𝑙 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 = 12(𝑘𝐽/𝑠)/40600(𝑘𝐽/𝑘𝑔) × ℎ = 0.21 𝑘𝑔/𝑘𝑊ℎ
5(𝑘𝑊)
139
𝑒𝑛𝑔𝑖𝑛𝑒 𝑝𝑜𝑤𝑒𝑟 ∗ 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑓𝑢𝑒𝑙 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛

fuel consumption =
kg
the fuel density L
5 𝐾𝑤 ∗ 0.21 𝑘𝑔/𝑘𝑊ℎ
fuel consumption =
kg
0.9 L
fuel consumption = 1.17 𝑙/ℎ
Fc = the fuel consumption L/h 18 km/h
P.F = the fuel density, kg/L (for solar = 0.9)
L.C.V. = the lowest calorific value of fuel (kcal/kg) average L.C.V of diesel is 11000 kcal/kg)
𝜂𝑡ℎ = the thermal efficiency of the engine, (considered to be about 35% for diesel engine)
427 = thermo-mechanical equivalent, kg.m/kcal
𝜂𝑚 = the mechanical efficiency of the engine, (considered to be 80% for diesel engine)
So, the energy can be calculated as following:
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦(𝑘𝑔/ℎ) = 𝐹𝑒 ∗ 𝑢
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦(𝑘𝑔/ℎ) = 0.306𝑓𝑒𝑑/ℎ ∗ 10,000 kg/fed
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦(𝑘𝑔/ℎ) = 3058.1𝑘𝑔/ℎ
𝑒𝑛𝑔𝑖𝑛𝑒 𝑝𝑜𝑤𝑒𝑟(𝑘𝑤)
𝐸𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 =
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦(𝑘𝑔/ℎ)
5 𝑘𝑤
𝐸𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = = 0.0454 𝑘𝑤𝑘𝑔/ℎ = 45.45 𝑤𝑘𝑔/ℎ
110𝑘𝑔/ℎ
Manual energy: the manual energy (EH) per feddan was calculated by considering the
power of one labor about 0.1 hp, Chancellor (1981).
0.1 ∗ 0.746 ∗ 𝑁𝐿 𝑁𝐿
𝐸𝐻 = = ∗ 0.0746
𝑝𝑎 𝑝𝑎
Where:
140
0.1 = hp of agricultural labor (hp/man)

𝑁𝐿 = number of labor 𝑁𝐿 = 4
Pa = actual productivity (fed/h) Pa = 0.418 ℎ𝑎/ℎ𝑟
0.746 = co-efficiently per conversion from hp to kW.
4
𝐸𝐻 = ∗ 0.0746 = 0.71
0.418 ℎ𝑎/ℎ𝑟
4.8 Cutting efficiency
Pre-harvest losses were measured by placing a square frame (1 m x 1m) in the un-harvest
area. All the grains lying on the ground were collected within the frame which used to remain
below the cutter bar in operation. Usually, the pre-harvest loss is occurred where the grain is
on the ground due to a result of wind shatter, lodging, down crop or weather conditions. A
few gains were found within the square from in the field. Three random sampling were done
and made average the numbers of the threshed grains found.
Figure 55 harvest area
141
The average grains loss per hectare was calculated. By using new modified cutter bar or knife
Figure 56 new modified cutter bar

𝐶𝐸𝑤ℎ𝑒𝑎𝑡 = Cutting Efficiency, %
𝑊1 = Number of plants before cutting = 171
𝑊2 = Number of plants left after cutting = 10

171 − 10
𝐶𝐸𝑤ℎ𝑒𝑎𝑡 = ∗ 100 = 94.1%
171
Cost Economics
The cost of mechanical harvesting can be calculated on basis of fuel required for the operation,
labor charges, etc and was compared with the manual operations.
𝐶𝑚 − 𝐶𝑟
Less Cost =
𝐶𝑀
Where:
𝐶𝑚 = Harvesting cost by manual, K/day
𝐶𝑟 = Harvesting cost by reaper, K/day
Percentage of Grain Losses
Percentage of grain losses was obtained by the following equation.
Where,
142
𝐺𝑦 − 𝑊𝑔
𝑝𝑔𝑙 =
𝐺𝑦
𝑝𝑔𝑙 = Percentage of grain losses, %
𝑁𝑔 = Number of output grain, kg/ha
𝑁𝑦 = Number grain yield, kg/ha
No. of wheat Grains
𝑁𝑔 = No. of Grains/ear head * Plant population on 1 m * width of the machine (1.2 m)
𝑁𝑔 = 39 ∗ 171 = 6669
𝑁𝑦 = No. of Grains/ear head * Plant population on 1 m * width of the machine (1.2 m)
𝑁𝑦 = 39 ∗ 161 = 6279
Percentage of wheat grain losses

6669 − 6279
𝑝𝑔𝑙 = ∗ 100 = 0.585%
6669
1.2 m
1m
1m
1.2m
Figure 57 After cut the corps
143
4.9 self- prospered riding reapers machine efficiency with respect to other similar
production
This new Reaper changed the way the world worked at the time; It created a leap in the
Industrial Revolution as farming suddenly provided enough food to be exported worldwide
as food was suddenly efficiently harvested. In the field operation of this new self- prospered
riding reapers machine have: -
 The required labor for harvesting one hectare of wheat and rice field in present reaper
machine was manually was 4 man-hr/ha compared to 2 man-hr/ha for this new
reapers machine. The Mechanical Reaper enabled more production of food in a smaller
amount of time. This means that manual labor was decreased, enabling former farmers
and their families to pursue other careers and an education.
 easy to gathering cutting crops. During harvesting of the crop the cutting unit collects
the harvest crop from on both left and right side and pushes towards the middle
position of machine for dropping or released to the ground between in the form of
bundles.
 Before operation it never needs to prepare the field by using traditional harvesting on
the four sides of field and on four corners of field, this new reaper machine can be
simply turn in field.
 During harvesting, the reaper machine easily changes its direction without stopping
harvesting process.
 The farmers harvesting by riding the reaper machine without tiredness.
 Low cost machine compere to other reaper harvesting machine.
144
The average value of some of the parameters that include total operating time, total cutting
area, forward speed, effective field capacity and field efficiency are shown in Table 5. The
field capacity 0.24 ha/hr, respectively.
Table 7 Comparative performance characteristics of self-prospered reaper with this new

reaper machine
Harvesting Methods
No. Parameters
Previse machine New machine
1. Power source 5 HP diesel engine 5 HP diesel engine
2. Date of harvesting 7-5-2014 9-15-2018
3. Study area(m2) 1 1
4. Speed of operation(km/h) 2.18 9.144
5. Width of operation(cm) 120 120
6. Time required(h/ha) 4 h 10 min 1 h 30 min
7. Theoretical field
0.262 1.1
capacity(ha/h)
8. Field efficiency (%) 0.24 0.306
Labor requirement /day

9. (including collecting and 4 2
building)
10. Fuel consumption(L/h) 1.89 1.17 l
binding the crops and

one end and windrows released to the
11. Crop gathering the crops on the ground ground between 6 m
uniformly. in the form of
bundles.
145
CHAPTER FIVE
5 Conclusion and Recommendation
5.1 Conclusion
Among agriculture operations, harvesting is one the most tedious jobs and requires large
numbers of laborers. self-propelled riding reapers machine can be use successful for quick
and economical harvesting of wheat and rice crops, and to reduce the peaks labor shortage
during the harvesting. The machine can be operated by single labor. Frame and other parts of
the reaper machine are made angle iron, square bar, flat bar, pipe. The materials include
standard parts and manufactured parts used in the above material the machine.
Working width of the reaper machine 120 cm and length of the reaper machine are 200 cm
and125 cm length of the machine. The cut crop material was tied into bundles by its gathering
mechanism and left on the field. During harvesting of the crop the cutting unit collects the
harvest crop from on both left and right side and pushes towards the middle position of
machine for dropping or released to the ground in the form of bundles the bundles where the
machine powered by 5 kW, single cylinder, water cooled diesel engine having rated engine
speed of 970rpm. This self-propelled reaper is operated at forward speed of 2.54 m/s. The
field capacity 0.306 ha/hr, respectively. The required labor for harvesting one hectare of
wheat and rice reaper harvesting field operation are needs 2 man-hr/ha. The quantity of fuel
required to fill the tank fully after harvesting the plot was measured to determine the quantity
of fuel consumed for reaping the test plot and fuel consumption 1.17 l/h. Before starting the
harvesting operation in the test plot, the fuel tank of the reaper was filled up to its full.
5.2 Recommendation
By designing this machine that can have standard component and other small unknown
issues that could only be found and fixed if a machine were built in manufacture company and
further time was spent on design and testing. This was not accomplished due to restrictions
in time, shortage of resources includes standard machine component and lack of
manufacturing workshop. Ideally, other designers would look at this model and prototype
determine a plan for the constructing of my design in manufacturing company level.
146
Budget Breakdown/details of expenditure:

Table 8 Material cost
DESCRIPTION
UNIT QUANT TOTAL
NO. COMPONENT/CATALOG NO. / LENGTH
PRICE ITY PRICE
(WITH IN M)
5 HP diesel engine or Petrol
1 Engine 8,00birr 1 pic 7,000birr
engine
2 1 thk. M.S. sheet metal 1x2m 350birr 2 pic 350birr
3 42thk hard rubber 1 x 2.5 m 200 birr 1 pic 200 birr
4 10 thk. Hard rubber 0.15 x 1m 100birr 1 pic 100birr
5 30x30 square tubing 6m 200 birr 2 pic 400birr
Angle bar
6 3.0 thk. X 30.0 x 30.0 angle bar 6m 350 2pic 350birr
7 4.0 thk. X 40.0 x 40.0 angle bar 6m 450 birr 2 pic 1000 birr
Round bar
8 5 Ø O.D. round bar 6m 150birr 1pic 150birr
9 20 Ø O.D. round bar 6m 450birr 1pic 450birr
10 30 Ø O.D. round bar 2.5m 500birr 1pic 500birr
Pipe Length
19.05 Ø O.D. sch. 40 B.I. pipe is
11 6m 200birr 1 pic 200birr
steel
12 27 Ø O.D. sch. 40 B.I. pipe is 6m 250birr 1 pic 250birr
steel
33.4 Ø O.D. sch. 40 B.I. pipe is
13 6m 350birr 1 pic 350birr
steel
Timing chain Length
14 Chain 1.3 m 400birr 2 pic 400birr
15 sprocket gear 180mm Ø 400birr 2 pic 400birr
16 sprocket gear 60mm Ø 400birr 2 400birr
V-belt and flat belt Length
17 "B" section 1.2 m 120birr 2 pic 240birr
18 "B" section 1.5 m 130birr 2 pic 260birr
Bearing In mm
147
19 Deep groove ball brg,#6203 (17x40x12) 50birr 6 pic 300birr

20 Taper roller 30x62x22 80birr 8 pic 640birr
bearing,#m88048-N
21 Deep groove ball brg,#6206 RS (30x62x16) 80birr 8 pic 640birr
BOLTS AND NUTS
M10Øx1.25x20.0
22 Hex. Head bolt, with nut 3birr 80 pic 240birr
long
Hex. Head bolt with nut and
23 M22ØX3.25 x60long 12birr 6 pic 72birr
with lock washer
24 Flat(escrow) head bolt with M8Øx1.25x25.0 long 2.5birr 70 pic 175birr
nut
1.5 thk.x8.0I.D x16.0
25 Flat washer 0.5birr 100 pic 50birr
O.D
26 Hex. Head bolt with lock M8Øx1.25x19.0 long 3bir 12 pic 36birr
washer
27 Hex. Head bolt M14Øx2.0x150long 5birr 6 pic 30bir
M12Øx1.75x50.0
28 Hex. Head bolt 10birr 8 pic 80birr
long
1.5 thk.x10.0 I.D
29 Flat washer, 0.5birr 12 pic 6birr
x20.0 O.D
10.0 mmx8.0 mm
30 Key way c-45 120birr 1 pic 120birr
x1.2 m
Pulley In mm
31 Pulley cast iron (75.0 ø x 45) 200birr 2 pic 400birr
32 V-pulley cast iron (180.0x45) 350birr 2 pic 700birr
33 V- pully cast iron (60.0øx45) 180birr 2 pic 360bir
Pneumatic tire 4x12 with
34 Motor cycle tire 600birr 3 pic 1,800birr
curcke and kemendary
Painting spray
35 Painting white, dark red and 100 birr 6 pic 600 birr
black
36 Breaking spare motorcycle All part 1,000 birr
breaking parts
37 Additional material 1,000 birr
Sub total 20,669birr
148
Table 9 Equipment
N.O Item Quantity Unit price Total price(birr)
Catia and ansys
1. Software 200 birr 200birr
Sub Total 300 birr
Table 10 Consumables
N.O Item Quantity Unit price Total price(birr)

1. Printing papers (Ream) 1 250*1 250 birr
3. Mobile card 2 100 *2 birr 200 birr
Sub Total 450 birr
Table 11Travel & Subsistence (Destination, No. of persons and days) Equipment
N.O Item Quantity days Unit price Total price(birr)

Transportation To/adama
1. << 5 80 birr 400birr
metec (tractor)
2. Transportation To/awash << 5 120 birr 600 birr
melkasa
Sub Total 1,000 birr
Table 12 Personnel and other costs

N.O Item Quantity days Unit price Total price(birr)
1. 1 researchers
labor 5 100 birr 500 birr
2. welder << 4 265 birr 1060 birr
3. machine cost << 2 500birr 1000 birr
Sub Total 2,560 birr
Grand Total: Total = 24,979 birr
149
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Appendix
I. Coefficient of friction between belt and pulley [R.S. KHURMI and J.K. GUPTA (2005)]
II. Physical properties of metals. [R.S. KHURMI and J.K. GUPTA (2005)]
III. Standard width of pulley [R.S. KHURMI and J.K. GUPTA (2005)]
153
IV. Values of allowable shear stress, Modulus of elasticity and Modulus of rigidity for various
spring materials. [R.S. KHURMI and J.K. GUPTA (2005)]
V. Standard wire gauge (SWG) number and corresponding diameter of spring wire [R.S.
KHURMI and J.K. GUPTA (2005)]
154

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ADDIS ABABA UNIVERSITY

ADDIS ABABA UNIVERSITY INSTITUTE OF

Design and Development of Self-Prospered Riding Reapers Machine.

Thesis Submitted to the Addis Ababa University Institute of Technology

3.5.3 Frame structure design ..................................................................................................... 36

4.8 Cutting efficiency ........................................................................................................................141

Figure 31 lateral force known grip characteristics ........................................................................... 51

1.1 Background and justification:

mechanized agriculture includes the use of tractors, trucks, combine harvesters,

1.2 Statement of the problems:

1.3 General objectives:

1.6 Scope of the Research:

2.1 Study on design and develop a reaper harvesting

1. tractor operated vertical conveyer reaper b) self-propelled vertical conveyer reapers

2.3 Study on tested and evaluated field performance of reaper machine

Figure 2 field area

Figure 3 Reaping method of left turn

Figure 4 Reciprocating reaping method

Figure 5 field edge

In the process of harvesting by using self-prospered reaper machine Before it needs to

2.4 Product development

Product development is the process of creating a new product to be sold by a business or

Generic Design Process

Figure 6 Generic Design Process

Figure 7 Planning process

Identify opportunities: - is called as opportunities funnel, the source of identifies are

 Marketing and sales personal

Complete pre-project planning

 difficult to harvesting and collecting the crops

3.2 Concept Design

search for solution

abstract to combine solution evaluat concept

Figure 8 concept generation structured

 Reaper machine and Deiseal fuel crop harvesting crops

Figure 9 overall function

pulley power chain &

cutter & crop crop

Figure 10 working structure

3.2.2 Concept generation

Figure 11 Concept one

 Concept two crop harvesting conveyor and binding

Figure 12concept two

 Concept three crop harvesting by simple reaper bundle machine

Figure 13 concept three

 Used tractor transmit ion power.

Figure 14 concept four

Figure 15 concept five

 Concept six harvesting by Self-Prospered Riding Reapers Machine

Figure 16 concept six

3.2.3.1 Evaluating and selecting alternatives

3.2.3.2 Concept Selection Process

2. Calculating a weighting factor for each criterion

4. Select the preeminent design based on the decision matrix.

1. Develop evaluation criteria

2. Assign importance rate to each criterion

3. Rate each concept with respect to each evaluation criterion

4. Rank the concepts

5. Combine and improve the concepts

6. Select one or more concepts